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ADE Spray 4.0 Installation Manual

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ADE039395
Rev04
INSTALLATION
GUIDE
ADE Spray 4.0
This guide is for use when installing an ADE Spray 4.0 System.
Refer to the Operation and Maintenance Manual for operation and maintenance procedures for the ADE Spray 4.0
System.
Refer to the Parts Pages for parts breakdown/replacement details on the ADE Spray 4.0 System.
Consult Australian Diversified Engineering if further information is required.
www.ade.net.au
Regarding welding, if any deviation from these instructions is required, please seek OEM approval.

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  • Page 1 ADE Spray 4.0 This guide is for use when installing an ADE Spray 4.0 System. Refer to the Operation and Maintenance Manual for operation and maintenance procedures for the ADE Spray 4.0 System. Refer to the Parts Pages for parts breakdown/replacement details on the ADE Spray 4.0 System.

  • Page 3: Table Of Contents

    Table of Contents ADE039334 –500 L/min Oil ........42 6.5.1 GENERAL INFORMATION ......... 1 6.5.2 ADE039337– 980 L/min Oil ........47 ADE041105 –500 L/min Oil specifically for HD605-8 ..52 6.5.3 SAFETY ............... 2 YDRAULIC OTOR OMPARISON ....2 (ADE039030) ............54 MPORTANT AFETY NFORMATION ........

  • Page 5: General Information

    To retrofit ADE Spray onto an existing water truck, the truck must already be fitted with a water tank. The existing spray bar can be modified, or a new spray bar can be built to specification.

  • Page 6: Safety

    Reference Information Safety Where applicable, the wording given underneath the DANGER, WARNING or CAUTION signal words will Important Safety Information convey nature hazard, possible Safety precautions and warnings may be listed in this consequences and means of avoidance. manual and applied to the product (supplied by Some signs placed on the product or machine (which do Australian Diversified Engineering) in the form of safety not contain a signal word such as Danger, Warning or...

  • Page 7: Change Management

    Reference Information Change Management A change management process should be followed giving due consideration to any new hazards introduced and assessing the impact on the unmodified machine design. Possible things to consider: • Visibility impacts • How the modification interfaces with the machine •...

  • Page 8: Reference Information

    Reference Information All welding must be performed to OEM welding procedure and/or AS1554.1 as applicable. If any deviation from these instructions is required, please seek OEM or ADE approval. Prior to welding, disconnect all electronic equipment. Fastener Torques Use Loctite 243 or approved equivalent when assembling bolts into tapped holes.
  • Page 9 Reference Information Imperial Bolts (Grade 8) Metric Bolts (Class 10.9) Nominal Dash Size Flange Size Thread Size Torque (Nm) Thread Size Torque (Nm) 1/2" (DN13) 5/16" - 18 3/4" (DN19) 3/8" - 16 1" (DN25) 3/8" - 16 1 1/4" (DN32) 7/16"...

  • Page 10: Ergonomic Considerations

    Operator ergonomics is an important factor to be considered when positioning ADE Spray system components. It is recommended that AS 4024.1401 be consulted when determining suitable layout of the ADE Spray system components. • Components shall be positioned to promote good working postures &...

  • Page 11: Installation Procedure

    When selecting a position, please consider the following a Job Safety Analysis to identify potential risks and constraints: methods to mitigate them. An ADE Job Safety Analysis ● Out of direct contact with water (i.e., protected form is provided in Appendix 6.1.

  • Page 12: Weld Mounts

    Installation Procedure Weld Mounts Boilermaking Refer to OEM welding procedures for correct methods and use in conjunction with the procedures outlined in this installation guide. 5.4.1 System Control Cabinet Refer to Parts Manual parts page ADE039300. Weld on cabinet mount bracket using this procedure: ●...

