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Vanguard CPW 125-4-S Series Operation And Maintenance Manual

Weld-deck welding package
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Table of Contents

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Vanguard
Equipment,
Inc.
Operation and
Maintenance Manual
Weld-Deck welding package CPW 125-4-S2
/ includes Slewing Canopy (037-08OP-003B)
/ includes Auto Tie-In Crane (037-08OP-004B)
S/NCB50600021 – UP (Weld-Deck)
To be used with Cummins® Operation and Maintenance Manual 4021531
037-08OP-002D-01
2017-12

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Summary of Contents for Vanguard CPW 125-4-S Series

  • Page 1 Vanguard 037-08OP-002D-01 Equipment, 2017-12 Inc. Operation and Maintenance Manual Weld-Deck welding package CPW 125-4-S2 / includes Slewing Canopy (037-08OP-003B) / includes Auto Tie-In Crane (037-08OP-004B) S/NCB50600021 – UP (Weld-Deck) To be used with Cummins® Operation and Maintenance Manual 4021531...
  • Page 2 VANGUARD EQUIPMENT, INC. 15627 EAST PINE ST TULSA, OKLAHOMA 74116, USA ℡/ : 918.437.1796 S/N CB50600021 – UP (Weld-deck)

  • Page 3: Table Of Contents

    Table of Contents FOREWORD..................................1 ............................. 1 ITERATURE NFORMATION ..............................1 ACHINE ESCRIPTION ................................... 1 AFETY ..................................1 PERATION ................................2 AINTENANCE .............................. 2 AINTENANCE NTERVALS 65 ............................2 ALIFORNIA ROPOSITION ..........................2 ERTIFIED NGINE AINTENANCE SAFETY SECTION ................................. 2 .............................
  • Page 4 ............................31 OUND EVEL NFORMATION Sound Level Information for Machines in European Union Countries and in Countries that Adopt the “EU Directives” ....................................31 ................................... 31 IBRATION ) ..........................31 UARDS PERATOR ROTECTION PRODUCT INFORMATION SECTION (CPW-124-4-S2) ................... 32 ..............................32 ENERAL NFORMATION Equipment Information Section ..........................
  • Page 5 ..............................70 ENSET SHUTDOWN ............................... 71 ACHINE ARKING ........................... 71 RANSPORTATION NFORMATION Shipping the Carrier-Mounted Weld-Deck ......................... 71 Towing the Carrier ..............................71 MAINTENANCE SECTION ............................73 .............................. 73 ORQUE PECIFICATIONS Torques for Standard Fasteners ..........................74 Torques for Metric Fasteners ............................ 74 Torques for Vibration Isolator Mounts ........................

  • Page 6: Foreword

    Read, study and keep this manual with the machine. Machine Description Vanguard’s Continuously Powered Welding (CPW) Package attachment is a modular, self powered design that can be mounted to a variety of carriers—pipelayers, crawler tractors, etc.—or on a self-contained skid-mount. It provides clean, stable alternating current (AC) to power a variety of welding power units and auxiliary equipment.

  • Page 7: Maintenance

    Do not use pressure washers to clean the safety signs. Replace any safety sign that is damaged, or missing. If a safety sign is attached to a part that is replaced, install a safety sign on the replacement part. Vanguard Equipment can provide new safety signs. 037-08OP-002D-01...
  • Page 8 037-08OP-002D-01 S/N CB50600021 – UP (Weld-deck)
  • Page 9 037-08OP-002D-01 S/N CB50600021 – UP (Weld-deck)
  • Page 10 The optional 4x1 welder enclosure replaces the 2x2 welder enclosure on the welddeck (the relative locations of 12 & 13 are shown on the previous page). 037-08OP-002D-01 S/N CB50600021 – UP (Weld-deck)

  • Page 11: Do Not Operate (1)

    Do Not Operate (1) WARNING! Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your dealer for replacement manuals. Proper care is your responsibility. Safety message (1) is located on main door of the control/distribution center.
  • Page 12 Safety message (2) is located on outer main door, and on the inner main panel door of the control/distribution center. Safety message (2) is also located on the rear access panel on the control/distribution center. 037-05-63-307A 037-05-63-311B 037-05-63-313A Figure 2: Electrical Shock (2) 037-08OP-002D-01 S/N CB50600021 –...

  • Page 13: Do Not Weld On The Machine (3)

    Do Not Weld on the Machine (3) Notice Do not weld on, or modify this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Improper welding or modifications to this machine could seriously damage the Genset Engine. See the Maintenance Welding to the Weld-deck section in the Operation and Maintenance Manual.

  • Page 14: Hot Surface (4)

    Hot Surface (4) WARNING! Hot parts or hot components can cause burns or personal injury. Do not allow hot parts or components to contact your skin. Use protective clothing or protective equipment to protect your skin. Keep away from hot surfaces.

  • Page 15: Hot Fluid Under Pressure (5)

    Hot Fluid Under Pressure (5) WARNING! Pressurized system! Hot coolant can cause serious burns, injury or death. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.

  • Page 16: Electrical Shock (6)

    Electrical Shock (6) WARNING! Shock/Electrocution Hazard! Read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could cause serious injury or death. Safety message (6) is located on the Genset Enclosure service door. Message (6) is also located on the Genset Enclosure service panel, and on the generator electrical connection box inside of the Genset Enclosure.

  • Page 17: Volt Dc System (7)

    24 Volt DC system (7) Notice The Genset Engine operates on a 24Volt DC electric system. This includes the batteries, charging, starter-motor, and control system. Do not attempt to connect to another system that operates on a different voltage than 24 Volts DC. Read and understand the instructions and warnings in the Operation and Maintenance Manual.
  • Page 18 Improper Connections for Jump Start Cables (8) Warning! Explosion Hazard! Improper jumper cable connections can cause an explosion resulting in serious injury or death. Batteries may be located in separate compartments. Refer to the Operation and Maintenance Manual for the correct jump starting procedure. Safety message (8) is located on the Genset Enclosure service panel, battery/charging system access.
  • Page 19 Fan Do Not Touch (9) Warning! Rotating Fan, do not touch. Serious injury can occur if body parts come into contact with the rotating fan. Keep body parts, and loose clothing away from the rotating fan at all times. Keep objects away from moving fan blades.
  • Page 20 Do Not Smoke (10) Warning! Explosion Hazard! Do Not Smoke inside the Genset Enclosure. Ether cylinder present, do not smoke inside the genset compartment. Do not smoke while changing ether cylinders. Safety message (10) is located inside the Genset Enclosure on both sides of the Engine. (10) 037-05-09-002 (10)

  • Page 21: Drain Air Receiver Daily (11)

    Drain Air Receiver Daily (11) Warning! Explosion Hazard! Drain Air Receiver Daily. Failure to drain moisture will corrode Air Receiver material and lead to Air Receiver failure. Read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could cause serious injury or death. Safety message (11) is located at the front of the Weld-Deck, under the Access-ways, above the air receiver drain valve (if an air receiver is installed).

  • Page 22: Do Not Step (12)

    Do Not Step (12) WARNING! Do not step on this surface. Do not walk on this surface. Refer to the Operation and Maintenance Manual for the intended use of the welder enclosure roof. Failure to follow the instructions or heed the warnings could result in serious injury or death.

  • Page 23: Maximum Surface Load Capacity (13)

    Maximum surface load capacity (13) Notice Do not overload the flat welder enclosure roof. The maximum load the roof can accommodate is 200 lb (90 Kg). Read the Operation and Maintenance Manual. Information message (13) is located on main roof of the flat welder enclosure (Optional Component). 037-09-35-001 Figure 13: Maximum surface load capacity (13) 037-08OP-002D-01...

  • Page 24: Ethyl Ether Cylinder

    ETHYL ETHER CYLINDER Warning! Explosion hazard! When maintaining or troubleshooting these systems, always make sure that you are in a well ventilated area away from heat, open flames, or sparks. Wear goggles when testing to avoid eye injury. Make sure that openings of the valve, tube, or atomizer are pointed away from yourself while testing. The ethyl ether used in this starting fuel for these systems is extremely flammable, toxic, harmful, or fatal if swallowed, do not induce vomiting.

  • Page 25: Batteries

    Batteries Warning! Poison! Explosion Hazard! Keep out of reach of children. Do not tip. Do not open battery! Shield eyes. Explosive gases can cause blindness or injury. No sparks, flames or smoking. Sulfuric Acid can cause blindness or severe burns. Keep vent caps tight and level.

  • Page 26: General Hazard Information

    (center of gravity). Be especially aware of the additional weight when climbing steep slopes or loading for transport. Additional front-mounted counter weight is available from Vanguard Equipment. Follow all safety regulations, procedures and precautions that govern the work site, including: wearing a hard hat, protective glasses and other protective equipment in order to accommodate job conditions.

  • Page 27: Pressure Air And Water

    Pressure Air and water Pressurized air and/or water can cause debris and/or hot water to be blown out. The debris and/or hot water could result in personal injury. When pressurized air and/or pressurized water is used for cleaning, wear protective clothing, protective shoes, and eye protection.

  • Page 28: Inhalation

    Asbestos Information Equipment and replacement parts that are shipped from Vanguard are asbestos free. Use only genuine OEM replacement parts. If any replacement parts that contain asbestos are used, follow the manufacturer's handling guidelines and procedures as outlined in their instruction documentation.

  • Page 29: Burn Prevention

    If it is necessary to remove guards in order to perform maintenance, always install the guards after the maintenance is performed. Keep objects away from moving fan blades. The fan blade will throw objects or cut objects. When you strike a retainer pin with force, the retainer pin can fly out. The loose retainer pin can injure personnel. Make sure that the area is clear of people when you strike a retainer pin.
  • Page 30 To minimize the risk of fire or explosion, the following actions are recommended. Always perform a Walk-Around Inspection, which may help you identify a fire hazard. Do not operate a machine when a fire hazard exists. Contact your dealer for service. Do not operate a machine with a fluid leak.

  • Page 31: Battery And Battery Cables

    Battery and Battery Cables The following actions are recommended to minimize the risk of fire or an explosion related to the battery. Do not operate a machine if battery cables or related parts show signs of wear or damage. Contact your dealer for service. Follow safe procedures for engine starting with jump-start cables.

  • Page 32: Wiring

    Wiring Check electrical wires daily. If any of the following conditions exist, replace parts before you operate the machine. • Fraying • Signs of abrasion or wear • Cracking • Discoloration • Cuts on insulation • Other damage Make sure that all clamps, guards, clips, and straps are reinstalled correctly. This action will help to prevent vibration, rubbing against other parts, and excessive heat during machine operation.

  • Page 33: Ether

    Ether Ether (if equipped) is commonly used in cold-weather applications. Ether is flammable and poisonous. Follow the correct cold engine starting procedures. Refer to the Operation and Maintenance Manual, “Ether Starting Aid”. Do not spray ether manually into an engine if the machine is equipped with a thermal starting aid for cold weather starting. Use ether in ventilated areas.

  • Page 34: Fire Extinguisher Location

    "General Hazard Information" section above. Replace electrical cables or wire-harnesses with the same electrical rating, properties, and specifications as the original. Contact your dealer or Vanguard for replacement parts. Replace electrical cables or wire-harnesses if any of the following conditions are present: •...

  • Page 35: Before Operating Equipment

    Machine Operating Temperature Range The standard machine configuration is intended for use within an ambient temperature range -40°C (-40°F) to 50°C (122°F). Special configurations for different ambient temperatures may be available. Consult Vanguard or your dealer for additional information on special configurations.

  • Page 36: Machine Parking

    Report any needed repairs that were noted during operation. Connect trailing equipment to a drawbar or to a hitch on the carrier-vehicle only. DO NOT connect trailing equipment to the weld-deck structure. Machine Parking Refer to the carrier’s Operation and Maintenance Manual for specific machine parking instructions. Genset Engine Stopping Do not stop the genset-engine immediately after the machine has been operated under electrical-load.

  • Page 37: Product Information Section (Cpw-124-4-S2)

    Product Information Section (CPW-124-4-s2) General Information Equipment Information Section Weld-Deck Module AIR RECEIVER Weld-Deck Module GENSET COMPRESSOR 037-05-05-110A DOGHOUSE (WELDER MODULE) CONTROL/ PACKAGE DISTRIBUTION SERIAL CENTER NUMBER 037-05-05-001A Bottle Rack (Front mount) 037-05-15-014A Figure 17: Equipment modules (Crawler Tractor) 037-08OP-002D-01 S/N CB50600021 –...
  • Page 38 CPW 125-4-S2–4-s2 Rear-mounted Welder Package Specification (Carrier-vehicle/Welding Gas and consumables/Crane weights not included) (A) Transport width (catwalks stowed) 2743 mm 108 in (B) Working width (catwalks extended) 3232 mm 127.25 in (C) Welding package height exhaust (transport) to ground (no carrier) 2680 mm 105.5 in (D) Welding package height exhaust installed (working) to ground...
  • Page 39 AIR RECEIVER Weld-Deck Module Weld-Deck Module GENSET Bottle Rack (Rear mount) DOGHOUSE FRONT PLATFORM (WELDER MODULE) CONTROL/ PACKAGE Module (If Equipped) COMPRESSOR DISTRIBUTION SERIAL 037-T8-05-001A NUMBER CENTER 037-05-05-001A Figure 18: Equipment modules (Flat Deck Mount) CPW 125-4-S2–4 Flat-Deck-mounted Welder Package Specification (Carrier-vehicle/Welding Gas and consumables/Crane weights not included) (A) Transport width (catwalks stowed) 2743 mm...

  • Page 40: Restrictions To Application And Configuration

    Restrictions to Application and Configuration To obtain the proper lubrication, a maximum slope should not exceed a grade of 119 percent or 50 degrees up and down angularity, and should not exceed 93 percent or 43 degrees side-to-side angularity. Do not exceed these limits. Do not exceed the angularity or slope grade limits of the carrier vehicle.

  • Page 41: Iso Symbols (Model Usage)

    ISO Symbols (Model Usage) The following list contains all of the ISO Symbols that appear in this publication. On: To identify the on position of a control. Off: To identify the off position of a control. Battery Disconnect: To identify the control that disconnects the battery from the electrical system. Engine Start: To identify the control used to start the engine.

  • Page 42: Declaration Of Conformity

    Declaration of Conformity Machines supplied with the "CE" plate are compliant to "2006/42/EC" and with EN 60439-1. 037-08OP-002D-01 S/N CB50600021 – UP (Weld-deck)

  • Page 43: Emissions Certification Film

    Emissions Certification Film Note: This information is pertinent in the United States, in Canada and in Europe. This label is located on the engine. This label lists EPA emission conformity for North America, and the EU emissions certificate number for Europe. For complete details on all Engine Identification tags and labels, refer to Cummins®...

  • Page 44: Operation Section

    Operation Section Mounting and Dismounting Warning! Crushing Hazard not attempt to mount or dismount the machine between the machine and any object that may RETAINING RETAINING LATCH LATCH 037-40-63-115A 037-05-14-001A STOW LATCH WHEN RETAINING LATCH EXTENDING WALKWAYS (BOTH SIDES) 037-05-14-004A 037-05-14-005A move.

  • Page 45: Battery Disconnect Switch

    Face the machine whenever getting on, off, or moving around the machine. Maintain three-point contact with the steps/walkways and with the handholds. Note: Three-point contact can be two feet and one hand. Three-point contact can also be one foot and two hands. Do not a moving machine.

  • Page 46: Operator Controls

    Turn the battery disconnect switch key to the off (O) position and remove the battery disconnect switch key when you service the electrical system or you service any other components on the equipment. See also the General Hazard Information section in this manual. Turn the battery disconnect switch key to the off (O) position and remove the battery disconnect switch key when the equipment is left for an extended period of one month or longer.

  • Page 47: Control Panel Illumination Button

    Control Panel Illumination Button 037-05-63-309A 037-05-63-310B Figure 24: Control Panel Illumination Press and hold the WHITE control panel illumination button in dark lighting conditions to turn on the panel display lights and illuminate the controls when the genset is stopped; the lights automatically turn on whenever the genset is running.

  • Page 48: Rated/Idle Switch

    Rated/Idle Switch IDLE — With rated/idle switch in this position, the genset engine runs idle speed approximately700 - 900 RPM. Use this position for start-up, warm-up, and during extended periods of running with no load. Note: Do not operate the engine at idle for long periods with the engine coolant...

  • Page 49: Genset Engine Gauges And Indicators

    037-05-63-309A 037-05-63-310C 037-05-63-310B Genset Engine Gauges and Indicators Figure 28: Genset Engine Gauges and Indicators Service Hour Meter (1) — This gauge indicates the total operating hours of the genset. The service hour meter should be used to determine service hour maintenance intervals. Genset Engine Coolant (1) —...
  • Page 50 Engine Digital Display(5) — This display shows the Genset Engine's operating parameters monitored by the Engine Control Module (ECM), as well as active and stored ECM trouble codes. The Engine Digital Display unit also powers and supplies all displayed engine information to the engine gauges (2), (3), and (4) above.

  • Page 51: Main Supply Ac Circuit Breaker

    Main Supply AC Circuit Breaker Warning! Shock/Electrocution Hazard! Read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could cause serious injury or death. High voltage poses an electrocution hazard; this equipment must be operated by qualified personnel only. DO NOT OPEN the inner main panel door unless you are a qualified service technician, and are familiar with the dangers of high voltage.

  • Page 52: Main Supply Ac Meters

    037-05-63-310B 037-05-63-312B Main Supply AC Meters’ Phase Selector Switch Figure 31: Main Supply AC Meters’ Phase Selector Switch Ф Main Supply AC Meters’ Phase Selector Switch — Use this switch to select which leg of the three-phase (3Ф) load current is displayed on the main AC-supply A1 Ammeter. The positions 1, 2, 3 correspond to each leg of the three-phase supply, while position 0 turns the meters off.
  • Page 53 Frequency Meter (1) — This meter displays the frequency, in Hertz, of the incoming main supply power, either 60Hz or 50Hz. Refer to the Genset Frequency Configuration—60Hz and 50Hz Modes section in this manual for more detailed info. Voltmeter (2) — This meter displays the main incoming supply voltage, in Volts, being supplied to the load by the genset;...

  • Page 54: Three Phase Equipment Circuit Breakers And Receptacles

    Three Phase Equipment Circuit Breakers and Receptacles Ф CB15 circuit breakers, CB10 - CB 15 CB14 CB13 CB12 CB11 CB10 037-05-63-311B REAR OF CONTROL/ DISTRIBUTION CENTER RC 9 RC 11 RC 8 COMPRESSOR (IF INSTALLED) RC 10 RC 12 037-05-63-314A 037-05-63-313A Figure 33: Three Phase Equipment Circuit Breakers and Receptacles Each of the three phase equipment circuit breakers energizes one of the three phase sub-circuits that exit the rear of the...

  • Page 55: 60Hz Single Phase Front-Mounted Equipment Receptacles And Circuit Breakers With Ground Fault Circuit Interrupters (Gfci) - Standard Receptacles

    60Hz Single Phase Front-Mounted Equipment Receptacles and Circuit Breakers with Ground Fault Circuit Interrupters (GFCI) — Standard Receptacles CB16 60Hz, Single Phase circuit breakers with GFCIs, CB17 - CB 23 037-05-63-311B RC 6 RC 7 RC 1 RC 2 RC 3 RC 4 RC 5 037-05-63-315A...
  • Page 56 from bare connectors or terminals, etc. Note: GFCI should be tested daily, refer to the Ground Fault Circuit Interrupters (GFCI)—Test Daily section of this manual. Move each of the 60Hz single phase equipment circuit breakers to the ON position to energize its corresponding receptacle. Move each of the 60Hz single phase equipment circuit breakers to the Off position to de-energize its corresponding receptacle, if required.

  • Page 57: 50Hz Single Phase Front-Mounted Equipment Receptacles And Circuit Breakers With Feeder Circuit Ground Fault Circuit Interrupters (Gfci) - Optional Receptacles

    CB22 037-05-63-311B (GFCI) CB23 (GFCI) 60Hz panel shown. Contact Vanguard for available 50 Hz front panels. 037-05-63-314A Figure 35: 50 Hz Single Phase Front-Mounted Equipment Receptacles and Circuit Breakers with Feeder Circuit Ground Fault Circuit Interrupters (GFCI) Each of the 50Hz single phase equipment circuit breakers energizes one of the dedicated 50Hz single phase receptacles, available optional receptacle plates, on the front of the control/distribution center.

  • Page 58: Single Phase Equipment Ground Fault Circuit Interrupters (Gfci)-Connecting To

    another path for the GFCI to trip. GFCIs do not protect against line to line or line to neutral contact hazards such as result from bare connectors or terminals, etc. Note: GFCI should be tested daily, refer to the Ground Fault Circuit Interrupters (GFCI)—Test Daily section of this manual.

  • Page 59: Air Compressor

    Air Compressor An air compressor may be installed, check the specific weld-deck. 037-05-09-302A Figure 36: Air Compressor (if installed) Note: Refer to the Air Compressor Operation/Maintenance Manual for detailed operation and maintenance instructions; see the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW 125-4- S2-4.

  • Page 60: Compressed Air Pressure Gauge

    compressor when not in use. The air compressor start/stop switch can be left in the on (I) for the duration of a job when the compressor is in use; it will automatically start-up as soon as the main supply AC circuit breaker (CB 1) is set. Note: Depending on the compressor run-mode, the compressor will automatically unload or shut-off once the set air- receiver pressure has been reached;...

  • Page 61: Compressed Air Receiver Drain Valve

    Compressed Air Receiver Drain Valve FRONT Front Left Side Air Receiver Drain Drain Valve on Valve, shown OPEN underside of deck. to drain Warning Film on 037-42-55-016A 037-05-05-112A side of deck. FRONT Left Side Warning! Explosion Hazard! Drain Air Receiver Daily. Failure to drain moisture will corrode Air Receiver material and lead to Air Receiver failure.

  • Page 62: Air Receiver Relief Valve

    Compressed Air Supply Line Tee —Two1-inch NPT pipe connections are provided for air supply to outboard auxiliary equipment. (1)A 1-inch NPT ball valve (female, open). (2) a 1-inch NPT ball valve with straight connection (male, capped). Note: Use appropriate lines and fittings that have adequate pressure ratings to carry the 1.724 MPa (250 psi) working pressure of the compressed air supply.

