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STG global TANVAC HDV3000 Operator's Manual

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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
1300 998 784
STGGLOBAL.NET

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

  • Page 3: Table Of Contents

    Index General Safety Precautions • Safety precautions for entering tanks • Safety precautions for handling material • Safety precautions for operating equipment General Safety Rules High Pressure Water safety • Medical Alert • General • General Safety Procedures Component Identification Vacuum/Blower/Tank Operation •...

  • Page 4: General Safety Precautions

    Congratulations on your purchase of an STG Global product. Your Tanvac Mounted Vacuum Tanker will give you years of dependable service if the proper operating and maintenance instructions are observed. We recommend that you read this manual carefully to become thoroughly familiar with your tanker equipment prior to operation.
  • Page 5 DANGER: DO NOT enter a transport, septic, or holding tank without using a respirator that supplies grade D breathing air or a self-contained breathing apparatus. In addition, DO NOT use this equipment without training and familiarity with it. Entering a tank exposed to sewage affluent without a correct breathing apparatus, or with improper use of it, can cause death.

  • Page 6: General Safety Rules

    Pressurised discharge can cause a hose end to whip about and create the potential for spraying persons in the area WARNING: Keep all shields in place. Shields and covers are designed to protect the operator from entanglement in moving parts, which can lead to serious injury or death.
  • Page 7 4. NEVER operate the machine with any of the covers removed. 5. NEVER attempt any repairs to this machine. Always refer to your dealer. 6. NEVER supply any liquid other than water to the water inlet. 7. NEVER use the detergent pickup facility to introduce flammable liquids/solvents, e.g.

  • Page 8: High Pressure Water Safety

    3. HIGH PRESSURE WATER SAFETY WARNING An injury caused by high pressure water jets can be serious. In the event of any water jet injury: • Seek medical attention immediately. Do not delay! • Inform the doctor of the cause of the injury. 
 •...
  • Page 9 General WARNING STG Global could not possibly, know, evaluate, and advise the service trade of all conceivable ways in which operation or service might be done or the possible hazardous consequences of each way. Anyone who uses operational procedures,...
  • Page 10 • Never use this unit in any type of rescue operation where the vacuum is used for the rescue. 
 • Operating the unit inside a building or confined areas can create additional risks to the unit, operators and building occupants. Engine exhaust gas can reach deadly levels.

  • Page 11: Component Identification

    4. COMPONENT IDENTIFICATION Engine Control Panel Control Panel...
  • Page 12 Hourmeter Tachometer Ignition Switch Indicator lights Hydraulic Enable Push Top -Enable Push Bottom -DISABLE Flashing Beacon Work Light...
  • Page 13 Throttle Turn CW or Push in -DECREASE RPM Turn CCW or Pull Out In -INCREASE Hydraulic Controls Emergency stop Rear Door Open/Close Push open -Raise door Collection Tank Push Close -Lower door Raised/lower Push up -RAISE TANK Push-Down-LOWER...
  • Page 14 Water System Water pump Switch Water Pump...
  • Page 15 Water Strainer Hose Reel...

  • Page 16: Vacuum System

    Water Tank Drain Valve Lever Vacuum System Suction Valve Dump valve...
  • Page 17 Blower Vacuum...
  • Page 18 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 Primary Shutoff Assembly (Collection Tank Interior) Bag House Lid...
  • Page 20 Bag House Drain Valve Tools Water Gun...

  • Page 21: Vacuum/Blower/Tank Operation

    5. VACUUM/BLOWER/TANK OPERATION Please refer to the truck manufactures operators manual Starting Procedure Starting - Machine preparation A. Check Caterpillar engine and machine fluid levels. Perform daily or as recommended in the manufactures operators manual B. Configure machine as follows: Water Pump Switch SWITCH OFF Suction Valve...

  • Page 22: Engaging The Vacuum

    4. To disengage, idle the engine rpm back and push the pressure washer switch to the off position 7. ENGAGING THE VACUUM Read the Gardner Denver operators manual before use. A. Always have the Caterpillar engine at idle before engaging the vacuum lever (4- way valve) B.

  • Page 23: Safe Work Procedures

    9. SAFE WORK PROCEDURES Safe work procedures for vacuum truck operations must address the potential for chemical reactions and the potential release of toxic gas or fumes. The variety of fluids or substances that vacuum trucks typically carry must also be taken into consideration.

  • Page 24: Atmospheric Testing

    Under normal conditions, the absence of oxygen minimises the risk of ignition in a vacuum truck. However, operating rotary lobe blowers and vacuum pumps at high speeds creates high air movement and high vacuum levels, resulting in high discharge air temperatures and high discharge vapor concentrations that can present potentially ignitable conditions.

  • Page 25: Bonding And Grounding

    possible, use a vertical exhaust stack to divert exhaust gases away from workers and ignition sources. • Check air monitoring equipment during operations to confirm that venting is proceeding safely. • Monitor the following: Tank level indicators to avoid overfilling. •...

  • Page 26: Training

    contact with the earth) such as a large storage tank or underground piping. A safe and proper ground to earth may be achieved by connecting to any properly grounded object including, but not limited to, any one or more of the following examples: •...
  • Page 27 • The safe operation of the vacuum equipment and be familiar with hazards of the petroleum products, byproducts, wastes and materials being transferred. 
 • Aware of relevant government and facility safety procedures and emergency response requirements. 
 • MSDS of the substances being vacuumed or transferred. 
 •...

  • Page 28: Hydraulic Operation

    13. HYDRAULIC OPERATION 1. Before running the hydraulics make sure the hydraulic oil is showing in the hydraulic sight glass at the correct level 2. For hydraulic 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.
  • Page 29 Emergency stop Collection Tank Raised (H2)Rear Door Open/Close /lower Push open -Raise door Push up -RAISE TANK Push Close -Lower door Push-Down-LOWER TANK...
  • Page 30 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: Maintenance

    14. MAINTENANCE Caterpillar Engine- refer to the manufactures operator and maintenance manual Garner Denver 5LR blower/vacuum- refer to the manufactures operator and maintenance manual. Comet rw6040 pressure washer - refer to the manufactures operator and maintenance manual. 15. HYDRAULIC SYSTEM Check the oil in the hydraulic reservoir daily.
  • Page 32 D. Reassemble in the reverse order. WARNING: Wear protective gloves, eye protection and appropriate clothing when cleaning the filter. Being a component of the vacuum system, the filter is subject to exposure by sewage or septage. These materials may contain hazardous chemicals and bacteria, which can cause infection, injury, or even death due to contact.
  • Page 33 18. VACUUM MODULE MOUNTING Check all module mounting bolts visually daily Check the 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 20. 3000lt ELECTRIC CONTROL BOX CIRCUIT DIAGRAM 1...
  • Page 35 21. 3000lt ELECTRIC CONTROL BOX CIRCUIT DIAGRAM 2...
  • Page 36 22. 3000lt VACUUM UNIT BOTTOM RAIL ASSEMBLE...
  • Page 37 OPERATORS MANUAL Cat 2.2 Opera�on Manual Sec�on 2 1300 998 784 STGGLOBAL.NET...
  • Page 38 SEBU8312-03 (en-us) February 2016 Operation and Maintenance Manual C0.5 , C0.7, C1.1 , C1.5 , C1.6 and C2.2 Industrial 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)
  • Page 39 i06558969 Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards, including human factors that can affect safety.
  • Page 40 SEBU8312-03 Table of Contents Table of Contents Maintenance Recommendations ....51 Maintenance Interval Schedule....... 53 Foreword ............4 Warranty Section Safety Section Warranty Information........92 Safety Messages..........5 Reference Information Section General Hazard Information......8 Engine Ratings ..........93 Burn Prevention..........12 Customer Service..........

  • Page 41: Foreword

    SEBU8312-03 Foreword Foreword Recommended service should be performed at the appropriate intervals as indicated in the Maintenance Interval Schedule. The actual operating environment Literature Information of the engine also governs the Maintenance Interval Schedule. Therefore, under extremely severe, dusty, This manual contains safety, operation instructions, wet or freezing cold operating conditions, more lubrication and maintenance information.

  • Page 42: Safety Section

    SEBU8312-03 Safety Section Safety Messages Safety Section i02639935 Safety Messages SMCS Code: 1000; 7405 There may be several specific safety messages on an engine. The exact location of the hazards and the description of the hazards are reviewed in this section.
  • Page 43 SEBU8312-03 Safety Section Safety Messages Illustration 1 g01324126 (A) Location of the warning labels (3) C1.1 (6) C2.2 (1) C0.5 (4) C1.5 (2) C0.7 (5) C1.6...
  • Page 44 SEBU8312-03 Safety Section Safety Messages Illustration 2 g01324528 (B) Location of ether warning labels (3) C1.1 (6) C2.2 (1) C0.5 (4) C1.5 (2) C0.7 (5) C1.6...

  • Page 45: General Hazard Information

    SEBU8312-03 Safety Section General Hazard Information Universal Warning (A) Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury. i06300340 General Hazard Information SMCS Code: 1000; 7405 Illustration 3 g01154807 Warning label (A) is installed in different locations.
  • Page 46 SEBU8312-03 Safety Section General Hazard Information • Start the engine with the operator controls. Never short across the starting motor terminals or the batteries. This method of starting the engine could bypass the engine neutral start system and/or the electrical system could be damaged. Pressurized Air and Water Pressurized air and/or water can cause debris and/or hot water to be blown out which could result in...
  • Page 47 SEBU8312-03 Safety Section General Hazard Information Static Electricity Hazard when Avoid direct spraying of water on electrical connectors, connections, and components. When Fueling with Ultra-low Sulfur Diesel using air for cleaning, allow the machine to cool to Fuel reduce the possibility of fine debris igniting when redeposited on hot surfaces.
  • Page 48 SEBU8312-03 Safety Section General Hazard Information Ensure that all of the clamps, the guards, and the • A vacuum cleaner that is equipped with a high heat shields are installed correctly. Correct efficiency particulate air filter (HEPA) can also be installation of these components will help to prevent used.

