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Vanair Goodall CAP-START Operation Manual And Parts List Download Page 42

SECTION 7: ILLUSTRATED PARTS LIST

7 - 8 

090189-OP_r0 (JUNE-2022)

 

VANAIR MANUFACTURING, INC.

(844) VAN-SERV • www.vanair.com

Cap•Start Hydraulic-Driven

12V/24V • Battery Starter • Charger

282577-005

282577-006

300A SENSOR

CLAMP (-)

CLAMP (+)

(+) CA

P

 2

 (-)

(+) CA

P

 1

 (-)

HARNESS

282039

HARNESS

282040

282418

CONTROLLER

DISPLAY

MANIFOLD

SOL VALVE CONN

ALTERNATOR

GN
D

FL
D NE

G

FL
D P

O

S

SENSOR

277892-02

7.2  FINISHED ASSEMBLY - 3 OF 3

6130217ID_r1_3of3

Summary of Contents for Goodall CAP-START

Page 1: ...inte nance instructions in this man ual will VOID THE EQUIPMENT WARRANTY NOTE This publication contains the latest information available at the time of preparation Every e ort has been made to ensure...

Page 2: ...sed and main tained in accordance with Vanair s specifications 4 Equipment which has been improperly installed and or improperly operated based upon Vanair s specifications for the equipment or indust...

Page 3: ...1 1 1 2 DANGERS WARNINGS CAUTIONS AND NOTES 1 1 1 3 SUMMARY OF DANGERS WARNINGS AND CAUTIONS 1 1 1 3 1 DANGERS 1 1 1 3 2 WARNINGS 1 1 1 3 3 CAUTIONS 1 2 1 4 SAFETY DECALS 1 2 1 5 CALIFORNIA PROPOSITIO...

Page 4: ...4 2 5 RESERVOIR FEATURES TO AVOID 3 5 3 4 2 6 RECOMMENDED HYDRAULIC SYSTEM SPECIFICATIONS 3 6 3 4 3 STANDARDS GUIDELINES 3 6 3 5 INSTALLATION 3 6 3 5 1 MACHINE LOCATION 3 6 3 5 2 CLEARANCES 3 6 3 5 3...

Page 5: ...CTION 6 TROUBLESHOOTING 6 1 6 1 GENERAL INFORMATION 6 1 6 2 TROUBLESHOOTING GUIDE HYDRAULICS 6 2 SECTION 7 ILLUSTRATED PARTS LIST 7 1 7 1 PARTS ORDERING INFORMATION 7 1 Figure 7 1 Machine Serial Plate...

Page 6: ...MANUFACTURING INC 844 VAN SERV www vanair com Cap Start Hydraulic Driven 12V 24V Battery Starter Charger SECTION 7 ILLUSTRATED PARTS LIST CONTINUED 7 10 WIRING DIAGRAM 1 OF 2 7 22 7 11 HOSE INSTALLAT...

Page 7: ...d inside the machine compartment on the wall of the enclosure near the hydraulic motor unit see Figure W 1 The machine and the alternator also have individual serial numbers respectively see Figure W...

Page 8: ...e RMA is void and any claims will be denied NOTE All labor claims or invoices must be approved by the Vanair Warranty Administrator prior to starting repair work along with the cost of the repair All...

Page 9: ...ns or indications to avoid any possible hazard 1 3 SUMMARY OF DANGERS WARNINGS AND CAUTIONS These boxed inserts are placed throughout this manual in the sections where they apply This subsection is a...

Page 10: ...hat because the Cap Start is in a STOPPED condition that power has been removed Install operate and maintain this equipment in full compliance with all applicable OSHA oth er Federal state local codes...

Page 11: ...eproductive harm Exposure to these chemicals may take place when products are acquired or used Exposure may also occur in homes workplaces or other environments in California By requiring that this in...

Page 12: ...1 4 090189 OP_r0 JUNE 2022 SECTION 1 SAFETY VANAIR MANUFACTURING INC 844 VAN SERV www vanair com Cap Start Hydraulic Driven 12V 24V Battery Starter Charger BLANK PAGE...

Page 13: ...found in this manual Refer to Figure 2 1 for general machine compo nent locations For additional information includ ing measurement specifications refer to Figure 3 1 machine and identification and di...