  • Page 63: Welder Doghouse Enclosure

    037-11-35-025A 037-11-35-015A Welder Doghouse Enclosure Figure 43: Welder Doghouse Enclosure, door latched open, door latched closed The Welder Doghouse Enclosure houses up to four welding power units. The welder doghouse enclosure’s door folds up and slides back into the top of the doghouse enclosure. The doghouse enclosure’s door latches in place in either the open or the closed position.

  • Page 64: Before Starting Genset-Engine

    Before Starting Genset-Engine Make a thorough walk-around inspection and specific module checks: Welding deck 1. Fully extend the catwalks all around the deck. 2. Check for obvious signs of damage, lose bolts, lose equipment, and foreign objects or debris on and under the deck. Welder Doghouse 1.

  • Page 65: Control/Distribution Center

    Warning! Pressurized system! Only remove the radiator filler cap when the engine is cool, then loosen cap slowly to relieve the pressure. To prevent the possibility of personal injury, do not remove the cap on a hot engine. Wait until the coolant temperature is below 50°C (120°F) before removing the radiator pressure cap.

  • Page 66: Genset Cold Weather Operation

    Maintenance Manual, Weld-Deck welding package CPW 125-4-S2-4. A 750W/120VAC coolant heater (1), and a 150W/120VAC oil heater (2) are fitted to the standard engine. Both plug into an external 120VAC power source. Contact Vanguard equipment for optional heaters. 037-40-50-148A...

  • Page 67: Winter-Fronts

    Winter-fronts The genset enclosure can be fitted with Winter-fronts, contact Vanguard Equipment, Inc. Winter-fronts can be used on the genset enclosure to reduce air flow through the radiator core. This can reduce the time required to warm the engine and help maintain the engine coolant temperature. The engine coolant temperature specifications are in the Maintenance Specification section of the CUMMINS®...

  • Page 68: Cold Weather Starting Below 0°C (32°F) With Ether Starting

    10. Observe the engine operation Walk completely around the machine and check for unusual operation—unusual noises or vibration, coolant or oil leaks—including inside the Genset compartment Listen for any unusual noises and IMMEDIATELY stop the genset and investigate if any are present. Stop the Genset and correct any deficiencies as required. Most failures give an early warning.

  • Page 69: Genset Engine Starting With Jump Start Cables

    Note: Never hold the Ether Starting Aid button in for more than five seconds. Note: Use the Ether Starting aid during start-up while cranking the engine only, do not push the button once the engine is running. Significant damage to the engine could occur if the button is pushed while the engine is running. Note: Refer to the Ether Starting Aid Cylinder –...

  • Page 70: Starting Procedure After Extended Shutdown Or Oil Change

    13. Start the engine on the machine that is the electrical source. Also you can energize the charging system on the auxiliary power source. 14. Allow the electrical source to charge the batteries for two minutes. 15. Attempt to start the stalled engine. Refer to the Operation and Maintenance Manual, Engine Starting section. 16.

  • Page 71: Ac Power-Up

    AC Power-UP Notice 037-05-63-308B 037-05-63-308A Figure 53: Emergency Stop Push the RED emergency stop button to IMMEDIATELY trip the main breaker and stop the Genset if any type of emergency condition exists. The emergency stop button can be used with the control door open or closed. It must be manually pulled out to reset before the engine can be restarted.

  • Page 72: Ground Fault Circuit Interrupters (Gfci) 60 Hz-Test Daily

    Ground Fault Circuit Interrupters (GFCI) 60 Hz—Test Daily To ensure that they are functioning properly, the ground fault circuit interrupters (GFCI) must be tested at the start of each working day, or whenever there is an unusual occurrence such as a severe electrical storm. 60Hz, Single Phase circuit breakers with Ground Fault...

  • Page 73: Ground Fault Circuit Interrupters (Gfci) 50 Hz-Test Daily

    TEST GFCI TEST 60Hz panel shown. Contact Vanguard for available 50 Hz front panels. 037-05-63-314A Figure 56: 50 Hz GFCI test With the genset running and the main breaker (CB1) set, ensure that all of the 50 Hz auxiliary-supply circuit breakers (CB17 through CB23) are set.

  • Page 74: Genset Shutdown

    Note: If a GFCI trips without pressing its test button with any type of load—test-load or normal operating load—plugged into its corresponding receptacle, then there is a problem with the load or the connected circuit which must be checked and corrected by a qualified electrician.

  • Page 75: Machine Parking

    Machine Parking Refer to the carrier’s Operation and Maintenance Manual for specific machine parking instructions. Transportation Information Do not transport the machine with the walkways extended. RETAINING RETAINING LATCH LATCH 037-40-63-115A 037-05-14-001A LATCH BOLTED RETAINING LATCH UNDERSIDE (BOTH SIDES) 037-05-14-004A 037-05-14-005A Figure 58: Secure walkway using retaining latches.
  • Page 76 (114 cm) front/back from the line between strong points 3 and 4 towards 5. Note: A spreader bar MUST be used to hoist the weld-deck to prevent serious damage to the genset and welder-doghouse modules. Contact Vanguard Equipment, Inc. to order an appropriate spreader bar. NOTE: Enclosure...

  • Page 77: Maintenance Section

    037-05-05-113A Figure 62: Weld-deck shipping—distribute and secure the load Evenly distribute the load by alternating the direction of consecutive weld-decks. One faces forward, the next faces rearward (A, B) and repeat. 4. Secure the weld-deck(s) to the transport deck with appropriately sized chains (6, 7), etc. Note: Refer to the Equipment Information Section of the Weld-Deck’s Operation and Maintenance Manual for Weld-deck weights and dimensions.

  • Page 78: Torques For Standard Fasteners

    Torques for Standard Fasteners The following tables show general torques for bolts, and for nuts. The components have a rating of at least SAE Grade 5. Torques for Bolts and for Nuts. Tread Size Standard Torques N·m lb-ft 1/4 inch 12 ±...

  • Page 79: Torques For Vibration Isolator Mounts

    Torques for Vibration Isolator Mounts Note: The following tables show the required torque values for the nuts and for the bolts that mount the equipment modules to the vibration isolator (the center mounting bolt and nut). The components have a rating of at least SAE Grade 5. Refer to the Torques for Standard Fasteners tables for the values required to secure the vibration isolators to the weld-deck.

  • Page 80: Maintenance Welding To The Weld-Deck

    Maintenance Welding to the Weld-deck Notice Do not use the welding power units on a weld-deck to perform any welding on the same weld-deck. The use of welding power units on one weld-deck to perform welding on a different weld-deck is permissible. Notice Do NOT use electrical components (ECM or sensors) or electronic component grounding points for grounding the welder.

  • Page 81: Recommended Service Intervals-Minimum Service

    2. For the first 100 hours of compressor operation, a careful and regular check of the oil level should be made. Maintain oil level at the full line. 10 Hours or Daily AIR CLEANER Check condition (service indicator on filter), and replace as required. Description Vanguard Part Number Quantity PRIMARY AIR ELEMENT 100323 SAFETY AIR ELEMENT...

  • Page 82: 250 Hours Or 3 Months

    Note: See also specific module’s—Compressor, Engine, Generator, etc.—operation and maintenance manuals in the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW 125-4-S2. AIR COMPRESSOR Description Vanguard Part Number Quantity • • 6-1/3 QUARTS or 100511 (hydrocarbon based lubricant for ambient •...

  • Page 83: 1000 Hours Or Yearly

    1000 Hours or Yearly Inspect mounting bolts between Weld-Deck and carrier vehicle, and adapter plate (if installed). Check for loose, damaged, or missing hardware, correct as required. Refer to Torque Specifications above. All Other Service Intervals See the specific module’s—Compressor, Engine, Generator, etc.—operation and maintenance manuals in the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW 125-4-S2.

  • Page 84: 60Hz Mode

    037-05-63-056A 037-05-63-058C Figure 66: Genset frequency selector switch SS60/SS50 (1) 60Hz Mode SS60 position for 60 Hz operation 037-05-63-057 037-05-63-059 Figure 67: 60Hz setting for Genset frequency selector switch SS60/SS50 (1) 1. Ensure the genset Stop/Run/Start switch is in the STOP () position. 2.
  • Page 85 3. Ensure the correct Single Phase Front-Mounted Equipment Receptacle plate is installed. Voltage will be present in the front-mounted equipment receptacles if the wrong plate is used. Refer to the section Single Phase Front- Mounted Equipment Receptacles—Installation in the Maintenance Section of this manual for changing over the different front mounted receptacle plates.

  • Page 86: 50Hz Mode

    The frequency meter should display 60Hz ± 3Hz. The genset frequency range is controlled by the engine ECM and is non-adjustable. If the frequency is out of range, verify that the engine RPM on the Engine Digital Display reads 1800 RPM ± 4 RPM. 7.
  • Page 87 3. Ensure the correct Single Phase Front-Mounted Equipment Receptacle plate is installed. Voltage will be present in the front-mounted equipment receptacles if the wrong plate is used. Refer to the section Single Phase Front- Mounted Equipment Receptacles—Installation in the Maintenance Section of this manual for changing over between the different receptacle plates.
  • Page 88 UNDER-FREQ ADJUST potentiometers do not normally need to be adjusted for this procedure. The Frequency Meter (F1) should display 50Hz ± 3Hz. The genset frequency range is controlled by the engine ECM and is non-adjustable. If the frequency is out of range, verify that the engine RPM on the Engine Digital Display reads 1500 RPM ±...

  • Page 89: Single Phase Front-Mounted Equipment Receptacles-Installation

    Single Phase Front-Mounted Equipment Receptacles—Installation Different Single Phase Front-Mounted Equipment Receptacle plates are required for operation at the two different AC voltage supply frequencies, 50 Hz or 60Hz. Voltage will not be present in the front-mounted equipment receptacles if the wrong plate is used for the 50Hz or 60Hz operation.
  • Page 90 4. Connect the replacement Front-Mounted Equipment Receptacle plate to the corresponding control/distribution center's quick-connector receptacle or quick-connector receptacles: the 50Hz Front-Mounted Equipment Receptacle plate uses the single quick-connector labeled "TB1", while the 60Hz Front-Mounted Equipment Receptacle plate uses the two quick-connectors labeled "TB2" and "TB3". Note: The quick-connectors are not interchangeable, TB1 SINGLE CONNECTOR "TB1"...

  • Page 91: Engine Lubricating Oil And Filter Change

    Engine Lubricating Oil Level - Check Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Notice Do not under fill or overfill engine crankcase with oil. Either condition can cause engine damage. Never operate the engine with oil level below the L (low) mark or above the H (high) mark shown on the dipstick (1), poor engine performance or engine damage can occur.
  • Page 92 1. Remove the brass cap under the deck from the drain fitting (1). Install a drain 037-40-50-156B hose under the deck onto (1) Figure 76: Oil and filter change 037-05-50-163A Install a drain hose (not shown) under the deck onto the drain fitting (1). The drain fitting is 3/8" NPT. 3.

  • Page 93: Cooling System: Core - Clean

    The cooling system radiator is contains two separate cooling cores. The Charge Air Cooling (CAC) core cools the intake combustion air from the turbocharger, and the engine coolant radiator core (RAD) cools the engine. Cooling System: Core - Clean On a cool engine with the coolant temperature is below 50°C (120°F), inspect the cooling system radiator cores for debris. Clean the radiator cores, if necessary.

  • Page 94: Cooling System: Service

    Cooling System: Service Coolant is toxic. Keep away from children and pets. To service the cooling system (Check, Drain, Flush), follow the instructions outlined in the Cummins® Operation and Maintenance Manual QSB4.5 and QSB6.7 Engine (Bulletin 4021531); see the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW 125-4-S2-4.

  • Page 95: Air Compressor

    Air Compressor An air compressor may be installed, check the specific weld-deck. 023A037-05-09- Figure 79: Air Compressor (if installed) Note: Refer to the Air Compressor Operation Maintenance Manual for detailed operation and maintenance instructions; see the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW 125-4- ENSURE THAT ALL Air Compressor Motor Bearings Standard grease fittings are provided at each end shield to permit the re-lubrication of the bearings.
  • Page 96 This Page Intentionally Left Blank. 037-08OP-002D-01 S/N CB50600021 – UP (Weld-deck)

  • Page 97: Troubleshooting

    Troubleshooting Notice This equipment is to be operated and serviced by qualified personnel only. Refer to the Safety section of this manual. Do not attempt to bypass any of the safety equipment or instrumentation on this equipment. Do not attempt to operate this equipment with any of the safety equipment or instrumentation bypassed. General Information The following faults are some of the typical problems that can be anticipated during normal operation of the CPW 125-4-S2- 4 Weld-Deck.

  • Page 98: Engine Won't Crank

    Engine Won’t Crank (SS2) 3, 4 037-05-63-308A 037-05-63-042A Figure 81: Engine Won’t Crank Troubleshooting— numbered callouts reference numbered problem list below Possible cause Solution Red emergency stop button (PB1) NOT pulled all the Pull the red emergency stop button (PB1) all the way out way out.

  • Page 99: Engine Won't Start

    Engine Won’t Start 037-05-50-163A 037-05-63-056A Figure 82: Engine Won’t Start Troubleshooting—numbered callouts reference numbered problem list below Possible cause Solution No fuel Fill fuel tank. Check fuel lines for restrictions. Check fuel supply line shut-off valve—if equipped—is open. Refer to genset engine’s Operation and Maintenance Manual for instructions on priming (see fuel filter replacement section).

  • Page 100: Engine Will Not Idle

    Engine Will Not Idle (SS2) 037-05-63-310B 037-05-63-042A Figure 83: Engine Will Not Idle Troubleshooting— numbered callouts reference numbered problem list below Possible cause Solution Engine fault. Refer to The Engine Digital Display unit to determine fault code. See the Engine Digital Display in the Operation section of this manual.

  • Page 101: Batteries Fail To Charge (Low Dc Voltage)

    Batteries fail to charge (low DC voltage) 037-40-50-148A Figure 84: Batteries fail to charge (low DC voltage) Troubleshooting— numbered callouts reference numbered problem list below Possible cause Solution 24VDC alternator not charging. Check 24VDC alternator circuit breaker (CB30) located besides 24VDC alternator and starter on turbo side of genset engine;...

  • Page 102: 24Vdc Alternator Overcharging (High Dc Voltage)

    24VDC Alternator Overcharging (High DC voltage) 037-40-50-148A Figure 85: 24VDC Alternator Overcharging (High DC voltage) Troubleshooting— numbered callouts reference numbered problem list below Possible cause Solution Batteries have failed. Check condition of batteries, replace batteries if required. Maintenance free batteries are originally supplied, and require maintenance inspection.

  • Page 103: Vac Three Phase Supply Voltage

    No or Low 480 VAC Three Phase Supply Voltage Refer to the Operation and Maintenance Manual — AC Generator for troubleshooting information; see the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW 125-4-S2-4. Main Breaker Will Not Set 3, 5 037-05-63-308A...

  • Page 104: Vac Ground Fault Interrupter (Gfci) Circuit Breakers Will Not Set

    120 VAC or 240 VAC Ground Fault Interrupter (GFCI) Circuit Breakers Will Not Set Possible cause Solution Connected device or external circuitry has a grounding Unplug the device or external circuit from the corresponding fault. receptacle, if the GFCI now sets then the problem is in the load or external circuit and must be checked by a qualified electrician;...

  • Page 105: Electrical Schematics

    Electrical Schematics 480VAC, 60 Hz Supply Schematic 037-08OP-002D-01 S/N CB50600021 – UP (Weld-deck)

  • Page 106: 24Vdc Controls Schematic

    24VDC Controls Schematic 037-08OP-002D-01 S/N CB50600021 – UP (Weld-deck)

  • Page 107: Compressor Faults

    Compressor Faults Refer to the Operation and Maintenance Manual — Compressor for troubleshooting information; see the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW 125-4-S2-4. 037-08OP-002D-01 S/N CB50600021 – UP (Weld-deck)

  • Page 108: Appendices: Equipment Modules' Operation And Maintenance Manuals

    Appendices: Equipment Modules’ Operation and Maintenance Manuals A) Air Cleaner Service B) Air Compressor C) AC Generator and Voltage Regulator D) Engine Diagnostic Trouble Codes E) Engine Digital Display F) Slewing Canopy G) Auto Tie-in Crane H) Genset Engine 037-08OP-002D-01 S/N CB50600021 –...

  • Page 109: Appendixa - Air Cleaner Service

    Appendix A — Air Cleaner Service The following pages are taken from information published by the original equipment manufacturer (OEM), and are subject to change without notice. 037-08OP-002D-01 S/N CB50600021 – UP (Weld-deck)
  • Page 110 FRG Air Cleaners FRG Service Parts Style A — Bolt/Clamp Service Cover Indicator port Body Clamp Access Cover primary Filter Safety Filter Cover Gasket Air Cleaner Housing Baffle metal body & cover vacuator valve ™ www.buydonaldson.com Engine Air Filtration •...
  • Page 111 FRG Air Cleaners Service Instructions This servicing information is provided as a best practices guide. It is not intended to replace or supersede the service instructions supplied by your engine or vehicle manufacturer. Check the Restriction Replace the filter only when the restriction level has reached the maximum recommended by the engine or equipment manufacturer or on a regular service...
  • Page 112 FRG Air Cleaners Service Instructions Inspect the old Filter Inspect the old filter for any signs of leaks. A streak of dust on the clean side of the filter is a telltale sign. Eliminate any source of air leaks before installing the new primary filter.
  • Page 113 FRG Air Cleaners Service Instructions Check Inlet Hoods and pre-Cleaners Check any intake hoods and pre- cleaner devices during maintenance routines. A missing inlet hood will significantly shorten filter life. If your unit had a hood or pre-cleaner originally, make sure you replace it. Check openings and tubes on pre-cleaners to make sure they are not plugged.

  • Page 114: Appendixb - Air Compressor

    Appendix B — Air Compressor The following pages are taken from information published by the original equipment manufacturer (OEM), and are subject to change without notice. 037-08OP-002D-01 S/N CB50600021 – UP (Weld-deck)
  • Page 116 OPERATION/MAINTENANCE MANUAL & PARTS LIST THIS MANUAL CONTAINS IMPORTANT SAFETY INFORMATION AND SHOULD ALWAYS BE AVAILABLE TO THOSE PERSONNEL OPERATING THIS UNIT. READ, UNDERSTAND AND RETAIN ALL INSTRUCTIONS BEFORE OPERATING THIS EQUIPMENT TO PREVENT INJURY OR EQUIPMENT DAMAGE. 2-Stage / Four Cylinder Base Mount Air Compressor &...
  • Page 117 MAINTAIN COMPRESSOR RELIABILITY AND PERFORMANCE WITH GENUINE CHAMPION COMPRESSOR PARTS AND SUPPORT SERVICES Champion Compressor genuine parts, manufactured to design tolerances, are developed for optimum dependability – specifically for Champion compressor systems. Design and material innovations are the result of years of experience with hundreds of different compressor applications. Reliability in materials and quality assurance are incorporated in our genuine replacement parts.
  • Page 118 TABLE OF CONTENTS _______________________________________________________ Subject Page Maintain Compressor Reliability And Performance With ..............1 Safety And Operation Precautions ....................3 Explanation Of Safety Instruction Symbols And Decals ..............4 Introduction ............................. 7 Warranty ............................7 Dimensions And Specifications ......................8 Installation ............................

  • Page 119: Safety And Operation Precautions

    SAFETY AND OPERATION PRECAUTIONS ___________________________________________________________________________________ Because an air compressor is a piece of machinery with moving and rotating parts, the same precautions should be observed as with any piece of machinery of this type where carelessness in operation or maintenance is hazardous to personnel. In addition to the many obvious safety rules that should be followed with this type of machinery, the additional safety precautions as listed below must be observed: Read all instructions completely before operating air compressor or unit.

  • Page 120: Explanation Of Safety Instruction Symbols And Decals

    EXPLANATION OF SAFETY INSTRUCTION SYMBOLS AND DECALS OBSERVE, UNDERSTAND AND RETAIN THE FOLLOWING INFORMATION GIVEN FOR DECALS. Indicates immediate hazards which will result in severe injury or death. High Voltage – Hazard of Shock, Burn, or Death Crush and Cutting of Finger or Hand Hazard – Present until Electrical Power is Removed Rotating Motor Sheave Crush and Cutting of Finger or Hand Hazard –...
  • Page 121 PROHIBITION/MANDATORY ACTION REQUIREMENTS Do not Operate Compressor with Guard Lockout Electrical Equipment in De-Energized Removed State Read the Operator’s Manual Before Proceeding Do Not Exceed 250 PSI (1725 kPa) with Task...
  • Page 122 SAFETY AND OPERATION PRECAUTIONS This reciprocating compressor must not be used for breathing air. To do so will cause serious injury whether air is supplied direct from the compressor source or to breathing tanks for later use. Any and all liabilities for damage or loss due to injury, death and/or property damage including consequential damages stemming from the use of this compressor to supply breathing air, will be disclaimed by the manufacturer.

  • Page 123: Introduction

    INTRODUCTION ______________________________________________________________________ Champion PL Series compressors 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, maintenance and adjustment.
  • Page 124 TWO STAGE AIR COMPRESSORS - MODEL PL70A DIMENSIONS ITEM PL70A Base-Width 12-7/8” Bolt Down-Width 5-11/16” (from center line) Bolt Down to Edge 3/4” Base to Crank Ctr 8-3/16” Overall Width 33” Overall Height 33-9/16” HP Exhaust Opening 1-1/4NPT Bolt Down Hole Dia. 9/16”...