  • Page 49: Burn Prevention

    SEBU8312-03 Safety Section Burn Prevention Reference: The applicable material safety data Ensure that the filler cap is cool before removing the filler cap. The filler cap must be cool enough to touch sheets can be found at the following web site by with a bare hand.
  • Page 50 SEBU8312-03 Safety Section Fire Prevention and Explosion Prevention Flammable fluids that are leaking or spilled onto hot Inspect all lines and hoses for wear or for surfaces or onto electrical components can cause a deterioration. Properly route all hoses. The lines and fire.

  • Page 51: Crushing Prevention And Cutting Prevention

    SEBU8312-03 Safety Section Crushing Prevention and Cutting Prevention Do not store ether cylinders in living areas or in the engine compartment. Do not store ether cylinders in direct sunlight or in temperatures above 49 °C (120 °F). Keep ether cylinders away from open flames or sparks.

  • Page 52: Mounting And Dismounting

    SEBU8312-03 Safety Section Mounting and Dismounting Stay clear of all rotating parts and of all moving parts. Leave the guards in place until maintenance is performed. After the maintenance is performed, Engine exhaust contains products of combustion reinstall the guards. which may be harmful to your health.

  • Page 53: Engine Stopping

    SEBU8312-03 Safety Section Engine Stopping Always start the engine according to the procedure Check the electrical wires daily for wires that are that is described in the Operation and Maintenance loose or frayed. Tighten all loose electrical wires Manual, “Engine Starting” topic in the Operation before the engine is started.
  • Page 54 SEBU8312-03 Safety Section Electrical System Correct grounding for the engine electrical system is necessary for optimum engine performance and reliability. Incorrect grounding will result in uncontrolled electrical circuit paths and in unreliable electrical circuit paths. Uncontrolled electrical circuit paths can result in damage to main bearings, to crankshaft bearing journal surfaces, and to aluminum components.

  • Page 55: Product Information Section

    SEBU8312-03 Product Information Section Model Views Product Information Section Model Views i02613456 Model View Illustrations SMCS Code: 1000 The following model views show typical features 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.
  • Page 56 SEBU8312-03 Product Information Section Model View Illustrations Illustration 16 g01300431 Typical view of the C1.5 turbocharged engine...
  • Page 57 SEBU8312-03 Product Information Section Model View Illustrations Illustration 17 g01304893 Right side view of the C2.2 turbocharged engine (1) Fuel shutoff solenoid (5) Throttle lever (9) Engine oil filter (2) Number one fuel injector (6) Cover plate for the accessory drive (10) Fuel injection pump (3) Water pump (7) Engine oil level gauge...
  • Page 58 SEBU8312-03 Product Information Section Engine Description Illustration 18 g01305224 Left side view of the C2.2 Engine (13) Top engine oil filler cap (19) Water temperature regulator housing (25) Fan drive belt (14) Crankcase breather (20) Starting motor solenoid (26) Crankshaft pulley (15) Rear Lifting eye (21) Electric starting motor (27) Coolant temperature switch...
  • Page 59 SEBU8312-03 Product Information Section Engine Description C0.5 Engine The timing gears are stamped with timing marks in order to ensure the correct assembly of the gears. When the No. 1 piston is at top center compression stroke, the teeth that are stamped on the crankshaft gear and the camshaft gear will be in alignment with the idler gear.
  • Page 60 SEBU8312-03 Product Information Section Engine Description C0.7 Engine C1.1 Engine Illustration 20 g00852304 Illustration 21 g00852304 (A) Exhaust valves (A) Exhaust valves (B) Inlet valves (B) Inlet valves Table 2 Table 3 C0.7 Engine Specifications C1.1 Engine Specifications Maximum Operating Speed Maximum Operating Speed 3600 rpm 3600 rpm...
  • Page 61 SEBU8312-03 Product Information Section Engine Description C1.5 Engine C1.5 Turbocharged Engine Illustration 22 g00852304 Illustration 23 g00852304 (A) Exhaust valves (A) Exhaust valves (B) Inlet valves (B) Inlet valves Table 4 Table 5 C1.5 Engine Specifications C1.5 Turbocharged Engine Specifications Maximum Operating Speed Maximum Operating Speed 3000 rpm...
  • Page 62 SEBU8312-03 Product Information Section Engine Description C1.6 Engine C2.2 Engine Illustration 24 g00296424 Illustration 25 g00296424 (A) Exhaust valves (A) Exhaust valves (B) Inlet valves (B) Inlet valves Table 6 Table 7 C1.6 Engine Specifications C2.2 Engine Specifications Maximum Operating Speed Maximum Operating Speed 3000 rpm 3000 rpm...
  • Page 63 SEBU8312-03 Product Information Section Engine Description C2.2 Turbocharged Engine C2.2 Turbocharged Aftercooled Engine Illustration 26 g00296424 Illustration 27 g00296424 (A) Exhaust valves (A) Exhaust valves (B) Inlet valves (B) Inlet valves Table 8 Table 9 C2.2 Turbocharged Engine Specifications C2.2 Turbocharged Aftercooled Engine Specifications Maximum Operating Speed Maximum Operating Speed 3000 rpm...

  • Page 64: Product Identification Information

    SEBU8312-03 Product Information Section Product Identification Information Product Identification Information i02656316 Plate Locations and Film Locations Illustration 29 g01131696 SMCS Code: 1000 Serial number plate i00610276 Reference Numbers SMCS Code: 1000 Information for the following items may be needed to order parts.
  • Page 65 SEBU8312-03 Product Information Section Emissions Certification Film Alternator Belt No. i06602168 Emissions Certification Film SMCS Code: 1000; 7405 Note: This information is pertinent in the United States and in Canada. Illustration 30 g01527177 Typical example Illustration 31 g06038952 Typical example Refer to illustration 31 .

  • Page 66: Operation Section

    SEBU8312-03 Operation Section Lifting and Storage Operation Section i05111635 Product Storage Lifting and 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 i04342729 from the piston rings.

  • Page 67: Gauges And Indicators

    SEBU8312-03 Operation Section Gauges and Indicators Gauges and Indicators 3. Determine if the engine must be shut down immediately or if the engine can be cooled by reducing the load. i01139916 Tachometer – This gauge indicates Gauges and Indicators engine speed (rpm). When the throttle control lever is moved to the full throttle SMCS Code: 1900;...

  • Page 68: Features And Controls

    SEBU8312-03 Operation Section Features and Controls Features and Controls NOTICE When an alarm is activated, corrective measures must be taken before the situation becomes an emer- i01007515 gency in order to avoid possible engine damage. Engine Shutoffs and Engine Alarms If corrective measures are not taken within a reasonable time, engine damage could result.
  • Page 69 SEBU8312-03 Operation Section Fuel Shutoff If an electronically controlled governor has been installed the governor operates the fuel rack in order to stop the engine.

  • Page 70: Engine Starting

    SEBU8312-03 Operation Section Engine Starting Engine Starting • 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. i01486758 Before Starting Engine •...
  • Page 71 SEBU8312-03 Operation Section Cold Weather Starting Note: If necessary, increase the throttle position so Note: If the glow plug indicator light flashes for 2 to 3 that the engine will start in cold conditions. The seconds or fails to illuminate, a malfunction exists in engine speed should not exceed 1500 rev/min until the cold start system.
  • Page 72 SEBU8312-03 Operation Section Starting with Jump Start Cables 6. Allow the engine to idle for 3 to 5 minutes, or allow 1. Turn the start switch on the stalled engine to the the engine to idle until the water temperature OFF position.

  • Page 73: Engine Operation

    SEBU8312-03 Operation Section Engine Operation Engine Operation 3. Perform another walk-around inspection. Check the engine for fluid leaks and air leaks. 4. Increase the rpm to the rated rpm. Check for fluid i06545704 leaks and air leaks. The engine may be operated Engine Operation at full rated rpm and at full load when the jacket water temperature reaches 60°C (140°F).
  • Page 74 SEBU8312-03 Operation Section Fuel Conservation Practices i01432412 Fuel Conservation Practices SMCS Code: 1000; 1250 The efficiency of the engine can affect the fuel economy. Caterpillar's design and technology in manufacturing provides maximum fuel efficiency in all applications. Follow the recommended procedures in order to attain optimum performance for the life of the engine.

  • Page 75: Engine Stopping

    SEBU8312-03 Operation Section Engine Stopping Engine Stopping Emergency Stop Button i01433818 Stopping the Engine SMCS Code: 1000; 7000 Note: Individual applications will have different control systems. Ensure that the shutoff procedures are understood. Use the following general guidelines in order to stop the engine. 1.
  • Page 76 SEBU8312-03 Operation Section After Stopping Engine NOTICE Only use antifreeze/coolant mixtures that are recom- mended in this Operation and Maintenance Manual, “Refill Capacities and Recommendations”. • Allow the engine to cool. Check the coolant level. Maintain the cooling system at 13 mm (0.5 inch) from the bottom of the pipe for filling.

  • Page 77: Cold Weather Operation

    SEBU8312-03 Operation Section Cold Weather Operation Cold Weather Operation There are three major differences between No. 1 and No. 2 diesel fuel. No. 1 diesel fuel has the following properties: i01457051 • Lower cloud point Radiator Restrictions • Lower pour point SMCS Code: 1353;...
  • Page 78 SEBU8312-03 Operation Section Fuel Related Components in Cold Weather Fuel tanks should contain some provision for draining Note: Fuel heaters that are controlled by the water water and sediment from the bottom of the tanks. temperature regulator or self-regulating fuel heaters Some fuel tanks use supply pipes that allow water should be used with this engine.