Page 14: ...P N KEY DESCRIPTION KEY DESCRIPTION A ULTRACAPACITOR L MANIFOLD B 500 AMP RELAY X 5 M INSTRUMENT PANEL MODULE C DRIVE BELT N PRESSURE D HYDRAULIC MOTOR P RETURN E OUTPUT CABLE CONNECTOR Q CONTROL MODU...

Page 15: ...ion ven tilation and other factors such as electrical and hydraulic power supply availability and location DISCLAIMER DO NOT install in any enclosed space without first contacting Vanair WARNING Insta...

Page 16: ...Refer to Figure 3 3 to determine the additional minimum space requirement measurements The external gauges display must be easily vis ible to the operator It is recommended for most installations to m...

Page 17: ...0 95 22 00 Figure 3 2 Identification and Dimension Diagram DISCLAIMER If machine package is to be mounted within a confi ned space such as beneath a can opy the area must be deter mined to allow for a...

Page 18: ...the hoses are laid out properly so that no chafing or kinking of the hoses is possible Refer to Section 7 12 Hose Installation Guide for assistance with proper hose layout and connecting functions NOT...

Page 19: ...ating oil This extends oil in tegrity which in turn helps to maintain system performance and reliability An in line filter on the return line is needed to protect the system against contaminants be in...

Page 20: ...around the ma chine to allow for adequate cooling ventilation through the canopy shroud unobstructed service access and a clear view of the control panel An approximate recommendation of ten 10 inches...

Page 21: ...lit loom to prevent corrosion and consequently loss due to down time 3 5 8 HYDRAULIC SYSTEM REQUIREMENTS Refer to Sections 7 19 through 7 22 for hydraulic system schematic layouts and components The f...

Page 22: ...SECTION 3 INSTALLATION 3 8 090189 OP_r0 JUNE 2022 VANAIR MANUFACTURING INC 844 VAN SERV www vanair com Cap Start Hydraulic Driven 12V 24V Battery Starter Charger BLANK PAGE...

Page 23: ...ers 4 3 INITIAL FIRST TIME START UP IMPORTANT If start up and shut down procedures are not followed damage to the system and its compo nents may occur NOTE Flow control needs to be set by the installe...

Page 24: ...ROU TINE IMPORTANT If start up and shut down procedures are not followed damage to the system and its compo nents may occur 1 Shut o Charge or Start mode 2 Shut o hydraulic power supply 4 5 EXTREME CO...

Page 25: ...RGING CA PACITORS X X READY VOLTAGE X XV AMPERAGE X XA TIME REMAINING XX XX X X READY VOLTAGE X XV AMPERAGE X XA TIME REMAINING XX XX XXX X SETTINGS Display Version x xx Controller Version x xxx XXX X...

Page 26: ...SECTION 4 OPERATION 4 4 090189 OP_r0 JUNE 2022 VANAIR MANUFACTURING INC 844 VAN SERV www vanair com Cap Start Hydraulic Driven 12V 24V Battery Starter Charger BLANK PAGE...

Page 27: ...ckage in a severe environment may require more frequent service intervals 5 2 REPLACEMENT PARTS Replacement parts should be purchased through your local Vanair representative or where the Cap Start Hy...

Page 28: ...elt can be loosened or tight ened 2A TO LOOSEN BELT Once the mounting capscrews have been loosened enough for the alternator plate to slide carefully move the plate toward the hydraulic motor As the u...

Page 29: ...e instructions above in Section 5 4 1 up to number 2A Loosen the belt enough to disegage the belt from the pulley system 2 Route the new belt route over the fan alter nator side of the drive assembly...

Page 30: ...SECTION 5 MAINTENANCE 5 4 090189 OP_r0 JUNE 2022 VANAIR MANUFACTURING INC 844 VAN SERV www vanair com Cap Start Hydraulic Driven 12V 24V Battery Starter Charger BLANK PAGE...

Page 31: ...the situa tion remain unresolved after exhausting available sources contact the Vanair Service Department at Toll Free 844 VAN SERV 844 826 7378 Phone 219 879 5100 Fax 219 879 5335 This section contai...

Page 32: ...eading below Valve is set incorrectly Install pressure gauge and adjust to correct pressure keep at least 125 psi difference between valve settings Valve is worn or damaged Rebuild or replace valve Fl...

Page 33: ...in the No Existing Flow and the Flow is Low columns under INCORRECT FLOW CONDITION in this guide Pressure relief valve is set too low Adjust pressure relief valve Rebuild or replace if necessary Pres...

