Service Manual
4 | MN260 B
TABLE OF CONTENTS
INDICATIONS FOR USE ................................................................................................................................................ 7
INDICATIONS ............................................................................................................................................................... 7
CONTRAINDICATIONS ................................................................................................................................................. 8
SAFETY GUIDELINES ............................................................................................................................................... 8
BATTERY SAFETY .................................................................................................................................................... 9
1.0 THEORY OF OPERATION ..................................................................................................................................... 11
2.0 OPERATOR MAINTENANCE & SERVICE .............................................................................................................. 16
2.1 CLEANING THE SAROS .................................................................................................................................. 16
2.2 ROUTINE MAINTENANCE .............................................................................................................................. 16
2.3 SAROS PERFORMANCE VERIFICATION TEST ................................................................................................. 18
3.0 ALERTS, ALARMS, AND TROUBLESHOOTING TABLE ........................................................................................ 20
3.1 SYSTEM TROUBLESHOOTING GUIDE ............................................................................................................ 21
4.0 REPROGRAMMING/CALIBRATION ...................................................................................................................... 22
5.0 SHIPPING AND TRANSPORTING THE SAROS ..................................................................................................... 22
6.0 STORING AND DISCARDING THE SAROS ........................................................................................................... 22
7.0 OVERHAUL & REPAIR .......................................................................................................................................... 23
7.1 TOOLS AND TEST EQUIPMENT ...................................................................................................................... 23
7.2 MAINTENANCE AND SERVICE PARTS ............................................................................................................ 23
7.3 REPROGRAMMING AFTER OVERHAUL AND REPAIR PROCEDURES ............................................................ 24
7.4 SAROS MAIN COMPONENTS ......................................................................................................................... 24
7.5 COMPREHENSIVE TROUBLESHOOTING GUIDE ............................................................................................. 25
7.6 REMOVAL PROCEDURES ................................................................................................................................ 27
7.6.1 BATTERY INTERFACE PLATE, RAIN GUARD, AND SLEEVE ......................................................................... 27
7.7.2 INLET CAP REMOVAL .................................................................................................................................. 28
7.7.3 REMOVE PCB ASSEMBLY............................................................................................................................. 30
7.7.4 PROPORTIONAL VALVE REMOVAL (5293-SEQ) .......................................................................................... 32
7.7.5 COMPRESSOR FAN REMOVAL (9767-SEQ) ................................................................................................. 33
7.7.6 BATTERY CABLE REMOVAL (21494875) ..................................................................................................... 34
7.7.7 RAIL REMOVAL ............................................................................................................................................ 35
7.7.8 ATF & COMPRESSOR / TANK ASSEMBLY REMOVAL .................................................................................. 36
7.8 INSTALLATION PROCEDURES ......................................................................................................................... 37
7.8.1 GENERAL PROCEDURE ................................................................................................................................ 37
7.8.2 ATF & COMPRESSOR/PRODUCT TANK INSTALLATION ............................................................................... 38
7.8.3 RAIL INSTALLATION ..................................................................................................................................... 40
7.8.4 BATTERY CABLE INSTALLATION ................................................................................................................. 41
7.8.5 COMPRESSOR FAN REPLACEMENT............................................................................................................. 43
7.8.6 PROPORTIONAL VALVE REPLACEMENT (5293-SEQ) .................................................................................. 44
7.8.7 INSTALLATION OF PCB ASSEMBLY .............................................................................................................. 44
7.8.8 POWER CONNECTOR REPLACEMENT (9766-SEQ) ..................................................................................... 47
7.8.9 MEMBRANE PANEL REPLACEMENT (9731-1-SEQ) ..................................................................................... 48
7.8.10 INLET CAP INSTALLATION (SP9756V2-SEQ) .............................................................................................. 49
7.8.11 INSTALLATION OF THE SLEEVE & BATTERY INTERFACE PLATE ............................................................... 51
8.0 CLASSIFICATION .................................................................................................................................................. 53
9.0 SERVICE RECORDS & RETENTION ....................................................................................................................... 53
9.1 RECORD HOURS OF OPERATION AND SOFTWARE VERSION ....................................................................... 53
9.2 SERVICE AND MAINTENANCE RECORD ........................................................................................................ 54
Summary of Contents for SAROS 4000
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