STG global TANVAC HDV3000 Operator'S Manual Download | Manualshive

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EP250 Panel Operation and Troubleshooting

14

463-3000-01 Rev D. 23-Sep-2013

Welding on Equipment with Electronic Controls

Proper welding procedures are required to avoid damage to electronic controls, sensors, and
associated components. The component should be removed for welding if possible.
The following procedure must be followed if the component must be welded while installed on
equipment with electronic controls. This procedure will minimize the risk of component damage.

Warning!

Do not ground the welder to electrical components such as the control ground or

sensors. Improper grounding can cause damage to electrical components

Clamp the ground cable from the welder to the component being welded. Place

the clamp as close as possible to the weld to reduce the possibility of damage.

1.

Stop the engine. Turn the key switch to the OFF position.

2.

Disconnect the negative battery cable from the battery.

3.

Open any installed battery disconnect switch.

4.

Unplug the panel if possible.

5.

Connect the welding ground cable as close as possible to the area to be welded.

6.

Protect the wiring harness from welding debris and spatter.

7.

Use standard welding methods to weld the materials.

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Summary of Contents for TANVAC HDV3000

Page 1: ...TGGLOBAL NET OPERATORS MANUAL TANVAC HDV3000 STG Tanvac HDV3000 Opera on Manual Cat 2 2 Opera on Manual Comet Manual Sutorbilt R Series Sutorbilt P Series Lofa Manual Excava on Hydro SWMS Pressure Cleaner Water SWMS ...

Page 2: ...1300 998 784 STGGLOBAL NET OPERATORS MANUAL TANVAC HDV3000 Sec on 1 ...

Page 3: ...Machine Operation Starting the Engine Shutdown Procedures Shutdown the Machine 6 Using the Pressure Washer 7 Engaging the Vacuum 8 Engaging the Pressure Blower 9 Safe Work Procedures 10 Atmospheric Testing 11 Bonding and Grounding 12 Training 13 Hydraulic Operation 14 Maintenance 15 Hydraulic System 16 Vacuum Final Filter 17 Primary Shutoff 18 Vacuum Module Mounting 19 Captured Mounting Bracket Sp...

Page 4: ...le near your work area or equipment Fatalities have occurred when children have fallen or climbed into unattended septic holding tanks Secure your work area from entry of unauthorized persons in the vicinity WARNING Secure all access covers against unauthorized entry after pumping a septic holding tank Fatalities have occurred where children have fallen into septic holding tank openings that had n...

Page 5: ... the tank An attempted rescue without the advantage of a rope and harness can be life threatening to the rescuer WARNING Entry into a transport septic or holding tank is confined space entry Persons entering these tanks for any purpose must be trained in and follow OSHA confined space safety procedures c Safety Precautions for Operating Equipment DANGER Stop the truck motor remove all persons from...

Page 6: ... precaution could result in persons falling off the truck and possibly getting run over which could cause serious injury or death WARNING Before backing up the truck inspect the area to be backed into and clear all hazards pets and people from it Make sure that backup lights and the back up alarm are maintained and in good working condition Because of the truck mounted tank the driver will experie...

Page 7: ...local water company Pressure washers may only be connected to the mains drinking water supply if a system separator also known as a backflow preventer is installed in the supply hose 13 ALWAYS disconnect from the water supply and ensure the system is completely drained when not in use Store in a cool dry location 14 ONLY use chemical cleaning agents detergents that are approved for pressure washer...

Page 8: ...dies distant from the site of injury Injuries to the extremities can involve extensive nerve muscle vessel damage as well as cause a distal compartment syndrome Injuries to the torso can involve internal organ damage Surgical consultation should be obtained Aggressive irrigation and debridement is recommended Surgical decompression and exploration may also be necessary Angiographic studies are rec...

Page 9: ...s equipment and proper waste disposal Transportation and disposal of waste may be subject to local state or federal laws Read and follow the safety practices described in this manual and in the common industry references that are also provided to help in the decision making process C General Safety Procedures Perform all operations with at least two operators Only trained personnel should operate ...

Page 10: ...air intake can cause engine acceleration and over speeding This can result in death injury and property damage Reference to OSHA regulations are for informational purposes only and not intended as legal advice The use of this equipment in the removal or handling of any regulated substance or material must be performed in strict accordance with all applicable federal state and local laws and regula...

Page 11: ...8 4 COMPONENT IDENTIFICATION Engine Control Panel Control Panel ...

Page 12: ...9 Hourmeter Indicator lights Tachometer Ignition Switch Hydraulic Enable Push Top Enable Push Bottom DISABLE Flashing Beacon Work Light ...

Page 13: ...ols Throttle Turn CW or Push in DECREASE RPM Turn CCW or Pull Out In INCREASE Emergency stop Collection Tank Raised lower Push up RAISE TANK Push Down LOWER Rear Door Open Close Push open Raise door Push Close Lower door ...

Page 14: ...11 Water System Water pump Switch Water Pump ...

Page 15: ...12 Water Strainer Hose Reel ...

Page 16: ...13 Water Tank Drain Valve Lever Vacuum System Dump valve Suction Valve ...

Page 17: ...14 Blower Vacuum ...

Page 18: ...15 Blower Pressure Vacuum Gauge Pressure Vacuum 4way valve lever option UP 45 Pressure Middle Horizontal Neutral Down 45 Vacuum Press Button UNLOCKS LEVER Release Button LOCKS LEVER ...

Page 19: ...16 Primary Shutoff Assembly Collection Tank Interior Bag House Lid ...

Page 20: ...17 Bag House Drain Valve Tools Water Gun ...

Page 21: ... Shutdown Procedures Shutdown the Machine 1 Before shutting down the engine make sure the pressure vacuum lever is in the neutral position 2 Make sure you allow the engine to cool down for 5 10minutes before shutting the engine down please refer to the Caterpillar engine guidelines 6 USING THE PRESSURE WASHER 1 When engaging the pressure washer make sure the Caterpillar engine is at idle 2 To enga...

Page 22: ...age the pressure by pulling the 4way valve lever down to the pressure position C Then increase the Caterpillar engine rpm to the desired pressure refer to the vacuum pressure gauge for accurate measurement D To disengage the pressure idle the Caterpillar engine down and then disengage the pressure lever to the neutral position During vacuum truck operations workers are at risk of being exposed to ...

Page 23: ...eases fires and explosions and accidents within the facility or on the highway B The evacuation and rescue procedures in the event of a toxic gas leak C Ensure that air quality monitoring at the work site is continuous at such locations as the discharge area of the vacuum truck venting hose D Ensure that first aid is readily available on site in the event of exposure to toxic gas E Consult the man...

Page 24: ...ors Testing shall be conducted prior to starting any operations and if necessary during operations including but not limited to the following When operations in the area are subject to change such as automatic pump start up or product receipt into or transfer out of a tank located near the transfer operations When off loading When atmospheric conditions change such as wind direction When an emerge...

Page 25: ...constructed of conductive materials or thick walled hose with imbedded conductive wiring shall be used when transferring flammable and combustible liquids when the potential for a flammable atmosphere exists for the area of operations Conductive hoses shall provide suitable electrical conductance less than or equal to 1 mega ohm per 100 feet as determined by the hose manufacturer Thin walled metal...

Page 26: ...ding the vacuum pump discharge away from the diesel engine air intake Vapors may be returned to the source container using conductive and closed connections Vapors may be vented into the atmosphere to a safe location using a safety venturi Vacuum truck operators may provide vertical exhaust stacks extending approximately 3m above the vacuum truck or higher if necessary to dissipate the vapors befo...

Page 27: ...he vacuum truck throughout the duration The requirement that vacuum truck operators shall monitor the transfer operation and be ready to quickly close the product valve and stop the pump in the event of a blocked line or release of material through a broken hose or connection The knowledge that smoking or any other source of ignition shall not be permitted within at least 100 depending on local pr...

Page 28: ...ic operation the caterpillar engine must be running 3 Once the engine is running engage the hydraulics by switching the hydraulic switch to the on position on the control panel 4 The hydraulics can be operated 4 ways by manual override on the hydraulic valve bank via the pendant with lead by wireless remote or by the electrical buttons on the electrical board ...

Page 29: ...26 Emergency stop Collection Tank Raised lower Push up RAISE TANK Push Down LOWER TANK H2 Rear Door Open Close Push open Raise door Push Close Lower door ...

Page 30: ...27 The red emergency stop button must be out for the pendant to work Also the work button must be pressed initially for the pendant to work the on button must be pressed ...

Page 31: ...ch can cause serious injury Before operating hydraulic components be sure all connections are tight and hoses are not damaged Relieve all pressure before disconnecting hydraulic lines or repairing leaks Hydraulic Oil System maintenance should be conducted by a qualified person the hydraulic oil should be changed at a maximum of every 1000hrs the hydraulic oil filter should be changed every 500hrs ...

Page 32: ...2 weeks to check the rubber ball seat and the tightness of all fasteners Your vacuum tanker is equipped with one of two styles of primary shutoff depending on which type of air line system the tank has To inspect the ball seat on external air line systems begin by removing the primary shutoff access lid Next gain access the ball seat Examine the ball seat for hardened rubber nicks in the rubber an...

Page 33: ... module mounting bolts monthly with spanners 19 CAPTURED MOUNTING BRACKET SPRINGS Check the tension on the spring mounts monthly Examine the spring mounts to make sure they have not loosened up due to vibration Adjust the springs on the captured mounting brackets to a compressed length ...

Page 34: ...31 20 3000lt ELECTRIC CONTROL BOX CIRCUIT DIAGRAM 1 ...

Page 35: ...32 21 3000lt ELECTRIC CONTROL BOX CIRCUIT DIAGRAM 2 ...

Page 36: ...33 22 3000lt VACUUM UNIT BOTTOM RAIL ASSEMBLE ...

Page 37: ...1300 998 784 STGGLOBAL NET OPERATORS MANUAL Cat 2 2 Opera on Manual Sec on 2 ...

Page 38: ...Engines C6F 1 UP Engine C6H 1 UP Engine C7H 1 UP Engine C7J 1 UP Engine C6J 1 UP Engine C6K 1 UP Engine G8N 1 UP Engine C6L 1 UP Engine C7Y 1 UP Engine G7P 1 UP Engine C6N 1 UP Engine C8W 1 UP Engine G7L 1 UP Engine C6M 1 UP Engine C8Y 1 UP Engine C8Z 1 UP Engine SEBU8312 03 en us February 2016 ...

Page 39: ...ot anticipate every possible circumstance that might involve a potential hazard The warnings in this publication and on the product are therefore not all inclusive You must not use this product in any manner different from that considered by this manual without first satisfying yourself that you have considered all safety rules and precautions applicable to the operation of the product in the loca...

Page 40: ...on Section Model Views 18 Product Identification Information 27 Operation Section Lifting and Storage 29 Gauges and Indicators 30 Features and Controls 31 Engine Starting 33 Engine Operation 36 Engine Stopping 38 Cold Weather Operation 40 Maintenance Section Refill Capacities 42 Maintenance Recommendations 51 Maintenance Interval Schedule 53 Warranty Section Warranty Information 92 Reference Infor...

Page 41: ...ate the indicated service meter reading Recommended service should be performed at the appropriate intervals as indicated in the Maintenance Interval Schedule The actual operating environment of the engine also governs the Maintenance Interval Schedule Therefore under extremely severe dusty wet or freezing cold operating conditions more frequent lubrication and maintenance than is specified in the...

Page 42: ...gasoline or harsh chemicals could loosen the adhesive that secures the warning signs The warning signs that are loosened could drop off of the engine Replace any damaged warning signs or missing warning signs If a warning sign is attached to a part of the engine that is replaced install a new warning sign on the replacement part Any Caterpillar dealer can provide new warning signs Do not work on t...

Page 43: ...Illustration 1 g01324126 A Location of the warning labels 1 C0 5 2 C0 7 3 C1 1 4 C1 5 5 C1 6 6 C2 2 6 SEBU8312 03 Safety Section Safety Messages ...

Page 44: ...Illustration 2 g01324528 B Location of ether warning labels 1 C0 5 2 C0 7 3 C1 1 4 C1 5 5 C1 6 6 C2 2 SEBU8312 03 7 Safety Section Safety Messages ...

Page 45: ...Information SMCS Code 1000 7405 Illustration 5 g03838041 Attach a Do Not Operate warning tag to the start switch or controls before the engine is serviced or repaired These warning tags Special Instruction SEHS7332 are available from your Cat dealer Attach the warning tags to the engine and to each operator control station When appropriate disconnect the starting controls Do not allow unauthorized...

Page 46: ...ervice has been performed make provisions to stop the engine if an overspeed occurs Shutting down the engine may be accomplished by shutting off the fuel supply and or the air supply to the engine Do not attempt any repairs that are not understood Use the proper tools Replace any equipment that is damaged or repair the equipment Start the engine with the operator controls Never short across the st...

Page 47: ...ing additive Many factors can reduce the effectiveness of the additive over time Static charges can build up in ULSD fuel while the fuel is flowing through fuel delivery systems Static electricity discharge when combustible vapors are present could result in a fire or explosion Ensure that the entire system used to refuel your machine fuel supply tank transfer pump transfer hose nozzle and others ...

Page 48: ...ntain asbestos is present there are several guidelines that should be followed Never use compressed air for cleaning Avoid brushing materials that contain asbestos Avoid grinding materials that contain asbestos Use a wet method in order to clean up asbestos materials A vacuum cleaner that is equipped with a high efficiency particulate air filter HEPA can also be used Use exhaust ventilation on per...

Page 49: ...evere burns Allow cooling system components to cool before the cooling system is drained Check the coolant level after the engine has stopped and the engine has been allowed to cool Ensure that the filler cap is cool before removing the filler cap The filler cap must be cool enough to touch with a bare hand Remove the filler cap slowly in order to relieve pressure Cooling system conditioner contai...