Page 34: ...or replace Hydraulic Motor Moves Erratically Pressure is erratic Refer to information under INCORRECT PRESSURE in this guide Air is present in fluid Refer to information under EXCESSIVE NOISE in this...

Page 35: ...ined form the Bill of Lading for the machine package or from the unit s serial number plate See Figure 7 1 for loca tion of machine package serial plate Consult Table 7A Recommend ed Spare Parts List...

Page 36: ...scope of this listing Should any part of the machine package that is not listed in Table 7A become damaged or inoperable contact the Vanair Service Department IMPORTANT If additional spare parts are b...

Page 37: ...SECTION 7 ILLUSTRATED PARTS LIST 090189 OP_r0 JUNE 2022 7 3 VANAIR MANUFACTURING INC 844 VAN SERV www vanair com Cap Start Hydraulic Driven 12V 24V Battery Starter Charger NOTES...

Page 38: ...tarter Charger NOTES 1 NUT SUPPLIED WITH BULKHEAD FITTING 2 SEAT HYDRAULIC TUBES ON FITTINGS BEFORE TIGHTENING MANIFOLD AND CASE DRAIN BRACKET BOLTS 3 ALL BOLTS TO BE TORQUED TO THEIR RESPECTIVE SAE T...

Page 39: ...DLE CS3KH 281332 1 22 WASHER LOCK 1 4 838504 062 6 7 HARNESS CS3KH POWER CONNECTOR A 282040 1 23 WASHER LOCK 5 16 838505 078 10 8 BELT DRIVE 3VX210 282389 3 24 WASHER LOCK 7 16 838507 109 1 9 TUBE MOT...

Page 40: ...Starter Charger ARROW TOWARD TERMINAL END SEE NOTE 1 2X ATTACH 282040 FUSE HOLDER CNTRL PWR HERE ATTACH 282040 FUSE HOLDER FLD PWR HERE 2X 2X 2X NOTES 1 HARDWARE SUPPLIED WITH RELAYS 2 ALL BOLTS TO BE...

Page 41: ...DLE CS3KH 281332 1 22 WASHER LOCK 1 4 838504 062 6 7 HARNESS CS3KH POWER CONNECTOR A 282040 1 23 WASHER LOCK 5 16 838505 078 10 8 BELT DRIVE 3VX210 282389 3 24 WASHER LOCK 7 16 838507 109 1 9 TUBE MOT...

Page 42: ...vanair com Cap Start Hydraulic Driven 12V 24V Battery Starter Charger 282577 005 282577 006 300A SENSOR CLAMP CLAMP CAP 2 CAP 1 HARNESS 282039 HARNESS 282040 282418 CONTROLLER DISPLAY MANIFOLD SOL VAL...

Page 43: ...MER CONN D 12VDC INPUT FROM A SWITCHED POWER SOURCE ON THE HOST VEHICLE NAME DESCRIPTION RELAY 1 RELAY 2 RELAY 3 RELAY 4 RELAY 5 CONNECTS ALTERNATOR POS CAP 2 POS TO JUMPER CABLE POS CONNECTS CAP 1 PO...

Page 44: ...lic Driven 12V 24V Battery Starter Charger NOTES 1 HARDWARE SUPPLIED WITH THE RELAYS 2 ALL BOLTS TO BE TORQUED TO THEIR RESPECTIVE SAE TORQUE SPECIFICATIONS FOR THEIR GRADES AND SIZES UNLESS OTHERWISE...

Page 45: ...S MTRON 278446 2 3 BAR COPPER BUS 280201 4 4 RELAY 500 AMP 12V COIL w STUDS N O 280203 5 5 BASE CAPSTART3000 HYDRAULIC 281312 1 6 HARNESS CS3KH CONTROLS CONNECTOR B 282039 1 7 KIT CABLE CAPSTART 3000...

Page 46: ...Driven 12V 24V Battery Starter Charger NOTES 1 NUT IS SUPPLIED WITH THE ALTERNATOR 2 ALL BOLTS TO BE TORQUED TO THEIR RESPECTIVE SAE TORQUE SPECIFICATIONS FOR THEIR GRADES AND SIZES UNLESS OTHERWISE...