  • Page 125: Installation

    INSTALLATION Do not operate unit if damaged during shipping, handling or use. Operating unit if damaged may result in injury. Permanently installed compressors must be located in a clean, well ventilated dry room so compressor receives adequate supply of fresh, clean, cool and dry air. It is recommended that a compressor, used for painting, be located in a separate room from that area wherein body sanding and painting is done.
  • Page 126 INSTALLATION (CONT’D) ELECTRICAL POWER SUPPLY It is essential that he power supply and the supply wiring are adequately sized and that the voltage correspond to the unit specifications. Branch circuit protection must be provided at installation a specified in the National Electrical Code. All wiring should be preformed by a licensed electrician or electrical contractor.
  • Page 127 ELECTRICAL POWER SUPPLY (CONT’D) Wiring must be such that when viewing compressor from opposite shaft end, rotation of shaft is clockwise as shown by arrow on guard. Wrong direction rotation for any length of time will result in damage to compressor. GROUNDING INSTRUCTIONS This product should be connected to a grounded, metallic, permanent wiring system, or an equipment-grounding terminal or lead on the product.

  • Page 128: Operation

    OPERATION This compressor has been inspected, thoroughly tested and approved at the factory. For this unit to give long satisfactory service it must be installed and operated properly. This compressor has been designed for a 80%/ON – 20%/OFF duty cycle. PL70A models are equipped with a pilot valve and head unloaders to provide continuous run capabilities.

  • Page 129: Maintenance

    GUIDE TO MAINTENANCE For Service contact an authorized Champion distributor. All requests should include model number and serial number. To obtain reliable and satisfactory service, this unit requires a consistent preventive maintenance schedule. Maintenance schedule form is included to aid in keeping the proper records.
  • Page 130 EVERY 90 DAYS OR 500 HOURS MAINTENANCE Change crankcase oil and oil filter. Use only Champlub recip lubricant. Check entire system for air leakage around fittings, connections, and gaskets, using soap solution and brush. Tighten nuts and cap screws as required. Check and clean compressor valves as required.
  • Page 131 GENERAL MAINTENANCE (Cont'd.) HYDRAULIC UNLOADER: This compressor is equipped with an unloading device operated by oil pressure. When the compressor is turned off, the unloader will open resulting in a short burst of air from the unloader (released through the intake filter.). When the compressor is restarted, as soon as oil pressure reaches normal operation range (between 15 and 30 PSIG) the unloader valve closes and the compressor begins to pump air.

  • Page 132: Compressor Pilot Valve Differential Pressure Adjustment

    COMPRESSOR PILOT VALVE PRESSURE ADJUSTMENT Proceed with the following instructions while compressor is running: Loosen locknut (4) and back off several turns. Do not turn differential pressure adjustment nut (3). Check reading on the tank pressure gauge. Set the compressor maximum pressure by turning threaded cap (1) clockwise to increase pressure or counter clockwise to decrease pressure.

  • Page 133: Compressor Oil Specifications

    COMPRESSOR OIL SPECIFICATIONS Compressors are factory filled with CHAMPLUB hydrocarbon based recip lubricant. This is an ISO 100 non-detergent industrial lubricant with rust and oxidation inhibitors specially formulated for reciprocating compressors. It is recommended this compressor be maintained using this oil for ambient temperatures above 32°F.

  • Page 134: Troubleshooting Chart

    TROUBLE SHOOTING CHART FOR COMPRESSOR Always disconnect unit from power supply and relieve all pressure from air tank before performing any maintenance. “Tag Out” or “Lock Out” all power sources. Failure to do so may result in equipment damage or injury. Never operate unit without belt guard in place.
  • Page 135 Troubleshooting Chart (cont’d) Symptom Possible Cause(s) Corrective Action Low or loss of oil pressure Low crankcase level. Check oil level. Add oil if required. Oil pickup screen clogged. Drain oil from crankcase. Remove oil pickup screen and clean. Reinstall screen and all clean oil to crankcase.
  • Page 136 REPAIR PARTS ILLUSTRATION: COMPRESSOR, MOTOR & DRIVE GRP 303CBB810-A (Ref. Drawing) Ref. No. Description Part Number BASEPLATE P14613C COMPRESSOR PL70A CC1086427 INTAKE FILTER P07447A SCREW M3470 M3486 MOTOR, 30HP 24CA6721 SCREW M3461 WIRE CONNECTOR P05017A PULLEY P14238A BUSHING P05621A BELT B100...
  • Page 137 REPAIR PARTS ILLUSTRATION: AFTERCOOLER & BELTGUARD 302CBB810-B (Ref. Drawing)
  • Page 138 REPAIR PARTS ILLUSTRATION: AFTERCOOLER & BELTGUARD Ref. No. Description Part Number AFTERCOOLER P09954A BRACKET P09962B SCREW M1454 WASHER M3056 BRACKET P09960B BRACKET P09961B BRACKET P14616A ELBOW M983B NIPPLE M2305 ELBOW M975B DISCHARGE TEE M1516 BUSHING M954B STREET ELBOW M3088 PRESSURE RELIEF VALVE VP1086417 NIPPLE M2128...
  • Page 139 COMPRESSOR REPAIR PARTS ILLUSTRATION Models: PL70A C316-D (Ref. Drawing)
  • Page 140 Repair Parts List Compressor Model PL70A Ref. Part Description Qty. Number Crankcase P07393D Pipe plug 64AA5 Oil level gauge RE714 Pipe nipple M492 Pipe cap M461 O-Ring P07428A Oil screen P07381B Spring P07427A Pipe plug M998B Pipe plug 64A5 Crankshaft P11547C Main bearing Z6506...
  • Page 141 Repair Parts List Compressor Model PL70A Ref. Part Description Qty. Number High pressure piston with pin ZM1393 High pressure piston pin M1383 High pressure piston ring set Z9088 Cylinder flange gasket M1391 Cylinder P05863D Hex head cap screw M3461 Low pressure intake valve assembly Z273 Low pressure valve gasket P07352A...
  • Page 142 COMPRESSOR REPAIR PARTS ILLUSTRATION Model: PL70A C317-B (Ref. Drawing) Repair Parts List Models PL70A Ref. No. Description Part Number Qty. 1/4 x 1/8" NPT 90 Compression fitting M2868 Manifold tube CC1061685 1/4 x 1/4 x 1/8" NPT Tee compression fitting M2879 Intermediate tube CC1061684...

  • Page 143: Decal Group

    DECAL GROUP 300CBB797-A Ref. No. Description Part Number DECAL – WARNING, BELT GUARD VP1088053 DECAL – WARNING, ELECTRIC SHOCK VP1076030 DECAL – WARNING, HOT SURFACE VP1088054 DECAL – WARNING, BREATHING AIR VP1088055 DECAL – MAXIMUM PRESSURE VP1088056 DECAL – ROTATION DIRECTION VP1088057...

  • Page 144: Record Of Maintenance Service

    RECORD OF MAINTENANCE SERVICE DAILY ● CHECK OIL LEVEL ● DRAIN MOISTURE FROM TANK WEEKLY MONTHLY EVERY 3 MONTHS ● CLEAN FILTER ● INSPECT AIR SYSTEM ● CHANGE OIL & OIL FILTER ● CLEAN COMPRESSOR ● INSPECT VALVE ASSEMBLIES ● CHECK V-BELTS ●...
  • Page 145 *CQF3333VER03* *CQF3333VER03* For additional information, contact your local representative or visit: www.championpneumatic.com/contactus.aspx ©2015 Gardner Denver, Inc. Printed in U.S.A.

  • Page 146: Appendixc - Ac Generator And Voltage Regulator

    Appendix C — AC Generator and Voltage Regulator The following pages are taken from information published by the original equipment manufacturer (OEM), and are subject to change without notice. 037-08OP-002D-01 S/N CB50600021 – UP (Weld-deck)
  • Page 147 E ast R S tr O . B o x 8 , WI 8 003 a x: 5 ) 67 6 361...
  • Page 148 S AFET Y ......................................E ................................. C KI H ANDLI N G ..............................S TO R AGE......................................N ..............................F IG U RE 1 U S C ..........................I RCU F IG R E 2 P LU ......................... P ICA G NA A YO ..................................
  • Page 149 E TURN E D G O ODS ..................................T ROUBL O OT N G................................... E NER A TOR PR O DUCES NO VOLT G E..........................E NER A TOR PR O DUCES LOW VO T AGE, N O LOA D ......................E NER A TOR PR O DUCES LOW VO...

  • Page 150: S Afet S Y

    than m k es c aused by a mis n ding of t he f orm t ion pres t ed h is m L EASE R EM A FETY F T . I f you are s ure T ORA f ied help f ore c ontinuing.

  • Page 151: F Igu Re

    P RINCIP F OP T IO PMG (optional) Rotating Assembly PMG Field Exciter Field Exciter Armature Main Field Main Armature (rotor) (stator) (rotor) (rotor) (stator) (in) (in) 3 Phase AC (out) 3 Phase AC (out) Armature (stator) Rotating Rectifier Assembly 3 Phase -- Full Bridge Exciter Field Power Input Power -- Single Phase...

  • Page 152: O L T A G E R E G U L A T I O N

    t ors l ly s u pply .3 t o . 4 hors w er per PRINCIPLE O t or k W in motor sta t ing c apability. F or s pecifi cont c t M t hon c tric M agnaPLU S generat e a brushles...
  • Page 153 driver and t h e generat ' s s n ing t e generat r and i ver t ely as pos s ible w ill reduce vibrat increas s bearing lif a nd s ure m m um c oupling w A BLE AND LOCKO U T AN N GI...
  • Page 154 t h the c m inimiz e trans m is s ion of v t ion, E NV T AL is es s ent t hat f lex c ondui t be us f or all elect c al entranc e gen t or c onduit b...
  • Page 155 VOLTAGE (LOW WYE) L - L L - N I GH DELT A CONN I ON VOLTAGE (HIGH DELTA) L - L L - N VOLTAGE (LOW DELTA) L - L L - L...
  • Page 156 U BLE D EL - SINGL E PH A SE VOLTAGE (DOUBLE DELTA) L - N L - N L - L ’ ’ VOLTAGE (LOW ZIGZAG) N ot : Single-ph / KVA t ings a e approx m at L - N L - N o 50% of t...

  • Page 157: S T A R T - Up

    D EDICAT D SINGL E PH A SE VOLTAGE (DEDICATED) L - N L - N L - L s ure tha c ommen d ste s and proc o wed. m aski t erials i xed during paint R E-ST A RT m ent to s ure...

  • Page 158: S Hut Down Pro C U R E

    T he s e of t h is init i al t es t with t he regulat x pos t he unit t o undue risk. Check t o line t er c irc i t is energiz t o neut v oltages for balanc v olt v olt...

  • Page 159: P Ace H E At E Rs

    D RYING W IND t ors in service may d vertentl y hav i r w x pos t o s s hing or sprayed w t er. t hat h ave i n t s it r storage f r long periods of t im y be...

  • Page 160: D I O D E T E S T I Ng

    When t s it v e test probe is connec t ed t o the o de' I nsul e and t e negative t s t probe is c onnected t t he ' s c a thod e (f w ard s ed), t he...

  • Page 161: B E A R I N G R E M O V A L

    Conti o pull the brack f ree f rom t e bearing . Vis s pec t he i ng bore for dam e or w ear. I f w n or F ai o remove the i ter fi e ld lead s fr o m th...
  • Page 162 A ME 0 FRAME 4 : R S EMB chec i rst v ent furthe damage w hen troubles t ing a s abled machine. s t s t ep of t l esh t ing i o gat r as m inform t ion as is poss e from operat...
  • Page 163 W ARNING H VOL T AGES M AY B E PR N ER R ’ T ER L S WHEN T H E U T IS R N G. B E K L EAR OF RO N G PA A ND ELECTRICAL C ON N EC N S.
  • Page 164 G EN R ATO D UC S LO A D A U SE C K AND REMEDY not be d on any leg. o tor s t art g or Motor st t ing c urrents are t oo e for the t or.
  • Page 165 G EN R ATO B UIL O LT U P, T H EN G R ESI D UA O LT U SE C K AND REMEDY o regulat r manual. G EN R ATO H EA U SE H EC A ND REMEDY c ulat i on o...
  • Page 166 M ODEL / FRAME R ESI T AN T OR T OR 2 , 283, 284 . 120 2 , 363 e phase . 120 2 , 363 - dedic t ed s e phase . 135 2 , 433 e phase .076 N ER...
  • Page 167 – – R eference N ame r en N ame b er Numb d Brac k et (und r end c ov r 360 & 4 m es Main Sta t or Main Rotor g (280 f rame o t or I nt l Key w ay...
  • Page 168 – – R eference N ame r en N ame b er Numb d Brac k et (und r end c ov r 360 & 4 m es Main Sta t or g (nondrive e Main Rotor g (280 f rame o t or I nt l Key...
  • Page 169 SE350 VOLTAGE REGULATOR INSTRUCTION MANUAL...
  • Page 170 INTRODUCTION The SE350 voltage regulator is an encapsulated electronic voltage regulator that controls the output of a brushless AC generator by regulating the current into the exciter field. SPECIFICATION SE350 REGULATOR Sensing & Power Input 190-240 Vac Burden 500 VA Output Power- Continuous 73 Vdc at 3.5 Adc (255w) Output Power - Forcing(240 Vac Input Power)
  • Page 171 The SE350 voltage regulator can be mounted in any plane, following are mounting dimensions. FIGURE 1 FUSE A 4 Amp, 250 V, 5 X 20 mm fuse is supplied with the regulator (Part A-527066). It can be located on the rear face of the voltage regulator. EXCITER POWER CIRCUIT Connect the regulator wire F+ to the generator F+ or Fl field terminal.
  • Page 172 FIGURE 2 VOLTAGE ADJUST The screwdriver adjustable potentiometer adjusts the generator output voltage. Adjustment clockwise increases the generator output voltage. When using a remote voltage adjust rheostat, remove the jumper wire across terminals 6 and 7 and install a 2000 ohm 1/2 watt (minimum) rheostat. This will give ±10% voltage variation from the nominal.
  • Page 173 PRELIMINARY SET-UP Ensure the voltage regulator is correctly connected to the generator. Refer to the specific connection diagram supplied with the generator. Set the regulator voltage adjust to full counter-clockwise (minimum voltage level). Set the remote voltage adjust (if used) to the center position. Set the stability control full clockwise (maximum stability level).
  • Page 174 TROUBLESHOOTING Symptom Cause Action Residual Voltage -No Residual voltage at regulator power Check wiring diagram for Output input wires 3 & 4 below 10 V ac. proper connections. Flash generator field. Refer to field flashing section in generator manual. Acceleration time to rated speed too Reduce acceleration time.

  • Page 175: Appendixd - Engine Diagnostic Trouble Codes

    Appendix D — Engine Diagnostic Trouble Codes The following pages are taken from information published by the original equipment manufacturer (OEM), and are subject to change without notice. 037-08OP-002D-01 S/N CB50600021 – UP (Weld-deck)
  • Page 176 Engine Diagnostic Trouble Codes Lamp RED=Shutdown Fault AMBER=Warning Code Fault Description MAINT= Engine Magnetic Speed/Position Lost Both of Two Signals - Data Erratic, Intermittent, or Incorrect Intake Manifold 1 Pressure Sensor Circuit - Voltage Above Normal, or Shorted to High Source AMBER Intake Manifold 1 Pressure Sensor Circuit - Voltage Below Normal, or Shorted to Low Source...
  • Page 177 Lamp RED=Shutdown Fault AMBER=Warning Code Fault Description MAINT= Intake Manifold 3 Temperature Sensor Circuit - Voltage 1132 Above Normal, or Shorted to High Source AMBER Intake Manifold 3 Temperature Sensor Circuit - Voltage 1132 Below Normal, or Shorted to Low Source AMBER Intake Manifold 3 Temperature - Data Valid but Above 1132...
  • Page 178 Lamp RED=Shutdown Fault AMBER=Warning Code Fault Description MAINT= Coolant Pressure - Data Valid but Below Normal Operational Range - Most Severe Level Coolant Pressure Sensor Circuit - Voltage Above Normal, or Shorted to High Source AMBER Coolant Pressure Sensor Circuit - Voltage Below Normal, or Shorted to Low Source AMBER Engine Crankshaft Speed/Position - Data Valid but...
  • Page 179 Lamp RED=Shutdown Fault AMBER=Warning Code Fault Description MAINT= Injector Solenoid Driver Cylinder 1 Circuit - Current Below Normal, or Open Circuit AMBER Injector Solenoid Driver Cylinder 5 Circuit - Current Below Normal, or Open Circuit AMBER Injector Solenoid Driver Cylinder 3 Circuit - Current Below Normal, or Open Circuit AMBER Injector Solenoid Driver Cylinder 6 Circuit - Current...
  • Page 180 Lamp RED=Shutdown Fault AMBER=Warning Code Fault Description MAINT= Battery 1 Voltage - Data Valid but Above Normal Operational Range - Moderately Severe Level AMBER Injector Metering Rail 1 Pressure - Data Valid but Above Normal Operational Range - Most Severe Level Injector Metering Rail 1 Pressure Sensor Circuit - Voltage Above Normal, or Shorted to High Source AMBER...
  • Page 181 Lamp RED=Shutdown Fault AMBER=Warning Code Fault Description MAINT= Exhaust Gas Temperature Deviation Low for Cylinder 5 - Data Valid But Below Normal Operating Range - Least 1327 Severe Level MAINT Exhaust Gas Temperature Deviation Low for Cylinder 7 - Data Valid But Below Normal Operating Range - Least 1329 Severe Level MAINT...
  • Page 182 Lamp RED=Shutdown Fault AMBER=Warning Code Fault Description MAINT= Exhaust Gas Temperature Deviation Low for Cylinder 16 - Data Valid But Below Normal Operating Range - 1338 Least Severe Level MAINT Exhaust Gas Temperature Sensor Circuit Cylinder 1 - 1137 Voltage Below Normal, or Shorted to Low Source MAINT Exhaust Gas Temperature Sensor Circuit Cylinder 3 - 1139...
  • Page 183 Lamp RED=Shutdown Fault AMBER=Warning Code Fault Description MAINT= Engine Speed / Position Camshaft and Crankshaft Misalignment - Mechanical system not responding or out of adjustment AMBER Intake Manifold 1 Temperature - Abnormal Rate of Change Power Lost With Ignition On - Data Erratic, Intermittent, 1117 or Incorrect NONE...
  • Page 184 Lamp RED=Shutdown Fault AMBER=Warning Code Fault Description MAINT= Post-Oil Filter Pressure Sensor Circuit - Voltage Above 1377 3549 Normal, or Shorted to High Source MAINT Post-Oil Filter Pressure Sensor Circuit - Voltage Below 1378 3549 Normal, or Shorted to Low Source MAINT Auxiliary Temperature Sensor Input 1 - Special 1381...
  • Page 185 Lamp RED=Shutdown Fault AMBER=Warning Code Fault Description MAINT= At Least One Module Has A Moderately Severe Fault - 1518 1484 Condition Exists AMBER At Least One Module Has A Least Severe Fault - 1519 1484 Condition Exists MAINT Exhaust Gas Temperature Sensor Circuit Cylinder 3 - 1521 1139 Voltage Above Normal, or Shorted to High Source...
  • Page 186 Lamp RED=Shutdown Fault AMBER=Warning Code Fault Description MAINT= Auxiliary Pressure Sensor Input 1 Circuit - Voltage 1542 1387 Above Normal, or Shorted to High Source MAINT Auxiliary Pressure Sensor Input 1 Circuit - Voltage 1543 1387 Below Normal, or Shorted to Low Source MAINT 1544 1387...
  • Page 187 Lamp RED=Shutdown Fault AMBER=Warning Code Fault Description MAINT= Exhaust Gas Temperature Sensor Circuit Cylinder 4 - 1619 1140 Voltage Above Normal, or Shorted to High Source MAINT Injector Solenoid Driver Cylinder 9 Circuit - Current 1622 Below Normal, or Open Circuit AMBER Intake Manifold 2 Pressure - Data Valid but Below 1638...
  • Page 188 Lamp RED=Shutdown Fault AMBER=Warning Code Fault Description MAINT= Intake Manifold 6 Temperature - Data Valid but Above 1988 1803 Normal Operational Range - Moderately Severe Level AMBER Engine Crankshaft Speed/Position - Data Valid but Above Normal Operational Range - Moderately Severe 1992 Level Exhaust Gas Temperature Cylinder 1 - Data Valid but...
  • Page 189 Lamp RED=Shutdown Fault AMBER=Warning Code Fault Description MAINT= Exhaust Gas Temperature Cylinder 6 - Data Valid but Above Normal Operational Range - Moderately Severe 2133 1142 Level AMBER Exhaust Gas Temperature Cylinder 8 - Data Valid but Above Normal Operational Range - Moderately Severe 2134 1144 Level...
  • Page 190 Lamp RED=Shutdown Fault AMBER=Warning Code Fault Description MAINT= Sensor Supply 4 Circuit - Voltage Below Normal, or 2186 3512 Shorted to Low Source AMBER Fuel Pump Delivery Pressure - Data Valid but Below 2215 Normal Operational Range - Moderately Severe Level AMBER Intake Manifold 5 Temperature - Data Valid but Above 2241...
  • Page 191 Lamp RED=Shutdown Fault AMBER=Warning Code Fault Description MAINT= Turbocharger 1 Speed - Data Erratic, Intermittent, or 2474 Incorrect MAINT Auxiliary PWM Driver 1 Circuit - Voltage Above Normal, 2557 or Shorted to High Source AMBER Auxiliary PWM Driver 1 Circuit - Voltage Below Normal, 2558 or Shorted to Low Source AMBER...
  • Page 192 Lamp RED=Shutdown Fault AMBER=Warning Code Fault Description MAINT= Start Enable Device 1 Canister Empty (Ether Injection) - Data Valid but Below Normal Operational Range - Least 2734 Severe Level NONE Exhaust Gas Temperature Sensor 1 Circuit - Voltage 2735 Above Normal, or Shorted to High Source MAINT Exhaust Gas Temperature Sensor 1 Circuit - Voltage 2736...