  • Page 79: Maintenance Section

    SEBU8312-03 Maintenance Section Refill Capacities Maintenance Section (Table 10, contd) CC, CD Refill Capacities CF-2 CD-2 API CH-4 and CI-4 oils are acceptable if the requirements of Caterpillar's ECF-1 (Engine Crankcase Fluid specifica- tion-1) are met. CH-4 and CI-4 oils that have not met the re- i04040209 quirements of Caterpillar's ECF-1 Specification may cause reduced engine life.
  • Page 80 SEBU8312-03 Maintenance Section Refill Capacities and Recommendations Caterpillar multigrade DEO can be used in other • API CF-4 multigrade oils are not recommended for diesel engines and in gasoline engines. See the this series of diesel engines. For all other smaller engine manufacturers guide for the recommended commercial diesel engines, the oil drain interval specifications.
  • Page 81 SEBU8312-03 Maintenance Section Refill Capacities and Recommendations Refill Capacities for the Lubrication Note: Generally, use the highest oil viscosity that is available to meet the requirement for the temperature System at start-up. The refill capacities for the engine crankcase reflect If ambient temperature conditions at engine start-up the approximate capacity of the crankcase or sump require the use of multigrade SAE 0W oil, SAE 0W-...
  • Page 82 SEBU8312-03 Maintenance Section Refill Capacities and Recommendations (Table 14, contd) Table 17 C1.1 Engine C2.2 Turbocharged Engines and Naturally Aspirated Approximate Refill Capacities Engines Approximate Refill Capacities Compartment or System Compartment or System External System (OEM) 8.9 L 10.6 L Crankcase Oil Sump (Standard) Total Lubrication System (9.4 qt)
  • Page 83 SEBU8312-03 Maintenance Section Refill Capacities and Recommendations • Labor Table 18 Territory Fuel Requirements from 2007 • Downtime Low Sulfur (500 ppm) maximum • Cost of the grease Sulfur/Power Low sulfur (300 Sulphur (1000 Greases that barely meet the minimum performance ppm) maximum ppm) maximum requirements can be expected to barely produce the...
  • Page 84 SEBU8312-03 Maintenance Section Refill Capacities and Recommendations Water NOTICE Never add coolant to an overheated engine. Engine damage could result. Allow the engine to cool first. NOTICE Never use water alone without Supplemental Coolant Additives (SCA) or without inhibited coolant. Water alone is corrosive at engine operating temperatures.
  • Page 85 SEBU8312-03 Maintenance Section Refill Capacities and Recommendations • Pitting and erosion from cavitation of the cylinder NOTICE liner Do not use propylene glycol in concentrations that exceed 50 percent glycol because of the reduced • Foaming of the coolant heat transfer capability of propylene glycol. Use ethyl- ene glycol in conditions that require additional protec- Many additives are depleted during engine operation.
  • Page 86 SEBU8312-03 Maintenance Section Refill Capacities and Recommendations Refer to Special Publication, SEBU6251, “Caterpillar • Identification of buildup of the impurities that Commercial Diesel Engine Fluids cause corrosion Recommendations” for additional information that relates to coolant. • Identification of buildup of the impurities that cause scaling S·O·S Coolant Analysis The results are reported, and appropriate...
  • Page 87 SEBU8312-03 Maintenance Section Refill Capacities and Recommendations Table 25 C0.7 Engine Table 28 Approximate Refill Capacities C1.6 Engine Approximate Refill Capacities Compartment or System Liters Quarts Compartment or System Engine Only Liters Quarts External System (OEM) Engine Only Total Cooling System External System (OEM) The External System includes a radiator or an expansion tank Total Cooling System...

  • Page 88: Maintenance Recommendations

    SEBU8312-03 Maintenance Section Maintenance Recommendations Maintenance Do not loosen the high pressure fuel lines in order to remove air pressure from the fuel system. Recommendations Engine Oil i02909163 To relieve pressure from the lubricating system, turn System Pressure Release off the engine. SMCS Code: 1250;...
  • Page 89 SEBU8312-03 Maintenance Section Welding on Engines with Electronic Controls 3. Disconnect the J1/P1 and J2/P2 connectors from 5. Connect the welding ground cable directly to the the ECM. Move the harness to a position that will part that will be welded. Place the ground cable as not allow the harness to move back accidentally, close as possible to the weld.

  • Page 90: Maintenance Interval Schedule

    SEBU8312-03 Maintenance Section Maintenance Interval Schedule “ Engine Oil Sample - Obtain” ....i03659171 Maintenance Interval Schedule Every 250 Service Hours or 1 Year SMCS Code: 1000;...
  • Page 91 SEBU8312-03 Maintenance Section Maintenance Interval Schedule “ Starting Motor - Inspect” ....89 Every Year “Cooling System Coolant Sample (Level 2) - Obtain” .
  • Page 92 SEBU8312-03 Maintenance Section Aftercooler Core - Clean/Test Pressurized water may also be used for cleaning. i03632427 The maximum water pressure for cleaning purposes Aftercooler Core - Clean/Test must be less than 275 kPa (40 psi). Use pressurized water in order to soften mud. Clean the core from (Air-To-Air Aftercooler) both sides.
  • Page 93 SEBU8312-03 Maintenance Section Alternator and Fan Belts - Inspect/Adjust If twin belts are installed, check and adjust the i02226340 tension on both belts. Alternator and Fan Belts - Adjustment Inspect/Adjust SMCS Code: 1357-025; 1357-040 Inspection To maximize the engine performance, inspect the belts for wear and for cracking.
  • Page 94 SEBU8312-03 Maintenance Section Alternator and Fan Belts - Replace 3. Tighten the adjusting bolt (1). Tighten the mounting i06103470 bolts (2). Refer to the Specifications Manual for Battery - Replace the correct torque settings. SMCS Code: 1401-510 i02226343 Alternator and Fan Belts - Replace Batteries give off combustible gases which can explode.
  • Page 95 SEBU8312-03 Maintenance Section Battery Electrolyte Level - Check i06064262 i01492654 Battery Electrolyte Level - Battery or Battery Cable - Check Disconnect SMCS Code: 1401-535 SMCS Code: 1402-029 When the engine has not run for long or short periods of time, the batteries may not fully recharge. Ensure a full charge in order to help prevent the battery from The battery cables or the batteries should not be freezing.
  • Page 96 SEBU8312-03 Maintenance Section Cooling System Coolant (DEAC) - Change Note: Inspect the water pump and the water 3. Fill the cooling system with a mixture of clean temperature regulator after the cooling system has water and Caterpillar Fast Acting Cooling System been drained.
  • Page 97 SEBU8312-03 Maintenance Section Cooling System Coolant (ELC) - Change 4. Start and run the engine at low idle for a minimum 4. Clean the cooling system filler cap. Inspect the of 90 minutes. The coolant temperature should be gasket that is on the cooling system filler cap. If at least 82 °C (180 °F).
  • Page 98 SEBU8312-03 Maintenance Section Cooling System Coolant (ELC) - Change 1. Stop the engine and allow the engine to cool. 5. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in Loosen the cooling system filler cap slowly in order to relieve any pressure.
  • Page 99 SEBU8312-03 Maintenance Section Cooling System Coolant Extender (ELC) - Add 5. Start the engine. Inspect the cooling system for NOTICE leaks and for proper operating temperature. Care must be taken to ensure that fluids are con- tained during performance of inspection, mainte- nance, testing, adjusting and repair of the product.
  • Page 100 SEBU8312-03 Maintenance Section Cooling System Coolant Sample (Level 1) - Obtain Note: Obtain a Coolant Sample (Level 1) if the cooling system is filled with any other coolant instead of Cat ELC including the following Pressurized System: Hot coolant can cause seri- coolants: ous burns.
  • Page 101 SEBU8312-03 Maintenance Section Cooling System Coolant Sample (Level 2) - Obtain • Obtain coolant samples directly from the coolant For additional information about coolant analysis, see Special Publication, SEBU6251, “Caterpillar sample port. You should not obtain the samples Commercial Diesel Engines Fluids from any other location.
  • Page 102 SEBU8312-03 Maintenance Section Cooling System Water Temperature Regulator - Replace Level 1 2. If necessary, drain some coolant from the cooling system into a suitable container in order to allow Level 1 is a basic analysis of the coolant. The space for the extra SCA.
  • Page 103 SEBU8312-03 Maintenance Section Driven Equipment - Check i06103535 NOTICE Failure to replace your water temperature regulator Engine - Clean on a regularly scheduled basis could cause severe engine damage. SMCS Code: 1000-070 Caterpillar engines incorporate a shunt design cool- ing system and require operating the engine with a water temperature regulator installed.
  • Page 104 SEBU8312-03 Maintenance Section Engine Air Cleaner Element (Dual Element) - Clean/Replace Servicing the Air Cleaner Elements If the air cleaner element becomes plugged, the air can split the material of the air cleaner element. Unfiltered air will drastically accelerate internal engine wear.

  • Page 105: Vacuum Cleaning

    SEBU8312-03 Maintenance Section Engine Air Cleaner Element (Dual Element) - Clean/Replace Pressurized Air 7. Reset the air cleaner service indicator. Pressurized air can be used to clean primary air Cleaning the Primary Air Cleaner cleaner elements that have not been cleaned more Elements than two times.
  • Page 106 SEBU8312-03 Maintenance Section Engine Air Cleaner Element (Single Element) - Inspect/Replace Inspecting the Primary Air Cleaner Elements Illustration 45 g00281693 Inspect the clean, dry primary air cleaner element. Use a 60 watt blue light in a dark room or in a similar Illustration 46 g02595738 facility.
  • Page 107 SEBU8312-03 Maintenance Section Engine Air Cleaner Service Indicator - Inspect S/N: G8N1–Up 5. Remove the seal from the opening of the air inlet. S/N: G7P1–Up 6. Install a clean, undamaged air filter element (2). S/N: C8W1–Up 7. Install air cleaner cover (1). S/N: C7Y1–Up 8.
  • Page 108 SEBU8312-03 Maintenance Section Engine Air Precleaner - Check/Clean Note: When a new service indicator is installed, excessive force may crack the top of the service indicator. Tighten the service indicator to a torque of 2 N·m (18 lb in). i02927289 Engine Air Precleaner - Check/ Clean SMCS Code: 1055-070;...
  • Page 109 SEBU8312-03 Maintenance Section Engine Mounts - Inspect 6. Install a new diaphragm and plate (4) for the breather assembly into the cavity (7) of the valve mechanism cover or the spacer (5) for turbocharged engines. 7. Install a new spring (3). 8.
  • Page 110 SEBU8312-03 Maintenance Section Engine Oil Sample - Obtain The 169-8373 Fluid Sampling Bottle is NOTICE recommended for use with the sampling valve. The Operating your engine when the oil level is above the fluid sampling bottle includes the parts that are “FULL”...
  • Page 111 SEBU8312-03 Maintenance Section Engine Oil and Filter - Change Do not drain the oil when the engine is cold. As the oil Nonferrous metals may indicate wear on the cools, suspended waste particles settle on the aluminum parts, brass parts or bronze parts of the bottom of the oil pan.
  • Page 112 SEBU8312-03 Maintenance Section Engine Protective Devices - Check 5. Install the oil filter. Tighten the oil filter until the oil filter seal contacts the cylinder block or the oil cooler. Tighten the oil filter by hand according to the instructions that are shown on the oil filter. Do not overtighten the oil filter.
  • Page 113 SEBU8312-03 Maintenance Section Engine Valve Lash - Inspect/Adjust Visual Inspection i02625315 Fuel Injector - Test/Change Visually check the condition of all gauges, sensors, and wiring. Look for wiring and components that are SMCS Code: 1290-510; 1290-081 loose, broken, or damaged. Damaged wiring or components should be repaired or replaced immediately.