Page 50: ...s that contain flammable fluid Clean any such lines or tanks thoroughly with a nonflammable solvent prior to welding or flame cutting Wiring must be kept in good condition Properly route and attach all electrical wires Check all electrical wires daily Repair any wires that are loose or frayed before you operate the engine Clean all electrical connections and tighten all electrical connections Elim...

Page 51: ...ay from open flames or sparks Dispose of used ether cylinders properly Do not puncture an ether cylinder Keep ether cylinders away from unauthorized personnel Do not spray ether into an engine if the engine is equipped with a thermal starting aid for cold weather starting Lines Tubes and Hoses Do not bend high pressure lines Do not strike high pressure lines Do not install any lines that are bent ...

Page 52: ...s products of combustion which may be harmful to your health Always start and operate the engine in a well ventilated area and if in an enclosed area vent the exhaust to the outside Inspect the engine for potential hazards Do not start the engine or move any of the controls if there is a DO NOT OPERATE warning tag or similar warning tag attached to the start switch or to the controls Before starti...

Page 53: ...e until the problem that caused the emergency stop has been corrected On the initial start up of a new engine or an engine that has been serviced make provisions to stop the engine if an overspeed condition occurs This may be accomplished by shutting off the fuel supply and or the air supply to the engine i02613441 Electrical System SMCS Code 1000 1400 Never disconnect any charging unit circuit or...

Page 54: ...lled without engine to frame ground straps can be damaged by electrical discharge To ensure that the engine and the engine electrical systems function correctly an engine to frame ground strap with a direct path to the battery must be used This path may be provided by way of a starting motor ground or a starting motor ground to the frame All grounds should be tight and free of corrosion The engine...

Page 55: ...atures of the C0 5 C0 7 C1 1 C1 5 C1 6 and C2 2 Engines Due to individual applications your engine may appear different from the illustrations Note Individual components are detailed on the C2 2 turbocharged engine only Illustration 15 g01299985 Typical view of the C0 5 Engine 18 SEBU8312 03 Product Information Section Model Views ...

Page 56: ...Illustration 16 g01300431 Typical view of the C1 5 turbocharged engine SEBU8312 03 19 Product Information Section Model View Illustrations ...

Page 57: ...er one fuel injector 3 Water pump 4 Lower engine oil filler cap 5 Throttle lever 6 Cover plate for the accessory drive 7 Engine oil level gauge 8 Engine oil cooler 9 Engine oil filter 10 Fuel injection pump 11 Transfer pump 12 Fuel filter 20 SEBU8312 03 Product Information Section Model View Illustrations ...

Page 58: ...ylinders are arranged in line The cylinder head assembly has one inlet valve and one exhaust valve for each cylinder Each cylinder valve has a single valve spring The pistons have two compression rings and an oil control ring It is important to ensure the correct piston height so that the piston does not contact the cylinder head The correct piston height also ensures efficient combustion of fuel ...

Page 59: ...cated oil line that runs from the main oil gallery to the cylinder head Coolant from the bottom of the radiator passes through the belt driven centrifugal water pump The coolant is cooled by the radiator and the temperature is regulated by a water temperature regulator Engine efficiency efficiency of emission controls and engine performance depend on adherence to proper operation and maintenance r...

Page 60: ...ng Exhaust 0 20 mm 0 008 inch Injection Indirect 1 Naturally Aspirated C1 1 Engine Illustration 21 g00852304 A Exhaust valves B Inlet valves Table 3 C1 1 Engine Specifications Maximum Operating Speed rpm 3600 rpm Cylinders and Arrangement In Line three cylinder Bore 77 mm 3 03 inch Stroke 81 mm 3 19 inch Displacement 1 131 L 69 0178 in3 Aspiration NA 1 Compression Ratio 23 1 Firing Order 1 2 3 Rot...

Page 61: ... 0 20 mm 0 008 inch Injection Indirect 1 Naturally Aspirated C1 5 Turbocharged Engine Illustration 23 g00852304 A Exhaust valves B Inlet valves Table 5 C1 5 Turbocharged Engine Specifications Maximum Operating Speed rpm 3000 rpm Cylinders and Arrangement In Line three cylinder Bore 84 mm 3 31 inch Stroke 90 mm 3 54 inch Displacement 1 496 L 91 2915 in3 Aspiration T 1 Compression Ratio 22 5 1 Firin...

Page 62: ...Exhaust 0 20 mm 0 008 inch Injection Indirect 1 Naturally Aspirated C2 2 Engine Illustration 25 g00296424 A Exhaust valves B Inlet valves Table 7 C2 2 Engine Specifications Maximum Operating Speed rpm 3000 rpm Cylinders and Arrangement In Line four cylinder Bore 84 0 mm 3 31 inch Stroke 100 0 mm 3 94 inch Displacement 2 216 cc 0 1352 in3 Aspiration NA 1 Compression Ratio 23 3 1 Firing Order 1 3 4 ...

Page 63: ... 20 mm 0 008 inch Injection Indirect 1 Turbocharged C2 2 Turbocharged Aftercooled Engine Illustration 27 g00296424 A Exhaust valves B Inlet valves Table 9 C2 2 Turbocharged Aftercooled Engine Specifications Maximum Operating Speed rpm 2800 rpm Cylinders and Arrangement In Line four cylinder Bore 84 0 mm 3 31 inch Stroke 100 0 mm 3 94 inch Displacement 2 216 cc 0 1352 in3 Aspiration TA 1 Compressio...

Page 64: ...6 Serial number plate i00610276 Reference Numbers SMCS Code 1000 Information for the following items may be needed to order parts Locate the information for your engine Record the information on the appropriate space Make a copy of this list for a record Retain the information for future reference Record for Reference Engine Model Engine Serial No Engine Arrangement No Modification No Engine Low I...

Page 65: ...tion 31 g06038952 Typical example Refer to illustration 31 The equipment manufacturer must install the label to the equipment This procedure is recommended by Caterpillar The label must be attached to the equipment near the fuel inlet to comply with the EPA regulations The equipment manufacturer may install another fuel label 28 SEBU8312 03 Product Information Section Emissions Certification Film ...

Page 66: ...ces are provided Consult your Cat dealer for information regarding fixtures for proper engine lifting i05111635 Product Storage SMCS Code 1000 1404 7002 If the engine will not be started for several weeks the lubricating oil will drain from the cylinder walls and from the piston rings Rust can form on the cylinder liner surface Rust on the cylinder liner surface will cause increased engine wear an...

Page 67: ...Pa 7 psi is 103 C 217 F Higher temperatures may occur under certain conditions The water temperature reading may vary according to load The reading should never exceed the boiling point for the pressurized system that is being used If the engine is operating above the normal range and steam becomes apparent perform the following procedure 1 Reduce the load and the engine rpm 2 Inspect the cooling ...

Page 68: ...e submerged in coolant in order to operate Engines may be equipped with alarms in order to alert the operator when undesirable operating conditions occur NOTICE When an alarm is activated corrective measures must be taken before the situation becomes an emer gency in order to avoid possible engine damage If corrective measures are not taken within a reasonable time engine damage could result The a...

Page 69: ...If an electronically controlled governor has been installed the governor operates the fuel rack in order to stop the engine 32 SEBU8312 03 Operation Section Fuel Shutoff ...

Page 70: ... to the outside Do not start the engine or move any of the controls if there is a DO NOT OPERATE warning tag or similar warning tag attached to the start switch or to the controls Ensure that the areas around the rotating parts are clear All of the guards must be put in place Check for damaged guards or for missing guards Repair any damaged guards Replace damaged guards and or missing guards Disco...

Page 71: ...engine start switch and allow the electric starting motor to cool Then repeat steps 2 through step 5 7 Turn the engine start switch to the OFF position to stop the engine i05287569 Cold Weather Starting SMCS Code 1000 1250 1450 1453 1456 1900 Do not use aerosol types of starting aids such as ether Such use could result in an explosion and personal injury Startability will be improved at temperatur...

Page 72: ...tion before attaching the jump start cables to the en gine being started 1 Turn the start switch on the stalled engine to the OFF position Turn off all accessories 2 Connect one positive end of the jump start cable to the positive cable terminal of the discharged battery Connect the other positive end of the jump start cable to the positive cable terminal of the electrical source 3 Connect one neg...

Page 73: ...different from that described above i00613522 Engine Warm up SMCS Code 1000 1 Run the engine at low idle for three to five minutes or run the engine at low idle until the jacket water temperature starts to rise More time may be necessary when the temperature is below 18 C 0 F 2 Check all of the gauges during the warm up period 3 Perform another walk around inspection Check the engine for fluid lea...

Page 74: ...s are properly adjusted The belts should be in good condition Ensure that all of the connections of the hoses are tight The connections should not leak Ensure that the driven equipment is in good working order Cold engines consume excess fuel Utilize heat from the jacket water system and the exhaust system when possible Keep cooling system components clean and keep cooling system components in goo...

Page 75: ...ine is stopped Emergency Stop Button Illustration 35 g00104303 Typical emergency stop button The emergency stop button is in the OUT position for normal engine operation Push the emergency stop button The engine will not start when the button is locked Turn the button clockwise in order to reset NOTICE Stopping the engine immediately after it has been working under load can result in overheating a...

Page 76: ... bottom of the pipe for filling If freezing temperatures are expected check the coolant for proper antifreeze protection The cooling system must be protected against freezing to the lowest expected outside temperature Add the proper coolant water mixture if necessary Perform all required periodic maintenance on all driven equipment This maintenance is outlined in the instructions from the OEM SEBU...

Page 77: ...he winter in the colder climates During cold weather operation if No 1 diesel fuel is not available use No 2 diesel fuel if necessary There are three major differences between No 1 and No 2 diesel fuel No 1 diesel fuel has the following properties Lower cloud point Lower pour point Lower rating of kJ BTU per unit volume of fuel When No 1 diesel fuel is used a decrease in power and in fuel efficien...

Page 78: ...e most common components that are affected by cold fuel NOTICE In order to maximize fuel system life and prevent pre mature wear out from abrasive particles in the fuel a two micron absolute high efficiency fuel filter is re quired for all Caterpillar Electronic Unit Injectors Cat erpillar High Efficiency Fuel Filters meet these requirements Consult your Caterpillar dealer for the proper part numb...

Page 79: ... hours 4 API CF oils are not recommended for this series of Caterpillar engines and smaller Direct Injection DI diesel engines 5 API CF 2 and CD 2 oils are classifications for two cycle diesel engines Caterpillar does not sell engines that utilize the CD 2 and the API CF 2 oils Note When oil meets more than one API classification the applicable footnote is determined by the highest API classificat...

Page 80: ...re used the oil drain interval should not exceed the standard oil drain interval for your engine API CF 4 multigrade oils are not recommended for this series of diesel engines For all other smaller commercial diesel engines the oil drain interval should not exceed 50 percent of the standard oil drain interval for your engine NOTICE In selecting oil for any engine application both the oil viscosity...

Page 81: ...e engine crankcase reflect the approximate capacity of the crankcase or sump plus standard oil filters Auxiliary oil filter systems will require additional oil Refer to the OEM specifications for the capacity of the auxiliary oil filter Table 12 C0 5 Engine Approximate Refill Capacities Compartment or System Min Max Crankcase Oil Sump Standard 1 1 6 L 1 7 qt 2 01 L 2 1 qt External System OEM 2 Tot...

Page 82: ...e Total Lubrication System includes the capacity for the Crankcase Oil Sump plus the capacity for the External System Enter the total in this row Table 17 C2 2 Turbocharged Engines and Naturally Aspirated Engines Approximate Refill Capacities Compartment or System Min Max Crankcase Oil Sump Standard 1 8 9 L 9 4 qt 10 6 L 11 2 qt External System OEM 2 Total Lubrication System 3 1 These values are t...

Page 83: ... in the fuel injectors reduced service life of the fuel system deposits in the combustion chamber and reduced service life of the engine Table 18 Territory Fuel Requirements from 2007 EPA Low Sulfur 500 ppm maximum EC Sulfur Power Low sulfur 300 ppm maximum for less than or equal to 19 kW Sulphur 1000 ppm maximum for greater than 19 kW Models C0 5 and C0 7 C1 1 C1 5NA C1 5T C1 6 C2 2NA C2 2T and C...

Page 84: ... heat exchangers and pitting of the cylinder liners These failures can be avoided with proper cooling system maintenance Cooling system maintenance is as important as maintenance of the fuel system and the lubrication system Quality of the coolant is as important as the quality of the fuel and the lubricating oil Coolant is normally composed of three elements water additives and glycol Water NOTIC...

Page 85: ...ne glycol in concentrations that exceed 50 percent glycol because of the reduced heat transfer capability of propylene glycol Use ethyl ene glycol in conditions that require additional protec tion against boiling or freezing Table 22 Propylene Glycol Concentration Freeze Protection Anti Boil Protection 50 Percent 29 C 20 F 106 C 223 F To check the concentration of glycol use the 1U 7298 Coolant Ba...

Page 86: ...enance Manual Cooling System Coolant Sample Level 2 Obtain for a sampling location and the maintenance interval for collecting the coolant samples Testing the engine coolant is important to ensure that the engine is protected from internal cavitation and from corrosion The analysis also tests the ability of the coolant to protect the engine from boiling and from freezing The S O S Coolant Analysis...

Page 87: ...h the following components heat exchanger aftercooler and piping Enter the capacity for the External System in this row Refer to either Caterpillar specifications or OEM specifications for further information 2 The Total Cooling System includes the capacity for the Engine Only plus the capacity for the External System Enter the total in this row Table 28 C1 6 Engine Approximate Refill Capacities C...

Page 88: ...e air pressure from the fuel system Engine Oil To relieve pressure from the lubricating system turn off the engine i05909227 Welding on Engines with Electronic Controls SMCS Code 1000 NOTICE Because the strength of the frame may decrease some manufacturers do not recommend welding onto a chassis frame or rail Consult the OEM of the equip ment or your Cat dealer regarding welding on a chas sis fram...

Page 89: ...is being welded and any electrical electronic component 9 The component that is being welded 10 Current path of the welder 11 Ground clamp for the welder 5 Connect the welding ground cable directly to the part that will be welded Place the ground cable as close as possible to the weld This location will reduce the possibility of welding current damage to bearings hydraulic components electrical co...