  • Page 193: Appendixe - Engine Digital Display

    Appendix E — Engine Digital Display The following pages are taken from information published by the original equipment manufacturer (OEM), and are subject to change without notice. 037-08OP-002D-01 S/N CB50600021 – UP (Weld-deck)
  • Page 194 Engine Digital Display Model PV-101 User’s Guide Rev 09-10-08 00-02-0605 Catalog Section 78...
  • Page 195 In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time. The latest version of this manual can be found at www.fwmurphy.com. Warranty - A limited warranty on materials and workmanship is given with this FW Murphy product.
  • Page 196 Table of Contents Introduction ................1 Engine and Transmission Parameters Faceplate Features Navigation and Keypad Functions Operation ................. 9 PowerView Menus (First Time Start Up) Setting Up the Display Main Menu Options Faults and Warnings Utilities Menu Modbus® Setup Selecting Engine ECU Troubleshooting ..............
  • Page 197 (THIS PAGE INTENTIONALLY LEFT BLANK)
  • Page 198 Introduction Congratulations on purchasing your PowerView display, a multifunction tool that provides a window into the many parameters and service codes of modern electronic engines and transmissions. This guide is intended to help you set up your PowerView display and identify navigation basics and product features. The display’s simple navigation and intuitive yet powerful features allow you to master the product in no time.
  • Page 199 Engine and Transmission Parameters The following are some of the engine and transmission parameters which may be displayed in standard or metric units as well as in English, Spanish, French, Italian, or German languages (when applicable, consult engine or transmission manufacturer for SAE J1939 supported parameters): •...
  • Page 200 Faceplate Features 00-02-0605 - 3 - Rev 09-10-08...
  • Page 201 Navigation and Keypad Functions The keypad on the PowerView display is a capacitive touch sensing system. There are no mechanical switches to wear or stick. When a key is touched, feedback is provided by the screen flashing. The keys on the keypad perform the following functions: Menu –...
  • Page 202 Basic Navigation 1. When Menu is pressed, the main menu items are displayed. 00-02-0605 - 5 - Rev 09-10-08...
  • Page 203 2. Touching the Arrow Keys will move the selection bar to other menu items. 00-02-0605 - 6 - Rev 09-10-08...
  • Page 204 3. Certain menus have multiple pages of items. Scrolling past the top item or bottom item on the current page will reveal other menu items on additional pages. 00-02-0605 - 7 - Rev 09-10-08...
  • Page 205 4. When the desired item is highlighted by the cursor, pressing Enter will select that item and display the corresponding screen. 5. Anytime the word MORE appears above the Arrow Keys there are more screens that may be viewed. Use the Arrow Keys to scroll to the next screen of information.
  • Page 206 Operation PowerView Menus (First Time Start Up) 1. When power is first applied to the display, the Murphy logo appears. 00-02-0605 - 9 - Rev 09-10-08...
  • Page 207 2. If the Engine ECU is broadcasting a 'Wait To Start' message, this screen will be shown. Engine manufacturers typically recommend against starting the engine while this message is broadcasted from the ECU. Once the ECU stops broadcasting this message, this screen will no longer be displayed.
  • Page 208 3. Once the engine has started, the single engine parameter appears with the engine RPM displayed. Pressing the Right Arrow Key will display the coolant temperature. The screen can be changed to other parameters by pressing Menu. 00-02-0605 - 11 - Rev 09-10-08...
  • Page 209 Setting Up the Display The screen may be configured to display a single engine parameter (1-up display), or four parameters at once (4-up display). Default options are provided or you may customize the display by selecting the parameters you want. 1-Up Display Three options are available for modification of the 1-Up display.
  • Page 210 1-Up Display Settings 1. Touch Menu and use the Arrow Keys to highlight SETUP 1-UP DISPLAY, then press Enter. 2. To select USE DEFAULTS, highlight the option and press Enter. A message indicating “RESTORED TO DEFAULTS” is displayed. 3. To select CUSTOM SETUP, highlight the option and press Enter.
  • Page 211 6. Continue to scroll and select additional parameters for the CUSTOM 1-UP DISPLAY. Touch Menu at any time to return to the CUSTOM SETUP menu. 7. Selecting the AUTOMATIC SCAN ON function will cause the 1-up display to scroll through the selected set of parameters one at a time.
  • Page 212 4-Up Display The 4-up display places the parameter data into four areas of the screen known as quadrants. Factory defaults for the 4-up display include coolant temperature, engine speed, oil pressure, and battery voltage. You may customize the 4-up display with parameters you define for each quadrant. 1.
  • Page 213 5. Touch Enter and a list of parameters will appear. The parameter that is highlighted is the selected parameter for the screen. The number to the right of the parameter indicates the quadrant in which it is displayed. 1 = upper left quadrant 2 = lower left quadrant 3 = upper right quadrant 4 = lower right quadrant...
  • Page 214 8. The parameter in the selected quadrant has changed to the parameter selected in the previous screen. 9. Repeat the parameter selection process until all spaces are filled. 00-02-0605 - 17 - Rev 09-10-08...
  • Page 215 Main Menu Options This section describes the features listed on the main menu of the PowerView. These menu options are displayed whenever you touch Menu. The Arrow Keys allow you to scroll the items, and Enter selects the highlighted option. Selecting a Language From LANGUAGES, you may select ENGLISH, ESPANOL, FRANCAIS, ITALIANO, or DEUTSCH.
  • Page 216 Backlight Adjustment ADJUST BACKLIGHT allows you to select the desired backlight intensity. Contrast Adjustment From ADJUST CONTRAST, you may select the desired contrast intensity. Select Units From SELECT UNITS, you may select how information is displayed. ENGLISH for Imperial units, i.e., PSI, °F or METRIC KPA, METRIC BAR for IS units, i.e., kPa, Bar, °C.
  • Page 217 Faults and Warnings The PowerView provides two means for detecting faults and warnings: visual LEDs on the casing (See “Faceplate Features”) and fault indicators on the display. Visual Indication • Amber LED (Warning) • Red LED (Derate / Shutdown) Fault Indicators 00-02-0605 - 20 - Rev 09-10-08...
  • Page 218 Auxiliary Gage Fault Murphy’s PVA Gages can be attached to the PowerView. If an auxiliary gage should fail, the 1-up or 4-up display will be replaced with the fault message “GAGE NOT RESPONDING”. NOTE: The fault can only be cleared by correcting the cause of the fault condition.
  • Page 219 Acknowledging Fault Codes 1. To acknowledge and hide the fault and return to the 1-up or 4-up display, touch Enter. The display will return to the 1-up or 4-up display, but the display will contain the shutdown icon. 2. Touch Enter to redisplay the hidden fault. Touch Enter once again will hide the fault and return the screen to the 1-up or 4-up display.
  • Page 220 Utilities Menu The following steps take place starting at the UTILITIES menu option. 1. GAGE DATA - View information for optional connected PVA gages. 2. REMOVE ALL GAGES - Reset the PowerView's gage memory. 3. SOFTWARE VERSION - View the PowerView's software version.
  • Page 221 being used. Most engine ECU’s use Version 4, therefore in most cases adjustment of this menu option will not be required. Upon receiving an unrecognizable fault, change to a different J1939 Version. If the fault SPN does not change when the version is changed, the ECU generating the fault is using Fault Conversion method 4.
  • Page 222 Modbus® Setup 1. From the UTILITIES menu, select MODBUS SETUP. 2. Select either the SLAVE ACTIVE (SCADA or remote Modbus master) or MASTER ACTIVE (auxiliary gages) modes. Touch Enter to toggle between master and slave. 3. Select SERIAL PORT SETUP (slave mode only), then touch Enter.
  • Page 223 Selecting Engine ECU 1. From the UTILITIES menu, choose SELECT ENGINE ECU. 2. The message “LISTEN TO ECU: ALL” is displayed as the default setting, and indicates the PV101 is listening to all devices on the network. 3. To change the setting to a specific address, press the Arrow Keys to scroll through the numbers (0-253).
  • Page 224 Troubleshooting “WAIT TO START PREHEATING” is displayed The ECU is broadcasting a 'Wait To Start' message. Engine manufacturers typically recommend against starting the engine while the ECU is broadcasting this message. Once the ECU stops broadcasting this message, this screen will no longer be displayed on the PowerView.
  • Page 225 “NO STORED CODES” is displayed The PowerView sent a request to the ECU for Stored Fault Code (DM2) information, and the ECU responded. There are zero stored codes. “NO GAGE DATA” is displayed The PowerView has no record of gages connected to the RS485 bus.
  • Page 226 “DATA ERROR” is displayed in place of a parameter value The ECU is sending a message that there is a data error with this parameter. Or (PV101 only) FUEL LEVEL has been selected for display, ANALOG INPUT has been set to FUEL LEVEL, but no Murphy Fuel Sender has been connected to the analog input.
  • Page 227 NOTES 00-02-0605 - 30 - Rev 09-10-08...
  • Page 228 Murphy, the Murphy logo, and PowerView are registered and/or common law trademarks of Murphy Industries, Inc. This document, including textual matter and illustrations, is copyright protected by Murphy Industries, Inc., with all rights reserved. (c) 2008 Murphy Industries, Inc. Other third party product or trade names referenced herein are the property of their respective owners and are used for identification purposes only.
  • Page 229 www.fwmurphy.com/PV101...
  • Page 230 Appendix F —Slewing Canopy 037-08OP-002D-01 S/N CB50600021 – UP (Weld-deck)
  • Page 231 Vanguard 037-08OP-003B Equipment, 2017-02 Inc. Operation and Maintenance Manual Slewing Canopy - An Attachment S/N 037201400021 – UP (T8 Slewing Canopy) S/N 037200370021 – UP (D6N LGP Slewing Canopy) To be used with the carrier vehicle’s Operation and Maintenance Manual...
  • Page 232 VANGUARD EQUIPMENT, INC. 15627 EAST PINE ST TULSA, OKLAHOMA 74116, USA ℡/ : 918.437.1796 S/N 037201400021 – UP (T8 Slewing Canopy) S/N 037200370021 – UP (D6N LGP Slewing Canopy)
  • Page 233 Table of Contents   FOREWORD ................................... 1   ..............................1 ITERATURE NFORMATION   ................................. 1 ACHINE ESCRIPTION   ....................................1 AFETY   .................................... 2 PERATION   ..................................2 AINTENANCE   ..............................2 AINTENANCE NTERVALS   SAFETY SECTION ................................2   ..............................

  • Page 234: Canopy

      Daily Inspection ................................23   ................................24 PERATOR ONTROLS   Slewing Canopy Controls ..............................25   ................................26 ACHINE ARKING   ............................26 RANSPORTATION NFORMATION   T8 Slewing canopy configure for transport ........................26   D6N Slewing canopy configure for transport ........................28  ...

  • Page 235: Foreword

    Read, study and keep this manual with the machine. Machine Description Vanguard’s Slewing Canopy attachment is an attachment that can be mounted onto a variety of self-propelled carrier vehicles: crawler tractors, Panther T8 tracked vehicle, etc. It is typically used in conjunction with a welding package such as Vanguard Equipment’s CPW-125-4 or CPW-125-4-S2.

  • Page 236: Operation

    Replace any safety sign that is damaged, or missing. If a safety sign is attached to a part that is replaced, install a safety sign on the replacement part. Vanguard Equipment can provide new safety signs. S/N 037201400021 – UP (T8 Slewing Canopy) 037-08OP-003B S/N 037200370021 –...
  • Page 237 Safety Sign locations - Slewing Canopy (On D6M/N) (On Panther T8) (On Panther T8) 3 (on D6M/N) S/N 037201400021 – UP (T8 Slewing Canopy) 037-08OP-003B S/N 037200370021 – UP (D6N LGP Slewing Canopy)
  • Page 238 Safety Sign locations - Panther T8 tracked vehicle Inside Cab 037-T8-09-001A S/N 037201400021 – UP (T8 Slewing Canopy) 037-08OP-003B S/N 037200370021 – UP (D6N LGP Slewing Canopy)
  • Page 239 Safety Sign locations - D6M/N tractor vehicle Cab (EROPS) Inside Cab (EROPS) Safety Sign locations - D6M/N tractor vehicle Canopy (OROPS) Inside Canopy (OROPS) S/N 037201400021 – UP (T8 Slewing Canopy) 037-08OP-003B S/N 037200370021 – UP (D6N LGP Slewing Canopy)

  • Page 240: Do Not Operate (1)

    Do Not Operate (1) WARNING! Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your dealer for replacement manuals. Proper care is your responsibility. Safety message (1) is located on the front of the left Slewing Canopy storage box (if equipped with a storage box), or on the left and right sides of the Slewing Canopy Base if not equipped with storage boxes.

  • Page 241: Not A Lifting Device (2)

    Not a Lifting Device (2) Dropping load hazard! Do not attempt to use the Slewing Canopy as a lifting device, crane, or as a lifting jib or boom to raise or support any type of load other than the intended use. Only use the Slewing Canopy to support and carry the welding cables and lightweight accessories used for Manual Metal Arc Welding operations, such as hand grinders or other similar tools.

  • Page 242: No Clearance (3)

    No Clearance (3) Crushing Hazard! Stay back a safe distance. No clearance for a person in this area when the Slewing Canopy turns. Severe injury or death from crushing could occur. Safety message (3) is located on the base of the Slewing Canopy Mast, above the lift cylinder attachment point. On the Panther T8 tracked vehicle, Safety message (3) is located on the exterior left and right hand sides of the carrier vehicle near the Slewing Canopy vehicle attachment supports.

  • Page 243: General Hazard Information

    General Hazard Information Before you service the equipment or before you repair the equipment, attach a “Do Not Operate” tag or similar tag to the start switch or controls. Know the width of your equipment in order to maintain proper clearance near fences, boundary obstacles, etc.

  • Page 244: Fluid Penetration

    Inhalation Asbestos Information Equipment and replacement parts that are shipped from Vanguard are asbestos free. Use only genuine OEM replacement parts. If any replacement parts that contain asbestos are used, follow the manufacturer's handling guidelines and procedures as outlined in their instruction documentation.

  • Page 245: Crushing Prevention And Cutting Prevention

    Improperly disposing of waste can threaten the environment. Potentially harmful fluids should be disposed of according to local regulations. Always use leak proof containers when you drain fluids. Do not pour waste onto the ground, down a drain, or into any source of water.

  • Page 246: Fire Prevention And Explosion Prevention

    Fire Prevention and Explosion Prevention General All fuels, most lubricants, and some coolant mixtures are flammable. To minimize the risk of fire or explosion, the following actions are recommended. Always perform a Walk-Around Inspection, which may help you identify a fire hazard. Do not operate a machine when a fire hazard exists.

  • Page 247: Lines, Tubes And Hoses

    Leaks can cause fires. Contact Vanguard Equipment for replacement parts. Check lines, tubes and hoses carefully. Wear Personal Protection Equipment (PPE) in order to check for leaks. Do not use your bare hands to check for leaks.

  • Page 248: Fire Extinguisher Location

    "General Hazard Information" section above. Replace electrical cables or wire-harnesses with the same electrical rating, properties, and specifications as the original. Contact your dealer or Vanguard for replacement parts. Replace electrical cables or wire-harnesses if any of the following conditions are present: •...

  • Page 249: Before Operating Equipment

    Before Operating Equipment Clear all personnel from the equipment and from the area. Check for obvious signs of damage, lose bolts, lose equipment, and foreign objects or debris on and around the equipment. Visibility Information Before you start the machine, perform a walk-around inspection in order to ensure that there are no hazards around the machine.

  • Page 250: Electrical Power Lines

    Electrical Power Lines Serious injury or death by electrocution can result if the machine or attachments are not kept the proper distance from electrical power lines. Use the following chart as a reference to determine the safe distance from high voltage wires during these conditions: •...

  • Page 251: Guards (Operator Protection)

    Guards (Operator Protection) There are different types of guards that are used to protect the operator. The machine and the machine application determines the type of guard that should be used. A daily inspection of the guards is required in order to check for structures that are bent, cracked or loose. Never operate a machine with a damaged structure.

  • Page 252: Product Information Section (Slewing Canopy)

    Product Information Section (SLEWING CANOPY) General Information Equipment Information Section (SLEWING CANOPY) CANOPY TARP CANOPY TUBE UPPER MAST SLEWING -STOP SLEWING DRIVE SLEWING CANOPY BASE WELDING ROD BOX CORD HOLDER AIR HOSE (MIDDLE HOLDER SET) CORD HOLDER (INNER SET) CONNECTION COMPRESSED CORDS AIR QUICK...

  • Page 253: Intended Use

    Slewing Canopy Attachment Specification (Carrier-vehicle weights not included) (A) Canopy Width 2368 mm 93.25 in (B) Overall Length with Canopy Horizontal (Shipping) 5260 mm 207.1 in (C) Maximum Height Above Canopy Horizontal (Shipping) 2206 mm 86.87 in Attachment Mounting Pads Canopy Fully Raised 2413 mm 95 in...

  • Page 254: Load Capacity

    Load Capacity The loading at each individual holder set (A), (B), (C), (D) must not be exceeded. The combined loading (A)+(B)+(C)+(D) must not be exceeded: (A) Total Combined load supported at INNER CORD HOLDER SET (B) Total Combined load supported at MIDDLE CORD HOLDER SET (C) Total Combined load supported at OUTER CORD HOLDER SET (D) Total Combined load supported at AIR HOSE HOLDER SET Figure 6: Slewing Canopy Load Capacity...

  • Page 255: Identification Information

    Identification Information Plate Locations and Film Locations - CE Mark The attachment/component information plate is attached to the component to identify the model name/number and the serial number. It is not a Product Information Number (PIN). The attachment/component information plate is located on the front of the Slewing Canopy Base, below the Slewing Drive, per the illustration below.

  • Page 256: Declaration Of Conformity

    Declaration of Conformity Machines supplied with the "CE" plate are compliant to "2006/42/EC". S/N 037201400021 – UP (T8 Slewing Canopy) 037-08OP-003B S/N 037200370021 – UP (D6N LGP Slewing Canopy)

  • Page 257: Operation Section

    Refer to the carrier vehicle's Operation and Maintenance Manual for specific instructions and machine access way information. Refer to Vanguard Equipment’s CPW-125-4 or CPW-125-4-S2 Weld-deck Operation and Maintenance Manuals for specific instructions and machine access way information for Vanguard Equipment’s weld-decks.

  • Page 258: Operator Controls

    Operator Controls The hydraulic functions of the Slewing Canopy Attachment are controlled by the carrier vehicle's implement controls. Refer to the specific carrier vehicle's Operation and Maintenance manual for information regarding the type and location of the implement controls. The implement controls may consist of either two separate levers, or there may be a single multifunction control. For two lever controls, there will be one lever to control the raise and lower functions and another for multifunction controls, such as the blade control on a dozer, one control axis will operate the raise and lower functions, and another axis will control the slewing functions.

  • Page 259: Slewing Canopy Controls

    The speed of the Slewing Canopy will be dependent on the engine RPM speed driving the hydraulic implement pump. The faster the engine RPM, the faster the Slewing Canopy operational speed. Slewing Canopy Controls HOLD: Move the control lever(s) to the centre position to stop the motion of the Slewing Canopy. The Slewing Canopy will remain at the position it is in.

  • Page 260: Machine Parking

    Machine Parking Refer to the carrier’s Operation and Maintenance Manual for specific machine parking instructions. Transportation Information Do not transport the machine with the Slewing Canopy unsecured. Do not transport the machine with the Slewing Canopy facing forwards. Note: The total combined weights and Dimensions of the Slewing Canopy, the Carrier Vehicle, and any additional attachments must be considered when transporting the machine.
  • Page 261 2. Ensure that there are no rips or worn sections that could result in damage during transport. Ensure that all of the hold down grommets are securely in place. 3. Rotate the Slewing Canopy rearward over the carrier vehicle, so that the canopy rest is centred on the stowing rest. 4.

  • Page 262: D6N Slewing Canopy Configure For Transport

    D6N Slewing canopy configure for transport TRACTOR STOWING REST STOWING LATCH PIN 037-20-204 (UNLOCKED) 037-D6N-05-002A 037-D6N-20-001A STOWING LATCH STOWING LATCH PIN UNLOCKED PIN LOCKED FOR WHEN WORKING TRANSPORT ONLY STOWING LATCH, CANOPY MIRROR ENGAGE LATCH PIN USE TO ASSIT THROUGH HOOK, STOWING LOCK SECURLY FOR TRANSPORT...
  • Page 263 1. Ensure that the canopy tarp is tightly secured to the canopy frame; tighten the canopy tarp hold down straps along each side of the canopy tarp as required. TIGHTEN TARP HOLD DOWN STRAPS 037-T8-20-003A 2. Ensure that there are no rips or worn sections that could result in damage during transport. Ensure that all of the hold down grommets are securely in place.

  • Page 264: Towing The Carrier

    Slowly lower the Slewing Canopy until it contacts the tractor-mounted stowing rest. 5. Engage the Stowing Latch Pin through the Stowing Latch. Move the Stowing Latch Pin handle to the LOCKED position for transport. STOWING LATCH PIN LOCKED FOR TRANSPORT ONLY 6.

  • Page 265: Capacities (Refill)

    Capacities (Refill) Compartment or System Roller Slewing drive bearing Slewing drive Worm Gear Ball Slewing drive bearings Cylinder Pin Bushings required required Canopy Pivot required required Table 3: Lubricant refill capacities Maintenance Interval Schedule (MIS) Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed.

  • Page 266: Every 2000 Service Hours Or 1 Year

    Every 2000 Service Hours or 1 Year • Slewing drive mounting bolts retighten to the prescribed torque - Check Slewing Drive Maintenance Refer to the Slewing Drive Manual in the appendix of this manual. Slewing Drive Bearing – Lubricate FORWARD Right Side Left Side Bearing (1)

  • Page 267: Slewing Drive Roller Bearings And Worm Gear - Lubricate

    Slewing Drive Roller Bearings and Worm Gear - Lubricate Roller Roller Bearing (1) Bearing (3) 037-T8-20-004A Worm Gear (2) Figure 13: Slewing Drive Roller Bearing and Worm Gear lubrication location While rotating the slewing drive, inject grease into all the cleaned grease nipples (1), (2), and (3) consecutively. S/N 037201400021 –...

  • Page 268: Canopy Support Cylinder Pivot Pins - Lubricate

    Canopy Support Cylinder Pivot Pins – Lubricate Cylinder Pivot Pin - UPPER (1) Cylinder Pivot Pin - LOWER (2) 037-T8-20-007B Figure 14: Canopy Cylinder Pivot Pins lubrication location Lubricate one fitting for the upper cylinder pin (1), and lubricate one fitting for the lower cylinder pin (2). S/N 037201400021 –...