  • Page 114: Primary Filter

    SEBU8312-03 Maintenance Section Fuel System - Prime 3. A faulty fuel injector may be identified when a fuel NOTICE line nut is loosened and the following conditions Care must be taken to ensure that fluids are con- are present: tained during performance of inspection, mainte- nance, testing, adjusting and repair of the product.
  • Page 115 SEBU8312-03 Maintenance Section Fuel System - Prime Illustration 55 g01327360 Illustration 57 g01327363 Element Spin-on filter with fuel priming pump (2) Fuel valve (5) Vent screw (3) Vent screw Vent screw (3) is installed on the filter that has an element.
  • Page 116 SEBU8312-03 Maintenance Section Fuel System - Prime Illustration 58 g01301853 (6) Hand priming pump (8) Electrical priming pump (7) In-line priming pump (9) Fuel transfer pump Illustration 59 g01304597 (10) Connector bolt (11) Fuel return line (12) Connector bolt Hand Priming Pump 6 1.
  • Page 117 SEBU8312-03 Maintenance Section Fuel System - Prime 2. Loosen vent screw (3 4 or 5) on the fuel filter. 1. Ensure that fuel valve (2) for the fuel filter that has an element is in the ON position. Refer to 3.
  • Page 118 SEBU8312-03 Maintenance Section Fuel System Primary Filter/Water Separator - Drain Note: Do not operate the starting motor for more than NOTICE 15 seconds. If the engine does not start after 15 The water separator is under suction during normal seconds, stop and wait for 30 seconds before trying engine operation.
  • Page 119 SEBU8312-03 Maintenance Section Fuel System Secondary Filter - Replace 6. Fasten 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”.
  • Page 120 SEBU8312-03 Maintenance Section Fuel System Secondary Filter - Replace 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 fuel filter with fuel.
  • Page 121 SEBU8312-03 Maintenance Section Fuel Tank Water and Sediment - Drain The fuel system will need to be primed after the new Check the fuel daily. Drain the water and sediment filter is installed. Refer to this Operation and from the fuel tank after operating the engine. Drain Maintenance Manual, “Fuel System - Prime”.

  • Page 122: Cooling System

    SEBU8312-03 Maintenance Section Hoses and Clamps - Inspect/Replace Note: Ensure that the hose is compatible with the Replace hoses that are cracked or soft. Replace hoses that show signs of leakage. Replace hoses application. that show signs of damage. Replace hose clamps that are cracked or damaged.
  • Page 123 SEBU8312-03 Maintenance Section Hoses and Clamps - Inspect/Replace 5. Drain the coolant from the cooling system to a NOTICE level that is below the hose that is being replaced. Do not allow dirt to enter the fuel system. Thoroughly Drain the coolant into a suitable clean container. clean the area around a fuel system component that The coolant can be reused.
  • Page 124 SEBU8312-03 Maintenance Section Overhaul Considerations Oil Consumption as an Overhaul 3. Disconnect the old hose. Indicator 4. Replace the old hose with a new hose. 5. Install hose clamps which have been inspected or Oil consumption, fuel consumption, and maintenance information can be used to estimate the total install new hose clamps.
  • Page 125 SEBU8312-03 Maintenance Section Radiator - Clean Obtain Coolant Analysis The concentration of supplemental coolant additive Personal injury can result from air pressure. (SCA) should be checked regularly with test kits or with S·O·S Coolant Analysis (Level I). Personal injury can result without following prop- er procedure.
  • Page 126 SEBU8312-03 Maintenance Section Starting Motor - Inspect • Oil selection and maintenance • Operating outside the intended application • Coolant selection and maintenance Improper Maintenance Procedures • Environmental qualities • Extending the maintenance intervals • Installation • Failure to use recommended fuel, lubricants and Refer to the standards for the engine or consult with coolant/antifreeze your Caterpillar dealer in order to determine if the...
  • Page 127 SEBU8312-03 Maintenance Section Walk-Around Inspection 4. Fasten the air intake pipe and the exhaust outlet NOTICE pipe to the turbocharger housing. Turbocharger bearing failures can cause large quan- tities of oil to enter the air intake and exhaust sys- tems. Loss of engine lubricant can result in serious i00632301 engine damage.
  • Page 128 SEBU8312-03 Maintenance Section Water Pump - Inspect • Inspect the lubrication system for leaks at the front Visually inspect the water pump for leaks. Renew the water pump seal or the water pump if there is an crankshaft seal, the rear crankshaft seal, the oil excessive leakage of coolant.

  • Page 129: Warranty Section

    SEBU8312-03 Warranty Section Warranty Information Warranty Section The aftertreatment system can be expected to function properly for the lifetime of the engine (emissions durability period) subject to prescribed maintenance requirements being followed. Warranty Information A detailed explanation of the Emission Control Warranty that is applicable to new non-road and stationary diesel engines, including the components i05549472...

  • Page 130: Reference Information Section

    SEBU8312-03 Reference Information Section Engine Ratings Reference Information i00819749 Section Engine Rating Definitions SMCS Code: 1000 Engine Ratings It is important to know the use of the engine so that the rating will match the operating profile. The proper rating selection is also important so that the customer's perception of price and value is realized.
  • Page 131 SEBU8312-03 Reference Information Section Engine Rating Definitions available. The horsepower and the rpm of the engine can be utilized continuously for a maximum of 15 minutes. This is followed by one hour of operation at the C rating or by the duration of the emergency. The engine should be run at full load.

  • Page 132: Customer Service

    SEBU8312-03 Reference Information Section Customer Service Customer Service Europe, Africa, and Middle East Caterpillar Overseas S.A. 76 Route de Frontenex i03910306 P.O. Box 6000 CH-1211 Geneva 6 Customer Assistance Switzerland Phone: 22-849-4444 SMCS Code: 1000 Fax: 22-849-4544 USA and Canada Far East Caterpillar Asia Pte.

  • Page 133: Ordering Replacement Parts

    SEBU8312-03 Reference Information Section Ordering Replacement Parts Australia and New Zealand Caterpillar of Australia Ltd. 1 Caterpillar Drive Private Mail Bag 4 Tullamarine, Victoria 3043 Australia Phone: 03-9953-9333 Fax: 03-9335-3366 i01028392 Ordering Replacement Parts SMCS Code: 7567 When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent speci- fications including, but not limited to, physical di-...

  • Page 134: Reference Materials

    SEBU8312-03 Reference Information Section Reference Materials Reference Materials • Label, PEEP5027, “Extended Life Coolant/ Antifreeze” i02627762 Miscellaneous Reference Material • Service Manual, REG1139F, “Service Manual SMCS Code: 1000 Contents Microfiche” The following literature can be obtained through any • Service Manual, KENR6925, “C0.5, C0.7, C1.1, Caterpillar dealer.
  • Page 135 SEBU8312-03 Reference Information Section Additional Reference Material • Label, SEHS7332, “Danger Do Not Operate” European classifications are established by the Counseil International Des Machines a Combustion (CIMAC) (International Council on Combustion Emissions Warranty Engines). This engine may be Certified and this engine may be CIMAC Central Secretariat covered by an Emissions Warranty.

  • Page 136: Maintenance Log

    SEBU8312-03 Reference Information Section Maintenance Log • Dealer work orders and itemized bills • Owner repair costs • Owner receipts • Maintenance log i01176304 Maintenance Log SMCS Code: 1000 Table 32 Engine Model Customer Identifier Arrangement Number Serial Number Service Quantity Of Service Item Date...
  • Page 137 SEBU8312-03 Reference Information Section Maintenance Log (Table 32, contd)

  • Page 138: Index

    SEBU8312-03 Index Section Index Test for SCA Concentration ......64 Cooling System Water Temperature Additional Reference Material ......98 Regulator - Replace........65 After Starting Engine ........35 Crushing Prevention and Cutting Prevention.. 14 After Stopping Engine ........38 Customer Assistance ........95 Aftercooler Core - Clean/Test (Air-To-Air Outside of the USA and of Canada .....
  • Page 139 SEBU8312-03 Index Section Engine Rating Definitions........ 93 Engine Ratings ..........93 Gauges and Indicators ........30 Engine Shutoffs and Engine Alarms ....31 General Hazard Information......8 Alarms............31 Containing Fluid Spillage......10 Shutoffs............31 Dispose of Waste Properly ......12 Testing the Shutoff and Alarm System ..
  • Page 140 SEBU8312-03 Index Section Maintenance Section........42 Severe Service Application - Check....88 Model View Illustrations ........18 Environmental Factors......... 89 Model Views ............ 18 Improper Maintenance Procedures ..... 89 Mounting and Dismounting ......15 Improper Operating Procedures....89 Starting Motor - Inspect ........89 Starting the Engine..........
  • Page 142 Product and Dealer Information Note: For product identification plate locations, see the section “Product Identification Information” in the Operation and 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:...
  • Page 143 SEBU8312 CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade ©2016 Caterpillar dress as well as corporate and product identity used herein, are trademarks of Caterpillar and All Rights Reserved may not be used without permission. February 2016...
  • Page 144 OPERATORS MANUAL Comet Manual Sec�on 3 1300 998 784 STGGLOBAL.NET...
  • Page 145 COMET PLUNGER PUMP SERVICE MANUAL INDEX 1. SAFETY INSTRUCTIONS, OPERATING PROCEDURES AND LIMITS ....1 Installation and Start-up Information TORQUE SETTING CHART ..................1-2 AXD Series Pump LW/ZW Series Pump FW/HW Series Pump 3. TROUBLE SHOOTING GUIDE ................2 4. MAINTENANCE SCHEDULE ................... 3 SPECIFICATIONS AND TECHNICAL DATA ............
  • Page 146 1. SAFETY INSTRUCTIONS, OPERATING PROCEDURES AND LIMITS Start-up Information LUBRICATION: Make sure crankcase is filled with Comet Pump oil. Running this pump without oil will cause damage and void any warranties. Change the pump oil after the initial 50 hours of operation. Change oil every 500 hours after the initial oil change. The oil level of the pump can be checked by removing the oil cap and inspecting the dip stick.