Page 90: ...or and Fan Belts Inspect Adjust 56 Engine Oil Sample Obtain Every 250 Service Hours or 1 Year Cooling System Supplemental Coolant Additive SCA Test Add 64 Initial 500 Hours for New Systems Refilled Systems and Converted Systems Cooling System Coolant Sample Level 2 Obtain Every 500 Service Hours Fuel System Secondary Filter Replace 81 Every 500 Service Hours or 1 Year Battery Electrolyte Level Che...

Page 91: ...ling System Coolant DEAC Change 58 Cooling System Water Temperature Regulator Replace 65 Every 4000 Service Hours Aftercooler Core Clean Test 55 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 62 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 60 Overhaul Overhaul Considerations 87 54 SEBU8312 03 Maintenance Section Maintenance Interval Schedule ...

Page 92: ...art the engine and accelerate the engine to high idle rpm This will help in the removal of debris and drying of the core Stop the engine Use a light bulb behind the core in order to inspect the core for cleanliness Repeat the cleaning if necessary Inspect the fins for damage Bent fins may be opened with a comb Note If parts of the aftercooler system are repaired or replaced a leak test is highly r...

Page 93: ...ly check the belt tension Gauge 144 0235 Belt Tension Gauge should be used Illustration 38 g01003936 Typical example 1 144 0235 Belt Tension Gauge Install the gauge 1 at the center of the belt between the alternator and the crankshaft pulley and check the belt tension The correct tension for a new belt is 400 N 90 lb to 489 N 110 lb The correct tension for a used belt that has been in operation fo...

Page 94: ...lp prevent electrical arcs and or sparks near batteries Do not smoke when batteries are serviced The battery cables or the batteries should not be removed with the battery cover in place The bat tery cover should be removed before any servic ing is attempted Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury Note Always r...

Page 95: ...ant petroleum jelly or MPGM i01492654 Battery or Battery Cable Disconnect SMCS Code 1402 029 The battery cables or the batteries should not be removed with the battery cover in place The bat tery cover should be removed before any servic ing is attempted Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury 1 Turn the start ...

Page 96: ...ure of clean water and Caterpillar Fast Acting Cooling System Cleaner Add 0 5 L 1 pint of cleaner per 15 L 4 US gal of the cooling system capacity Install the cooling system filler cap 4 Start and run the engine at low idle for a minimum of 30 minutes The coolant temperature should be at least 82 C 180 F NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and...

Page 97: ...el within 13 mm 0 5 inch to the proper level on the sight glass if equipped 4 Clean the cooling system filler cap Inspect the gasket that is on the cooling system filler cap If the gasket that is on the cooling system filler cap is damaged discard the old cooling system filler cap and install a new cooling system filler cap If the gasket that is on the cooling system filler cap is not damaged perf...

Page 98: ... to drain Flush the cooling system with clean water Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to Torque Specifications SENR3130 for more information on the correct torques Fill NOTICE Do not fill the cooling system faster than 5 L 1 3 US gal per minute to avoid air locks Cooling system air locks may result in engine damage 1 Fill the cooling system with ...

Page 99: ...ntains alkali Avoid contact with skin and eyes NOTICE Care must be taken to ensure that fluids are con tained during performance of inspection mainte nance testing adjusting and repair of the product Be prepared to collect the fluid with suitable contain ers before opening any compartment or disassem bling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Ser...

Page 100: ...terpillar Engine Coolant Specification 1 Caterpillar EC 1 Cat DEAC Diesel Engine Antifreeze Coolant Commercial heavy duty coolant antifreeze Table 30 Recommended Interval Type of Coolant Level 1 Level 2 Cat DEAC Every 250 service hours Every year 1 Conventional heavy duty coolant Commercial coolant that meets the re quirements of the Caterpillar EC 1 standard Cat ELC or conven tional EC 1 coolant ...

Page 101: ...ucts Dispose of all fluids according to local regulations and mandates Refer to Operation and Maintenance Manual Cooling System Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant Submit the sample for Level 2 analysis For additional information about coolant analysis see Special Publication SEBU6251 Caterpillar Commercial Diesel Engines Fluids Recommendations or co...

Page 102: ...system filler cap in order to relieve the pressure Remove the cooling system filler cap Note Always discard drained fluids according to local regulations 2 If necessary drain some coolant from the cooling system into a suitable container in order to allow space for the extra SCA 3 Add the proper amount of SCA Refer to the Special Publication SEBU6251 Caterpillar Commercial Diesel Engines Fluids Re...

Page 103: ... Personal injury or death can result from high voltage Moisture can create paths of electrical conductivity Make sure that the electrical system is OFF Lock out the starting controls and tag the controls DO NOT OPERATE NOTICE Accumulated grease and oil on an engine is a fire hazard Keep the engine clean Remove debris and fluid spills whenever a significant quantity accumu lates on the engine Perio...

Page 104: ...mary air cleaner element and a secondary air cleaner element The primary air cleaner element can be used up to six times if the element is properly cleaned and inspected The primary air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings The secondary air cleaner element is not serviceable or washable The secondar...

Page 105: ... ements with damaged pleats gaskets or seals Dam aged elements will allow dirt to pass through Engine damage could result Visually inspect the primary air cleaner elements before cleaning Inspect the air cleaner elements for damage to the seal the gaskets and the outer cover Discard any damaged air cleaner elements There are two common methods that are used to clean primary air cleaner elements Pr...

Page 106: ...air cleaner elements Storing Primary Air Cleaner Elements If a primary air cleaner element that passes inspection will not be used the primary air cleaner element can be stored for future use Illustration 46 g02595738 Typical example Do not use paint a waterproof cover or plastic as a protective covering for storage An airflow restriction may result To protect against dirt and damage wrap the prim...

Page 107: ...r cover 1 Clean the body that holds the air cleaner element 4 Inspect the replacement element for the following items damage dirt and debris 5 Remove the seal from the opening of the air inlet 6 Install a clean undamaged air filter element 2 7 Install air cleaner cover 1 8 Reset the air cleaner service indicator i06103548 Engine Air Cleaner Service Indicator Inspect If Equipped SMCS Code 7452 040 ...

Page 108: ... service indicator more frequently in environments that are severely dusty Replace the service indicator annually regardless of the operating conditions Replace the service indicator when the engine is overhauled and whenever major engine components are replaced Note When a new service indicator is installed excessive force may crack the top of the service indicator Tighten the service indicator t...

Page 109: ...e spacer 5 for turbocharged engines 7 Install a new spring 3 8 Install the breather cover 2 and the four screws 1 Tighten the screws i02456872 Engine Mounts Inspect SMCS Code 1152 040 Inspect the engine mounts for deterioration and for proper bolt torque Engine vibration can be caused by the following conditions Improper mounting of the engine Deterioration of the engine mounts Any engine mount th...

Page 110: ... valve is used The location of the sampling valve allows oil that is flowing under pressure to be obtained during normal engine operation The 169 8373 Fluid Sampling Bottle is recommended for use with the sampling valve The fluid sampling bottle includes the parts that are needed for obtaining oil samples Instructions are also provided NOTICE Always use a designated pump for oil sampling and use a...

Page 111: ...ting system Only use oil filters recom mended by Caterpillar 1 Remove the oil filter with a 1U 8760 Chain Wrench Note The following actions can be carried out as part of the preventive maintenance program 2 Cut the oil filter open with a 175 7546 Oil Filter Cutter Gp Break apart the pleats and inspect the oil filter for metal debris An excessive amount of metal debris in the oil filter may indicat...

Page 112: ... in order to ensure that the lubrication system has oil and that the oil filters are filled Inspect the oil filter for oil leaks 3 Stop the engine and allow the oil to drain back to the sump for a minimum of ten minutes Illustration 53 g00110310 4 Remove the oil level gauge in order to check the oil level Maintain the oil level between the ADD and FULL marks on the oil level gauge i05264151 Engine...

Page 113: ...urate measurement allow the valves to cool before this maintenance is performed Refer to the Service Manual for more information i02625315 Fuel Injector Test Change SMCS Code 1290 510 1290 081 Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be dis...

Page 114: ...ording to local regulations and mandates Use the following procedure in order to prime the fuel system If air enters the fuel system the air must be purged from the fuel system before the engine can be started Air can enter the fuel system when the following events occur The fuel tank is empty or the fuel tank has been partially drained The low pressure fuel lines are disconnected A leak exists in...

Page 115: ...osen vent screws 1 Refer to illustration 54 Operate the priming pump When fuel free from air flows from the vent screw tighten the vent screw Note Some fuel system will use gravity in order to prime the primary fuel filter If gravity is used ensure that the fuel tank is full and that all stop valves in the fuel line are open There is four different types of systems that can be installed on the eng...

Page 116: ...ion 59 g01304597 10 Connector bolt 11 Fuel return line 12 Connector bolt Hand Priming Pump 6 In order to identify the hand priming pump refer to illustration 58 1 Ensure that fuel valve 2 for the fuel filter that has an element is in the ON position Refer to illustration 55 SEBU8312 03 79 Maintenance Section Fuel System Prime ...

Page 117: ...re that fuel valve 2 for the fuel filter that has an element is in the ON position Refer to illustration 55 2 Loosen vent screw 3 4 or 5 on the fuel filter 3 Operate electrical priming pump 8 When fuel free from air flows from the vent screw tighten the vent screw Switch off the electrical priming pump 4 Loosen connection 10 or 12 at the fuel injection pump Refer to illustration 59 Note Fuel retur...

Page 118: ...ne operation Ensure that the drain valve is tight ened securely to help prevent air from entering the fuel system i02627769 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire To help prevent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills...

Page 119: ...asten the assembly to the fuel filter base with setscrew 2 The fuel system will need to be primed after the new filter is installed Refer to this Operation and Maintenance Manual Fuel System Prime Fuel Filter with Element 1 Close the fuel supply valve 1 Illustration 63 g01334893 Typical example 2 Clean the outside of the fuel filter assembly 3 Loosen locking ring 2 4 Remove the casing for the filt...

Page 120: ... filter is installed Refer to this Operation and Maintenance Manual Fuel System Prime Fuel filter with priming pump 1 Close the fuel supply valve 2 Clean the outside of the fuel filter assembly Illustration 65 g01306131 Typical example 3 Remove spin on filter 1 Use a 1U 8760 Chain Wrench in order to remove the filter Ensure that any fluid is drained into a suitable container Note Do not fill the f...

Page 121: ...t from the fuel tank after operating the engine Drain the water and sediment from the fuel tank after the fuel tank has been filled Allow 5 to 10 minutes before performing this procedure Fill the fuel tank after operating the engine in order to drive out moist air This procedure will help prevent condensation Do not fill the tank to the top The fuel expands as the fuel gets warm The tank may overf...

Page 122: ...are cracked or soft Replace hoses that show signs of leakage Replace hoses that show signs of damage Replace hose clamps that are cracked or damaged Tighten or replace hose clamps which are loose Replace the Hoses and the Clamps NOTICE Care must be taken to ensure that fluids are con tained during performance of inspection mainte nance testing adjusting and repair of the product Be prepared to col...

Page 123: ...oughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over any disconnected fuel system components Note High pressure fuel lines may be installed between the high pressure fuel pump and the fuel injectors High pressure fuel lines are constantly charged with high pressure Do not check the high pressure fuel lines with the engine or the starting motor in...

Page 124: ... conditions The results of the S O S analysis Oil Consumption as an Overhaul Indicator Oil consumption fuel consumption and maintenance information can be used to estimate the total operating cost for your Caterpillar engine Oil consumption can also be used to estimate the required capacity of a makeup oil tank that is suitable for the maintenance intervals Oil consumption is in proportion to the ...

Page 125: ... using pressure air wear a protective face shield and protective clothing The maximum air pressure for cleaning purposes must be reduced to 205 kPa 30 psi when the air nozzle is deadheaded Pressurized air is the preferred method for removing loose debris Direct the air in the opposite direction of the air flow Hold the nozzle approximately 6 mm 0 25 inch away from the fins Slowly move the air nozz...

Page 126: ...components Altitude Problems can arise when the engine is operated at altitudes that are higher than the intended settings for that application Necessary adjustments should be made Improper Operating Procedures Extended operation at low idle Frequent hot shutdowns Operating at excessive loads Operating at excessive speeds Operating outside the intended application Improper Maintenance Procedures E...

Page 127: ...triction of the line for the intake air clogged air filters which causes the turbocharger to slobber 3 Inspect the bore of the housing of the turbine outlet for corrosion 4 Fasten the air intake pipe and the exhaust outlet pipe to the turbocharger housing i00632301 Walk Around Inspection SMCS Code 1000 040 Inspect the Engine for Leaks and for Loose Connections A walk around inspection should only ...

Page 128: ...d condition Inspect the engine to frame ground strap for a good connection and for good condition Disconnect any battery chargers that are not protected against the current drain of the starting motor Check the condition and the electrolyte level of the batteries unless the engine is equipped with a maintenance free battery Check the condition of the gauges Replace any gauges which are cracked or ...

Page 129: ...ry engines 37 kW but excluding locomotive and other marine engines operated and serviced in the state of California including all parts of their emission control systems emission related components are a Designed built and equipped so as to conform at the time of sale to all applicable regulations adopted by the California Air Resources Board ARB b Free from defects in materials and workmanship wh...

Page 130: ...g is used for heavy duty applications that are operated at rated load and at rated rpm up to 100 percent This rating is used for engines that operate without interruption of load cycling Typical applications include the following examples pipeline pumping and ventilation B Rating This rating is used when power and or rpm are cyclic The engine should be run at full load The engine should not exceed...

Page 131: ...n at full load The engine should not exceed 5 percent of the duty cycle Typical applications include the following examples standby centrifugal water pumps oil field well servicing crash trucks portable air compressors and gas turbine starting motors NOTICE Operating engines above the rating definitions can result in shorter service life before overhaul 94 SEBU8312 03 Reference Information Section...