  • Page 269: Slewing Canopy Pivot Pin - Lubricate

    Slewing Canopy Pivot Pin - Lubricate Slewing Canopy Pivot Pin (1) Figure 15: Slewing Canopy Pivot Pin lubrication location Lubricate one fitting for Slewing Canopy Pivot Pin (1). S/N 037201400021 – UP (T8 Slewing Canopy) 037-08OP-003B S/N 037200370021 – UP (D6N LGP Slewing Canopy)

  • Page 270: Slewing Drive Mounting Bolts Retighten To The Prescribed Torque - Check

    Slewing drive mounting bolts retighten to the prescribed torque - Check To compensate for possible settling, it is necessary to retighten the bolts to the prescribed torque .This shall be done without an external load applied to the bolt connection. This inspection shall be repeated annually, or 100 hours after installation. Inspection: The following procedure is to be used only as an indication that minimum assembly requirements have been achieved or maintained: 1.

  • Page 271: Appendices: Equipment Modules' Operation And Maintenance Manuals

    Appendices: Equipment Modules’ Operation and Maintenance Manuals 1) Slewing Drive Manual S/N 037201400021 – UP (T8 Slewing Canopy) 037-08OP-003B S/N 037200370021 – UP (D6N LGP Slewing Canopy)

  • Page 272: Appendix 1) - Slewing Drive Manual

    Appendix 1) — Slewing Drive Manual The following pages are taken from information published by the original equipment manufacturer (OEM), and are subject to change without notice. S/N 037201400021 – UP (T8 Slewing Canopy) 037-08OP-003B S/N 037200370021 – UP (D6N LGP Slewing Canopy)
  • Page 273 Contents Facilities ................................2 Preface ................................4 Model Code ............................... 5 Transport, Handling & Storage ........................... 7 Installation ................................8 Preparation ......................................8 Cleaning .........................................8 Permissible Flatness Deviation ................................9 Mounting Bolts ...................................... 10 Install the Slewing Drive ..................................11 Determine Tilting Clearance ................................. 13 Primary Movers ..............................

  • Page 274: Preface

    Preface The following instructions give you the information you need to be able to correctly install and maintain a KMI slew drive. These instructions replace earlier versions. All instructions are provided with a revision number. Installation and maintenance instructions with previous revision numbers are invalid. The latest version is published on our homepage and can be downloaded from there (www.kinematicsmfg.com).
  • Page 275 8-C: C-Capped end (no hex extrusion). E-Supply Encoder. None- Worm hex extrusion. 9- 2: None-Worm number/ Blank-Single, 2-Dual 10-XXXX: Blank-RAL9017, Traffic black . XXXX-RAL code(customer choice). Example: SE-17-C-26112M-25M-24VDC-R-XXXX-REV.A S - Slewing drive, E - Enclosed housing 17 - 17'' ball path diameter C - Engineering Level 26112 - reduction ratio, M-Metric threads 25M - 25 mm keyed input shaft diameter...

  • Page 276: Transport, Handling & Storage

    Transport, Handling & Storage Transport only in horizontal position, impacts should be avoided. Wear work gloves and be careful when handling the slewing drives. Use the holes of the rings in the slewing drives to fix bolts for safe hoisting, handling and placement. Store only in a horizontal position and in closed rooms, keep it away from getting wet, the surface corrosion protection of exposed mating surfaces lasts approximately 5 months in closed packaging.

  • Page 277: Installation

    Installation Preparation Check the slewing drive for physical damage. Clean the slewing drive and the mounting structure, see Cleaning. Remove extraneous materials from supporting surfaces. Cleaning S o l a r S l e w D r i v e M a n u a l...

  • Page 278: Permissible Flatness Deviation

    Permissible Flatness Deviation Table 1: permissible flatness including perpendicularity deviations for Slewing drives Size of Permissible perpendicularity Permissible perpendicularity Slew Drive deviation in length deviation in angle dimension [in] [mm] degree 3” 0.009 0.237 0.32 5” 0.031 0.335 0.32 7” 0.016 0.405 0.32...

  • Page 279: Mounting Bolts

    Mounting Bolts As the gearbox manufacturer, we do not supply, warrant or recommend the mounting fasteners used. Please take great care in specifying this item which will attach our product to yours. Prescribed sizes, number and quality grades shall be used. Grip ratio (grip length to diameter of bolt) shall be observed, from minimum ≥2 to maximum ≤10.

  • Page 280: Install The Slewing Drive

    Install the Slewing Drive Clean the mounting structure, e.g. from welding, galvanizing, residues, dirt, etc. Lift the slewing drive with eye bolts. The slewing drive shall be mounted in unloaded condition. Remove the shipping bolts after setting on the final mounting structure. The following procedure shall be followed in order to avoid deviations between bolt tightening forces.
  • Page 281 Figure 2.2 First completely torque inner or outer ring, then do the other ring. Once the screw is tightened, please permanently mark the position of the screw head to that of the stationary structure. This will be used later during inspection to be sure the screw head has not unwound. 12 | S o l a r S l e w D r i v e M a n u a l...

  • Page 282: Determine Tilting Clearance

    Determine Tilting Clearance The tilting clearance increases with raceway wear. To determine the increase in tilting clearance, it is necessary to take basic periodic measurements. Permanently designate the measuring point in the main load direction. Record all measured values into Table 3. Procedure Determine and mark the measuring spot at the point of load, both on the housing as well as on the worm wheel or on the slewing ring.

  • Page 283: Maintenance & Safety Checks

    Maintenance & Safety Checks Mounting Bolts To compensate for possible settling, it is necessary to retighten the bolts to the prescribed torque .This shall be done after no more than 100 hours of operation and without external load applied to the bolt connection. This inspection shall be repeated annually.
  • Page 284 Tilting Clearance Measuring tilting clearance on new product without rated load Figure 4.1 • Fix the dial gauge. The use of magnetic dial would be ideal in this case. • Apply a 20kg load in “A” direction. • Set the dial gauge on zero. •...
  • Page 285 17” 0.013 0.32 0.09 21” 0.017 0.42 0.09 25” 0.019 0.49 0.09 Measuring tilting clearance on new product under rated load • Install slew drive into customer specific equipment using customer’s standard load, as long as the load falls within maximum guideline ratings of the KMI slewing drive. •...

  • Page 286: Torsional Clearance

    Torsional Clearance Gear wear leads to increased rotational backlash. Procedure: • Clip a dial gage between the stationary and rotating structure. Determine the rotational play by gently turning the upper structure against the stationary structure, • reading the total difference in measurement from a clockwise to a counterclockwise turn. Figure 4.2 Do not force the turning or the measurement will be inaccurate.

  • Page 287: Lubrication Instruction

    Lubrication Instruction Provisions about handling the respective lubricants must be observed. While rotating the slewing drive, inject grease into all the cleaned grease nipples consecutively until a continuous collar of fresh grease forms at least on one sealing lip. Ball bearings lubricate point Roller bearing lubricate point Worm gear lubricate point Roller bearing lubricate point...

  • Page 288: Weather Protection

    Weather Protection Paint spec Epoxy Epicon Zinc HB-2 KMI drives are coated with a special two part epoxy coating in KMI’s automated painting line to give the drive excellent heat and weather protection. Epoxy Brand: EPICON ZINC HB-2 EPICON ZINC HB-2 is a high-build type epoxy zinc rich paint based on a combination of epoxy resin and polyamide resin pigmented with metallic zinc power.

  • Page 289: Fastener And/Or Coating

    Fastener and/or Coating Stainless Steel is used for every fastener to ensure no rust and long life. If the customer requires a non-stainless fastener, then it is coated with Zinc-Co-Nl to reduce the bolts rust. Features: 1. Excellent resistance to corrosion resistance, salt spray test 8-10 times for the traditional function of zinc, zinc and iron or zinc-nickel alloy plating for 2 to 4 times, 5um can be achieved when more than 1000 hours (red rust), 8μm when 2,000 hours or more (red rust), 24um, when up to 6000 hours or more (red rust).

  • Page 290: Grease Spec

    Grease Spec There are four places which are lubricated, they are (1)slewing ring ball bearings, (2)worm gear, (3)taper roller bearings and (4)planetary gears. Slewing drives are supplied fully lubricated. Table 5: Eco Friendly Grease Specifications Taper Bearing Parts needed to be lubricated Ring raceway Worm Gear Thread Condition of Lubricate...

  • Page 291: Rubber Spec

    Rubber Spec Composite rubber of NBR and PVC specification NBR has good oil resistance and wearing resistance, but lacks of age resistance and ozone proof of climate. To overcome this shortage, by research and test, adding PVC greatly improves NBR’s age resistance, ozone protection, oil resistance, wearing resistance and heat resistance.

  • Page 292: Liquid Sealant

    Comparison Test Report Client: Jiangyin KMI Date: 2009-7-31 Item Name: Rubber Seal Material: NBR/PVC Inspection Items NBR sample data NBR+PVC sample Unit Inspection data Condition Normal test: Room temp Hardness Shore A The tensile-strength 13.2 13.7 The elongation at break Heat resistance Hardness change Tensile strength change...
  • Page 293 Product Description LOCTITE® 510™ provides the following product characteristics: Technology Acrylic Chemical Type Dimethacrylate ester Appearance (uncured) Opaque pink paste Components One component - requires no mixing Viscosity High Cure Anaerobic Application Gaskets and Sealing Strength Medium LOCTITE® 510™ cures when confined in the absence of air between close fitting metal surfaces. This product is a general gasket product suitable for hand dispensing or screen printing.
  • Page 294 TYPICAL CURING PERFORMANCE Cure Speed vs. Substrate The rate of cure will depend on the substrate used. The graph below shows the shear strength developed with time on grit blasted steel lap shears compared to different materials and tested according to ISO4587. Cure Speed vs.
  • Page 295 Cure Speed vs. Temperature The rate of cure will depend on the temperature. The graph below shows the shear strength developed with time at different temperatures on grit blasted steel lap shears and tested according to ISO 4587. Cure Speed vs. Activator Where cure speed is unacceptably long, or large gaps are present, applying activator to the surface will improve cure speed.
  • Page 296 Coefficient of Thermal Expansion, ISO 11359-2, K-1 80×10-6 • • Coefficient of Thermal Conductivity, ISO 8302, W/(m·K) • Specific Heat, kJ/(kg·K) • TYPICAL PERFORMANCE OF CURED MATERIAL Adhesive Properties: Cured for 1 hour @ 22 °C Compressive Shear Strength, ISO 10123: ≥1 Steel pins and collars (grit blasted) N/mm²...
  • Page 297 TYPICAL ENVIRONMENTAL RESISTANCE The following tests refer to the effect of environment on strength. This is not a measure of sealing performance. Cured for 1 week @ 22 °C Lap Shear Strength, ISO 4587:Steel (grit blasted) Hot Strength Tested at temperature Heat Aging Aged at temperature indicated and tested @ 22 °C 30 |...
  • Page 298 Chemical/Solvent Resistance Aged under conditions indicated and tested @ 22°C. % of initial strength Environment °C 100 h 500 h 1000 h Motor oil (MIL-L-46152) Unleaded Petrol Water/glycol 50/50 General Information This product is not recommended for use in pure oxygen and/or oxygen rich systems and should not be selected as a sealant for chlorine or other strong oxidizing materials.
  • Page 299 Loctite Material Specification LMS Storage Store product in the unopened container in a dry location. Storage information may be indicated on the product container labeling. Optimal Storage: 8 °C to 21 °C. Storage below 8 °C or greater than 28 °C can adversely affect product properties.

  • Page 300: Thread Lock Liquid

    Thread Lock Liquid Tighten thread locking adhesives Tighten thread locking adhesives are widely used for sealing, locking and corrosion resistance of threaded fasteners in various environments, can replace spring washers, pins and other traditional mechanical locking methods. TS242 Thread locking adhesive Medium strength General purpose, chemotropic viscosity, For locking and sealing M6-M20 threads.

  • Page 301: Limited Warranty

    Limited Warranty PURPOSE. This limited warranty to Buyer, is to provide for repair or replacement of equipment that Seller does not correctly manufacture. The equipment must be operated within the design specifications. 2. LIMITED WARRANTY. Seller guarantees that the equipment, when in good repair, properly adjusted and in the hands of a competent operator, is capable of performing as specified.
  • Page 302 6. DISCLAIMER. Equipment and accessories not of Seller's manufacture are warranted only to the extent that they are warranted by the manufacturer. There are no other warranties, express or implied, either for merchantability or of fitness for a particular purpose. Buyer agrees that there have been no representations upon which Buyer relied, other than those set forth in this Warranty.
  • Page 303 ©2017 Vanguard Equipment, Inc. All Rights Reserved Printed in U.S.A.
  • Page 304 Appendix G —Auto Tie-In Crane 037-08OP-002D-01 S/N CB50600021 – UP (Weld-deck)
  • Page 305 Vanguard 037-08OP-004B Equipment, 2017-03 Inc. Operation and Maintenance Manual Auto Tie-in Crane - An Attachment S/N 037202650021 – UP (Auto Tie-in Crane) To be used with the carrier vehicle’s Operation and Maintenance Manual...
  • Page 306 VANGUARD EQUIPMENT, INC. 15627 EAST PINE ST TULSA, OKLAHOMA 74116, USA ℡/ : 918.437.1796 037202650021 – UP (Auto Tie-in Crane)
  • Page 307 Table of Contents FOREWORD ................................... 1 ..............................1 ITERATURE NFORMATION ................................. 1 ACHINE ESCRIPTION ....................................1 AFETY .................................... 3 PERATION ..................................3 AINTENANCE ..............................3 AINTENANCE NTERVALS SAFETY SECTION ................................3 ..............................3 AFETY IGNS AND ABELS Do Not Operate (1) ..............................4 Pinch Point (2) ...................................
  • Page 308 Daily Inspection ................................28 ................................30 PERATOR ONTROLS Auto Tie-in Crane Controls ............................. 30 ................................33 ACHINE ARKING ............................33 RANSPORTATION NFORMATION T12 Auto Tie-in Crane configure for transport ....................... 33 T12 Shack Deck configure for transport .......................... 34 Towing the Carrier ................................35 MAINTENANCE AND LUBRICATION SECTION ......................

  • Page 309: Foreword

    Machine Description Vanguard’s Auto Tie-in Crane attachment is an attachment that can be mounted onto a Panther T12 tracked vehicle, tracked utility vehicle, track crawler carrier, etc.. It is typically used in conjunction with a welding package such as Vanguard Equipment’s CPW-125-4 or CPW-125-4-S2.
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  • Page 311: Operation

    Replace any safety sign that is damaged, or missing. If a safety sign is attached to a part that is replaced, install a safety sign on the replacement part. Vanguard Equipment can provide new safety signs. 037202650021 – UP (Auto Tie-in Crane)
  • Page 312 Safety Sign locations - Auto Tie-in Crane - Panther T12 tracked vehicle 037202650021 – UP (Auto Tie-in Crane) 037-08OP-004B...

  • Page 313: Do Not Operate (1)

    Do Not Operate (1) WARNING! Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death.

  • Page 314: Pinch Point (2)

    Pinch Point (2) Pinch Point Hazard! Stay back a safe distance. Pinch points present in this area when Auto Tie-in crane turns. Severe injury or death from crushing could occur. Safety message (2) is located near the left hand door on the genset enclosure front side, and the front of the control/distribution centre on the main door.

  • Page 315: Electrical Power Lines (3)

    Electrical Power Lines (3) Electrocution Hazard! Keep the machine and attachments a safe distance from electrical power. Stay clear 3 M (10 ft) plus twice the line insulator length. Read and understand the instructions and warnings in the Operation and Maintenance Manual.

  • Page 316: Load May Rotate (4)

    Load May Rotate (4) Overhead load crushing hazard! Overhead load may rotate when supported by the Auto Tie-in Crane. Do not work under load or in rotation zone, maintain a safe distance from the load and rotation zone at all times. Failure to keep clear may result in severe injury or death.

  • Page 317: Overhead Load (5)

    Overhead Load (5) Crushing hazard! Overhead load crushing hazard is present when load is being supported by the Auto Tie-in Crane. Do not work under load, maintain a safe distance from the load at all times. Failure to keep clear may result in severe injury or death.

  • Page 318: Overload (6)

    Overload (6) Overload hazard! Boom overload hazard is present when load is being supported by the Auto Tie-in Crane with the boom below horizontal. Do not lift or support a load with the boom below horizontal. Attempting a lift in this situation could cause severe injury or death.

  • Page 319: General Hazard Information

    General Hazard Information Before you service the equipment or before you repair the equipment, attach a “Do Not Operate” tag or similar tag to the start switch or controls. Know the width of your equipment in order to maintain proper clearance near fences, boundary obstacles, etc.

  • Page 320: Fluid Penetration

    Inhalation Asbestos Information Equipment and replacement parts that are shipped from Vanguard are asbestos free. Use only genuine OEM replacement parts. If any replacement parts that contain asbestos are used, follow the manufacturer's handling guidelines and procedures as outlined in their instruction documentation.

  • Page 321: Dispose Of Waste Properly

    Dispose of Waste Properly Improperly disposing of waste can threaten the environment. Potentially harmful fluids should be disposed of according to local regulations. Always use leak proof containers when you drain fluids. Do not pour waste onto the ground, down a drain, or into any source of water.

  • Page 322: Fire Prevention And Explosion Prevention

    Fire Prevention and Explosion Prevention General All fuels, most lubricants, and some coolant mixtures are flammable. To minimize the risk of fire or explosion, the following actions are recommended. Always perform a Walk-Around Inspection, which may help you identify a fire hazard. Do not operate a machine when a fire hazard exists.

  • Page 323: Lines, Tubes And Hoses

    Leaks can cause fires. Contact Vanguard Equipment for replacement parts. Check lines, tubes and hoses carefully. Wear Personal Protection Equipment (PPE) in order to check for leaks. Do not use your bare hands to check for leaks.

  • Page 324: Fire Extinguisher Location

    "General Hazard Information" section above. Replace electrical cables or wire-harnesses with the same electrical rating, properties, and specifications as the original. Contact your dealer or Vanguard for replacement parts. Replace electrical cables or wire-harnesses if any of the following conditions are present: •...

  • Page 325: Before Operating Equipment

    Before Operating Equipment Clear all personnel from the equipment and from the area. Remove all obstacles from the path of the machine. Beware of hazards such as wires, ditches, etc. Reference: Refer to Operation and Maintenance Manual, "Daily Inspection" in this manual, “Preparing the Crane for Operation”...

  • Page 326: Stability

    Report any needed repairs that were noted during operation. Stability A well trained operator that follows the instructions in the Operation and Maintenance Manual has the greatest impact on stability. Operator training provides a person with the following abilities: observation of working and environmental conditions, feel for the machine, identification of potential hazards, and operating the machine safely by making appropriate decisions.

  • Page 327: Equipment Lowering With Engine Stopped

    Equipment Lowering with Engine Stopped Before lowering any equipment with the engine stopped, clear the area around the equipment of all personnel. The procedure will lower the boom against the counterbalance valve. Wear appropriate personal protective equipment and follow the established procedure in the crane Owner’s Manual, "EMERGENCY CRANE OPERATION”...

  • Page 328: Guards (Operator Protection)

    Guards (Operator Protection) There are different types of guards that are used to protect the operator. The machine and the machine application determine the type of guard that should be used. A daily inspection of the guards is required in order to check for structures that are bent, cracked or loose. Never operate a machine with a damaged structure.

  • Page 329: Product Information Section (Auto Tie-In Crane)

    Product Information Section (Auto Tie-in Crane) General Information Equipment Information Section (Auto Tie-in Crane) CRANE BOOM HOOK BLOCK CRANE BASE BOOM REST CRANE PLATFORM MOUNTING BRACKETS Figure 7: Auto Tie-in Crane Attachment - components 037202650021 – UP (Auto Tie-in Crane) 037-08OP-004B...
  • Page 330 Auto Tie-in Crane Attachment Specification (Carrier-vehicle weights not included) (A) Overall Width 1125.5 mm 44.31 in (B) Overall Length with Boom Horizontal (Shipping) 4838 mm 190.47 in (C) Maximum Height Above Boom Horizontal (Shipping) 2473.4 mm 97.38 in Top of C-Rail Boom Fully Raised 11342.7 mm 446.56 in...
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  • Page 332: Intended Use

    Intended Use The primary use of this attachment is to lift a lightweight automatic welding-shack or other miscellaneous lightweight equipment for petroleum-product pipeline construction. Load Capacity The machine may tip and personal injury may occur if the maximum load capacities are exceeded. Load capacities assume that the machine is stationary on a level concrete surface.
  • Page 333 Figure 9: Slope Operation Load Capacity Reduction When operating on a slope above 15% grade (8.5°) reduce the maximum load to the values shown in Figure 9 above. When approaching the maximum slope or maximum load the boom operation will drop to 50% speed and the yellow light on the boom will illuminate.
  • Page 334 Notice Do not attempt a lift a load with the crane’s boom over the cab as per OSHA 1910.180(h)(3)(vii). Lifting over the cab is a crushing hazard. Failure to exclude this lifting area may result in severe injury or death. See Appendix 2. Do not exceed the load capacity shown on the load chart.

  • Page 335: Identification Information

    Identification Information Plate Locations and Film Locations The attachment/component information plate is attached to the component to identify the model name/number and the serial number. It is not a Product Information Number (PIN). The attachment/component information plate is located on the rear of the Auto Tie-in Crane Base, below the platform, per the illustration below.

  • Page 336: Operation Section

    Refer to the carrier vehicle's Operation and Maintenance Manual for specific instructions and machine access way information. Refer to Vanguard Equipment’s CPW-125-4 or CPW-125-4-S2 Weld-deck Operation and Maintenance Manuals for specific instructions and machine access way information for Vanguard Equipment’s weld-decks.
  • Page 337 Daily Checks After you inspect the machine, perform the daily maintenance that is listed in the maintenance interval schedule. Perform the daily maintenance before you mount the machine in order to operate the machine. Refer to Operation and Maintenance Manual, "Maintenance Interval Schedule" for the correct procedures for the following checks: •...