  • Page 147: Trouble Shooting Guide

    FW/HW Series Pump POSITION# TORQUE FLUID TO BE SETTING USED 18 FT/LB 37 FT/LB LOCTITE 542 7 FT/LB LOCTITE 542 3 FT/LB 18 FT/LB 6 FT/LB 3. TROUBLE SHOOTING GUIDE SYMPTOMS CAUSES REMEDIES The pump does not start Air suction Control inlet device Closed lance Open the lance...
  • Page 148 4. MAINTENANCE SCHEDULE OPERATION Every 8 hours Every 50 hours Every 500 hours Check oil level Check tubes-fittings Check & clean inlet filter Control pump connection to the engine Change oil X –FIRST CHANGE Check suction/delivery valves Check pump bolt and nut setting Check regulation valve 5.
  • Page 149 Fig. B Fig. C Fig. A 6. PUMP SERVICE GUIDE 6.1. AXD Series Pump A. Valve Maintenance Press down firmly on the top of valve Using a 17mm wrench, remove the six assembly or riser tube with your finger. valve caps on manifold of pump. (Fig. A) (Fig.
  • Page 150 Fig. A Fig. B Fig. C Insert low-pressure seal using Comet repair C. Seals and V-Packing Maintenance tools. (Fig. D) Place the brass retainer ring Remove the manifold as described in on stand (Fig. D-1). Place tapered stainless section 6.1-B. It is possible that the seal steel cylinder (Fig.
  • Page 151 Fig. A Fig. B Fig. C E. Plunger Maintenance To service the oil seal, take a small flat Remove the manifold as described in head screwdriver and apply pressure at a section 6.1-B. slight side and downward angle. (Fig. D) Remove the 6mm allen bolts securing the One side of the seal will pop up and can be two halves of the crankcase.
  • Page 152 Fig. A Fig. B Fig. C G. Crankcase Maintenance H. Crankcase Reassembly Unscrew the four hex bolts and take the two Assemble shaft/bearing assembly. Stack halves apart as shown in section 6.1-D. all of the shaft & bearing components. There are internal springs pushing these Secure using the 6mm allen bolt &...
  • Page 153 Fig. B Fig. C Fig. A 6.2 LW/ZW SERIES PUMP A. Valve Maintenance Replace valve caps by applying LOCTITE Using a 22mm wrench or socket, remove 243 to valve cap and torque to 33 ft. lbs. the six valve caps on manifold of pump. (Fig.
  • Page 154 Fig. A Fig. B Fig. C C. Seals and V-Packing Maintenance Replace the outer o’ring by simply starting Remove the manifold as described in on one side and working it into the groove. section 6.2-B. It is possible that the seal (Fig.
  • Page 155 Fig. C Fig. A Fig. B F. Plunger Reassembly the oil seal with a flat head screwdriver. Generously grease piston guide. Pry it out of the crankcase and over the Replace the o’ring making sure it does not shaft. (Fig. E) twist or roll.
  • Page 156 Fig. A Fig. B Fig. C H. Crankcase Reassembly Secure the snap rings into place by securing Insert the piston guides by sliding them into the bearing into the crankcase, and the shaft the crankcase by hand. (Fig A) into the bearing. Press the small bearing into the crankcase.
  • Page 157 Fig. A Fig. B Fig. C 6.3. FW/HW SERIES PUMP A. Valve Maintenance Replace valve caps by applying LOCTITE Using a 22mm wrench, remove the six 243 to valve cap and torque to 33 ft. lbs. valve caps on manifold of pump. Examine the valve cap o’ring for cuts or B.
  • Page 158 Fig. B Fig. A Fig. C C. Seals and V-Packing Maintenance Reinstall the manifold onto the pump as Remove manifold as described in section described in section 6.3-B 6.3-B. It is possible that the seal and brass retainer ring assembly stays on the piston E.
  • Page 159 Fig. C Fig. A Fig. B F. Crankcase Maintenance Place the bearing cover into place and secure the four bolts onto cover. (Fig. D) Remove manifold and pistons as explained Install the crankshaft by eyeing it through the in sections 6.3-A and 6.3-B. connecting rods and pressing it into the small Remove crankcase back by removing the bearing opposite of the flange.
  • Page 160 7. PUMP LIMITED WARRANTY 7.1 Comet Pump Limited Warranty The Comet pump is warranted by the manufacturer to the original purchaser to be free from defects in material and workmanship under normal use and service. “Normal use and service” means not in excess of the recommended maximum speeds, pressures and temperatures or handling fluids not compatible with component materials.
  • Page 161 OPERATORS MANUAL Sutorbilt R Series Sec�on 4 1300 998 784 STGGLOBAL.NET...

  • Page 162: Parts List

    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 MAINTAIN BLOWER RELIABILITY AND PERFORMANCE WITH GENUINE GARDNER DENVER PARTS AND SUPPORT SERVICES Factory genuine parts, manufactured to design tolerances, are developed for optimum dependability - - - specifically for your blower. Design and material innovations are born from years of experience with hundreds of different blower applications.
  • Page 164 GARDNER DENVER LUBRICANT ORDER INFORMATION Re-order Part Numbers for Factory Recommended Lubricants. Gear and Drive End AEON PD Synthetic Lubricant, AEON PD-XP—Extreme Duty Synthetic Lubricant or AEON PD-FG—Food Grade Synthetic Lubricant AEON PD Synthetic Lubricant Description Part Number 1 Quart 28G23 Case/12Quarts 28G24...
  • Page 165 FOREWORD  Sutorbilt blowers are the result of advanced engineering and skilled manufacturing. To be assured of receiving maximum service from this machine, the owner must exercise care in its operation and maintenance. This manual is written to give the operator and maintenance department essential information for day-to-day operation, maintenance and adjustment.
  • Page 166 SAFETY PRECAUTIONS Safety is everybody’s business and is based on your use of good common sense. All situations or circumstances cannot always be predicted and covered by established rules. Therefore, use your past experience, watch out for safety hazards and be cautious. Some general safety precautions are given below: Failure to observe these notices could result in injury to or death of personnel.
  • Page 167 TABLE OF CONTENTS Maintain Blower Reliability And Performance ......................2 Foreword ..................................4 Safety Precautions ..............................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 ..............................
  • Page 168 INDEX Aeon PD Extreme Duty Lubricant ........20 Mechanical Seals Only ..........31, 32 Aeon PD Food Grade Lubricant ........20 Mounting Configurations ..........12 Aeon PD Synthetic Lubricant .......... 20 Air Filters And Filter Silencers ......... 16 Operation, Section 4 ............22 Assembly Instructions, Section 7 ........
  • Page 169 SUTORBILT LEGEND SERIES 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 APPROPRICATE CONSTRUCTION OPTION WITH WHICH YOUR MACHINE IS EQUIPPED.
  • Page 170 INTRODUCTION YOUR KEY TO TROUBLE FREE SERVICE Thank you for investing in Gardner Denver quality. The Gardner Denver reputation for rugged dependability has been earned by over 50 years of service in demanding, industrial operations where downtime cannot be tolerated and efficient blower performance is expected.
  • Page 171 SECTION 1 EQUIPMENT CHECK Before uncrating, check the packing slip carefully to be sure all the parts have been received. All accessories are listed as separate items on the packing slip, and small important accessories such as relief valves can be overlooked or lost.
  • Page 172 Blower inlet and outlet are temporarily capped to keep out dirt and other contaminants during shipment. These covers must be removed before start-up. The internal surfaces of all Sutorbilt units are mist sprayed with a rust preventative to protect the machine during shipment.

  • Page 173: Repositioning The Mounting Feet

    SECTION 2 INSTALLATION LOCATION Install the blower in a well lit, clean dry place with plenty of room for inspection and maintenance. FOUNDATIONS For permanent installation we recommend concrete foundations be provided, and the equipment should be grouted to the concrete. It is necessary that a suitable base be used, such as a steel combination base under blower and motor, or a separate sole plate under each.
  • Page 174 FIGURE 2-1 – BLOWER MOUNTING CONFIGURATIONS 4. Secure the mounting feet capscrews to the torque value in Figure 7-9, page 38. NOTICE When changing mounting configuration, it may be necessary to reposition breather/oil fill (B), oil level gauge (H) and drain plug (A). Refer to Figure 3-1, page 17, for correct location. DRIVE INSTALLATION When selecting a V-belt drive, check to be sure the shaft overhung load limitation is not exceeded.
  • Page 175 Exceeding overhung load limitations leads to unwarrantable premature bearing failure and shaft breakage. The location of the sheave on the blower shaft greatly affects the stress in the shaft. The optimum blower sheave positioning is as close as possible to the blower drive cover, not to exceed dimension “C” in Drive Shaft Illustration, FIGURE 2-2, page 15 The calculated shaft moment must not exceed the maximum allowable moment listed in Maximum Allowable Moment Chart, FIGURE 2-2 page 15.
  • Page 176 GREASE SPLASH Maximum Dimensions Gear Allowable (Inches) Diameter Moment (Inches) (LB-IN) (Max) 2.88 3.49 1.10 3.90 1.40 1245 MAXIMUM ALLOWABLE MOMENT DUAL SPLASH LUBE Maximum Dimensions Gear Allowable (Inches) Diameter Moment (Inches) (LB-IN) (Max) 3.07 1.18 3.62 1.27 3.85 1.39 1370 MAXIMUM ALLOWABLE MOMENT 0.000...