Page 132: ...ership facilities equipment and personnel Therefore follow the steps in sequence when a problem is experienced Outside of the USA and of Canada If a problem arises outside the USA and outside Canada and if the problem cannot be resolved at the dealer level consult the appropriate Caterpillar office Latin America Mexico Carribean Caterpillar Americas Co 701 Waterford Way Suite 200 Miami FL 33126 46...

Page 133: ...The parts stocks include all of the parts that are normally needed to protect your Caterpillar engine investment When you order parts please specify the following information Part number Part name Quantity If there is a question concerning the part number please provide your dealer with a complete description of the needed item When a Caterpillar engine requires maintenance and or repair provide t...

Page 134: ...r Cooling System Special Publication SEBD0970 Coolant and Your Engine Label PEEP5027 Extended Life Coolant Antifreeze Miscellaneous Service Manual REG1139F Service Manual Contents Microfiche Service Manual KENR6925 C0 5 C0 7 C1 1 C1 5 C1 6 and C2 2 Industrial Engines Systems Operation Testing and Adjusting KENR6228 C0 5 C0 7 C1 1 C1 5 C1 6 and C2 2 Industrial Engines Specifications KENR6227 C0 5 C...

Page 135: ...ropean classifications are established by the Counseil International Des Machines a Combustion CIMAC International Council on Combustion Engines CIMAC Central Secretariat Lyoner Strasse 18 60528 Frankfurt Germany Telephone 49 69 6603 1567 Facsimile 49 69 6603 1566 i05264255 Maintenance Records SMCS Code 1000 Caterpillar Inc recommends the retention of accurate maintenance records Accurate maintena...

Page 136: ...ipts Maintenance log i01176304 Maintenance Log SMCS Code 1000 Table 32 Engine Model Customer Identifier Serial Number Arrangement Number Service Hours Quantity Of Fuel Service Item Date Authorization continued SEBU8312 03 99 Reference Information Section Maintenance Log ...

Page 137: ... Table 32 contd 100 SEBU8312 03 Reference Information Section Maintenance Log ...

Page 138: ...entration 64 Cooling System Water Temperature Regulator Replace 65 Crushing Prevention and Cutting Prevention 14 Customer Assistance 95 Outside of the USA and of Canada 95 USA and Canada 95 Customer Service 95 D Driven Equipment Check 66 E Electrical System 16 Grounding Practices 16 Emergency Stopping 38 Emergency Stop Button 38 Emissions Certification Film 28 Emissions Warranty Information 92 Eng...

Page 139: ... and Sediment Drain 84 Drain the Water and the Sediment 84 Fuel Storage Tanks 84 Fuel Tank 84 G Gauges and Indicators 30 General Hazard Information 8 Containing Fluid Spillage 10 Dispose of Waste Properly 12 Fluid Penetration 10 Inhalation 11 Lines Tubes and Hoses 10 Pressurized Air and Water 9 Softwrap 11 Static Electricity Hazard when Fueling with Ultra low Sulfur Diesel Fuel 10 H Hoses and Clam...

Page 140: ...ndations 42 Coolant Recommendations 48 Engine Oil 42 General Coolant Information 46 General Fuel Information 46 Lubricating Grease 45 Refill Capacity of the Cooling System 49 S O S Coolant Analysis 49 S Safety Messages 5 No Ether B 8 Universal Warning A 8 Safety Section 5 Severe Service Application Check 88 Environmental Factors 89 Improper Maintenance Procedures 89 Improper Operating Procedures 8...

Page 141: ......

Page 142: ...Maintenance Manual Delivery Date Product Information Model Product Identification Number Engine Serial Number Transmission Serial Number Generator Serial Number Attachment Serial Numbers Attachment Information Customer Equipment Number Dealer Equipment Number Dealer Information Name Branch Address Dealer Contact Phone Number Hours Sales Parts Service ...

Page 143: ...Reserved CAT CATERPILLAR their respective logos Caterpillar Yellow and the POWER EDGE trade dress as well as corporate and product identity used herein are trademarks of Caterpillar and may not be used without permission 106 February 2016 ...

Page 144: ...1300 998 784 STGGLOBAL NET OPERATORS MANUAL Comet Manual Sec on 3 ...

Page 145: ...moving and Replacing Manifold c Seal V Packing Maintenance d Seal V Packing Reassembly e Plunger Maintenance f Plunger Reassembly g Crankcase Maintenance h Crankcase Reassembly i Unloader Maintenance 6 2 LW ZW Series Pump 8 11 a Valve Maintenance b Removing and Replacing Manifold c Seal V Packing Maintenance d Seal V Packing Reassembly e Plunger Maintenance f Plunger Reassembly g Crankcase Mainten...

Page 146: ...e run dry Running the pump dry will cause premature wear on the seals packing and plungers Running the pump dry for a prolonged period of time may cause damage that cannot be repaired Do not start a pump with frozen water in the manifold c STORAGE If there is a risk of freezing run antifreeze through the pump Empty any extra liquid inside the pump by running the pump without water for no more than...

Page 147: ...ty blocked valves Worn packing Check that there is no water leaking as it enters the pump Clean and or replace nozzle Pull the trigger to release air in system Clean filter Make sure tap is completely open and or connect to a tap that has adequate flow rate Replace check valve Install new seal kit Drop in pressure Worn nozzle Dirty or blocked valves Worn packing Replace the nozzle Replace check va...

Page 148: ...ck pump bolt and nut setting X Check regulation valve X 5 PUMP SPECIFICATION AND TECHNICAL DATA 5 1 Pump Identification Model Positions 1 2 3 4 5 a Model eg AX D 30 20 G POSITIONS 1 Model AX radial axial LW small frame ZW medium duty FW heavy duty HW super duty 2 RPM D 3400 RPM S 1750 RPM 1450 RPM 3 GPM eg 55 5 5 GPM 4 PSI eg 30 3000 PSI 5 Flange G Gasoline engine mounting flange or 1 E Electric M...

Page 149: ...alve change in one pump 5 Replace old valves by placing assembly in the valve chamber Replace riser tube on top of the check valve where necessary Press down firmly on the top of valve assembly or riser tube with your finger Fig D 6 Replace valve caps by applying LOCTITE 243 to valve cap and torque to 33 ft lbs B Removing Replacing Pump Manifold 1 Using a 6mm allen head wrench remove the four head...

Page 150: ...t low pressure seal using Comet repair tools Fig D Place the brass retainer ring on stand Fig D 1 Place tapered stainless steel cylinder Fig D 2 on top of brass retainer ring with the tapered narrow end on the brass retainer Insert a new low pressure seal closed side facing up on top of tapered stainless steel cylinder so it lays flat across the top Fig E Gently push the seal down through the tape...

Page 151: ...lling down from the inside of the crankcase with your hand Fig C 5 To service the oil seal take a small flat head screwdriver and apply pressure at a slight side and downward angle Fig D One side of the seal will pop up and can be easily removed 6 Inspect ceramic piston all parts for wear Replace if worn Fig E F Plunger Reassembly 1 Slide the piston assembly through the crankcase piston holes Fig ...

Page 152: ...ress or tap shaft out of the bearing 6 Remove oil seal by working around the edges with a small flat headed screwdriver Lift out once completed Replace the oil seal once it is removed H Crankcase Reassembly 1 Assemble shaft bearing assembly Stack all of the shaft bearing components Secure using the 6mm allen bolt wrench Place LOCTITE 243 on the bolt before threading Torque to 18 ft lbs Fig D 2 Ins...

Page 153: ... with new valves by placing assembly in the valve chamber Press down firmly on the top of the valve assembly Fig D 6 Replace valve caps by applying LOCTITE 243 to valve cap and torque to 33 ft lbs B Removing Replacing Pump Manifold 1 Remove the manifold of the pump by taking a 5mm allen head wrench and removing the eight head bolts 2 With the pump firmly secured take a medium sized flat head screw...

Page 154: ...mponents for any damage or water residue build up 2 Insert low pressure sealing working it in by hand 3 Replace the outer o ring by simply starting on one side and working it into the groove Fig C 4 Stack the V packing in the correct order and firmly press the assembly into the manifold Fig D 5 Install a new oil seal by laying the seal into the opening and evenly pressing it into place Fig E 6 Rei...

Page 155: ...oil seal by piercing a hole in the surface of the oil seal with a flat head screwdriver Pry it out of the crankcase and over the shaft Fig E 6 Remove the large snap ring securing the flange side bearing into the crankcase 7 Remove the small snap ring securing the shaft to the bearing 8 Using an industrial press or something equivalent press out the shaft from the side where the plastic cover was r...

Page 156: ...D 5 Slide the large bearing over the crankshaft and press it into the crankcase 6 Secure the snap rings into place by securing the bearing into the crankcase and the shaft into the bearing 7 Install the large oil seal on the flange side of the crankcase to cover the large bearing Fig E 8 Install the plastic spacer o ring and metal cover Secure the three bolts with a 4mm allen wrench Torque to 3 ft...

Page 157: ...simply placing the assembly in the valve chamber Press down firmly on the top of valve assembly Fig C 6 Replace valve caps by applying LOCTITE 243 to valve cap and torque to 33 ft lbs B Removing Replacing Pump Manifold 1 Remove the manifold of the pump by taking a 6mm allen head wrench and removing the eight head bolts 2 With the pump firmly secured take a medium sized flat head screwdriver and ap...

Page 158: ...o manifold Fig A B 4 Install a new oil seal by laying seal into the opening and pressing it into place Fig F 5 Reinstall the manifold onto the pump as described in section 6 3 B E Plunger Maintenance 1 Remove manifold as described in section 6 3 B It is possible that the seal and brass retainer ring assembly stays on the piston or remains in the manifold when removing 2 Remove the 15mm nut and was...

Page 159: ...r into place and secure the four bolts onto cover Fig D 4 Install the crankshaft by eyeing it through the connecting rods and pressing it into the small bearing opposite of the flange 5 Install the larger tapered bearing Press the inner portion of the bearing onto the shaft 6 Place outer portion of bearing into place and press into crankcase using the flange between the press and the bearing Fig E...

Page 160: ...ufacturers The period of Limited Warranty on the LW ZW FW HW models shall be five years from the date of sale to the end user Liability of manufacturer under the foregoing warranty is limited to repair or replacement at the option of the manufacturer of that product which according to the manufacturer s investigation was deemed defective at the time of shipment This warranty is in lieu of all othe...

Page 161: ...1300 998 784 STGGLOBAL NET OPERATORS MANUAL Sutorbilt R Series Sec on 4 ...

Page 162: ...l PARTS LIST OPERATING AND SERVICE MANUAL LEGEND R SERIES BLOWERS 3 5 GEAR DIAMETER Models GAB_ _ R _ GAC_ _ R _ GAE_ _ R _ SB 7 632 Version 04 June 29 2012 ...

Page 163: ...ians are factory trained and skilled in blower maintenance and repair They are ready to respond and assist you by providing fast expert maintenance and repair service INSTRUCTIONS FOR DETERMINING BLOWER CONFIGURATION 1 Face the blower drive shaft 2 In a VERTICAL configuration air flow is horizontal 3 In a HORIZONTAL configuration air flow is vertical 4 In a vertical configuration a BOTTOM HAND exi...

Page 164: ...lon Drum 28G28 AEON PD XD Extreme Duty Synthetic Lubricant Description Part Number 1 Quart 28G46 Case 12Quarts 28G47 1 Gallon Container 28G42 Case 6 Gallons 28G43 5 Gallon Pail 28G44 55 Gallon Drum 28G45 AEON PD FG Food Grade Synthetic Lubricant Description Part Number 1 Quart 28H97 Case 12Quarts 28H98 1 Gallon Container 28H333 Case 6 Gallons 28H334 5 Gallon Pail 28H99 55 Gallon Drum 28H100 Drive ...

Page 165: ...n economical operation and minimum downtime Danger is used to indicate the presence of a hazard which will cause severe personal injury death or substantial property damage if the warning is ignored Warning is used to indicate the presence of a hazard which can cause severe personal injury death or substantial property damage if the warning is ignored Caution is used to indicate the presence of a ...

Page 166: ...eved Electrical shock can and may be fatal Blower unit must be grounded in accordance with the National Electrical Code A ground jumper equal to the size of the equipment ground conductor must be used to connect the blower motor base to the unit base Open main disconnect switch tag and lockout before working on the control Disconnect the blower from its power source tag and lockout before working ...

Page 167: ...ns 5 Sutorbilt Legend Series Blowers Matrix Menu 8 Introduction 9 Section 1 Equipment Check 10 Section 2 Installation 12 Section 3 Lubrication 17 Section 4 Operation 22 Section 5 Special Tools Required 25 Section 6 Disassembly Instructions 27 Section 7 Assembly Instructions 31 Section 8 Parts List 39 thru 62 ...

Page 168: ...e 10 Trouble Shooting 24 Warranty 63 LIST OF ILLUSTRATIONS FIGURE 2 1 BLOWER MOUNTING CONFIGURATION 13 FIGURE 2 2 BELT DRIVE OVERHUNG LOAD CALCULATIONS 15 FIGURE 3 1 LUBRICATION 17 FIGURE 3 2 APPROXIMATE OIL CAPACITIES 18 FIGURE 3 3 AEON PD SYNTHETIC LUBRICANT 20 FIGURE 3 4 SYNTHETIC LUBRICANT CHART 20 FIGURE 3 5 LUBRICATION RECOMMENDATION 21 FIGURE 4 1 MAXIMUM MINIMUM OPERATING LIMITATIONS 22 FIG...

Page 169: ... COLUMN 2 PRODUCT FAMILY COLUMN 3 GEAR DIAMETER B 3 E 5 C 4 COLUMN 4 CASE LENGTH L Low Pressure M Medium Pressure H High Pressure COLUMN 5 CONFIGURATION A Vertical Top Hand Central Timed B Vertical Bottom Hand Central Timed C Horizontal Left Hand Central Timed D Horizontal Right Hand Central Timed COLUMN 6 DESIGN VERSION COLUMN 7 ADDITIONAL DESCRIPTION SEALS CLEARANCES LUBRICATION A Lip Standard G...