  • Page 338: Operator Controls

    Operator Controls The hydraulic functions of the Auto Tie-in Crane Attachment are controlled by a remote control. Figure 13: Typical crane remote control layout The speed of the Auto Tie-in Crane will be dependent on the engine RPM speed driving the hydraulic implement pump. The faster the engine RPM, the faster the Auto Tie-in Crane operational speed.
  • Page 339 Figure 14: Typical crane remote screen layout 1. Capacity – The current load on the boom as a percentage of total capacity. The unloaded value of the boom may be higher than 0% due to the boom weight beyond the retracted position. 2.
  • Page 340 MODE DESCRIPTION In 1-AXIS operation, once the joystick is moved in the direction of the desired function, the other functions are locked out until the joystick returns to the center position. For example, if you are booming up, you cannot rotate at the same time. But one function of the other joystick will be available to use.

  • Page 341: T12 Auto Tie-In Crane Configure For Transport

    Machine Parking Refer to the carrier’s Operation and Maintenance Manual for specific machine parking instructions. Transportation Information Do not transport the machine with the Auto Tie-in Crane unsecured. Do not transport the machine with the Shack Deck unsecured. Do not transport the machine with the Auto Tie-in Crane facing forwards. Note: The total combined weights and Dimensions of the Auto Tie-in Crane, the Carrier Vehicle, and any additional attachments must be considered when transporting the machine.

  • Page 342: T12 Shack Deck Configure For Transport

    1. Rotate the Auto Tie-in Crane rearward over the carrier vehicle, so that the boom is centred on the boom rest. 2. Slowly lower the Auto Tie-in Crane boom until it contacts the boom rest. Note, when the crane is stowed in the rest the green and yellow lights will flash on the boom.

  • Page 343: Towing The Carrier

    Towing the Carrier Note: DO NOT connect to any part of the Auto Tie-in Crane or its mounting base for towing purposes of any kind. Refer to the carrier vehicle’s Operation and Maintenance Manual for correct towing procedures. Maintenance and Lubrication Section Lubricant Viscosities General •...

  • Page 344: Maintenance Interval Schedule (Mis)

    Maintenance Interval Schedule (MIS) Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. The user is responsible for the performance of maintenance, including all adjustments, the use of proper lubricants, fluids, filters, and the replacement of components due to normal wear and aging. Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and/or accelerated wear of components.

  • Page 345: Every 10 Service Hours Or Daily

    Every 10 Service Hours or Daily • Controls for proper operation of Auto Tie-in Crane – Check • Hydraulic Hoses and fittings for leaks – Check • Electrical cables for signs of damage to insulation - Check, replace if damaged •...

  • Page 346: Every 500 Service Hours Or 6 Months Service

    Auto Tie-in Crane Lubrication & Maintenance Schedule Figure 19: Auto Tie-in Crane Lubrication & Maintenance Schedule Every 500 Service Hours or 6 months Service Figure 17 Check the torque on the crane base mounting threaded studs, see for inspection torque. See the Break-in Period section. Every 1000 Service Hours or Yearly Service Check carrier frame below crane base for cracks or damage to the vehicle structure.
  • Page 347 This Page Intentionally Left Blank. 037202650021 – UP (Auto Tie-in Crane) 037-08OP-004B...

  • Page 348: Appendices: Equipment Modules' Operation And Maintenance Manuals

    Appendices: Equipment Modules’ Operation and Maintenance Manuals 1. Crane Owner’s Manual 2. Panther T12 Specific Warning Decals 037202650021 – UP (Auto Tie-in Crane) 037-08OP-004B...

  • Page 349: Appendix 1) - Crane Owner's Manual

    Appendix 1) — Crane Owner’s Manual The following pages are taken from information published by the original equipment manufacturer (OEM), and are subject to change without notice. 037202650021 – UP (Auto Tie-in Crane) 037-08OP-004B...
  • Page 350 HC-12 NEXSTAR III OWNERS MANUAL Serial No. _______________________________________ Mailing Address: Physical Address: Phone: 1-800-777-2760 P.O. Box 580697 4707 N. Mingo Rd. Fax: (918) 269-6688 Tulsa, OK 74158-0697 Tulsa, OK 74117-5904 http://www.autocrane.com 475000103-0816-A...
  • Page 351 At the time of publishing this manual is accurate to the best of our knowledge. Auto Crane reserves the right to change any or all items, components and parts, necessary for any reason. This right does not obligate Auto Crane to immediately update the manual.
  • Page 352 Table of Contents 1.1 WARNINGS ..................................6 2.1 INTRODUCTION ................................7 3.1 GENERAL SPECIFICATIONS .............................. 8 DIMENSIONS ................................... 8 CAPACITY ..................................8 REACH ..................................... 8 CABLE ....................................8 CHASSIS AND MOUNTING REQUIREMENTS ........................8 HYDRAULIC REQUIREMENTS ............................8 ELECTRICAL SYSTEM REQUIREMENTS ..........................8 ROTATION ..................................
  • Page 353 5.6 OPERATION – VALVE OVERRIDE ..........................21 6.1 NEXSTAR III TROUBLESHOOTING ..........................22 6.1.1 TROUBLESHOOTING FLOW CHART ........................22 6.1.2 NEXSTAR III REMOTE CONTROL TROUBLESHOOTING TABLE ................. 23 6.1.3 NEXSTAR III ERROR CODE TABLE ..........................24 6.1.4 NEXSTAR III MECHANICAL TROUBLESHOOTING TABLE..................25 6.1.5 NEXSTAR III ELECTRICAL TROUBLESHOOTING TABLE .....................
  • Page 354 HC-12NEXSTAR III, MAIN HARNESS P/N: 366823220 ....................... 57 HC-12NEXSTAR III, ELECTRICAL SCHEMATIC P/N: 366823221 ..................58...

  • Page 355: 1.1 Warnings

    1.1 WARNINGS Indicates a hazardous situation which, if not avoided, will result in death or serious injury. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. Indicates information considered important, but not hazard-related.

  • Page 356: 2.1 Introduction

    2.1 INTRODUCTION Keep this manual with the crane at all times. Auto Crane products are designed to provide many years of safe, trouble-free, dependable service when properly used and maintained. To assist you in obtaining the best service from your crane and to avoid untimely crane and/or vehicle failure, this manual provides the following operating and service instructions.

  • Page 357: 3.1 General Specifications

    3.1 GENERAL SPECIFICATIONS DIMENSIONS • Width: 27.0 in. (0.69 m) • Height: 39.0 in. (0.99 m) • Length: 15 ft. 9 in. (4.80 m), stored length. • Weight: 3,040 lbs. (1379 kg) CAPACITY • 85,000 ft-lbs (11.75 ton-m) • Ft-lbs = horizontal distance from centerline of rotation to free hanging weight (feet) x amount of weight (pounds). REACH •...

  • Page 358: 3.2 Hc-12 Nexstar Iii, General Dimensions

    3.2 HC-12 NEXSTAR III, GENERAL DIMENSIONS Figure 1. General Dimensions...

  • Page 359: 3.3 Load Chart

    3.3 LOAD CHART Figure 2. Load Chart All load ratings are based on crane capacity, not the vehicle stability. When lifting a heavy load, the weight can create enough tipping moment to overturn the vehicle. DO NOT USE the overload shutdown device to determine maximum rated loads, if the crane is equipped with this type of device.

  • Page 360: Nexstar Iii Decal Layout, P/N 475000202

    3.4 HC-12 NEXSTAR III DECAL LAYOUT, P/N 475000202...

  • Page 361: Qualifications And Operating Practices

    4.1 QUALIFICATIONS AND OPERATING PRACTICES THIS IS ONLY AN OVERVIEW OF ALL APPLICABLE QUALIFICATION REQUIREMENTS. REFERENCE ASME B30.5A AND OSHA 1910.180 FOR COMPLETE QUALIFICATION REQUIREMENTS. 4.2 OPERATORS 1. Crane operation shall be limited to personnel with the following minimum qualifications: A.

  • Page 362: Operating Practices/Handling The Load

    5. Before closing the switch or starting the engine, the operator shall see that all controls are in the “OFF” or neutral position and all personnel are in the clear. 6. If power fails during operation, the operator shall: A. Move power controls to the “OFF” or neutral position. B.

  • Page 363: Operating Near Electrical Power Lines

    4.6 OPERATING NEAR ELECTRICAL POWER LINES Never operate the crane near electrical lines or in the danger zone area. Figure 3. Danger Zone 1. Do not place any part of the crane or load inside the Danger Zone. EXCEPTIONS: A. The Danger Zone may be entered after confirmation by an appointed person the electrical distribution and transmission lines are de-energized and visibly grounded at the point work.

  • Page 364: 4.7 Preparing The Crane For Operation

    b. Exceptions ensuring equivalent protection are allowed, if approved by the administrative or regulatory authority in writing. c. Install durable signs at the operator’s station and on the outside of the crane, warning that electrocution or serious bodily injury may occur if the Table 1. Safe Operating Distance limits aren’t adhered to. 4.7 PREPARING THE CRANE FOR OPERATION 1.

  • Page 365: After Operation

    AFTER OPERATION 1. After completing the lifting operations, return the boom to the stowed position on the boom support. 2. Replace remote control to its storage location. 3. Return the Outriggers to the stowed position. Ensure they are pinned in place or jacklegs are returned to the storage compartment.

  • Page 366: 5.1 Nexstar Iii Operation

    5.1 NEXSTAR III OPERATION This section describes the general operation for cranes with the NEXSTAR III control system. Before operating the Remote Control, read and understand all safety information in this manual, any manual supplements, and any applicable local, state, or federal rules and regulations. Never drive with a load suspended from the crane.

  • Page 367: 5.3 Remote Control Layout

    5.3 REMOTE CONTROL LAYOUT Figure 4. Nexstar III Remote Control 1. Emergency Stop Button – Push to activate. Pull to release. When activated the Emergency Stop Button stops all outputs from the receiver. 2. Display Screen – LCD screen that displays many crane operating parameters. See Figure 4. 3.

  • Page 368: 5.4 Display Screen Layout

    5.4 DISPLAY SCREEN LAYOUT Figure 5. Display Screen Layout 1. Capacity – The current load on the boom as a percentage of total capacity. The unloaded value of the boom may be higher than 0% due to the boom weight beyond the retracted position. 2.

  • Page 369: 5.5 Speed And Mode Selection

    5.5 SPEED AND MODE SELECTION 5.5.1 SPEED SELECTION 1. Press and hold the Link Switch in the up position. 2. While holding the Link Switch in the up position: a. Move the Left Joystick up to increase the max speed. b.

  • Page 370: 5.6 Operation - Valve Override

    5.6 OPERATION – VALVE OVERRIDE 1. Push the unloader valve (ULV) red button. This will send hydraulic fluid to the valve block. 2. Select the desired function. 3. Close the gap between the collar and the end on the override button. 4.

  • Page 371: 6.1 Nexstar Iii Troubleshooting

    6.1 NEXSTAR III TROUBLESHOOTING 6.1.1 TROUBLESHOOTING FLOW CHART Table 2. Troubleshooting Flow Chart...

  • Page 372: Nexstar Iii Remote Control Troubleshooting Table

    6.1.2 NEXSTAR III REMOTE CONTROL TROUBLESHOOTING TABLE Problem Possible Reason Action Remote control Emergency Stop Switch is Ensure the E-Stop switch is pulled up. down or pressed. Replace the battery pack with the label Batteries are dead or installed backwards; facing out.

  • Page 373: 6.1.3 Nexstar Iii Error Code Table

    6.1.3 NEXSTAR III ERROR CODE TABLE Error Code Cause Effect Solution S1 CAN RX TO Reception of a can message All outputs will be disabled Determine why messages are not timed out being received. When problem is corrected the alarm will clear S2 TEMP OUT OF Outside of operating temperature All outputs will be disabled...

  • Page 374: Nexstar Iii Mechanical Troubleshooting Table

    6.1.4 NEXSTAR III MECHANICAL TROUBLESHOOTING TABLE Problem Cause Effect Solution Jammed cartridge Try to manually override the valve. If Replace the cartridge unable to move stem, cartridge is jammed. CRANE MOVES Counter-balance set too low Adjust the counter-balance out to see if Contact Auto Crane for proper UNEXPECTEDLY (boom up and boom down)

  • Page 375: Nexstar Iii Electrical Troubleshooting Table

    6.1.5 NEXSTAR III ELECTRICAL TROUBLESHOOTING TABLE Problem Cause Effect Solution Jammed transmitter button Activate e-stop to see if movement Verify that nothing had stops depressed the button at the time of movement. If it was not depressed, replace the transmitter Short in wiring harness Unexpected movement would only Verify there is no damage to the...
  • Page 376 Problem Cause Effect Solution Reached limit for cw rotation Check screen for error code. It will Verify the CW limit switch is not display "CW limit" activated. This should normally ROTATE CW IS be closed. INOPERABLE Bad coil or damaged wire Screen will display 0% next to sp but the Switch coil with another function.

  • Page 377: 7.1 Maintenance

    7.1 MAINTENANCE 7.1.1 INSPECTION REQUIREMENTS Reference ASME B30.5a and OSHA 1910.180 for complete inspection requirements. All inspections shall be performed by designated personnel only. 7.1.2 INSPECTION CLASSIFICATION 1. Initial Inspection a. Prior to initial use, all new, altered, modified, or extensively repaired cranes shall be inspected by a designated person to ensure compliance with provisions of this standard.

  • Page 378: 7.1.4 Periodic Inspection

    7.1.4 PERIODIC INSPECTION Any deficiencies, such as those listed below, shall be carefully examined and determination made as to whether they constitute a hazard: 1. Inspect for deformed, cracked or corroded members in the crane structure and entire boom. 2. Inspect for loose bolts, particularly mounting bolts. 3.

  • Page 379: 7.1.5 Cranes Not In Regular Use

    7.1.5 CRANES NOT IN REGULAR USE A crane, which has been idle for a period of more than one month or more, shall be given an inspection conforming to the “initial” and “periodic” inspection requirements of this section. 7.1.6 INSPECTION RECORDS Dated records of periodic inspection should be made on critical items such as brakes, crane hooks, rope, cylinders, and relief pressure valves.

  • Page 380: 7.3.2 Adjustments And Repairs

    7.3.2 ADJUSTMENTS AND REPAIRS 1. Any hazardous conditions disclosed by the inspection requirement shall be corrected before operation of crane is resumed. 2. Adjustments shall be maintained to assure correct of functioning of components, the following are examples: a. Function operating mechanism. b.

  • Page 381: 7.3.6 Paint Finish Maintenance

    5. Rope should be maintained in a well-lubricated condition. It is important that lubricant applied as a part of the maintenance program shall be compatible with the original lubricant and to this end the rope manufacturer should be consulted. Lubricant applied shall be the type that does not hinder visual inspection. Those sections of rope that are located over sheaves or otherwise hidden during inspection and maintenance procedures require special attention when lubricating rope.

  • Page 382: Lubrication And Maintenance Schedule

    7.4 LUBRICATION AND MAINTENANCE SCHEDULE SERVICE INSTRUCTIONS DAILY WEEKLY 3 MONTHS 6 MONTHS YEARLY PERFORMED Load Hook Inspect hook and latch for deformation, cracks, and corrosion. Cable Drum Ensure cable is wound evenly on drum. Hoist/Boom Check for flattening, kinks, broken Cable strands.

  • Page 383: 7.5 Lubrication Points

    7.5 LUBRICATION POINTS 1. Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product Liability. 2. Once a bolt has been tightened to specification then removed, the bolt should be replaced with a new one. 3.

  • Page 384: 7.6 Rotation Bearing Replacement

    7.6 ROTATION BEARING REPLACEMENT All bearings wear over time, including the main rotation bearing of the crane. There are no precise rules for replacing the main rotation bearing because of many variable factors. There are common symptoms during crane operation that may indicate rotation bearing wear.

  • Page 385: Hc-12Nexstar Iii, Cartridge Maintenance

    7.7 HC-12NEXSTAR III, CARTRIDGE MAINTENANCE VERIFY MOVEMENT IN PORTS WHILE MANUALLY OVERRIDING CARTRIDGE Table 8. Cartridge Maintenance Use the following procedure to inspect the cartridge for proper operation. 1. Clean the area around the valve spool before it is removed from the valve bank. 2.

  • Page 386: Crane Mounting And Installation

    8.1 CRANE MOUNTING AND INSTALLATION For information specific to your crane, such as mounting hole diameter, bolt size and grade, and hydraulic requirements, see General Dimensions. 1. Refer to the Bill of Materials included with your ship kit. Ensure all items listed on the Bill of Materials are included with your crane.
  • Page 387 Failure to correctly plumb and wire crane can cause inadvertent operation and damage to crane and/or personnel. 11. With crane installed and plumbed on the truck, fill the reservoir to the top of the sight glass using Mobile DTE 13 or equivalent.

  • Page 388: Nexstar Iii, Counterbalance Valve Adjustment

    8.1.1 HC-12 NEXSTAR III, COUNTERBALANCE VALVE ADJUSTMENT Do not try to adjust valves while the boom is moving. 1. Ensure the PTO is disengaged and the boom is properly supported. 2. Remove the plug on the counterbalance valve. 3. Install a pressure gauge (0-3000 psi) into the port. 4.
  • Page 389 HC-12NEXSTAR III, MAIN HARNESS P/N: 366823220 96" 78" 56" 48" 32" 24" R UN POWER/ENGINE 15" 27" J24 ON LY MESH LOOM 6" 19 8 7 TAPE GASKET & SCREW TO CONNECTOR 12" 36" CONNEC TOR ID CONNEC TOR DESCRIPTION RECIEVER 18 PIN CONNECTION RECIEVER 30 PIN CONNECTION USB CONNECTION...
  • Page 390 HC-12NEXSTAR III, ELECTRICAL SCHEMATIC P/N: 366823221...
  • Page 391 HC-12NEXSTAR III, ELECTRICAL SCHEMATIC P/N: 366823221...
  • Page 392 Appendix 2) — Panther T12 Specific Warning Decals OVER CAB LOAD OVER CAB LOAD MACHINE MAY TIP MACHINE MAY TIP Figure 20: Panther T12 Specific Warning Decal Locations 037202650021 – UP (Auto Tie-in Crane) 037-08OP-004B...
  • Page 393 Over Cab Load Crushing hazard! Over cab lift crushing hazard is present when load is being lifted by the Auto Tie-in Crane over the cab. Failure to exclude this lifting area may result in severe injury or death. Prinoth Over Cab safety message is located on the Panther T12 rear guarding on the left hand and right hand side. Figure 21: Do Not Lift Over Cab Decal 037202650021 –...
  • Page 394 Machine May Tip Tipping hazard! The vehicle may tip if the load capacity is exceeded which may result in severe injury or death. Prinoth Over Cab safety message is located on the Panther T12 rear guarding on the left hand and right hand side. Figure 22: Machine May Tip Decal 037202650021 –...
  • Page 395 ©2017 Vanguard Equipment, Inc. All Rights Reserved Printed in U.S.A.
  • Page 396 Appendix H — Genset Engine • Cummins® Operation and Maintenance Manual 4021531 The following pages are taken from information published by the original equipment manufacturer (OEM), and are subject to change without notice. 037-08OP-002D-01 S/N CB50600021 – UP (Weld-deck)
  • Page 397 Owners Manual QSB4.5 and QSB6.7 Engine Cummins Customer Assistance Center 1-800-DIESELS 1-800-343-7357 APPLICABLE ONLY IN U.S.A. AND CANADA...
  • Page 398 Owners Manual QSB4.5 and QSB6.7 Engine Copyright© 2017 Bulletin 4915973 Cummins Inc. Printed 05-FEBRUARY-2017 All rights reserved To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com...
  • Page 399 Foreword Thank you for depending on Cummins® products. If you have any questions about this product, please contact your Cummins® Authorized Repair Location. You can also visit cumminsengines.com or quickserve.cummins.com for more information, or go to locator.cummins.com for Cummins® distributor and dealer locations and contact information. Read and follow all safety instructions.
  • Page 400 Table of Contents Section Introduction ................................ Engine and System Identification ........................Operating Instructions ............................Maintenance Guidelines ............................ Service Literature .............................. Service Assistance ............................Maintenance Specifications ..........................Warranty ................................Back ..................................back To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com...
  • Page 401 Important Reference Numbers Fill in the blank spaces provided below. This will provide a reference whenever service or maintenance is required. Description Number Comments/Additional Information Engine Engine Model Engine Serial Number (ESN) Control Parts List (CPL) Electronic Control Module (ECM) Part Number(s) Electronic Control Module (ECM) Serial Number(s)
  • Page 402 Description Number Comments/Additional Information Eliminator™ Filter Centrifuge (if equipped) *The number of fuel filters may vary by application. Record all fuel filters. Aftertreatment (if applicable): Aftertreatment Diesel Particulate Filter (if equipped) Aftertreatment Diesel Exhaust Fluid Dosing Unit Filter (if equipped) Aftertreatment Diesel Exhaust Fluid Dosing Air Oil Separator (if equipped) Clutch or Marine Gear (if applicable):...
  • Page 404 QSB4.5 and QSB6.7 Section i - Introduction Page i-a Section i - Introduction Section Contents Page Acronyms and Abbreviations ........................... i-37 General Information..............................i-37 General Safety Instructions ............................i-9 Aftertreatment................................i-22 Best Practices................................i-9 Common Hazards..............................i-29 Common Substances..............................i-24 Electrical Components............................... i-28 Fuels..................................