  • Page 177: Air Filters And Filter Silencers

    AIR FILTERS AND FILTER SILENCERS Servicing the air filters is one of the most important maintenance operations to be performed to insure long blower life. Servicing frequency of filter elements is not time predictable. A differential pressure indicator, with a continuous gauge reading, should be installed across the inlet filter.
  • Page 178 SECTION 3 LUBRICATION A. OIL DRAIN PLUG B. BREATHER/OIL FILL C. GREASE FITTING GREASE VENTS H. OIL LEVEL GAUGE FIGURE 3-1 - LUBRICATION DRIVE END LUBRICATION (For Grease – Splash Lube Blowers) Drive end bearings are grease lubricated at the factory with Lithium Complex based grease. For relubrication, use Gardner Denver AEON PD Grease, Part Number 28H283.
  • Page 179 DRIVE END LUBRICATION (For Dual Splash Lube Blowers) At the drive end, the bearings are lubricated by the slinger, which must be on the lowest rotor when in a vertical configuration. Approximate oil sump capacities are listed in Figure 3-2. NOTICE Machines are shipped without oil in the sump.
  • Page 180 Do not overfill as this will tend to cause excessive heating of the gears and may damage the unit. NOTICE Machines are shipped without oil in the sump. Do not operate before adding lubricant. LUBRICATION 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).

  • Page 181: Aeon Pd Synthetic Lubricant

    RECOMMENDED LUBRICANT AEON PD Synthetic Blower Lubricant is recommended. Refer to FIGURE 3-3, for AEON PD, AEON PD-FG (Food Grade) and AEON PD-XD (Extreme Duty) part numbers. Order AEON PD from your Gardner Denver Distributor or call Gardner Denver directly. Convenient AEON PD AEON PD-FG...

  • Page 182: Figure 3-3 - Aeon Pd Synthetic Lubricant

    AEON PD Synthetic Lubricant should be drained after 6000 hours of operation. Re-fill with fresh AEON PD oil. If mineral oil is used, perform the above oil change maintenance every 1500 hours. Recommended service intervals are for normal blower operating conditions. Severe operating conditions may warrant more frequent oil changes.

  • Page 183: Figure 4-1 - Maximum / Minimum Operating Limitations

    SECTION 4 OPERATION Future operating problems can be avoided if proper precautions are observed when the equipment is first put into service. Before starting under power, the blower should be turned over by hand to make certain there is no binding or internal contact.
  • Page 184 BLOWER STARTUP CHECKLIST This startup procedure should be followed during the initial installation and after any shutdown periods or after the blower has been worked on or moved to new location. It is suggested that the steps be followed in sequence and checked off (√) in the boxes provided.

  • Page 185: Safety Precautions

    SAFETY PRECAUTIONS Do not operate blower with open inlet or outlet port. Do not exceed specified vacuum or pressure limitations. Do not operate above or below recommended blower speed range. Blower is not to be used where non-sparking equipment is specified. Do not operate without belt guard or coupling shield.

  • Page 186: Figure 5-1 - Puller Plate

    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 SB-7-632 Page 25...

  • Page 187: Figure 5-3 - Mechanical Seal Installation Tool

    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 SB-7-632 Page 26...
  • Page 188 SECTION 6 DISASSEMBLY INSTRUCTIONS NOTICE Numbers in parentheses ( ) refer to key numbers in assembly drawings on pages 39 and 43. 1. Drain oil from gear case by removing drain plug (2). 2. Remove the socket head bolts (5) from the gear cover (3). 3.
  • Page 189 FIGURE 6-4 FIGURE 6-3 NOTICE If backlash is above the specified limit, the gears are not necessarily unusable. Excessive play could be caused by worn bearings. If timing gears appear to be reusable, match marktiming gear toothmesh by making small punch marks on the ends of meshing gear teeth with a pin punch and hammer (see FIGURE 6-2, page 27).
  • Page 190 Remove the socket head cap screws (30) from the drive end bearing cover (29) and remove the cover. Support the external surface of the drive end cover near the oil seal with blocks of wood. Drive the oil seal from the cover using a hammer and punch. Discard the seal as it will not be reused. Replace oil seals each time the drive end cover is removed.
  • Page 191 14. Remove the four bearing retaining screws (10), and washers (12) from the gear headplate. For Mechanical Seal Version Remove bearing retainer plate by removing 8 screws. 15. Attach puller plate to the gear headplate using the tapped holes on the bearing housing. 16.

  • Page 192: Assembly Instructions

    SECTION 7 ASSEMBLY INSTRUCTIONS NOTICE Numbers in parentheses ( ) refer to key numbers in assembly drawings on pages 39 and 43. 1. Make sure all metallic parts are clean and free of any nicks or burrs. 2. Lubricate the outside diameter of the lip seal (15) with a light oil or grease. Install seals in both the drive headplate (24) and gear headplate (18).
  • Page 193 FIGURE 7-3 FIGURE 7-2 3. Assemble gear headplate (18) and mounting foot (17) to the impeller case with cap screws (21) and where the mounting foot is secured to the headplate use capscrews (16). The two positioning dowel pins (19) will ensure proper alignment of the headplate and impeller case.
  • Page 194 INTERNAL CLEARANCES FOR STANDARD UNITS ONLY TOTAL END CLEARANCE 0.007-0.011 0.007-0.011 0.007-0.011 IMPELLER TO GEAR HEADPLATE 0.003-0.005 0.003-0.005 0.003-0.005 0.005- 0.006- .007- IMPELLER TIMING (A-A) (C-C) 0.007 .006-.008 0.008 .007-.010 .010 .008-.010 TIP TO CASE CLEARANCE (B-B) 0.002 min. 0.002 min. 0.002 min.

  • Page 195: 13. Setting Impeller End Clearances

    For Mechanical Seal Version Install 8 bearing retaining screws and washers into the gear bearing retainer plates. Tighten screws evenly. A. Dual Splash Version Install slingers on both shafts. Hold .31” +/_.01” gap between face of the bearing and back of the slingers. Rotate slingers approximately 90 degree apart, apply Loctite 246 on the socket cup screw and tight.

  • Page 196: Setting Impeller End Clearance With Mechanical Seals

    NOTICE Check the clearance over the entire width of the impeller and consider the tightest spot. B. Divide the end clearance by 3 and distribute approximately 1/3 on the gear end and the remaining 2/3 on the drive end. C. To move the impeller assembly toward the drive end, lightly tap the shaft at the gear end with a soft face mallet.

  • Page 197: Installing The Timing Gears

    INSTALLING THE TIMING GEARS If reusing the timing gears, the gears should be returned to their original positions. A. Obtain 2 gear locking assemblies. Clean the inside and outside diameters of both locking assemblies. Clean the inside diameter of 2 gears. Clean the outside diameter of the both rotor shafts. Lightly oil the surfaces that have been cleaned.
  • Page 198 These impeller-to-impeller and impeller-to-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 defection. If the clearances are not sufficient, the impellers may contact each other or the housing with destructive results.