  • Page 13: Motor Control Manifold

    Installation Procedure 5.4.2 Motor Control Manifold 5.4.2.2 Manifold Plate (If Applicable) Refer to Parts Manual parts page ADE039304. 5.4.2.1 ADE039304 (500 L/min) (If Weld on manifold plate mount bracket using this Applicable) procedure: Refer to Parts Manual parts page ADE039304. ●...

  • Page 14: Filter

    Installation Procedure 5.4.2.3 ADE039309 (980L/MIN) (If 5.4.3 Filter Applicable) Refer to Parts Manual parts page ADE039291. Refer to Parts Manual parts page ADE039309. Weld on filter mount bracket using this procedure: NOTE: This manifold must be mounted as close as ●...

  • Page 15: Fitment Of Delivery System Components

    Installation Procedure Fitment of Delivery System For the spray heads, this is when both Components the left and right spray patterns touch in the middle of the truck without Fitting overlapping. 5.6.1 Spray Heads ● Fit the spray bar center position components as Refer to Parts Manual parts page ADE039020 Figure 12...
  • Page 16 Installation Procedure • Fit spray bank manifolds to each spray bank as shown in Figure 15. • Fit motor control manifold to welded mounts Figure 16 using provided fasteners as shown in & Figure 17. • Fit spray sensor into port plate, as shown in Figure 18 •...

  • Page 17: Fitment Of Hoses

    2500psi, suitably rated hoses must be used. Route and secure the hoses appropriately. Refer to Appendix 6.7 for suggested hose sizing. Refer to Appendix 6.5 for the ADE Spray hydraulic schematic. The “Drain” port on the motor control manifold MUST be connected directly into the hydraulic tank.
  • Page 18 Installation Procedure NOTE: Allow some slack in the spray head control hoses for adjustment. If the optional hose clamp group was provided, weld the hose clamps where appropriate to secure hoses sufficiently (Refer to OEM weld procedures). There should be a hydraulic manifold mounted to each spray head group, which should be plumbed up as detailed below.

  • Page 19: Machine Specific Hydraulic Connections

    ADE Spray, remove the hose connecting the hoist pump outlet to the hoist control valve (See Figure 23) and discard. Connect the hoist pump outlet to the ADE motor control manifold ‘INLET’ port. Connect the ADE motor control manifold ‘OUTLET’ port back to the hoist control valve inlet.

  • Page 20: Komatsu Hd785-7 Off-Highway Truck

    (previously connected to the (see Figure 25). See Figure 26 for example of typical hoist control valve inlet) to the ADE motor control installation on a Komatsu HD785-7. Refer to the manifold ‘INLET’ port. Connect the ADE motor control Installation Guide Supplement supplied with the group manifold ‘OUTLET’...

  • Page 21: Installation Of Electric Control

    Refer to Figure 28 for typical locations. Refer to Parts Manual parts page ADE039024 NOTICE: The maximum tightening torque for the ADE Install the IO Controller module at rear of driver’s cab Spray Primary Keypad fasteners (Figure 27) is 0.8 Nm.
  • Page 22 Installation Procedure Route GPS antenna into the operator’s cab and utilise the magnetic base to mount it in a location that ensures the GPS antenna has a clear view path to the sky; preferably close to a window on the front pillars. Do not mount the antenna under any object that may impede its signal.

  • Page 23: Wiring Harness Connections

    In-Cab Primary Keypad accessories are installed. For example, installation of an ● J1939 Junction ADE Cannon to a base system will add a second IO Controller with GPS (J1939) independent CANbus network. ADE Cannon Keypad Joystick (If fitted) ●...

  • Page 24: Chassis Wiring Harness

    Installation Procedure ● ● Install the additional bulkhead mount bracket Hydraulic Pressure Sensor (see Section 5.6.2) ● provided at the rear of the truck in the same Left Spray Head Harness ● vicinity as the manifold plate. Refer to Parts Right Spray Head Harness Manual parts page ADE039511.

  • Page 25: Post Installation Checklist

    6.2. This checklist is required to be competed, to ensure each component has been installed. 5.12 Site Specific Settings The ADE Spray system has been shipped with a default user configuration. Some site-specific settings may require configuring; to achieve the optimal user experience from the system.