Page 47: ...BER QTY 1 ALTERNATOR 240A PAD MOUNT MULIT VOLT 276942 1 2 SHEAVE 3Vx3 3 65IN DIA 277163 1 3 FAN 7IN PULL MECH 280908 1 4 WASHER FAN MOUNTING 280975 1 5 BRACKET ALTERNATOR SLIDE CS3KH 281320 1 6 NUT HE...

Page 48: ...24V Battery Starter Charger NOTES 1 MOUNTING HARDWARE SUPPLIED WITH BUSHING 2 ALL BOLTS TO BE TORQUED TO THEIR RESPECTIVE SAE TORQUE SPECIFICATIONS FOR THEIR GRADES AND SIZES UNLESS OTHERWISE SPECIFI...

Page 49: ...1 2 CONNECTOR O RING 3 4 x 3 4 JIC 260387 112 1 3 SHEAVE GATES QD 3 3V 6 00 262812 1 4 BUSHING SPLIT TAPER SDS 3 4 267308 1 5 BOLT TAP 3 8 16 x 2 270075 1 6 BRACKET H YDRAULIC MOTOR 281319 1 7 MOTOR H...

Page 50: ...Starter Charger NOTES 1 LUBRICATE ALL ELASTOMERIC SEALS GASKETS O RINGS BEFORE TIGHTENING 7 6 MANIFOLD ASSEMBLY 6120460ID_r0 ITEM DESCRIPTION PART NUMBER QTY 1 CONNECTOR O RING 3 4 x 3 4 JIC 260387 1...

Page 51: ...ESPECTIVE SAE TORQUE SPECIFICATION FOR THEIR GRADES AND SIZES UNLESS OTHERWISE SPECIFIED 7 7 CONTROL MODULE ASSEMBLY 6060352ID_r0 ITEM DESCRIPTION PART NUMBER QTY 1 PLATE CONTROLLER MOUNT CS3KH 282179...

Page 52: ...TION 7 ILLUSTRATED PARTS LIST 7 18 090189 OP_r0 JUNE 2022 VANAIR MANUFACTURING INC 844 VAN SERV www vanair com Cap Start Hydraulic Driven 12V 24V Battery Starter Charger 7 8 CANOPY AND PARTS 6030207ID...

Page 53: ...M DESCRIPTION PART NUMBER QTY 1 PLUG 5 8 PLASTIC LOCKING 680 510 1 2 PLUG 0 875 BLACK PLASTIC 680 892 1 3 WASHER NYLON FLAT 1 4 262704 26 4 SCREW TRUSS 1 4 20 X 3 4 SS 262953 26 5 PANEL BACK CS3KH 281...

Page 54: ...COVER ANY SAFE TY DECAL Replace any safety decal that becomes damaged or illegible ITEM DESCRIPTION PART NUMBER QTY 1 DECAL WARN ING ELECTRIC TAMPER 271510 1 2 DECAL WARN QUALIFIED PERSONNEL 271535 1...

Page 55: ...ged or illegible 6110154ID_r1_1of2 ITEM DESCRIPTION PART NUMBER QTY ITEM DESCRIPTION PART NUMBER QTY 8 LOGO CAPSTART BY STARTALL 300 0 AMPS 12 24V 282481 3 12 DECAL VANAIR SERIAL TAG 281373 002 1 9 LO...

Page 56: ...77096 HIGH AMPERAGE JUMPER CABLES 6A DIODE HARNESS 277892 02 M12 5 PIN A CODED HARNESS 282040 HARNESS 282039 CLAMP RELAY 1 RELAY 2 RELAY 3 RELAY 4 RELAY 5 CLAMP CAP 2 CAP 1 CAP 2 GND FLD NEG FLD POS F...

Page 57: ...so that machine motion produces bending rather than twisting 4 Use elbows or other adapters as necessary to eliminate excess hose length and to insure neater installation for easier main tenance 2 Amp...

Page 58: ...LIST 7 24 090189 OP_r0 JUNE 2022 VANAIR MANUFACTURING INC 844 VAN SERV www vanair com Cap Start Hydraulic Driven 12V 24V Battery Starter Charger TABLE 7B MAINTENANCE TRACKING LOG DATE DESCRIPTION OF...

Page 59: ...BLANK PAGE...

Page 60: ...hone toll free 800 526 8817 Service toll free 844 VAN SERV 844 826 7378 Telephone 219 879 5100 Service Fax 219 879 5335 Parts Fax 219 879 5340 Sales Fax 219 879 5800 www vanair com Printed in the U S...

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