  • Page 199: Figure 7-9 - Torque Ft Lbs

    Exercise care not to damage the seal lip as it passes over the shaft keyway. 16. Assemble the gear cover (3) and gasket (7) to the gear headplate (18) using socket head screw (5). Tighten the capscrews alternately and evenly. Refer to FIGURE 7-9 for torque specifications. 17.
  • Page 200 SECTION 8 PARTS LIST SB-7-632 Page 39...
  • Page 201 Order by Part Number and Description. Reference Numbers are for your convenience only. Model GAB Lip Seal Grease Splash Lube Ref. Size – 3H Size – 3M Size -- 3L GABH_R ∆ GABM_R ∆ GABL_R ∆ Description Req’d ∆= (A or C) ∆= ( A or C) ∆= ( A or C) Plug ....................
  • Page 202 SB-7-632 Page 41...
  • Page 203 Order by Part Number and Description. Reference Numbers are for your convenience only. Model GAC Lip Seal Grease Splash Lube Ref. Size – 4H Size – 4M Size -- 4L GACH_R ∆ GACM_R ∆ GACL_R ∆ Description Req’d ∆= (A or C) ∆= ( A or C) ∆= ( A or C) Plug ....................
  • Page 204 301GAE810-A (Ref. Drawing) SB-7-632 Page 43...
  • Page 205 Order by Part Number and Description. Reference Numbers are for your convenience only. Model GAE Lip Seal Grease Splash Lube Ref. Size – 5H Size – 5M Size -- 5L GAEH_R ∆ GAEM_R ∆ GAEL_R ∆ Description Req’d ∆= (A or C) ∆= ( A or C) ∆= ( A or C) Plug ....................
  • Page 206 SB-7-632 Page 45...
  • Page 207 Order by Part Number and Description. Reference Numbers are for your convenience only. Model GAB Mechanical Seal Grease Splash Lube Ref. Size – 3H Size – 3M Size -- 3L Description Req’d GABH_RB GABM_RB GABL_RB Plug ....................64AC2 64AC2 64AC2 Gear Case ..................
  • Page 208 SB-7-632 Page 47...
  • Page 209 Order by Part Number and Description. Reference Numbers are for your convenience only. Model GAC Mechanical Seal Grease Splash Lube Ref. Size – 4H Size – 4M Size -- 4L Description Req’d GACH_RB GACM_RB GACL_RB Plug ....................64AC3 64AC3 64AC3 Gear Case ..................
  • Page 210 303GAE810-A (Ref. Drawing) SB-7-632 Page 49...
  • Page 211 Order by Part Number and Description. Reference Numbers are for your convenience only. Model GAE Mechanical Seal Grease Splash Lube Ref. Size – 5H Size – 5M Size -- 5L Description Req’d GAEH_RB GAEM_RB GAEL_RB Plug ..................64AC3 64AC3 64AC3 Gear Case ................
  • Page 212 SB-7-632 Page 51...
  • Page 213 Order by Part Number and Description. Reference Numbers are for your convenience only. Model GAB Lip Seal Dual Splash Lube Ref. Size – 3H Size – 3M Size -- 3L GABH_R ∆ GABM_R ∆ GABL_R ∆ Description Req’d ∆= ∆= ∆= (D or F) ( D or F)
  • Page 214 SB-7-632 Page 53...
  • Page 215 Order by Part Number and Description. Reference Numbers are for your convenience only. Model GAC Lip Seal Dual Splash Lube Ref. Size – 4H Size – 4M Size -- 4L GACH_R ∆ GACM_R ∆ GACL_R ∆ Description Req’d ∆= ∆= ∆= (D or F) ( D or F)
  • Page 216 300GAE810-A (Ref. Drawing) SB-7-632 Page 55...
  • Page 217 Order by Part Number and Description. Reference Numbers are for your convenience only. Model GAE Lip Seal Dual Splash Lube Ref. Size – 5H Size – 5M Size -- 5L GAEH_R ∆ GAEM_R ∆ GAEL_R ∆ Description Req’d ∆= ∆= ∆= (D or F) ( D or F)
  • Page 218 SB-7-632 Page 57...
  • Page 219 Order by Part Number and Description. Reference Numbers are for your convenience only. Model GAB Mechanical Seal Dual Splash Lube Ref. Size – 3H Size – 3M Size -- 3L GABH_R ∆ GABM_R ∆ GABL_R ∆ Description Req’d ∆= ∆= ∆= (E or G) (E or G)
  • Page 220 SB-7-632 Page 59...
  • Page 221 Order by Part Number and Description. Reference Numbers are for your convenience only. Model GAC Mechanical Seal Dual Splash Lube Ref. Size – 4H Size – 4M Size -- 4L GACH_R ∆ GACM_R ∆ GACL_R ∆ Description Req’d ∆= ∆= ∆= (E or G) (E or G)
  • Page 222 302GAA810-A (Ref. Drawing) SB-7-632 Page 61...
  • Page 223 Order by Part Number and Description. Reference Numbers are for your convenience only. Model GAE Mechanical Seal Dual Splash Lube Ref. Size – 5H Size – 5M Size -- 5L GAEH_R ∆ GAEM_R ∆ GAEL_R ∆ Description Req’d ∆= ∆= ∆= (E or G) (E or G)
  • 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 OPERATORS MANUAL Sutorbilt P Series Sec�on 5 1300 998 784 STGGLOBAL.NET...
  • Page 227 PARTS LIST OPERATING AND SERVICE MANUAL LEGEND “P” SERIES BLOWERS 6” - - 8” GEAR DIAMETER Models GAF_ _P_ GAG_ _P_ GAH_ _P_ SB- -7- - 622 Version 03 November, 2005...

  • Page 228: Maintain Blower Reliability And Performance

    MAINTAIN BLOWER RELIABILITY AND PERFORMANCE WITH GENUINE GARDNER DENVER PARTS AND SUPPORT SERVICES Factory genuine parts, manufactured to design toler- blower investment with these services: ances, are developed for optimum dependability ------ Trained parts technical representatives to assist specifically for your blower. Design and material innova- you in selecting the correct replacement parts.

  • Page 229: Foreword

    FOREWORD Sutorbilt blowers are the result of advanced engineering and skilled manufacturing. To be assured of receiving maximum service from this machine the owner must exercise care in its operation and maintenance. This book is written to give the operator and maintenance department essential information for day-to-day operation, mainte- nance and adjustment.

  • Page 230: Safety Precautions

    SAFETY PRECAUTIONS Safety is everybody’s business and is based on your use of good common sense. All situations or circumstances cannot always be predicted and covered by established rules. Therefore, use your past experience, watch out for safety hazards and be cautious. Some general safety precautions are given below: Failure to observe these notices could result in injury to or death of personnel.
  • Page 231 TABLE OF CONTENTS Page Maintain Blower Reliability and Performance with Genuine Gardner Denver Parts and Support Services ..Instructions for Ordering Repair Parts ..............Instructions for Determining Blower Configuration .

  • Page 232: Mounting Configurations

    INDEX Air Filters and Filter--Silencers ....Gear End ....... . Lubrication Service .

  • Page 233: Sutorbilt Legend Series Blowers Matrix/Menu

    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 FIND...

  • Page 234: Introduction

    INTRODUCTION YOUR KEY TO TROUBLE FREE SERVICE Thank you for investing in Sutorbilt quality. The Sutor- nance procedures that you must observe to assure bilt reputation for rugged dependability has been optimum blower performance. There is no guesswork earned by over 50 years of service in demanding, in the manufacture of your highly advanced Sutorbilt industrial operations where downtime cannot be blower and there must be none in preparing the blower...

  • Page 235: Section 1, Equipment Check

    SECTION 1 EQUIPMENT CHECK Before uncrating, check the packing slip carefully to be sure all the parts have been received. All accessories are listed as separate items on the packing slip, and small important accessories such as relief valves can Before running the blower, drain the be overlooked or lost.

  • Page 236: Section 2, Installation

    SECTION 2 INSTALLATION LOCATION MOUNTING CONFIGURATIONS The blower flex--mount design enables horizontal and If possible, install the blower in a well lit, clean, dry place vertical mounting configurations with top or bottom with plenty of room for inspection and maintenance. hand, right or left hand shaft positioning.
  • Page 237 Secure the mounting feet capscrews to the torque sheave positioning is as close as possible to the blower value in FIGURE 24, page 24. 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.
  • Page 238 Dimensions Maximum Gear (Inches) Allowable Diameter Moment (Inches) (LB--IN) (Max) 4.08 1.14 1788 4.50 1.31 3000 5.57 1.77 4144 MAXIMUM ALLOWABLE MOMENT DRIVE SHAFT ILLUSTRATION 0.000 1.000 0.250 0.966 0.500 0.926 0.750 0.879 1.000 0.823 1.250 0.751 0.025 0.997 0.275 0.962 0.525 0.922...

  • Page 239: Section 3, Lubrication

    SECTION 3 LUBRICATION OIL DRAIN PLUG BREATHER / OIL FILL GREASE FITTING GREASE VENTS OIL LEVEL GAUGE FIGURE 3 - - LUBRICATION At the gear end the timing gear teeth are lubricated by bearings through grease fittings located at (C). When being partially submerged in oil.
  • Page 240 Blower Factory Tested Discharge Recommended and Temperature Approved Lubricant Servicing the air filters is one of the most important maintenance opera- AEON PD tions to be performed to insure long Synthetic Blower Lubricant blower life. 100_ One Superior Lubricant 275_ 135_ Servicing frequency of filter elements is not time 350_...

  • Page 241: Section 4, Operation

    SECTION 4 OPERATION Future operating problems can be avoided if proper should be tested at initial startup to be sure they are ad- precautions are observed when the equipment is first justed to relieve at or below the maximum pressure dif- put into service.
  • Page 242 BLOWER STARTUP CHECKLIST This startup procedure should be followed during the initial installation and after any shutdown periods or after the blower has been worked on or moved to a new location. It is suggested that the steps be followed in sequence and checked off ( ) in the boxes provided.
  • Page 243 SAFETY PRECAUTIONS Do not operate blower with open inlet or outlet port. Do not exceed specified vacuum or pressure limitations. Do not exceed sheave or coupling Do not operate above or below recommended manufacturers’ rim speed limit. blower speed range. Blower is not to be used where non--sparking equipment is specified.

  • Page 244: Section 5, Special Tools Required

    SECTION 5 SPECIAL TOOLS REQUIRED 6” 7” 8” 11.00 13.00 16.00 NOTE: 6.000 7.000 8.000 REMOVE SHARP EDGES MAT’L: MED. CARBON STEEL 2.500 3.000 4.000 3.000 3.500 4.000 1.503 1.679 2.210 11.00 13.00 15.00 0.437 0.500 0.500 1.500 1.688 1.875 5.500 6.500 7.500...
  • Page 245 PIPE -- STEEL 2” SCH 80 MED. CARBON STEEL 1/2” FIGURE 9 - - GEAR DRIVER - - SK2150 SB- -7- -622 Page 12...
  • Page 246 NOTES: BREAK SHARP EDGES MATERIAL: 4140 HEAT TREAT TO RC 48 -- 52 UNIT SIZE 6” 2.748 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 SB- -7- -622 Page 13...
  • Page 247 NOTES: BREAK SHARP EDGES MATERIAL: 4140 HEAT TREAT TO RC 52 -- 56 UNIT SIZE 6” 1.900 5.000 7” 2.087 5.500 8” 2.406 6.000 FIGURE 11 - - BEARING PRESS TOOL - - MECHANICAL SEAL UNITS - - SK2156 SB- -7- -622 Page 14...

  • Page 248: Section 6, Disassembly Instructions

    SECTION 6 DISASSEMBLY INSTRUCTIONS THEY CAN BE REASSEMBLED IN THE SAME POSI- TION (IMPELLERS, HEADPLATES, AND GEARS). If the timing gears appear undamaged, the gear Numbers in parentheses ( ) refer to backlash must be checked to see if the gears can key numbers in assembly drawings be salvaged.
  • Page 249 FIGURE 14 FIGURE 15 If backlash is above the specified lim- it, the gears are not necessarily unus- able. Excessive play could be caused by worn bearings. If timing gears appear to be reusable, matchmark timing gear toothmesh by making small punch marks on the ends of meshing gear teeth with a pin punch and hammer (see FIGURE 13, page 15).
  • Page 250 FIGURE 17 FIGURE 15, page 16). After the headplate has 14. Remove the four cap screws (10) which fasten been removed, detach the puller plate. each bearing retainer (12) to the gear headplate. 12. Remove the two drive end bearings (14) from the 15.