Page 170: ...i As with other precision machinery there are several relatively simple installation operation and maintenance procedures that you must observe to assure optimum blower performance There is no guesswork in the manufacture of your highly advanced Sutorbilt blower and there must be none in preparing the blower to get the job done in the field The purpose of this manual is to help you properly instal...

Page 171: ...tore the blower in a clean dry heated if possible area 2 Make certain inlet and discharge air ports are tightly covered to prevent foreign material from entering the air box 3 All exposed non painted surfaces should be protected against rust and corrosion 4 Provide adequate protection to avoid accidental mechanical damage 5 In high humidity or corrosive environments additional measures may be requ...

Page 172: ... discharge connections are in the vertical position vertical airflow On vertically mounted units it will be necessary to lay the unit on its side supporting the ends of the unit so as not to restrict the port on the bottom side Place a shallow pan on the under side of the unit With the blower disconnected from power spray the solvent in the top port rotating the impellers by spinning the shaft man...

Page 173: ... jack screws or wedges are used during grouting they must be backed off and wedges removed before final tightening of anchor bolts Refer to grouting instructions Where a concrete foundation is not feasible care must be taken to insure that equipment is firmly anchored to adequate structural members restricting movement and vibration MOUNTING CONFIGURATIONS The blower flex mount design enables hori...

Page 174: ...ully aligned Motor and blower pulleys must be parallel to each other and in the same plane within 1 32 inch Belt tension should be carefully adjusted to the belt manufacturer s recommendation using a belt tension gauge Check tension frequently during the first day of operation Over tightening belts leads to heavy bearing loads and premature failure On the direct connected units alignment and lubri...

Page 175: ...t Figure 2 2 page 15 2 Insert the calculated belt pull into the formula for Calculation of Shaft Moment FIGURE 2 2 page 15 to arrive at the calculated shaft moment PIPING Inlet and discharge connections on all blowers are large enough to handle maximum volume with minimum friction loss Reducing the pipe diameter on either inlet or discharge will only create additional line loss and increase the ov...

Page 176: ...1 0 600 0 908 0 850 0 858 1 100 0 796 1 350 0 716 0 125 0 983 0 375 0 947 0 625 0 904 0 875 0 852 1 125 0 789 1 375 0 706 0 150 0 980 0 400 0 943 0 650 0 899 0 900 0 847 1 150 0 782 1 400 0 697 0 175 0 977 0 425 0 939 0 675 0 894 0 925 0 841 1 175 0 774 1 425 0 687 0 200 0 973 0 450 0 935 0 700 0 889 0 950 0 835 1 200 0 767 0 225 0 969 0 475 0 930 0 725 0 884 0 975 0 829 1 225 0 759 ARC OF CONTACT...

Page 177: ...ement has been used It will also eliminate both premature filter servicing and premature blower failure due to a plugged filter when the filter pressure drop is used to establish maintenance points In all cases refer to the filter manufacturer s service instructions Due to the many types of filters it is not practical to give specific instructions covering all models NOTICE No matter what type of ...

Page 178: ...AEON PD Grease select compatible base grease The grease should be NLGI Grade 2 EP contain rust inhibitors and be suitable for blower discharge temperatures up to 350 F 177 C Completely clean or purge the factory filled grease from the blower Do not mix different types of grease as they may not be compatible Substitutions may cause early bearing failure Re grease bearings every 500 hours of operati...

Page 179: ... Gear End Drive End Total Gear End Drive End Total 3 3 5 0 6 PT 9 oz grease 0 6 PT 9 oz 1 1 PT 18 oz grease 1 1 PT 18 oz 4 4 0 9 PT 14 oz grease 0 9 PT 14 oz 1 5 PT 24 oz grease 1 5 PT 24 oz 5 5 1 1 PT 18 oz grease 1 1 PT 18 oz 2 5 PT 40 oz grease 2 5 PT 40 oz Note Quantities are for purchase estimates only Legend R Series Dual Splash Lube Blower Oil Capacities Approximate Sump capacity in pints o...

Page 180: ...N INSTRUCTIONS Filling procedure Refer to FIGURE 3 1 page 17 Remove the breather B from the gear cover Add oil to the gear case until oil reaches the center of the oil level gauge H Secure breather B in the gear cover Add fresh oil as required to maintain proper level The oil level should be at the middle of the sight glass when the machine is not operating Refer to Figure 3 2 page 18 for approxim...

Page 181: ...EON PD SYNTHETIC LUBRICANT AEON PD is formulated especially for positive displacement blower service to provide maximum blower protection at any temperature One fill of AEON PD will last a minimum of 4 times longer than a premium mineral oil Refer to FIGURE 3 4 Ambient Temperatures Less than 10 F 10 F to 32 F 32 F to 90 F Greater than 90 F Blower Discharge Temperature Less than 32 F AEON PD AEON P...

Page 182: ...o normal level of the blower which is at the middle of the sight glass when the machine is not operating Run the blower for one hour Shut off the blower and drain the lubricant completely Refill the blower again with the new lubricant Blower Discharge Temperature Ambient Temperature Less than 10 F 10 F to 32 F 32 F to 90 F Greater than 90 F Less than 32 F 0 C ISO 100 ISO 100 32 F to 100 F 0 C to 3...

Page 183: ...int than the blower maximum in order to protect the motor or the equipment served by the blower Discharge temperature switches are recommended to protect against excessive inlet restriction or inlet temperatures Check valves in the discharge line on pressure blowers and in the inlet line on vacuum blowers are recommended to protect the blower from motoring backwards when shut down under load LIMIT...

Page 184: ...nd incidental contact 5 Check the unit for proper lubrication Proper oil level cannot be over emphasized Too little oil will ruin bearings and gears Too much oil will cause overheating and can ruin gears and cause other damage Insure that grease lubricated bearings are properly lubricated 6 With motor electrical power locked out and disconnected turn the drive shaft by hand to be certain the impel...

Page 185: ...ure differential 4 Worn gears 5 Worn bearings 1 Re time impellers 2 Check mounting alignment and relieve pipe strains 3 Reduce to manufacturer s recommended pressure Examine relief valve re set if necessary 4 Replace timing gears 5 Replace bearings Excessive blower temperature 1 Too much oil in gear case 2 Too low operating speed 3 Dirty air Filter 4 Clogged filter or muffler 5 Excessive pressure ...

Page 186: ...32 Page 25 SECTION 5 MAINTENANCE ORDER SPECIAL TOOLS BY PART NUMBER SEE PAGE 2 FOR ORDERING INSTRUCTIONS Unit Size Part Number 3 201GAA340 4 202GAA340 5 203GAA340 FIGURE 5 1 PULLER PLATE FIGURE 5 2 SEAL DRIVE ...

Page 187: ...26 Unit Size Part Number 3 205GAA074 4 206GAA074 5 207GAA074 FIGURE 5 3 MECHANICAL SEAL INSTALLATION TOOL Unit Size Part Number 3 201GAA074 4 202GAA074 5 203GAA074 FIGURE 5 4 BEARING PRESS TOOL MECHANICAL SEAL UNITS ...

Page 188: ...Y CAN BE REASSEMBLED IN THE SAME POSITION IMPELLERS HEADPLATES AND GEARS 4 If the timing gears appear undamaged the gear backlash must be checked to see if the gears can be salvaged A Mount a magnetic base dial indicator on the gear headplate see FIGURE 6 1 B Lock one impeller stationary by wedging a feeler gauge between the impeller and the headplate C The tip of the indicator should be placed at...

Page 189: ...ler tip to valley throat and the case to headplates should also be matchmarked to facilitate blower reassembly 6 Remove all cap screws from both gear locking assemblies see FIGURE 6 3 Thread 3 of these cap screws into the threaded holes in the outer ring of each locking assembly Tighten the screws evenly to remove the locking assembly from each gear Remove the gears 9 from both rotor shafts NOTICE...

Page 190: ...ler case 22 10 Using the puller plate shown on page 25 bolt to the drive headplate using the tapped holes on used to secure the drive cover 11 Install a gear puller to each shaft and attach puller arms to the plate Turn each puller only half a revolution at a time keeping the advance of the shafts as uniform as possible see Figure 6 4 After the headplate has been removed detach the puller plate 12...

Page 191: ...emoving 4 capscrews 16 18 Push the impeller shaft through the gear headplate and remove the impeller assembly 23 see Figure 6 6 Remove the other impeller assembly following the same procedure 19 Remove the cap screws 21 securing the gear headplate to the impeller case Located near each dowel pin on the headplate is a threaded hole Insert a 5 16 18 UNC capscrew into each of the threaded holes Tight...

Page 192: ... time the headplate is removed NOTICE Make sure seals are fully seated Use extreme care when installing MECHANICAL SEALS ONLY A Lightly coat the headplate bores with assembly lubricant B Refer to Figure 7 1 Install mechanical seal A into the headplate bore C using a press and the correct driver shown on page 26 Drive the seal securely on to its seat Use extreme care when installing seals in the he...

Page 193: ...r the unit to set level Measure the total end clearance using a depth micrometer see Figure 7 2 NOTICE If more than 007 shim is required put 007 on the drive end and the remaining on the gear end If total clearance is not within the limits specified in Figure 7 4 page 33 it may be necessary to shim the case to obtain the proper total end clearance The shim should be placed between the drive headpl...

Page 194: ...ssible without force Use the plate used to install the drive end bearings to press the bearings on the shafts as described in Step 8 Press bearings into the gear headplate until completely seated in the bearing bore NOTICE Bearings will not be flush with gear headplate bores when completely seated 10 Impellers should now be checked for free axial movement by hitting the ends of the impeller shafts...

Page 195: ...k of the slingers Rotate slingers approximately 90 degree apart apply Loctite 246 on the socket cup screw and tight Recommended torque is 3 3 5 FT LBS See FIGURE 7 6 13 SETTING IMPELLER END CLEARANCES Refer to FIGURE 7 7 page 34 The outer races of the gear end bearings are clamped against the headplate F by the bearing retaining screws or by bearing retainer plate mechanical seal version B This is...

Page 196: ...een the shaft H and the bearing inner race E keeps the shaft from moving axially End clearance adjustment is by movement of the bearing retainer K Tightening the bearing retainer screws M moves the bearing to load the wavy spring J and the impeller is forced toward the drive end Relaxing the screws allows the wavy spring to return the impeller toward the gear end A Assemble drive cover to drive he...

Page 197: ...mplished by determining the maximum feeler gauge thickness that will fit between the rotor lobes near the pitch diameter The clearance should be measured along the entire length of the meshing lobes This measurement should be taken for each of the 2 interlobe meshes The location of the smallest total interlobe clearance should be marked on the rotor lobes Refer to diagram in FIGURE 7 4 page 33 Use...

Page 198: ... gauge over the entire length of the impeller to ensure that the tips do not bind along their length FIGURE 7 8 NOTICE Replacement gears have minimum backlash marks on the outside diameter of the gear face These marks should be located 180 degrees from each other see FIGURE 7 8 NOTICE The gear used for adjustment should be flush with its mate on completion of the timing NOTICE If any of the four g...

Page 199: ...16 and level the unit up The bench or blower base flatness should be within 002 of an inch Re tighten cap screws 16 to the specification in FIGURE 7 9 NOTICE If the unit is not flat within 002 of an inch it will be necessary to shim the blower feet at installation GEAR DIAMETER FASTENERS 3 4 5 CAPSCREW 21 23 30 42 45 42 45 CAPSCREW 16 23 30 42 45 42 45 SOCKET HD CAPSCREW 5 6 8 16 18 11 13 SOCKET H...

Page 200: ...SB 7 632 Page 39 SECTION 8 PARTS LIST ...

Page 201: ...4301 900873033801 900873034201 23 Rotor Group 3 Standard Clearances 1 307GAB4028 309GAB4028 308GAB4028 3 High Temperature Clearances 1 To be assigned To be assigned To be assigned 24 Bearing Housing Drive End 1 900873033501 900873033501 900873033501 25 Key Square 1 900639910304 900639910304 900639910304 26 Pipe Fitting 2 40E9 40E9 40E9 27 Cap 2 40P58 40P58 40P58 29 Drive Cover 1 9010873033701 9010...

Page 202: ...SB 7 632 Page 41 ...

Page 203: ...41801 900883042001 23 Rotor Group 4 Standard Clearances 1 307GAC4028 306GAC4028 305GAC4028 4 High Temperature Clearances 1 To be assigned To be assigned To be assigned 24 Bearing Housing Drive End 1 300GAC006 300GAC006 300GAC006 25 Key Square 1 900639910304 900639910304 900639910304 26 Pipe Fitting 2 40E9 40E9 40E9 27 Cap 2 40P58 40P58 40P58 29 Drive Cover 1 900883040301 900883040301 900883040301 ...

Page 204: ...SB 7 632 Page 43 301GAE810 A Ref Drawing ...

Page 205: ...1701 900883051801 900883051901 23 Rotor Group 5 Standard Clearances 1 327GAE4028 326GAE4028 325GAE4028 5 High Temperature Clearances 1 To be assigned To be assigned To be assigned 24 Bearing Housing Drive End 1 206GAE006 206GAE006 206GAE006 25 Key Square 1 900639910305 900639910305 900639910305 26 Pipe Fitting 2 40E9 40E9 40E9 27 Cap 2 40P58 40P58 40P58 29 Drive Cover 1 900883050401 900883050401 9...

Page 206: ...SB 7 632 Page 45 ...

Page 207: ...873034201 23 Rotor Group 3 Standard Clearances 1 307GAB4028 309GAB4028 308GAB4028 3 High Temperature Clearances 1 To be assigned To be assigned To be assigned 24 Bearing Housing Drive End 1 900883030301 900883030301 900883030301 25 Key Square 1 900639910304 900639910304 900639910304 26 Pipe Fitting 2 40E9 40E9 40E9 27 Cap 2 40P58 40P58 40P58 28 Wavy Spring 2 900669170203 900669170203 900669170203 ...