  • Page 405: Introduction

    QSB4.5 and QSB6.7 Page i-b Section i - Introduction This Page Left Intentionally Blank...
  • Page 406 QSB4.5 and QSB6.7 Symbols Section i - Introduction Page i-1 Symbols General Information The symbols have been used in this manual to help communicate the intent of the instructions. When one of the symbols appears, it conveys the meaning defined below. NOTE: It is possible to have four symbols for each text and graphic combination.
  • Page 407 Symbols QSB4.5 and QSB6.7 Page i-2 Section i - Introduction CAUTION Minor personal injury can result or a part, and assembly, or the engine can be damaged if the caution instructions are not followed. Indicates a REMOVAL or Dissassembly step. To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com...
  • Page 408 QSB4.5 and QSB6.7 Symbols Section i - Introduction Page i-3 Indicates an INSTALLATION or ASSEMBLY step. INSPECTION is required. To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com...
  • Page 409 Symbols QSB4.5 and QSB6.7 Page i-4 Section i - Introduction CLEAN the part or assembly. PERFORM a mechanical or time MEASUREMENT. To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com...
  • Page 410 QSB4.5 and QSB6.7 Symbols Section i - Introduction Page i-5 LUBRICATE the part or assembly. Indicates that a WRENCH or TOOL SIZE will be given. To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com...
  • Page 411 Symbols QSB4.5 and QSB6.7 Page i-6 Section i - Introduction TIGHTEN to a specific torque. PERFORM an electrical MEASUREMENT. To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com...
  • Page 412 QSB4.5 and QSB6.7 Symbols Section i - Introduction Page i-7 Refer to another location in this manual or another publication for additional information. The component weighs 23kg [50 lbs] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift the component.
  • Page 413 Illustrations QSB4.5 and QSB6.7 Page i-8 Section i - Introduction Illustrations General Information Some of the illustrations throughout this manual are generic and will not look exactly like the engine or parts used in your application. The illustrations can contain symbols to indicate an action required and an acceptable or not acceptable condition.
  • Page 414 QSB4.5 and QSB6.7 General Safety Instructions Section i - Introduction Page i-9 General Safety Instructions Important Safety Notice Read and understand the safety information and precautions before performing any repair or operating equipment. This procedure contains general safety precautions that must be followed to provide personal safety. Always follow procedures to mitigate safety concerns.
  • Page 415 General Safety Instructions QSB4.5 and QSB6.7 Page i-10 Section i - Introduction • Do not perform any repairs, or operate equipment, when fatigued or impaired due to drugs or alcohol. • Always use tools that are in good condition. • Do not work on equipment with the key switch ON or that is running unless otherwise directed by troubleshooting procedures.
  • Page 416 QSB4.5 and QSB6.7 General Safety Instructions Section i - Introduction Page i-11 • Always allow the product to cool. • Always ensure the product is properly supported by blocks or stands. Do not work on a product supported only by lifting jacks or hoists. •...
  • Page 417 General Safety Instructions QSB4.5 and QSB6.7 Page i-12 Section i - Introduction • Shade or arc rated eyewear. Exposure to welding. Use appropriate filter ratings. Foot Protection Protective shoes must alwaysbe worn. Wear appropriate foot protection based on the task being completed. Types of protective footwear to consider are listed below.
  • Page 418 QSB4.5 and QSB6.7 General Safety Instructions Section i - Introduction Page i-13 Wear appropriate type and fit of gloves based on the task being completed. Types of protective gloves to consider are listed below. • Heat resistant or insulated. Exposure to hot items. •...
  • Page 419 General Safety Instructions QSB4.5 and QSB6.7 Page i-14 Section i - Introduction • Chemical resistant. Exposure to chemicals. • High visibility. Exposure to reduced visibility working environments. Working on mining, oil and gas, or sites with large equipment. Respiratory Protection Wear appropriate respiratory protection based on the task being completed.
  • Page 420 QSB4.5 and QSB6.7 General Safety Instructions Section i - Introduction Page i-15 • Protect skin. • Always test for fuel leaks as instructed. • Do not dilute. • Avoid sparks, arcing switches and equipment, cigarettes, pilot lights, flames, and other sources of ignition. •...
  • Page 421 General Safety Instructions QSB4.5 and QSB6.7 Page i-16 Section i - Introduction • Vapors accumulate near the floor. Check the work floor, sumps, and low lying areas for ignition sources before servicing equipment.. • Provide extra ventilation to the work area. •...
  • Page 422 QSB4.5 and QSB6.7 General Safety Instructions Section i - Introduction Page i-17 • If material is spilled, avoid contact and dispersal with runoff, soil, waterways, drains, and sewers. Absorb with sand, clay, or commercial absorbent. Transfer to containers and neutralize the material. Flush spill area with soap and excess water.
  • Page 423 General Safety Instructions QSB4.5 and QSB6.7 Page i-18 Section i - Introduction • Store and service natural gas fueled equipment in large, well-ventilated areas, or outside. • Provide extra ventilation to the work area. • Natural gas accumulates near the ceiling. Check the ceiling of the work area for ignition sources before servicing equipment.
  • Page 424 QSB4.5 and QSB6.7 General Safety Instructions Section i - Introduction Page i-19 • Natural gas ignites when there is a 5% - 15% mixture in the air. Asphyxiation can occur when concentration reaches 21% or more. • Do not start equipment or nearby equipment until a suspected gas leak is corrected and the area is ventilated. •...
  • Page 425 General Safety Instructions QSB4.5 and QSB6.7 Page i-20 Section i - Introduction Liquefied Petroleum Gas • Protect eyes. • Protect skin. • Always be alert for the smell of gas. Liquefied petroleum gas is typically treated with an odor producing chemical for leak detection.
  • Page 426 QSB4.5 and QSB6.7 General Safety Instructions Section i - Introduction Page i-21 • Liquefied petroleum gas exhaust systems operate at higher temperatures than similar diesel exhaust systems. Do not touch exhaust components. Do not route lines or hoses which deteriorate from heat exposure near exhaust components or in the flow path of the exhaust..
  • Page 427 General Safety Instructions QSB4.5 and QSB6.7 Page i-22 Section i - Introduction • Lock the generator set circuit breaker in the "Open" position. • Activate the manual "Emergency Stop" device. • Do not step on the generator set when servicing, entering, or leaving the generator room. Aftertreatment Follow these recommended practices when interacting with equipment that utilize aftertreatment systems.
  • Page 428 QSB4.5 and QSB6.7 General Safety Instructions Section i - Introduction Page i-23 aromatic hydrocarbons. Potentially toxic materials found in these filters are oxides of calcium, zinc, phosphorous, silicon, sulfur, and iron. • Proper disposal of the exhaust dust and filter are required. Dispose of in accordance with local and environmental regulations.
  • Page 429 General Safety Instructions QSB4.5 and QSB6.7 Page i-24 Section i - Introduction • Protect skin. • Avoid stirring up exhaust catalyst dust. • Avoid inhalation of exhaust catalyst dust. Wear a dust mask. If respiratory irritation or discomfort occurs, leave the dusty area.
  • Page 430 QSB4.5 and QSB6.7 General Safety Instructions Section i - Introduction Page i-25 • Report spills effecting water source contamination to local authorities immediately. • Proper disposal is required. Dispose of in accordance with local and environmental regulations. Liquid Nitrogen • Work in a well-ventilated area.
  • Page 431 General Safety Instructions QSB4.5 and QSB6.7 Page i-26 Section i - Introduction Solvents • Follow the manufacturer's instructions for safe handling practices. • Follow the manufacturer's recommendations for use. • Some solvents are flammable and toxic.. • Protect eyes. In case of contact with eyes, follow manufacturer's recommendations. •...
  • Page 432 QSB4.5 and QSB6.7 General Safety Instructions Section i - Introduction Page i-27 • Protect skin. In case of contact with skin, wash with soap and water. • Avoid inhalation. Lubricating Oil • Protect eyes. In case of contact with eyes, flush with water for a minimum of 15 minutes. •...
  • Page 433 General Safety Instructions QSB4.5 and QSB6.7 Page i-28 Section i - Introduction • Proper disposal is required. Dispose of in accordance with local and environmental regulations. Electrical Components Follow these recommended practices when interacting with electrical components. Batteries • Protect eyes. Wear safety glasses or goggles. In case of battery acid contact with eyes, flush with water for a minimum of 15 minutes.
  • Page 434 QSB4.5 and QSB6.7 General Safety Instructions Section i - Introduction Page i-29 Common Hazards Follow these recommended practices when interacting with equipment as the following hazards may exist. High Temperature Area Be alert for high temperature areas which may cause severe burns. High temperature areas may be encountered in the following situations.
  • Page 435 General Safety Instructions QSB4.5 and QSB6.7 Page i-30 Section i - Introduction • Use mechanical help to move items whenever possible. Make sure the load is securely fastened to the equipment. • Make sure lifting devices, like chains, hooks, slings, etc., are in good condition and are rated for the correct capacity before use.
  • Page 436 QSB4.5 and QSB6.7 General Safety Instructions Section i - Introduction Page i-31 • Protect skin. Wear impervious gloves. If skin penetration from high pressure spray occurs, it is a medical emergency. Receive medical attention immediately. • Check for pressure leaks as instructed. Never check for pressure leaks with your hand. •...
  • Page 437 General Safety Instructions QSB4.5 and QSB6.7 Page i-32 Section i - Introduction Ascending or Descending • Maintain 3 points of contact when using steps, ladders, or entering and exiting a unit. Communication • When working with others, make sure you understand what each other is doing to safely complete the task. Eyes On Hands and Work.
  • Page 438 QSB4.5 and QSB6.7 General Safety Instructions Section i - Introduction Page i-33 • Avoid bending forward more than 45 at your waist. • Avoid working with your back twisted with loads over 23 kg [ 50 lb ]. Knee • Avoid bending your knee more than 90.
  • Page 439 General Safety Instructions QSB4.5 and QSB6.7 Page i-34 Section i - Introduction • Confirm that safety devices are in place before use. • Use the tool or equipment as directed. • Follow the manufacturer's instructions. Personal Protective Equipment (PPE) Eye, Face, and Head Protection •...
  • Page 440 QSB4.5 and QSB6.7 General Safety Instructions Section i - Introduction Page i-35 • Body parts should be protected from work hazards. • Avoid contact with sharp edges, hot surfaces, etc. Work Prcedures Training • Confirm if you have received task and safety training for the job being performed. Working Alone •...
  • Page 441 General Safety Instructions QSB4.5 and QSB6.7 Page i-36 Section i - Introduction • Maintain separation between ignition sources and fuel sources. Place Wheel Chocks • Place wheel chocks at either the front or back tire of the unit prior to starting the task. Spotter •...
  • Page 442 QSB4.5 and QSB6.7 Acronyms and Abbreviations Section i - Introduction Page i-37 Acronyms and Abbreviations General Information The following list contains some of the acronyms and abbreviations used in this manual. ANSI American National Standards Institute American Petroleum Institute ASTM American Society of Testing and Materials ATDC After Top Dead Center...
  • Page 443 Acronyms and Abbreviations QSB4.5 and QSB6.7 Page i-38 Section i - Introduction Control Parts List Centistokes Diesel Exhaust Fluid Diesel Oxidation Catalyst Diesel Particulate Filter Engine Control Module Electronic Fuel Control Exhaust Gas Recirculation Environmental Protection Agency Engine Serial Number °F Fahrenheit ft-lb...
  • Page 444 QSB4.5 and QSB6.7 Acronyms and Abbreviations Section i - Introduction Page i-39 Job Safety Assessment km/l Kilometers per Liter Kilopascal Liquefied Natural Gas Liquefied Petroleum Gas Low Temperature Aftercooler MCRS Modular Common Rail System Malfunction Indicator Lamp Megapascal Miles Per Hour Miles Per Quart N•m Newton-meter...
  • Page 445 Acronyms and Abbreviations QSB4.5 and QSB6.7 Page i-40 Section i - Introduction Parts Per Million Pounds Per Square Inch Power Takeoff QSOL QuickServe® Online REPTO Rear Engine Power Takeoff Rear Gear Train Revolutions Per Minute Society of Automotive Engineers Supplemental Coolant Additive Selective Catalytic Reduction Step Timing Control Subsystem Identification Descriptions...
  • Page 446 QSB4.5 and QSB6.7 Section E - Engine and System Identification Page E-a Section E - Engine and System Identification Section Contents Page Engine Identification ..............................E-1 Air Compressor................................E-7 Cummins® Engine Nomenclature..........................E-5 Engine Control Module Dataplate..........................E-6 Engine Dataplate................................E-1 Fuel Injection Pump Dataplate...........................

  • Page 447: Engine And System Identification

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  • Page 448 QSB4.5 and QSB6.7 Engine Identification Section E - Engine and System Identification Page E-1 Engine Identification Engine Dataplate The engine dataplate provides important information about the engine. The engine serial number (ESN) and control part list (CPL) provide information for service and for ordering parts. The engine dataplate must not be changed unless approved by Cummins Inc.
  • Page 449 Engine Identification QSB4.5 and QSB6.7 Page E-2 Section E - Engine and System Identification NOTE: The engines covered by this manual are produced worldwide. The dataplates used on engines may differ in appearance and location of information. The following illustrations show examples of common dataplates used and the information contained on the dataplate.
  • Page 450 QSB4.5 and QSB6.7 Engine Identification Section E - Engine and System Identification Page E-3 1 Engine serial number 2 Engine model information 3 Control parts list (CPL) 4 Valve lash (overhead) setting 5 Horsepower and rpm rating. 1 Engine serial number 2 Engine model information 3 Horsepower and rpm rating 4 Valve lash (overhead) setting.
  • Page 451 Engine Identification QSB4.5 and QSB6.7 Page E-4 Section E - Engine and System Identification NOTE: Depending on the manufacturing plant, calibration data may also be found on the engine dataplate. NOTE: If the engine dataplate (1) is not legible, the engine serial number (2) can be found on the engine block, on top of the lubricating oil cooler housing.
  • Page 452 QSB4.5 and QSB6.7 Engine Identification Section E - Engine and System Identification Page E-5 Cummins® Engine Nomenclature The Cummins® engine nomenclature provides the data as shown in the illustration. Fuel Injection Pump Dataplate The Bosch™ fuel injection pump dataplate is located on the fuel pump.
  • Page 453 Engine Identification QSB4.5 and QSB6.7 Page E-6 Section E - Engine and System Identification Engine Control Module Dataplate The electronic control module (ECM) dataplate shows information about the ECM and how the ECM was programmed. The dataplate is located on the ECM. The following information is available on the ECM dataplate: •...
  • Page 454 QSB4.5 and QSB6.7 Engine Identification Section E - Engine and System Identification Page E-7 Air Compressor NOTE: Not all engines are equipped with an air compressor. The Cummins® branded air compressor dataplate, identified by the Cummins Inc. logo, is typically located on the side of the air compressor.
  • Page 455 Engine Identification QSB4.5 and QSB6.7 Page E-8 Section E - Engine and System Identification Notes...
  • Page 456 QSB4.5 and QSB6.7 Section 1 - Operating Instructions Page 1-a Section 1 - Operating Instructions Section Contents Page Cold Weather Starting ..............................1-8 General Information..............................1-8 Using Starting Aids..............................1-9 Electromagnetic Interference (EMI) ........................1-14 General Information..............................1-14 System EMI Radiation Levels...........................1-15 System EMI Susceptibility............................

  • Page 457: Operating Instructions

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  • Page 458 QSB4.5 and QSB6.7 Operating Instructions - Overview Section 1 - Operating Instructions Page 1-1 Operating Instructions - Overview General Information Correct care of your engine will result in longer life, better performance, and more economical operation. Follow daily maintenance checks listed Maintenance Guidelines (Section 2).
  • Page 459 Operating Instructions - Overview QSB4.5 and QSB6.7 Page 1-2 Section 1 - Operating Instructions Check the oil pressure indicators, temperature indicators, warning lights, and other gauges daily to make sure they are operational. Check the oil pressure, coolant temperature, and other engine parameters daily via the OEM front panel to make sure they are operational.
  • Page 460 QSB4.5 and QSB6.7 Operating Instructions - Overview Section 1 - Operating Instructions Page 1-3 WARNING Do not operate a diesel engine where there are or can BE COMBUSTIBLE vapors. These vapors can be sucked through the air intake system and cause engine acceleration and over speeding that can result in a fire, an explosion, and extensive property damage.
  • Page 461 Normal Starting Procedure QSB4.5 and QSB6.7 Page 1-4 Section 1 - Operating Instructions Normal Starting Procedure General Information WARNING Do not depress the accelerator pedal or move the accelerator lever from the idle position while cranking the engine. This can result in engine overspeed and severe damage to the engine.
  • Page 462 QSB4.5 and QSB6.7 Normal Starting Procedure Section 1 - Operating Instructions Page 1-5 CAUTION The engine must have adequate oil pressure within 15 seconds after starting. WARNING lamp indicating low oil pressure has not gone out or there is no oil pressure indicated on a gauge within 15 seconds, shut off the engine immediately to avoid engine damage.
  • Page 463 Normal Starting Procedure QSB4.5 and QSB6.7 Page 1-6 Section 1 - Operating Instructions After starting a cold engine, increase the engine speed (rpm) slowly to provide adequate lubrication to the bearings and to allow the oil pressure to stabilize. CAUTION Do not operate engine at low idle for long periods with engine coolant temperature below the minimum specification in Maintenance Specifications (Section...
  • Page 464 QSB4.5 and QSB6.7 Normal Starting Procedure Section 1 - Operating Instructions Page 1-7 Jump Starting WARNING Batteries can emit explosive gases. To avoid personal injury, always ventilate compartment before servicing the batteries. To avoid arcing, remove the negative (-) battery cable first and attach the negative(-) battery cable last.
  • Page 465 Cold Weather Starting QSB4.5 and QSB6.7 Page 1-8 Section 1 - Operating Instructions This illustration shows a typical series battery connection. This arrangement, positive (+) to negative (-), doubles the voltage. NOTE: Always reference the relevant OEM literature for jump starting procedures. Failure to follow correct procedures can result in damage to the ECM and other electrical equipment.
  • Page 466 QSB4.5 and QSB6.7 Starting Procedure After Extended Shutdown or Oil Chang [...] Section 1 - Operating Instructions Page 1-9 Using Starting Aids WARNING Do not use starting fluids with this engine. This engine is equipped with an intake air heater: use of starting fluid can cause an explosion, fire, personal injury, severe damage to the engine, and property damage.
  • Page 467 Operating the Engine QSB4.5 and QSB6.7 Page 1-10 Section 1 - Operating Instructions Operating the Engine Normal If equipped, monitor the oil pressure and coolant temperature gauges frequently. Refer to Lubricating Oil System specifications and Cooling System specifications, Maintenance Specifications (Section recommended operating pressures and temperatures.
  • Page 468 QSB4.5 and QSB6.7 Operating the Engine Section 1 - Operating Instructions Page 1-11 If an overheating condition starts to occur, reduce the power output of the engine by releasing the accelerator pedal or lever or shifting the transmission to a lower gear, or both, until the temperature returns to the normal operating range.
  • Page 469 Engine Operating Range QSB4.5 and QSB6.7 Page 1-12 Section 1 - Operating Instructions Engine Operating Range General Information CAUTION Do not operate the engine at full throttle below peak torque rpm (refer to engine dataplate for peak torque rpm) for more than 30 seconds. Operating the engine at full throttle below peak torque will shorten engine life to overhaul, can cause serious engine damage, and is considered engine abuse.
  • Page 470 QSB4.5 and QSB6.7 Engine Operating Range Section 1 - Operating Instructions Page 1-13 CAUTION Do not idle the engine for excessively long periods. Long periods of idling, more than 10 minutes, can cause poor engine performance. To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com...
  • Page 471 Electromagnetic Interference (EMI) QSB4.5 and QSB6.7 Page 1-14 Section 1 - Operating Instructions Engine Shutdown General Information CAUTION Failure to follow the correct shutdown procedure may result in damage to the turbocharger and shorten the turbocharger life. NOTE: For engines equipped with an electronic control module (ECM) ensure the keyswitch is turned off for a minimum of 100 seconds prior to disconnecting the continuous (unswitched) battery power supply.
  • Page 472 QSB4.5 and QSB6.7 Electromagnetic Interference (EMI) Section 1 - Operating Instructions Page 1-15 performance problems with either the electronically controlled systems or the accessory due to EMI. EMI is not considered by Cummins to be a system failure and therefore is not warrantable. System EMI Susceptibility Your Cummins product has been designed and tested for minimum sensitivity to incoming electromagnetic energy.
  • Page 473 Electromagnetic Interference (EMI) QSB4.5 and QSB6.7 Page 1-16 Section 1 - Operating Instructions Make sure your accessory equipment model is built for maximum filtering to reject incoming electromagnetic noise. To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com...
  • Page 474 QSB4.5 and QSB6.7 Section 2 - Maintenance Guidelines Page 2-a Section 2 - Maintenance Guidelines Section Contents Page Maintenance Guidelines - Overview ......................... 2-1 General Information..............................2-1 Maintenance Record Form ............................2-6 Maintenance Data...............................2-6 Maintenance Schedule ............................... 2-2 General Information..............................2-2 Oil Drain Intervals...............................

  • Page 475: Maintenance Guidelines

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  • Page 476 QSB4.5 and QSB6.7 Maintenance Guidelines - Overview Section 2 - Maintenance Guidelines Page 2-1 Maintenance Guidelines - Overview General Information Cummins Inc. recommends that the system be maintained according to the Maintenance Schedule in this section. If the system is operating in ambient temperatures below -18°C [0°F] or above 38°C [100°F], perform maintenance at shorter intervals.
  • Page 477 Maintenance Schedule QSB4.5 and QSB6.7 Page 2-2 Section 2 - Maintenance Guidelines Maintenance Schedule General Information Perform maintenance at whichever interval occurs first. At each scheduled maintenance interval, perform all previous maintenance checks that are due for scheduled maintenance. Maintenance Procedures at Daily Interval •...
  • Page 478 QSB4.5 and QSB6.7 Maintenance Schedule Section 2 - Maintenance Guidelines Page 2-3 • Fan, Cooling - Check • Coolant Level - Check • Drive Belts - Check 1, 2, 3 Maintenance Procedures at 500 Hours or 6 Months Section 5 •...
  • Page 479 Maintenance Schedule QSB4.5 and QSB6.7 Page 2-4 Section 2 - Maintenance Guidelines 1 The lubricating oil and lubricating oil filter interval is determined by the sulfur content of the fuel used, the lubricating oil type used, and the engine rating. See the Oil Drain Intervals in this section. 2 Antifreeze check interval is every oil change or 500 hours or 6 months, whichever occurs first.
  • Page 480 QSB4.5 and QSB6.7 Maintenance Schedule Section 2 - Maintenance Guidelines Page 2-5 Table 1: Recommended Oil Change and Filter Change Intervals American Petroleum European Fuel Sulfur Content Engine Rating is 261 Engine Rating is 260 Institute Classification Hp [195 kW] or Hp [194 kW] or less Classification (API) (ACEA)
  • Page 481 Maintenance Record Form QSB4.5 and QSB6.7 Page 2-6 Section 2 - Maintenance Guidelines Maintenance Record Form Maintenance Data Maintenance Record Product Serial No.: Product Model: Owner's Name: Equipment Model/Number: Key to table headings: A = Date B = Schedule km [Miles], Hours or Time Interval C = Actual km [Miles] Hour or Time D = Maintenance Check Performed E = Check Performed By...
  • Page 482 QSB4.5 and QSB6.7 Maintenance Record Form Section 2 - Maintenance Guidelines Page 2-7 To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com...
  • Page 483 Maintenance Record Form QSB4.5 and QSB6.7 Page 2-8 Section 2 - Maintenance Guidelines Notes...
  • Page 484 QSB4.5 and QSB6.7 Section L - Service Literature Page L-a Section L - Service Literature Section Contents Page Additional Service Literature .............................L-1 General Information..............................L-1 Cummins Customized Parts Catalog ........................L-5 General Information..............................L-5 Ordering the Customized Parts Catalog........................L-5 Service Literature Ordering Location ........................L-4 Contact Information..............................