  • Page 251: Section 7, Assembly Instructions

    SECTION 7 ASSEMBLY INSTRUCTIONS INSTALLING MECHANICAL SEALS Lightly coat the headplate bores with assem- bly lubricant. Numbers in parentheses ( ) refer to Refer to FIGURE 18. Install mechanical seal key numbers in assembly drawings (A) into the headplate bore using a press and on pages 25, 27 and 29.

  • Page 252: Mechanical Seals Only

    FIGURE 19 FIGURE 20 Assemble gear headplate (18) and mounting foot If total clearance is not within the limits specified (17) to the impeller case with cap screws (21) and in FIGURE 21, page 20, it may be necessary to where the mounting foot is secured to the head- shim the case to obtain the proper total end clear- plate use capscrews (16).
  • Page 253 FIGURE 21 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- Do not drive the mating ring down to ing in the bores without force.
  • Page 254 in Step 9. Press bearings into the gear headplate until completely seated in the bearing bore. GEAR HEADPLATE BEARING Bearings will not be flush with gear headplate bores when completely seated. SHAFT 11. Impeller should now be checked for free axial movement by hitting the ends of the impeller shafts with the palm of your hand.
  • Page 255 16. SETTING IMPELLER END CLEARANCE Refer to FIGURE 18, page 18. The gear end bearings are held in position by the force created by the wavy spring (28) on the drive end and the bearing retainer (12) on the gear end. The inter- ference fit between the shaft (H) and the bearing inner race (E) keeps the shaft from moving axially.
  • Page 256 If any of the four gear backlash read- Replacement gears have minimum ings are not within the specified backlash marks on the outside diame- limits, the gears must be replaced. ter of the gear face. These marks should be located 180 degrees from each other (see FIGURE 23).
  • Page 257 GEAR DIAMETER Ref. FASTENERS Screw -- Gear Case to Headplate Screw -- Bearing Retainer to Headplate Screw -- Mounting Foot to Headplate Screw -- Headplate to Impeller Case Screw -- Drive Cover to Headplate Screw -- Timing Hub to Gear NOTE: REF.

  • Page 258: Section 8, Parts List

    SECTION 8 PARTS LIST 300GAF810- -B (Ref. Drawing) SB- -7- -622 Page 25...
  • Page 259 Order by Part Number and Description. Reference Numbers are for your convenience only. MODEL GAF Ref. Size - - 6H Size - - 6M Size - - 6L Description Req’d GAFH_P_ GAFM_P_ GAFL_P_ NAMEPLATE ......... 301GAE496 301GAE496 301GAE496...
  • Page 260 300GAG810- -A (Ref. Drawing) SB- -7- -622 Page 27...
  • Page 261 Order by Part Number and Description. Reference Numbers are for your convenience only. MODEL GAG Ref. Size - - 7H Size - - 7M Size - - 7L Description Req’d GAGH_P_ GAGM_P_ GAGL_P_ NAMEPLATE ......... 301GAE496 301GAE496 301GAE496...
  • Page 262 300GAH810- -A (Ref. Drawing) SB- -7- -622 Page 29...
  • Page 263 Order by Part Number and Description. Reference Numbers are for your convenience only. MODEL GAH Ref. Size - - 8H Size - - 8M Size - - 8L Description Req’d GAHH_P_ GAHM_P_ GAHL_P_ NAMEPLATE ......... 301GAE496 301GAE496 301GAE496...
  • Page 264 WARRANTY SUTORBILT BLOWERS SUTORBILT LEGEND SERIES GENERAL PROVISIONS AND LIMITATIONS Company’s judgment is proved not to be as warranted. Labor shall be limited to the amount specified in the Gardner Denver (the “Company”) warrants to each orig- Company’s labor rate schedule. inal retail purchaser (“Purchaser”) of its new products from the Company or its authorized distributor that such Labor costs in excess of the Company rate schedule...
  • Page 266 OPERATORS MANUAL Lofa Manual Sec�on 6 1300 998 784 STGGLOBAL.NET...
  • Page 267 EP250 Panel Operation ™ and Troubleshooting 463-3000-01 Rev D. 23-Sep-2013 © 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 This page intentionally left blank 463-3000-01 Rev D. 23-Sep-2013...
  • Page 269 EP250 Panel Operation and Troubleshooting Introduction This document provides general information on LOFA™ EP250 panel operation and troubleshooting. EP250 control panels are a flexible platform for diesel engine control, monitoring, and protection, featuring LOFA’s powerful First Fault Diagnostics (FFD). After pinpointing the initial failure, FFD stores it in memory and alerts the end user via a single bright LED.
  • Page 270 EP250 Panel Operation and Troubleshooting Important Safety Information The warnings in this publication are not all inclusive. LOFA Industries cannot anticipate every potential hazard. Appropriate safety rules and precautions should be followed with any tool, work method or operating procedure. Improper procedures, tools and materials may cause damage or make the equipment unsafe to operate.
  • Page 271 EP250 Panel Operation and Troubleshooting Operation Turning the panel key to the run position starts a self-test which causes all LEDs to illuminate once, activates the alarm output for one second and enables the fuel run/stop solenoid output. After self-test, the LEDs indicate the state of the inputs they monitor. The normal indications are battery charge and oil pressure on most applications.
  • Page 272 EP250 Panel Operation and Troubleshooting The panel has the ability to shut down the engine for over speed. Over speed will be indicated via a blinking Battery Charge LED. The panel senses RPM either by the frequency terminal of the alternator, proximity switch or magnetic pick-up with the optional magnetic pick-up amplifier/divider.
  • Page 273 EP250 Panel Operation and Troubleshooting Warning! Low oil pressure is not an indication of low oil level. For best possible protection LOFA recommends using our solid-state oil level shutdown switch. Note Most shutdown switches are grounded through the switch body. Do not use insulating sealant (i.e.
  • Page 274 EP250 Panel Operation and Troubleshooting ground contact switch. Auxiliary inputs are equipment specific and determined by the equipment manufacturer. 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.

  • Page 275: Oil Pressure Gauge

    EP250 Panel Operation and Troubleshooting Gauges Voltmeter The voltmeter is connected to the fuel run/stop solenoid output. If the voltmeter does not indicate in the run position, this indicates a problem with the solenoid circuit. 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.
  • Page 276 EP250 Panel Operation and Troubleshooting Warning! If the temperature sensor is not in contact with coolant due to coolant loss the gauge will not accurately indicate engine temperature. Note Senders and gauges must be matched to indicate correctly. Most senders are grounded through the sender body. Do not use insulating sealant (i.e.
  • Page 277 EP250 Panel Operation and Troubleshooting 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. 463-3000-01 Rev D.
  • Page 278 EP250 Panel Operation and Troubleshooting Battery Circuit Requirements Battery Positive Connection The electronic panel operates on either a 12 VDC or 24 VDC electrical systems. The unswitched battery positive connection to the panel is made at the weather proof connector. The panel provides switched positive battery protected by a 15 Amp fuse (12 V or 24 V systems).
  • Page 279 EP250 Panel Operation and Troubleshooting engine. Since the panel did not sense a start signal, the fuel run/stop solenoid deactivates after 10 seconds. Voltage drops can be caused by external equipment inrush current, improper wire sizes or faulty wiring. Relays may be needed for long wire runs. Suppression of Voltage Transients (Spikes) Warning! The installation of voltage transient suppression at the transient source is required.
  • Page 280 EP250 Panel Operation and Troubleshooting 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.

  • Page 281: General Troubleshooting

    EP250 Panel Operation and Troubleshooting General Troubleshooting For additional information, refer to engine manufacturer troubleshooting guide. No response from starter motor Possible Cause Possible Remedy No battery voltage to Verify wiring and battery connection (power and ground) starter Battery discharged Charge or replace battery, verify alternator charging Tripped overcurrent Correct fault, replace or reset overcurrent protection...

  • Page 282: Trouble Shooting

    EP250 Panel Operation and Troubleshooting Alternator not charging battery Possible Cause Possible Remedy Broken or slipping Adjust or replace alternator drive belt alternator drive belt Alternator not excited Verify excitation circuit connected, replace faulty regulator, add additional excitation resistor Alternator output not Install charge wire connected Alternator not grounded...
  • Page 283 EP250 Panel Operation and Troubleshooting Preheat Troubleshooting Engine is hard to start in cold conditions Possible Cause Possible Remedy Start attempt before Wait for preheat time to elapse, crank as soon as time elapses preheat complete Incorrect preheat Correct panel configuration, install correct panel specification Heater faulty Replace heater...
  • Page 284 EP250 Panel Operation and Troubleshooting Testing Shutdown Inputs Shutdown switches signal a fault by ground contact in most systems. Shutdown operation can be verified by grounding the shutdown inputs individually. It may be necessary to remove the wire from the shutdown switch to perform this test. Note Most shutdown switches are grounded through the switch body.
  • 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 290 Software License Agreement This LICENSE AGREEMENT (“Agreement”) is made as of the Effective Date noted below by and between LOFA™ Industries Inc. (“LOFA”), a Georgia corporation with a principal place of business at 250 Hembree Park Drive, Suite 122, Roswell GA 30076, and Licensee as defined below. Standard Terms and Conditions Definitions.
  • Page 291 Software License Agreement errors in the Licensed Product can be found in order to be corrected. All warranties provided in in this Agreement are solely for the benefit of, and may not be transferred by, Licensee, to any third party. Limits on Scope of Indemnity.
  • Page 292 Software License Agreement without further action by LOFA. A change of control of Licensee, whether by sale or issuance of shares (except in the ordinary course of raising capital by public offering), or merger, or otherwise, will be deemed to be an assignment. The laws in force in the State of Georgia will govern this Agreement;...
  • Page 293 MANUFACTURER OF QUALITY ENGINE COMPONENTS 250 Hembree Park Suite Roswell GA Drive 30076 770-569- 770-569- PHONE www.LOFA.net 9828 9829 463-3000-01 Rev D. 23-Sep-2013...
  • Page 294 OPERATORS MANUAL Excava�on Hydro SWMS Sec�on 7 1300 998 784 STGGLOBAL.NET...
  • Page 314 OPERATORS MANUAL Pressure Cleaner Water SWMS Sec�on 8 1300 998 784 STGGLOBAL.NET...

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