Page 208: ...SB 7 632 Page 47 ...

Page 209: ... 23 Rotor Group 4 Standard Clearances 1 307GAC4028 306GAC4028 305GAC4028 4 High Temperature Clearances 1 To be assigned To be assigned To be assigned 24 Bearing Housing Drive End 1 900883041201 900883041201 900883041201 25 Key Square 1 900639910304 900639910304 900639910304 26 Pipe Fitting 2 40E9 40E9 40E9 27 Cap 2 40P58 40P58 40P58 28 Wavy Spring 2 900669170304 900669170304 900669170304 29 Drive ...

Page 210: ...SB 7 632 Page 49 303GAE810 A Ref Drawing ...

Page 211: ...051801 900883051901 23 Rotor Group 5 Standard Clearances 1 327GAE4028 326GAE4028 325GAE4028 5 High Temperature Clearances 1 To be assigned To be assigned To be assigned 24 Bearing Housing Drive End 1 207GAE006 207GAE006 207GAE006 25 Key Square 1 900639910305 900639910305 900639910305 26 Pipe Fitting 2 40E9 40E9 40E9 27 Cap 2 40P58 40P58 40P58 28 Wavy Spring 2 900669170405 900669170405 900669170405...

Page 212: ...SB 7 632 Page 51 ...

Page 213: ...or Group 3 Standard Clearances 1 307GAB4028 309GAB4028 308GAB4028 3 High Temperature Clearances 1 To be assigned To be assigned To be assigned 24 Bearing Housing Drive End 1 303GAB006 303GAB006 303GAB006 25 Key Square 1 900639910304 900639910304 900639910304 29 Drive Cover 1 302GAB477 302GAB477 302GAB477 30 Screw 8 75P7 75P7 75P7 31 Oil Seal 1 60DD725 60DD725 60DD725 35 Bearing Spherical 1 12BA153...

Page 214: ...SB 7 632 Page 53 ...

Page 215: ... 23 Rotor Group 4 Standard Clearances 1 307GAC4028 306GAC4028 305GAC4028 4 High Temperature Clearances 1 To be assigned To be assigned To be assigned 24 Bearing Housing Drive End 1 303GAC006 303GAC006 303GAC006 25 Key Square 1 900639910304 900639910304 900639910304 29 Drive Cover 1 302GAC477 302GAC477 302GAC477 30 Screw 8 75P40 75P40 75P40 31 Oil Seal 1 60DD716 60DD716 60DD716 35 Bearing Spherical...

Page 216: ...SB 7 632 Page 55 300GAE810 A Ref Drawing ...

Page 217: ... Rotor Group 5 Standard Clearances 1 327GAE4028 326GAE4028 325GAE4028 5 High Temperature Clearances 1 To be assigned To be assigned To be assigned 25 Key Square 1 900639910305 900639910305 900639910305 29 Drive Cover 1 300GAE477 300GAE477 300GAE477 30 Screw 8 75P40 75P40 75P40 31 Oil Seal 1 60DD726 60DD726 60DD726 35 Bearing Spherical 1 12BA253 12BA253 12BA253 40 Oil Level Gauge 2 40P34 40P34 40P3...

Page 218: ...SB 7 632 Page 57 ...

Page 219: ...028 309GAB4028 308GAB4028 3 High Temperature Clearances 1 To be assigned To be assigned To be assigned 24 Bearing Housing Drive End 1 305GAB006 305GAB006 305GAB006 25 Key Square 1 900639910304 900639910304 900639910304 28 Wavy Spring 2 900669170203 900669170203 900669170203 29 Drive Cover 1 302GAB477 302GAB477 302GAB477 30 Screw 6 75P7 75P7 75P7 31 Oil Seal 1 60DD725 60DD725 60DD725 35 Bearing Sph...

Page 220: ...SB 7 632 Page 59 ...

Page 221: ...rances 1 307GAC4028 306GAC4028 305GAC4028 4 High Temperature Clearances 1 To be assigned To be assigned To be assigned 24 Bearing Housing Drive End 1 305GAC006 305GAC006 305GAC006 25 Key Square 1 900639910304 900639910304 900639910304 28 Wavy Spring 2 900669170304 900669170304 900669170304 29 Drive Cover 1 302GAC477 302GAC477 302GAC477 30 Screw 8 75P40 75P40 75P40 31 Oil Seal 1 60DD716 60DD716 60D...

Page 222: ...SB 7 632 Page 61 302GAA810 A Ref Drawing ...

Page 223: ...28 325GAE4028 5 High Temperature Clearances 1 To be assigned To be assigned To be assigned 24 Bearing Housing Drive End 1 304GAE006 304GAE006 304GAE006 25 Key Square 1 900639910305 900639910305 900639910305 28 Wavy Spring 2 900669170405 900669170405 900669170405 29 Drive Cover 1 300GAE477 300GAE477 300GAE477 30 Screw 8 75P40 75P40 75P40 31 Oil Seal 1 60DD726 60DD726 60DD726 35 Bearing Spherical 1 ...

Page 224: ...SB 7 623 Page 63 ...

Page 225: ...For additional information contact your local representative or visit www contactgd com mobile 2012 Gardner Denver Inc Printed in U S A ...

Page 226: ...1300 998 784 STGGLOBAL NET OPERATORS MANUAL Sutorbilt P Series Sec on 5 ...

Page 227: ...PARTS LIST OPERATING AND SERVICE MANUAL SB 7 622 Version 03 November 2005 Models GAF_ _P_ GAG_ _P_ GAH_ _P_ LEGEND P SERIES BLOWERS 6 8 GEAR DIAMETER ...

Page 228: ...d in blower maintenance and repair They are ready to respond and assist you by providing fast expert maintenance and repair services INSTRUCTIONS FOR DETERMINING BLOWER CONFIGURATION 1 Face the blower drive shaft 2 In a VERTICAL configuration air flow is horizontal 3 In a HORIZONTAL configuration air flow is vertical 4 In a vertical configuration a BOTTOM HAND exists when the drive shaft is below ...

Page 229: ...lt in economical operation and minimum downtime Danger is used to indicate the presence of a hazard which will cause severe personal injury death or substantial property damage if the warning is ignored Warning is used to indicate the presence of a hazard which can cause severeperson al injury death or substantial property damage if the warning is ignored Caution is used to indicate the presence o...

Page 230: ...has been relieved D Electrical shock can and may be fatal D Blower unit must be grounded in accordance with the National Electrical Code A ground jumper equal to the size of the equipment ground conductor must be used to connect the blower motor base to the unit base D Open main disconnect switch tag and lockout before working on the control D Disconnect the blower unit from its power source tag a...

Page 231: ...tion i Foreword ii Safety Precautions iii Index v List of Illustrations v Sutorbilt Legend Series Sutorbilt Blowers Matrix Menu vi Introduction Your Key To Trouble Free Service 1 Section 1 Equipment Check 2 Section 2 Installation 3 Section 3 Lubrication 6 Section 4 Operation 8 Section 5 Special Tools Required 11 Section 6 Disassembly Instructions 15 Section 7 Assembly Instructions 18 Section 8 Par...

Page 232: ...ATION SECTION 4 8 Outline Drawing and Parts List Model GAF 25 26 Model GAG 27 28 Model GAH 29 30 PARTS LIST SECTION 5 25 Piping 4 Precautions Safety 10 Protective Materials Removing 2 Recommended Lubricant 6 Removing Protective Materials 2 Repair Parts Ordering Instructions i Safety Precautions iii 10 Setting Impeller End Clearance 22 SPECIAL TOOLS REQUIRED SECTION 5 11 Startup Checklist Blower 9 ...

Page 233: ...rizontal Right Hand Central Timed COLUMN 6 DESIGN VERSION COLUMN 7 ADDITIONAL DESCRIPTION A Lip Seal B Mechanical Seal SUTORBILT LEGEND SERIES SUTORBILT BLOWERS MATRIX MENU NOTICE TO CUSTOMER To find the construction options for your blower unit FILL IN THE BALANCE OF LETTERS OR NUMBERS FROM YOUR UNIT NAMEPLATE COLUMN NUMBER FOLLOW THE LINE DOWN AND OVER FROM EACH SPACE THUS FILLED IN TO FIND THE ...

Page 234: ...ry in Sedalia Missouri As with other precision machinery there are several relatively simple installation operation and mainte nance procedures that you must observe to assure optimum blower performance There is no guesswork in the manufacture of your highly advanced Sutorbilt blower and there must be none in preparing the blower to get the job done in the field The purpose of this manual is to he...

Page 235: ...quate protection to avoid accidental mechanical damage 5 In high humidity or corrosive environments addi tional measures may be required to prevent rust ing of the blower internal surfaces 6 To prevent rusting of gears bearings etc the oil reservoirs may be filled with normal operating oil Before running the blower drain the oil and replace to the proper operat ing level with clean fresh lubricant...

Page 236: ...ing they must be backed off or removed before final tightening of anchor bolts Where a concrete foundation is not feasible care must be taken to insure that equipment is firmly anchored to adequate structural members MOUNTING CONFIGURATIONS The blower flex mount design enables horizontal and vertical mounting configurations with top or bottom hand right or left hand shaft positioning The units are...

Page 237: ...blower drive cover not to exceed dimension C in Drive Shaft Illustration FIGURE 2 page 5 The calculated shaft moment must not exceed the maximum allowable moment listed in Maximum Allow able Moment Chart FIGURE 2 page 5 If the calcu lated shaft moment exceeds the maximum allowable moment D Increase Sheave Diameters to Reduce Belt Pull D Use Jackshaft Drive D Use Direct Coupled or Gearbox Drive To ...

Page 238: ...4 0 875 0 852 1 125 0 789 1 375 0 706 0 150 0 980 0 400 0 943 0 650 0 899 0 900 0 847 1 150 0 782 1 400 0 697 0 175 0 977 0 425 0 939 0 675 0 894 0 925 0 841 1 175 0 774 1 425 0 687 0 200 0 973 0 450 0 935 0 700 0 889 0 950 0 835 1 200 0 767 0 225 0 969 0 475 0 930 0 725 0 884 0 975 0 829 1 225 0 759 2 5 Ac 125954 x Hp x S F Ac D x RPM Key Ac Arc of Contact Factor Refer to Arc of Contact Factors C...

Page 239: ...il drain plug is located at A Do not overfill as this will tend to cause excessive heating of the gears and may damage the unit Bearings on the drive end of the blower require grease lubrication every 500 hours of operation Lubricate the bearings through grease fittings located at C When regreasing the old grease will be forced out of the vents E To prevent damage to seals these vents must be open...

Page 240: ...rential pressure indicator with a continuous gauge reading should be installed across the inlet filter It will tell how much of the service life of the filter element has been used It will also eliminate both premature filter servicing and premature blower failure due to a plugged filter when the filter pressure drop is used to establish maintenance points In all cases refer to the filter manufact...

Page 241: ...w the maximum pressure dif ferential rating of the blower Relief valves should be placed as close as possible to the blower inlet or discharge In some instances pressure may be relieved at a lower point than the blower maximum in order to protect the motor or the equipment served by the blower Discharge temperature switches are recommended to protect against excessive inlet restriction or inlet te...

Page 242: ...perator from severe personal injury from incidental contact V 5 Check the unit for proper lubrication Proper oil level cannot be overemphasized Too little oil will ruin bearings and gears Too much oil will cause overheating and can ruin gears and cause other damage Insure drive end bearings are greased V 6 With motor locked out turn the drive shaft by hand to be certain the impellers do not bind V...

Page 243: ...time impellers 2 Distortion due to improper 2 Check mounting alignment and mounting or pipe strains relieve pipe strains Knocking 3 Excessive pressure differential 3 Reduce to manufacturer s recommended pressure Examine relief valve re set if necessary 4 Worn gears 4 Replace timing gears 5 Worn bearings 5 Replace bearings 1 Too much oil in gear case 1 Reduce oil level Excessive blower 2 Too low op...

Page 244: ... 11 00 13 00 16 00 B 6 000 7 000 8 000 C 2 500 3 000 4 000 D 3 000 3 500 4 000 E 1 503 1 679 2 210 F 11 00 13 00 15 00 H 0 437 0 500 0 500 J 1 500 1 688 1 875 K 5 500 6 500 7 500 NOTE 1 REMOVE SHARP EDGES 2 MAT L MED CARBON STEEL FIGURE 8 PULLER PLATE SK2154 ...

Page 245: ...SB 7 622 Page 12 1 PIPE STEEL 2 SCH 80 2 MED CARBON STEEL 1 2 FIGURE 9 GEAR DRIVER SK2150 ...

Page 246: ... 748 3 150 0 515 1 890 2 450 0 125 1 400 7 3 000 3 543 0 424 1 863 2 423 0 150 1 616 8 3 250 3 938 0 407 2 000 2 800 0 150 1 813 FIGURE 10 MECHANICAL SEAL INSTALLATION TOOL SK2152 NOTES 1 BREAK SHARP EDGES 2 MATERIAL 4140 3 HEAT TREAT TO RC 48 52 ...

Page 247: ...SB 7 622 Page 14 UNIT SIZE A B 6 1 900 5 000 7 2 087 5 500 8 2 406 6 000 FIGURE 11 BEARING PRESS TOOL MECHANICAL SEAL UNITS SK2156 NOTES 1 BREAK SHARP EDGES 2 MATERIAL 4140 3 HEAT TREAT TO RC 52 56 ...

Page 248: ... CAN BE REASSEMBLED IN THE SAME POSI TION IMPELLERS HEADPLATES AND GEARS 4 If the timing gears appear undamaged the gear backlash must be checked to see if the gears can be salvaged A Mount a magnetic base dial indicator on the gear headplate see FIGURE 12 B Lock one impeller stationary by wedging a feeler gage between the impeller and the headplate C The tip of the indicator should be placed at t...

Page 249: ...lacing the timing gears 9 re move the timing hub taper pins 36 by placing washers or an oversized nut over the extending threaded area of the pin Tighten a proper sized nut on the pin and it will eject 7 Remove the four socket head cap screws 30 from the drive end bearing cover 29 and remove FIGURE 16 the cover Drive shaft oil seal 31 should come free when cover is removed 8 Remove mounting foot 1...