  • Page 485: Service Literature

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  • Page 486 QSB4.5 and QSB6.7 Additional Service Literature Section L - Service Literature Page L-1 Additional Service Literature General Information The following publications can be purchased: Additional Service Literature Bulletin Title of Publication 4021271 ISB, ISBe, ISBe4, QSB4.5, QSB5.9, and QSB6.7 (Common Rail Fuel System) Service Manual 4021578 ISB CM2150 and ISB CM2150 E Service Manual...
  • Page 487 Additional Service Literature QSB4.5 and QSB6.7 Page L-2 Section L - Service Literature Additional Service Literature Bulletin Title of Publication 4021670 ISBe2 / ISBe3 CM850 Wiring Diagram 4022230 ISB6.7 CM2250 Wiring Diagram 4021531 QSB4.5 and QSB6.7 Operation and Maintenance Manual 4021546 ISBe4 (Common Rail Fuel System) Operation and Maintenance Manual 4021602...
  • Page 488 QSB4.5 and QSB6.7 Additional Service Literature Section L - Service Literature Page L-3 Additional Service Literature Bulletin Title of Publication 3810340 Cummins® Engine Oil and Oil Analysis Recommendations 4021566 Diesel Exhaust Fluid (DEF) Specifications for Cummins® Selective Catalytic Reduction (SCR) Systems (1) Revision 01 or newer is required for ISBe4+/ISBe5- (Minus) To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com...
  • Page 489 Service Literature Ordering Location QSB4.5 and QSB6.7 Page L-4 Section L - Service Literature Service Literature Ordering Location Contact Information Service literature can be obtained from the appropriate location listed below: • Any Cummins® Distributor • Iron Mountain Fulfillment Services •...
  • Page 490 QSB4.5 and QSB6.7 Cummins Customized Parts Catalog Section L - Service Literature Page L-5 Cummins Customized Parts Catalog General Information Cummins is pleased to announce the availability of a parts catalog compiled specifically for you. Unlike the generic versions of parts catalogs that support general high volume parts content; Cummins Customized catalogs contain only the new factory parts that were used to build your engine.
  • Page 491 Cummins Customized Parts Catalog QSB4.5 and QSB6.7 Page L-6 Section L - Service Literature • International Distributors and Original Equipment Manufacturers order the CPC from their regional Cummins Parts Distribution Centers (PDC). • International PDC orders are called into Iron Mountain at (++) 630-283-2420. •...
  • Page 492 QSB4.5 and QSB6.7 Cummins Customized Parts Catalog Section L - Service Literature Page L-7 Unfortunately not all Cummins Engines can be supported by Customized Parts Catalogs. Engines older than 1984 or newer than 3 months may not have the necessary parts information to compile a catalog. We will contact you if this occurs and explain why we are unable to fill your order.
  • Page 493 Cummins Customized Parts Catalog QSB4.5 and QSB6.7 Page L-8 Section L - Service Literature Notes...
  • Page 494 QSB4.5 and QSB6.7 Section S - Service Assistance Page S-a Section S - Service Assistance Section Contents Page Routine Service and Parts ............................S-2 General Information..............................S-2 Service Assistance ..............................S-1 General Information..............................S-1 To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com...
  • Page 495 QSB4.5 and QSB6.7 Page S-b Section S - Service Assistance This Page Left Intentionally Blank...

  • Page 496: Service Assistance

    QSB4.5 and QSB6.7 Service Assistance Section S - Service Assistance Page S-1 Service Assistance General Information To contact the nearest Cummins® Authorized Repair Location, utilize the Service Locator at www.cummins.com. Cummins Inc. provides a 24-hour, toll free telephone number to aid in technical and emergency service when a Cummins®...
  • Page 497 Routine Service and Parts QSB4.5 and QSB6.7 Page S-2 Section S - Service Assistance • Email: emea.customerassistance@cummins.com China • 400 810 5252 or (+86) 400 810 5252 • Email: customersupport@cummins.com India • 800 210 2525 • Email: powermaster-India@cummins.com Russia • Primary: +7 495 926 8624 •...
  • Page 498 QSB4.5 and QSB6.7 Section V - Maintenance Specifications Page V-a Section V - Maintenance Specifications Section Contents Page Coolant Recommendations and Specifications ....................V-14 Cooling System Sealing Additives..........................V-17 Cooling System Soluble Oils............................ V-17 Fully Formulated Coolant/Antifreeze........................V-14 Cooling System ................................V-4 Specifications................................

  • Page 499: Maintenance Specifications

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  • Page 500 QSB4.5 and QSB6.7 General Engine Section V - Maintenance Specifications Page V-1 General Engine Specifications Listed below are the general specifications for this engine. Bore and Stroke......................107 mm [4.21 in] x 124 mm [4.88 in] Horsepower..........................Refer to engine dataplate Displacement Four-Cylinder Engine........................4.5 liters [274 C.I.D.] Six-Cylinder Engine........................
  • Page 501 Lubricating Oil System QSB4.5 and QSB6.7 Page V-2 Section V - Maintenance Specifications Lubricating Oil System Specifications Oil Pressure Low idle (minimum allowed)........................69 kPa [10 psi] At rated (minimum allowed)......................... 207 kPa [30 psi] Oil-regulating valve-opening pressure range............. 448 kPa [65 psi] to 517 kPa [75 psi] Oil filter differential pressure to open bypass....................
  • Page 502 QSB4.5 and QSB6.7 Lubricating Oil System Section V - Maintenance Specifications Page V-3 Total System..........................16.7 liters [17.6 qt] High to Low (on dipstick)........................ 1.9 liters [2.0 qt] Oil Capacity of Standard Engine (six-cylinder) 6.7 liters [409 C.I.D] Engines (Suspended Oil Pan) Pan only ............................17.2 liters [18.5 qt] Total System..........................
  • Page 503 Cooling System QSB4.5 and QSB6.7 Page V-4 Section V - Maintenance Specifications Cooling System Specifications Coolant Capacity (four-cylinder engine only)..................8.5 liters [2.2 gal] Coolant Capacity (six-cylinder engine only).....................10 liters [2.6 gal] Standard Modulating Thermostat - Range - Industrial Applications........... 88 to 97°C [190 to 207°F] Maximum Allowed Operating Temperature - Industrial Applications ............
  • Page 504 QSB4.5 and QSB6.7 Filter Specifications Section V - Maintenance Specifications Page V-5 Filter Specifications General Information Fleetguard®/Nelson® is a subsidiary of Cummins Inc. Fleetguard®/Nelson® filters are developed through joint testing at Cummins® and Fleetguard®/Nelson®. Fleetguard®/Nelson® filters are standard on new Cummins® engines. Cummins Inc.
  • Page 505 Fuel Recommendations and Specifications QSB4.5 and QSB6.7 Page V-6 Section V - Maintenance Specifications Fuel Recommendations and Specifications Fuel Recommendations WARNING Do not mix gasoline, alcohol, or gasohol with diesel fuel. This mixture can cause an explosion. CAUTION Due to the precise tolerances of diesel injection systems, it is extremely important that the fuel be kept clean and free of dirt or water.
  • Page 506 QSB4.5 and QSB6.7 Fuel Recommendations and Specifications Section V - Maintenance Specifications Page V-7 Acceptable Substitute Fuels Number Number Number Jet-A Jet-A1 JP-5 JP-8 Jet-B JP-4 CITE Kerosene Diesel Diesel (2) (3) Not OK Not OK Not OK Not OK An "A"...
  • Page 507 Lubricating Oil Recommendations and Specifications QSB4.5 and QSB6.7 Page V-8 Section V - Maintenance Specifications Lubricating Oil Recommendations and Specifications General Information CAUTION The fuel sulphur content should not exceed 0.5 mass percent sulphur. If the fuel sulphur content is greater than 0.5 mass percent sulphur, seek advice from your local Cummins®...
  • Page 508 QSB4.5 and QSB6.7 Lubricating Oil Recommendations and Specifications Section V - Maintenance Specifications Page V-9 Cummins Inc. recommends the use of a high-quality Society of Automotive Engineers (SAE) 15W-40 heavy-duty engine oil, such as Valvoline Premium Blue™, which meets or exceeds the American Petroleum Institute (API) performance classification CH-4/SJ or CI-4/SK and the Association des Constructeurs Européen d'Automobiles (ACEA) performance classification E5 or E7.
  • Page 509 Lubricating Oil Recommendations and Specifications QSB4.5 and QSB6.7 Page V-10 Section V - Maintenance Specifications Use of "synthetic engine oils" (those made with API group 3 or group 4 base stocks) is permitted subject to the same performance and viscosity limitations of petroleum (mineral) based engine oils. The same oil change intervals must be applied to synthetic oils that are applied to petroleum (mineral) based engine oils.
  • Page 510 QSB4.5 and QSB6.7 Lubricating Oil Recommendations and Specifications Section V - Maintenance Specifications Page V-11 CAUTION An SAE 10W-30 designation on a product is a viscosity designation only. This designation alone does not imply that the product meets Cummins Inc. requirements. Only 10W-30 oils with diesel performance credentials listed in table above can be used in Cummins®...
  • Page 511 Lubricating Oil Recommendations and Specifications QSB4.5 and QSB6.7 Page V-12 Section V - Maintenance Specifications An example of the API service symbols are shown in the accompanying illustration. The upper half of the symbol displays the appropriate oil categories. The center section identifies the SAE oil viscosity grade. As the engine oil becomes contaminated, essential oil additives are depleted.
  • Page 512 QSB4.5 and QSB6.7 Lubricating Oil Recommendations and Specifications Section V - Maintenance Specifications Page V-13 New Engine Break-in Oils CAUTION A sulfated ash limit of 1.85 percent has been placed on all engine lubricating oils recommended for use in Cummins® engines. Higher ash oils can cause valve and/or piston damage and lead to excessive oil consumption.
  • Page 513 Coolant Recommendations and Specifications QSB4.5 and QSB6.7 Page V-14 Section V - Maintenance Specifications Coolant Recommendations Specifications Fully Formulated Coolant/Antifreeze Cummins Inc. recommends the use of fully formulated antifreeze/ coolant meeting Cummins Engineering Standards (C.E.S.) 14603. For further details and discussion of coolant for Cummins® engines, refer to Coolant Requirements and Maintenance, Bulletin 3666132.
  • Page 514 QSB4.5 and QSB6.7 Coolant Recommendations and Specifications Section V - Maintenance Specifications Page V-15 Cummins Inc. recommends using Fleetguard® Compleat. It is available in both glycol forms (ethylene and propylene). Fully formulated antifreeze must be mixed with good- quality water at a 50/50 ratio (40- to 60-percent working range).
  • Page 515 Coolant Recommendations and Specifications QSB4.5 and QSB6.7 Page V-16 Section V - Maintenance Specifications A refractometer must be used to measure the freezing point of the coolant accurately. Use Fleetguard® refractometer, Part Number C2800. Do not use a floating ball hydrometer. The use of floating ball hydrometers can give an incorrect reading.
  • Page 516 QSB4.5 and QSB6.7 Coolant Recommendations and Specifications Section V - Maintenance Specifications Page V-17 Cooling System Sealing Additives Do not use sealing additives in the cooling system. The use of sealing additives will: • Buildup in coolant low-flow areas • Plug the radiator and oil cooler •...
  • Page 517 Coolant Recommendations and Specifications QSB4.5 and QSB6.7 Page V-18 Section V - Maintenance Specifications Notes...
  • Page 518 QSB4.5 and QSB6.7 Section W - Warranty Page W-a Section W - Warranty Section Contents Page California Emission Control System Warranty, Off-Highway ................W-13 Owner's Warranty Responsibilities ........................W-17 ....................................W-14 All Engines International Industrial (Off-Highway) ....................W-8 All Engines United States And Canada Industrial (Off-Highway) ................. W-1 To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com...

  • Page 519: Warranty

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  • Page 520 QSB4.5 and QSB6.7 All Engines United States And Canada Industrial (Off-Hi [...] Section W - Warranty Page W-1 All Engines United States And Canada Industrial (Off-Highway) Coverage Products Warranted This Warranty applies to new Engines sold by Cummins and delivered to the first user on or after April 1, 1999, that are used in Industrial (Off-Highway) applications in the United States* and Canada, except for Engines used in marine, generator drive, QSK95 T4 locomotive and certain defense applications, for which different Warranty Coverage is provided.
  • Page 521 All Engines United States And Canada Industrial (Off-Hi [...] QSB4.5 and QSB6.7 Page W-2 Section W - Warranty Consumer Products The Warranty on Consumer Products in the United States* is a LIMITED Warranty. CUMMINS IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. Any implied Warranties applicable to Consumer Products in the United States* terminate concurrently with the expiration of the express Warranties applicable to the product.
  • Page 522 QSB4.5 and QSB6.7 All Engines United States And Canada Industrial (Off-Hi [...] Section W - Warranty Page W-3 Cummins will pay for the repair or, at its option, replacement of the defective Covered Part and any Covered Part damaged by a Warrantable Failure of the defective Covered Part. Owner Responsibilities During The Base Engine Warranty Owner is responsible for the cost of lubricating oil, antifreeze, filter elements and other maintenance items provided...
  • Page 523 All Engines United States And Canada Industrial (Off-Hi [...] QSB4.5 and QSB6.7 Page W-4 Section W - Warranty Owner is responsible for non-Engine repairs, "downtime" expenses, cargo damage, fines, all applicable taxes, all business costs and other losses resulting from a Warrantable Failure. Limitations Engines with an emissions certification listed below must be operated using only diesel fuel having no more than the corresponding maximum sulfur content.
  • Page 524 QSB4.5 and QSB6.7 All Engines United States And Canada Industrial (Off-Hi [...] Section W - Warranty Page W-5 Before a claim for excessive oil consumption will be considered, Owner must submit adequate documentation to show that consumption exceeds Cummins published standards. Failures of belts and hoses supplied by Cummins are not covered beyond the first 500 hours or one year of operation, whichever occurs first.
  • Page 525 All Engines United States And Canada Industrial (Off-Hi [...] QSB4.5 and QSB6.7 Page W-6 Section W - Warranty Cummins warrants to the ultimate purchaser and each subsequent purchaser that the Engine is designed, built and equipped so as to conform at the time of sale by Cummins with all U.S. Federal emission regulations applicable at the time of manufacture and that it is free from defects in workmanship or material which would cause it not to meet these regulations within the longer of the following periods: (A) **Five years or 3,000 hours of operation for industrial applications, five years or 3,500 hours of operation for industrial spark-ignited Engines (GTA855, G855, G5.9C, G8.3-...
  • Page 526 QSB4.5 and QSB6.7 All Engines United States And Canada Industrial (Off-Hi [...] Section W - Warranty Page W-7 Failures, other than those resulting from defects in materials or workmanship, are not covered by this Warranty. Cummins is not responsible for failures or damage resulting from what Cummins determines to be abuse or neglect, including, but not limited to: operation without adequate coolant or lubricants;...
  • Page 527 All Engines International Industrial (Off-Highway) QSB4.5 and QSB6.7 Page W-8 Section W - Warranty All Engines International Industrial (Off-Highway) Coverage Products Warranted This Warranty applies to new Engines sold by Cummins and delivered to the first user on or after April 1, 1999, that are used in Industrial (Off-Highway) applications anywhere in the world where Cummins approved service is available, except the United States and Canada.
  • Page 528 QSB4.5 and QSB6.7 All Engines International Industrial (Off-Highway) Section W - Warranty Page W-9 These Warranties are made to all Owners in the chain of distribution, and Coverage continues to all subsequent Owners until the end of the periods of Coverage. Cummins Responsibilities During The Base Engine Warranty Cummins will pay for all parts and labor needed to repair the damage to the Engine resulting from a Warrantable...
  • Page 529 All Engines International Industrial (Off-Highway) QSB4.5 and QSB6.7 Page W-10 Section W - Warranty Owner is responsible for the cost of all labor needed to repair the Engine, including the labor to remove and reinstall the Engine. When Cummins elects to repair a part instead of replacing it, Owner is not responsible for the labor needed to repair the part.
  • Page 530 QSB4.5 and QSB6.7 All Engines International Industrial (Off-Highway) Section W - Warranty Page W-11 Maximum sulfur levels by emissions certification level as listed on the Engine's dataplate are: EPA 2007/2010/2013 max. 15 parts per million EPA Tier 4 Interim / Final max.
  • Page 531 All Engines International Industrial (Off-Highway) QSB4.5 and QSB6.7 Page W-12 Section W - Warranty For all A Series Applications, including Industrial, travel reimbursement for non-transportable equipment will be limited to 4.0 hours, $0.25/mile and 250 miles maximum. Any costs beyond this limit are the customer's responsibility. CUMMINS DOES NOT COVER WEAR OR WEAROUT OF COVERED PARTS.
  • Page 532 QSB4.5 and QSB6.7 California Emission Control System Warranty, Off-Highwa [...] Section W - Warranty Page W-13 California Emission Control System Warranty, Off-Highway Products Warranted This Emission Control System Warranty applies to off-road diesel engines certified with the California Air Resources Board beginning with the year 1996 for engines up to 750 horsepower, beginning with the year 2000 for 751 horsepower and over, marketed by Cummins, and registered in California for use in industrial off-highway applications.
  • Page 533 QSB4.5 and QSB6.7 Page W-14 Section W - Warranty Coverage This emission control system warranty applies only to the following A series, B3.3, B3.9, B4.5s, B5.9, B6.7s, QSB3.9-30, QSB4.5-30, QSB5.9-30, QSB5.9-44, C8.3, QSC8.3, QSF2.8, QSF3.8, and QSL9 emission control parts: EPA Diesel Aftertreatment System Base Engine System...
  • Page 534 QSB4.5 and QSB6.7 Section W - Warranty Page W-15 EPA Diesel DEF Dosing Controller (DCU) EGR Differential Pressure Sensor DEF Dosing Unit (Pump) EGR Mixer/Venturi DEF Dosing Valve EGR Temperature Sensor Diesel Oxidation Catalyst EGR Valve Diesel Particulate Filter (except for ash maintenance) Diesel Particulate Filter Differential Pressure Sensor NH3 Sensor NOx Sensors...
  • Page 535 QSB4.5 and QSB6.7 Page W-16 Section W - Warranty EPA Diesel Intake Manifold Intake Manifold Air Temperature Sensor Fuel System Air Handling (cont') Component Component Intake Manifold Temperature/Pressure Sensor Fuel Control Valve Turbocharger Actuator Fuel Lines Turbocharger Assembly Fuel Pressure Sensor Turbocharger Compressor Inlet Air Temperature Sensor Fuel Pump Turbocharger Speed Sensor...
  • Page 536 QSB4.5 and QSB6.7 Section W - Warranty Page W-17 Owner's Warranty Responsibilities As the off-road diesel engine owner, you are responsible for the performance of the required maintenance listed in your Cummins Operation and Maintenance Manual. Cummins recommends that you retain all receipts covering maintenance on your off-road diesel engine, but Cummins cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
  • Page 537 QSB4.5 and QSB6.7 Page W-18 Section W - Warranty Cummins recommends that any service parts used for maintenance, repair or replacement of emission control systems be new, genuine Cummins or Cummins approved rebuilt parts and assemblies, and that the engine be serviced by a Cummins distributor, authorized dealer or the repair location approved by Cummins.
  • Page 538 QSB4.5 and QSB6.7 Section W - Warranty Page W-19 The manufacturer warrants to the ultimate purchaser and each subsequent purchaser that the engine is designed, built, and equipped so as to conform with all applicable regulations adopted by the Air Resources Board, and that it is free from defects in materials and workmanship which cause the failure of a warranted part.
  • Page 539 QSB4.5 and QSB6.7 Page W-20 Section W - Warranty Notes...
  • Page 540 Index Page X-1 Acronyms and Abbreviations ................i-37 Fuel Recommendations and Specifications ............V-6 General Information..................i-37 Fuel Recommendations..................V-6 Additional Service Literature ................L-1 General Engine ....................V-1 General Information..................L-1 Specifications....................V-1 California Emission Control System Warranty, Off-Highway ......W-13 General Safety Instructions ................i-9 Owner's Warranty Responsibilities ...............
  • Page 541 Index Page X-2 All Engines United States And Canada Industrial (Off-Highway) ....W-1 Operating Instructions - Overview ..............1-1 General Information..................1-1 Operating the Engine ..................1-10 Normal......................1-10 Winterfronts and Shutters................1-11 Routine Service and Parts ................S-2 General Information..................S-2 Service Assistance .................... S-1 General Information..................S-1 Service Literature Ordering Location ...............L-4 Contact Information...................L-4...
  • Page 542 CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
  • Page 543 Cummins Inc. Cummins Customer Assistance Center Box 3005 1-800-DIESELS 1-800-343-7357 Columbus, Indiana, U.S.A., 47202 APPLICABLE ONLY IN U.S.A. AND CANADA Registered Office Cummins Ltd. 49 - 51 Gresham Road, Staines, Middlesex TW18 2BD, England Registration 573951 England Copyright 2017 © Cummins Inc.
  • Page 545 ©2017 Vanguard Equipment, Inc. All Rights Reserved Printed in U.S.A.

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