Page 250: ...e 15 Attach fabricated puller plate to the gear head plate using the tapped holes used to secure the bearing retainers 16 Install a gear puller to one of the shafts and attach the puller arms to the fabricated plate see FIGURE 17 17 Push the impeller shaft through the gear head plate and remove the impeller assembly 23 see FIGURE 17 Remove the other impeller assem bly following the same procedure ...

Page 251: ... headplate is removed Make sure seals are fully seated Use extreme care when installing INSTALLING MECHANICAL SEALS A Lightly coat the headplate bores with assem bly lubricant B Refer to FIGURE 18 Install mechanical seal A into the headplate bore using a press and the correct driver shown on page 13 Drive the seal securely on to its seat Use extreme care when installing seals in the headplate bore...

Page 252: ... the drive end on top It will be necessary to use blocks in order for the unit to set level Measure the total end clearance using a depth micrometer see FIGURE 19 If total clearance is not within the limits specified in FIGURE 21 page 20 it may be necessary to shim the case to obtain the proper total end clear ance The shim should be placed between the drive headplate and impeller case If more tha...

Page 253: ...late 8 Apply a light oil to the drive headplate bearing bore bearing inside diameter and shaft seat Install the spherical roller bearing 35 on the drive end drive shaft and the double row ball bearing 14 on the drive end driven shaft Start the bear ing in the bores without force 9 Attach the puller plate shown on page 11 to the drive headplate using the tapped holes used to se cure the drive cover...

Page 254: ...o case clearances are extremely critical Even though the blower may turn freely by hand when cold under operating conditions the parts expand and the rotors are subject to slight deflection If the clearances are not sufficient the impellers may contact each other or the housing with destructive results If the clearances are too great the blower may not develop the pressure or airflow that is requi...

Page 255: ...r closer to the gear headplate and remove shims to move the impellers away from the gear headplate 17 INSTALLING THE TIMING GEARS Impellers are held in time by gears which are taper pinned and bolted to a timing hub which in turn is pressed and taper pinned onto the shaft The timing gears can be rotated in relation to the hub by removing the taper pins in the web of the gear and loosening the caps...

Page 256: ...sh four places at 90 degree intervals as described in the disas sembly procedure Item 4 If any of the four gear backlash read ings are not within the specified limits the gears must be replaced K Reream taper pin hole between the shaft and hub with a hand reamer and replace taper pin 8 if movement between the shaft and hub 39 was negligible If rereaming fails to elim inate edges due to slight misa...

Page 257: ...earing Retainer to Headplate 16 30 30 16 Screw Mounting Foot to Headplate 30 75 75 21 Screw Headplate to Impeller Case 30 75 75 30 Screw Drive Cover to Headplate 16 30 30 38 Screw Timing Hub to Gear 30 75 75 NOTE REF NO DENOTES ITEMS IN EXPLODED VIEW DRAWINGS ON PAGES 25 27 AND 29 FIGURE 24 TORQUE FT LBS ...

Page 258: ...SB 7 622 Page 25 SECTION 8 PARTS LIST 300GAF810 B Ref Drawing ...

Page 259: ... 655ED050 22 IMPELLER CASE 1 900883063901 900883064001 900883064101 23 SHAFT ASSEMBLY GROUP 1 GAF81952 GAF81954 GAF81953 SHAFT ASSEMBLY GROUP CONSISTS OF 1 ASSEMBLY SHAFT LONG 1 ASSEMBLY SHAFT SHORT 24 HOUSING BEARING DRIVE END LIP SEAL 1 900883064901 900883064901 900883064901 MECHANICAL SEAL 1 900883064801 900883064801 900883064801 25 DRIVE KEY 1 900639910406 900639910406 900639910406 26 GREASE F...

Page 260: ...SB 7 622 Page 27 300GAG810 A Ref Drawing ...

Page 261: ...PELLER CASE 1 900893070101 900893070201 900893070301 23 SHAFT ASSEMBLY GROUP 1 GAG81960 GAG81962 GAG81961 SHAFT ASSEMBLY GROUP CONSISTS OF 1 ASSEMBLY SHAFT LONG 1 ASSEMBLY SHAFT SHORT 24 HOUSING BEARING DRIVE END LIP SEAL 1 900893070601 900893070601 900893070601 MECHANICAL SEAL 1 900893072601 900893072601 900893072601 25 DRIVE KEY 1 900639910407 900639910407 900639910407 26 GREASE FITTING 2 911659...

Page 262: ...SB 7 622 Page 29 300GAH810 A Ref Drawing ...

Page 263: ... 36 655EE060 655EE060 655EE060 22 IMPELLER CASE 1 900653021708 910613746808 910613747008 23 SHAFT ASSEMBLY GROUP 1 GAH81968 GAH81970 GAH81969 SHAFT ASSEMBLY GROUP CONSISTS OF 1 ASSEMBLY SHAFT LONG 1 ASSEMBLY SHAFT SHORT 24 HOUSING BEARING DRIVE END LIP SEAL 1 900894082101 900894082101 900894082101 MECHANICAL SEAL 1 201GAH006 201GAH006 201GAH006 25 DRIVE KEY 1 900639910407 900639910407 900639910407...

Page 264: ...the amount specified in the Company s labor rate schedule Labor costs in excess of the Company rate schedule amounts or labor provided by unauthorized service personnel is not provided for by this warranty Transportation of Company s choice within the conti nental United States is covered by this warranty for replacement of any blower which in the Company s judgement proved not to be as warranted ...

Page 265: ......

Page 266: ...1300 998 784 STGGLOBAL NET OPERATORS MANUAL Lofa Manual Sec on 6 ...

Page 267: ...ing 463 3000 01 Rev D 23 Sep 2013 1 2006 2013 LOFA Industries Inc All rights reserved LOFA the LOFA logo CANplus and EP250 are trademarks of LOFA Industries Inc All rights reserved Windows is a registered trademark of Microsoft Corporation ...

Page 268: ...EP250 Panel Operation and Troubleshooting 2 463 3000 01 Rev D 23 Sep 2013 This page intentionally left blank ...

Page 269: ...s The EP250 features LOFA s new modular Function Enhancement Packs FEP The plug and play FEP modules allow various feature upgrades to be easily added to the standard platform FEPs include Automatic Start Stop Operation Precision Actuator Control Custom OEM Solutions All standard panels include feature a 12 inch wiring harness terminating into a sealed weather proof plug This robust universal wiri...

Page 270: ...amage or make the equipment unsafe to operate Only persons with appropriate training skills and tools should perform these functions Improper operation maintenance or repair of this product can be dangerous and may result in injury or death Do not operate or perform any maintenance or repair on this product until all operation maintenance and repair information is read and understood The informati...

Page 271: ...e run position The fuel run stop solenoid output is turned off after 10 seconds even if preheating As soon as the key switch is turned to the start position the solenoid output is enabled The afterglow cycle begins when the key switch returns to the run position Note If conditions do not warrant preheat the engine may be started by turning the key to the start position without waiting for the preh...

Page 272: ...round control Indicators Battery LED Red A solidly illuminated Battery LED indicates a battery charge failure A battery charge failure may be caused by a faulty alternator broken drive belt or the alternator not excited A battery voltage reading of approximately 14 volts on a 12 volt system 28 volts on a 24 volt system while the engine is running indicates the battery is charging properly Irregula...

Page 273: ...oolant due to coolant loss the engine is not protected from overheating For best possible protection LOFA recommends using our solid state coolant level shutdown switch Note Most shutdown switches are grounded through the switch body Do not use insulating sealant i e Teflon tape when installing switches Some thermostat housings are composites and do not provide ground for the switch AUX 1 LED Red ...

Page 274: ...anufacturer A defective switch or shorting the shutdown input to ground can cause fault indications The panel can be configured with auxiliary 2 shutdown Preheat LED Red A solidly illuminated Preheat LED is the panel preheat indication When the LED extinguishes the preheat period is complete and the engine may be cranked The LED illuminates again to indicate afterglow ...

Page 275: ...auge expects a low resistance for low pressure and a higher resistance for higher pressure If a powered gauge is not connected to the sender the gauge will read full scale pegged A defective sender or shorting the gauge input to ground will cause the gauge to read no pressure When using sender switch combinations swapping the WK and G terminal prevents the gauge from working and may cause unintend...

Page 276: ...installing the gauge Power connections are provided with the standard configuration Harness Sealed Connectors The provided sealed weather proof plug includes a grey locking device which must be released to separate the connectors Press the tab on the connector housing to release the connectors Warning LOFA does not recommend using dielectric grease or sealant with sealed connectors These chemicals...

Page 277: ...3 3000 01 Rev D 23 Sep 2013 11 Note For harness length in excess of 10 ft a relay must be added to the start solenoid circuit A relay may also be required for the fuel run stop solenoid LOFA offers starter relay kits for mounting near the engine ...

Page 278: ...ecting the battery while the engine is running may damage electrical components When using a battery disconnect switch LOFA recommends using a 2 pole switch to disconnect both the battery and alternator output Battery Negative Connection Grounding Warning Improper grounding can cause electrical noise unreliable operation and may damage the panel or other components All ground connections must be f...

Page 279: ...s and motors generate voltage transients and noise in electrical circuits Unsuppressed voltage transients can exceed SAE specifications and damage electronic controls I Relays and solenoids with built in voltage transient suppression diodes are recommended whenever possible Refer to the illustration for proper installation of diodes when built in voltage transient suppression is not available Loca...

Page 280: ...not ground the welder to electrical components such as the control ground or sensors Improper grounding can cause damage to electrical components Clamp the ground cable from the welder to the component being welded Place the clamp as close as possible to the weld to reduce the possibility of damage 1 Stop the engine Turn the key switch to the OFF position 2 Disconnect the negative battery cable fr...

Page 281: ... Troubleshooting below Tripped overcurrent protection Correct fault replace or reset overcurrent protection No preheat cold condition See Preheat Troubleshooting Engine runs for 10 seconds and shuts down Possible Cause Possible Remedy Shutdown switch input active Verify shutdown source exists correct condition or correct faulty circuit Battery not charging Verify alternator charging see Alternator...

Page 282: ... or replace solenoid linkage Fuel valve without check valve Install or repair check valve Fuel run stop solenoid does not engage Possible Cause Possible Remedy No power to solenoid Locate reason for lack of power and correct Circuit overloaded Failed suppressor diode Faulty wiring No power to solenoid pull coil Correct faulty wiring check pull control circuit see Power Box Troubleshooting below In...

Page 283: ...l See Panel Troubleshooting below Panel Troubleshooting Panel does not perform self test Possible Cause Possible Remedy Tripped overcurrent protection Correct fault replace or reset overcurrent protection Faulty connection to battery Correct battery connections see Battery Circuit Requirements above Panel performs normal self test engine cranks runs and shuts down Possible Cause Possible Remedy On...

Page 284: ...ost shutdown switches are grounded through the switch body Do not use insulating sealant i e Teflon tape when installing switches Some thermostat housings are composites and do not provide ground for the switch Document Revision History Rev A 22 May 2006 Corrected typographical errors Rev B 26 Oct 2006 Add symbols to Indicators corrected typographical errors Rev C 8 Jan 2007 Updated schematics rem...

Page 285: ...Typical Schematics The following pages show typical schematics Details vary from installation to installation See the specific schematics for installation for details ...

Page 286: ...Description Date Units Scale Tolerance Unless Otherwise Noted Decimals INCH METRIC 1 x x 2 x xx 3 x xxx Angle 0 1 mm 0 02 mm 1 N A 0 1 in 0 02 in 0 005 in 0 x A 2 mm 250 Hembree Park Dr Ste 122 Roswell GA 30076 Phone 770 569 9828 Fax 770 569 9829 Rev 1 of 1 MANUFACTURER OF QUALITY ENGINE COMPONENTS INDUSTRIES INC www LOFA net 26 Feb 2012 EP250A with GT Plug N A N A 2005 2012 LOFA Industries Inc Al...

Page 287: ...production or dissemination in whole or in part in any form or medium without express prior written permission is strictly prohibited Aluflex CANplus and the CANplus logo are registered trademarks of LOFA Industries Inc CP600 CP750 EL240 EP250 and the LOFA logo are trademarks of LOFA Industries Inc Note WK Switch G Sender Preheat Relay 30 85 86 87 Shutdown Solenoid 2 Wire 1 2 Shutdown Solenoid 3 W...

Page 288: ...lk 14 AWG Red Wht 12 AWG Red 16 AWG Black 16 AWG Red 16 AWG Black 16 AWG Black 16 AWG White 16 AWG Orange 16 AWG Lt Blue 16 AWG White 1 J4 D Alternator 2 Bat 30 3 Starter 50 4 Preheat 5 Ground 6 Ground 7 Aux Switch 1 8 Solenoid 1 J3 Temp Switch 2 Temp Gauge 3 Aux Switch 2 4 Tachometer 5 Solenoid 6 Ground 7 Oil Pres Switch 8 Oil Pres Gauge 16 AWG Dk Green 12 AWG Red 12 AWG Red Blk 16 AWG Yellow 16 ...

Page 289: ...Industries Inc All Rights Reserved INFORMATION CONTAINED IN THIS DOCUMENT IS CONFIDENTIAL AND THE SOLE PROPERTY OF LOFA INDUSTRIES INC Reproduction or dissemination in whole or in part in any form or medium without express prior written permission is strictly prohibited LOFA the LOFA logo Aluflex EL240 EP250 EP200 EP150 and EP100 are trademarks of LOFA Industries Inc All rights reserved 14 AWG Red...

Page 290: ...the techniques algorithms ideas concepts code and processes contained in the Materials constitute LOFA s trade secrets and are subject to confidentiality protection As such Licensee agrees not to reverse engineer disassemble or decompile or otherwise attempt to derive the source code for or perform cryptographic analysis upon any Licensed Products to the extent this restriction is permitted by law...

Page 291: ...and remain the exclusive property of LOFA Nothing contained in this Agreement may be deemed to give Licensee any right title or interest in any LOFA Marks Subject to notice from LOFA in writing which modifies or cancels such license at LOFA s sole discretion during the continuance of this Agreement LOFA hereby grants Licensee a nonexclusive revocable license to the LOFA Marks for normal advertisin...

Page 292: ...eral inclusive remain in force and effect after the termination of this Agreement Special License Terms THE LICENSE GRANTED HEREUNDER IS RESTRICTED SOLELY TO THE OPERATION OF THE LOFA HARDWARE AND FOR NO OTHER PURPOSE NO SUCH LICENSEE DEVICE INCORPORATING ANY OF THE MATERIALS MAY BE DISTRIBUTED LICENSED SOLD RENTED OR OTHERWISE PROVIDED TO THIRD PARTIES WITHOUT LOFA S EXPRESS WRITTEN PERMISSION Ex...

Page 293: ...463 3000 01 Rev D 23 Sep 2013 MANUFACTURER OF QUALITY ENGINE COMPONENTS 250 Hembree Park Drive Suite 122 Roswell GA 30076 PHONE 770 569 9828 FAX 770 569 9829 www LOFA net ...

Page 294: ...1300 998 784 STGGLOBAL NET OPERATORS MANUAL Excava on Hydro SWMS Sec on 7 ...

Page 295: ...ditional site hazards Work must cease immediately if incident or near miss occurs SWMS must be amended in consultation with relevant persons Amendments must be approved by ______________ and communicated to all affected workers before work resumes SWMS must be made available for inspection or review as required by WHS legislation Record of SWMS must be kept as required by WHS legislation until job...

Page 296: ...KELIHOOD I NSIGNIFICANT M INOR M ODERATE M AJOR C ATASTROPHIC S CORE A CTION HIERARCHY OF CONTROLS M OST E FFECTIVE A LMOST CERTAIN 3 H IGH 3 H IGH 4 A CUTE 4 A CUTE 4 A CUTE L IKELY 2 M ODERATE 3 H IGH 3 H IGH 4 A CUTE 4 A CUTE 4A A CUTE DO NOT PROCEED P OSSIBLE 1 L OW 2 M ODERATE 3 H IGH 4 A CUTE 4 A CUTE 3H H IGH Review before commencing work U NLIKELY 1 L OW 1 L OW 2 M ODERATE 3 H IGH 4 A CUTE...

Page 297: ...ure suitable soils for nozzles clay sand rocks etc Develop written bore plan o Developed by suitably competent persons o Detail environmental impacts risk assessments and controls o Manhole confined space entry requirements ensure permit system in place See section 7 of this SWMS 2M 2 Training and Capabilities Lack of training or the assessment of capability may lead to personal injury property da...

Page 298: ...ged Reversing beepers functioning Vehicle break down equipment o High visibility gear suited for day night combinations o Wet weather gear o Traffic cones signs reflectors o Emergency contact details Mirrors are present functional and adjusted correctly All stored items in cabin are secured Pump casing and fittings in good condition Do not use if any fault damage missing parts Report immediately a...

Page 299: ...t a moving truck Never carry another person on the truck unless equipped to do so Never leave operator seat with engine running 2M Pedestrian safety 4A Follow o Manufacturer s instructions o Site safety rules o Traffic control plan Ensure no persons in vicinity before and during start up and operation Maintain exclusion zone and cease work if approached Travel at appropriate speed for conditions o...

Page 300: ...e under observation during the operation 2M Hit by objects under pressure 3H Fitting Standpipe Obtaining Water from Hydrant Check standpipe for o Any visible signs of defects o Possible leaks slight O ring seal weeps may be acceptable o Clear the area around the pit cover plate from debris o Remove the pit cover plate and the cover plate on the spring hydrant o Lock standpipe in place on hydrant p...

Page 301: ...ound track conditions for operation of truck Flat even firm surface no recently backfilled earth voids pits or excavations in close proximity o Within manufacturer s slope gradient limits o Suitable lighting including night works include flood lighting and operator head lamps as applicable o Take note of other vehicle plant movement Conduct risk assessment to identify potential hazards such as 2M ...

Page 302: ...rk areas Identify underground assets location and type Ensure correct equipment provided o For metallic properties use electromagnetic locating device o For non metallic use Ground Penetrating Device GPD mini cameras or sonar technology o Ensure all equipment is serviced calibrated as per manufacturer s instructions and functioning correctly Mark line of excavation and identify exact entry locatio...

Page 303: ...s required o Work positions should be in clear sight of other truck operators o Follow traffic management plan requirements NOTE Some traffic management plans may say that pedestrians have right of way Never assume this Make visual and verbal contact with truck operator as required 2M Environmental conditions 3H Appropriate protective clothing Wear hand protection Wear non slip footwear slippery s...

Page 304: ...ants Note Do not enter any manhole pit in which a person s head or upper body will be within the space without ensuring a confined space entry permit is issued for each confined space entry requiring o A risk assessment o Atmospheric monitoring o Use of respiratory and recovery equipment where indicated if to be entered If a person has entered or fallen into a manhole DO NOT ENTER THE MANHOLE TO A...

Page 305: ...nd shields are in place while operating pump Do not allow pump to overheat If pump overheats turn it off immediately and allow it to cool Do not touch pump engine or exhaust during or immediately after operation it will be hot 2M Operator error Lack of information 3H Permanently mount a name plate on pump which provides the following information 2M o Manufacturer s name o Model designation serial ...

Page 306: ... supply valve open o Hoses used for high pressure cleaning are rated for pressures at least 2 5 times that of the intended operating pressure Hoses must be tagged to indicate o Manufacturers identification o Date of manufacture o Maximum operating pressure Damaged or faulty hoses shall not be used It shall be tagged OUT OF SERVICE and repaired or disposed of Using High Pressure Hoses and lances En...

Page 307: ...uum relief valve tested before each use and in good working condition 2M Vacuum injuries entrapment 3H Perform all operations with at least two operators Turn of pump power source and release pressure in system before opening any door or hatch Never open any hatches or doors while the unit is pressurised Keep vacuum tools and hoses away from face and body never point vacuum hose at a person Stay c...

Page 308: ...ere is no over spill 7 Ensure cap has been secured and any vapour residue has been wiped away 8 Check for leaks DO NOT smoke during re fuelling Ensure re fueling is undertaken in well ventilated area clear of ignition sources o NOTE Ignition sources include cigarettes matches lighters grinding welding power points lighting light switches Material Safety Data Sheets M SDS for all fuel products on h...

Page 309: ...ebris before leaving site Ensure any contaminated wastewater is captured as per Local State Environment Laws Do not wash truck where residue can enter and sensitive areas such as storm water drains and waterways Avoid cross contamination o Disassemble and clean all equipment o Dispose of all waste in accordance with regulations o Maintain an M SDS for all chemicals used 2M Public safety 3H Report ...

Page 310: ...VIEW ISSUE DATE REVISION DATE SafetyCulture All Rights Reserved J OB S TEP P OTENTIAL H AZARD S IR C ONTROL M EASURES TO R EDUCE R ISK RR R ESPONSIBLE P ERSON I NHERENT R ISK RATING IR R ESIDUAL R ISK RATING RR from plant and resourced Emergency Responders ...

Page 311: ...s Fittings valves good condition Water Hoses couplings Fuel Pump fueled check starts and runs Danger areas guarded Moving motor parts Tank securely fixed to tray tipper models Shafts Traffic Pedestrian control equipment Hydraulic hoses valves etc Locking pins in place Hot engine muffler parts Gauges Lamps Warning systems Tyres wheels tracks Correct type Lights front rear stop turning beacons Do no...

Page 312: ...ons SA Tasmania Work Health and Safety Act 2012 Work Health and Safety Regulations 2012 Codes of Practice Safe Work Australia 2011 Construction Work First Aid in the Workplace Managing the Risk of Falls at Workplaces Managing the Risk of Truck in the Workplace Managing Noise and Preventing Hearing Loss in the Workplace How to Manage Work Health and Safety Risks Hazardous Manual Tasks Managing Risk...

Page 313: ...VIEW Ensure all controls are reviewed as per the following If controls fail to reduce risk adequately When changes to the workplace or work activity occur that create new different risks where controls may no longer be effective New hazards identified After an incident involving work activities relevant to this SWMS During consultation with relevant persons indicate review is needed A Health and S...

Page 314: ...1300 998 784 STGGLOBAL NET OPERATORS MANUAL Pressure Cleaner Water SWMS Sec on 8 ...

Page 315: ...ool Box Talks will be undertaken to identify control and communicate additional site hazards Work must cease immediately if incident or near miss occurs SWMS must be amended in consultation with relevant persons Amendments must be approved by ______________ and communicated to all affected workers before work resumes SWMS must be made available for inspection or review as required by WHS legislati...

Page 316: ...LIHOOD I NSIGNIFICANT M INOR M ODERATE M AJOR C ATASTROPHIC S CORE A CTION HIERARCHY OF CONTROLS M OST E FFECTIVE A LMOST CERTAIN 3 H IGH 3 H IGH 4 A CUTE 4 A CUTE 4 A CUTE L IKELY 2 M ODERATE 3 H IGH 3 H IGH 4 A CUTE 4 A CUTE 4A A CUTE DO NOT PROCEED P OSSIBLE 1 L OW 2 M ODERATE 3 H IGH 4 A CUTE 4 A CUTE 3H H IGH Review before commencing work U NLIKELY 1 L OW 1 L OW 2 M ODERATE 3 H IGH 4 A CUTE 2...

Page 317: ...ting procedures 2M 2 Training and Capabilities Lack of training or the assessment of capability may lead to personal injury property damage or environmental incident 3H Ensure all persons entering site have a General Construction Induction Card white card Ensure all relevant workers have undertaken training and or received instruction in the use of control measures Include Reporting procedures for...

Page 318: ...le space for operation of equipment Suitable lighting including night works include flood lighting and operator head lamps as applicable Take note of mobile plant movement Conduct site inspection to identify potential hazards such as Work at heights above 2m Lighting Ventilation Dust Temperature etc Exposed electrical switchboards power points Duration of manual handling tasks such as working with...

Page 319: ... protected or shielded from water and or being hit by flying debris o Remove all objects such as rocks broken glass nails wire debris toys or anything that may become a hazard during Water Jet Cleaner operation Hoses Check o Restrained to restrict their movement in the event of a hose end failure o Nozzles checked and cleared of debris that could cause obstructions o Attachments should be fitted a...

Page 320: ...nd aware 2M Contact with electricity 3H Any electrical equipment in the immediate area of the operation that presents a potential hazard and is not required during the job must be de energised shielded or otherwise made safe Ensure equipment rated for atmospheric requirements water or explosion proof for flammable zones Ensure fire protection equipment accessible as required Ensure equipment is no...

Page 321: ...e of product and safety information Appropriate containers spray bottles are used o Never use food drink containers for storing decanting chemicals PPE as prescribed in M SDS for decanting e g eye face protection apron enclosed shoes is provided and used Spill kit Fire protection equipment 2M 5 Operating the water jet cleaner Water under pressure injection injury 4A Wear eye protection and protect...

Page 322: ...ediately Expose power tool to rain or wet conditions Abuse the cord never use the cord to carry the tool or pull the plug from the outlet 2M Fire explosion 3H Do not operate power water jet cleaner in explosive atmospheres i e presence of flammable liquids gases or dust 2M Dust debris 3H Wear eye protection and protective clothing 2M Struck by moving objects 3H Use a Whip Check if possible to redu...

Page 323: ...control of the jetting gun High pressure Water Jet Cleaners should not be directly aimed at electrical wiring switches relays alternators starter motors bearing seals window rubbers or vulnerable components that water might affect 2M Strong reaction force vibration Muscular stress MSD 3H Always push the Water Jet Cleaner when moving it Use triggers that can lock into place for use over longer peri...

Page 324: ...elevated work platform EWP Use tool lanyards to pass water jet cleaner to persons at height and ensure water jet cleaner cannot fall onto workers below Ensure kickboards installed on elevated work areas to prevent water jet cleaner falling off 2M Slips trips falls causing injury 3H Identify all hazards Consider Ground floor surface condition Experience of workers Weather conditions rain wind loads...

Page 325: ...or proposed weight and span Have an overhang of at least 150 mm and not more than 250mm at each end and be locked together Example clamped near the centre span to prevent individual movement Have an unobstructed surface width of at least 450mm two planks wide Must be matched pairs i e the rungs should be equivalent heights and spacing 2M 8 Remote and or isolated work Personal Injury from delay in ...

Page 326: ...her available and in date Diesel Fire extinguisher Water foam dry chemical powder CO 2 Unleaded petrol Fire extinguisher Dry chemical powder foam CO 2 Never use water to extinguish an Unleaded Petrol fire 2M Exposure to hazardous chemicals substances 3H Avoid breathing vapours or contact with fuel If clothing is splashed with fuel change immediately Do not siphon or swallow fuel as this can be fat...

Page 327: ...et cleaner and secure all fittings hoses and nozzles into working vehicle 2M Contact with electricity electric powered units 3H Disconnect the cleaner extension leads from power point before winding up so that you don t get a shock if the lead is damaged Inspect leads and power equipment for damage If safe to do so remove isolation locks tags and test appliance for function 2M Water under pressure...

Page 328: ... Tasmania Work Health and Safety Act 2012 Work Health and Safety Regulations 2012 Codes of Practice Safe Work Australia 2011 Construction Work First Aid in the Workplace Managing the Risk of Falls at Workplaces Managing the Risk of Plant in the Workplace Managing Noise and Preventing Hearing Loss in the Workplace How to Manage Work Health and Safety Risks Hazardous Manual Tasks Managing Risks of H...

Page 329: ...VIEW Ensure all controls are reviewed as per the following If controls fail to reduce risk adequately When changes to the workplace or work activity occur that create new different risks where controls may no longer be effective New hazards identified After an incident involving work activities relevant to this SWMS During consultation with relevant persons indicate review is needed A Health and S...

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