  • Page 26: Appendix

    Appendix Appendix Page | 22 Installation Guide...
  • Page 27 Appendix Job Safety Analysis (ADE012039) Installation Guide Page | 23...

  • Page 28: Job Safety Analysis (Ade012039)

    JOB SAFETY ANALYSIS JOB/TASK BEING ANALYSED: COMPANY: SITE: DEPARTMENT: SUPERVISOR: CREATED DATE: REVIEWED DATE: FREQUENCY OF JOB/TASK: FUNCTIONAL LOCATION(S): PPE, SKILLS & TOOLS REQUIRED: RELATED WORK INSTRUCTIONS/ PROCEDURES. Describe Job Step Hazard/Potential Risk Score Risk Control Methods Residual Risk Person Incidents Required Responsible...
  • Page 29 JOB SAFETY ANALYSIS Describe Job Step Hazard/Potential Risk Score Risk Control Methods Residual Risk Person Incidents Required Responsible List the natural steps of the job (not too broad and not What can happen at each step. Can any person be Describe how defined hazards can be managed or removed.
  • Page 30 JOB SAFETY ANALYSIS Participants Name(s): Signature (Please print) Signature Signature Signature Residual Risk Category Authorisation Levels Supervisors Name: Signature: LOW (Please print) Supervisors Name: Signature: MODERATE (Please print) Supervisors Name: Signature: HIGH (Please print) EXTREME Escalate to a Higher Level of Risk Assessment Non-Consensus Items Participant Issue/Concern...

  • Page 31: Post Installation Checklist

    Appendix Post Installation Checklist Tick each box if complete. Complete Skill Set Description Boilermaker Modify spray bar - make flange ready Boilermaker Modify spray bar - weld flanges as required Fitter Modify spray bar - fit spray head assemblies, gaskets and port plate Boilermaker Locate Motor Control Manifold - weld on mount bosses Fitter...

  • Page 32: Commissioning Report (Ade040259)

    Appendix Commissioning Report (ADE040259) Page | 28 Installation Guide...
  • Page 33  Deluge Spray Enabled  Other (please list): PO Box 7136, Brendale, QLD 4500, Australia 26 Kingsbury Street, Brendale, QLD 4500, Australia Phone: +61 7 3863 5800 | Fax: +61 7 3863 4044 ADE040259 Rev01 Email: sales@ade.net.au | web: ade.net.au...

  • Page 34: System Health

    Head 1 Pos 1 & 2 & Head 2 Pos 1 & 2 PO Box 7136, Brendale, QLD 4500, Australia 26 Kingsbury Street, Brendale, QLD 4500, Australia Phone: +61 7 3863 5800 | Fax: +61 7 3863 4044 ADE040259 Rev01 Email: sales@ade.net.au | web: ade.net.au...

  • Page 35: System Calibration

    Cam0 Cam1 Cam2 Cam3 Input Configurations: Output Configurations: PO Box 7136, Brendale, QLD 4500, Australia 26 Kingsbury Street, Brendale, QLD 4500, Australia Phone: +61 7 3863 5800 | Fax: +61 7 3863 4044 ADE040259 Rev01 Email: sales@ade.net.au | web: ade.net.au...

  • Page 36: Electrical Schematic (Ade038999)

    Appendix Electrical Schematic (ADE038999) Page | 32 Installation Guide...
  • Page 37 23/02/22 Updated wire colour designations to match build diagrams Electrical Schematic any manufacturing rights. 22/03/22 Replaced foam sensor with RPM sensor Project ADE Spray 4.0 It is to be considered a 29/08/22 Added foam level sensor, fixed spray head valve names. confidential document and must not be...
  • Page 38 Date Description Client Description The furnishing of this drawing does not convey Electrical Schematic any manufacturing rights. Project ADE Spray 4.0 It is to be considered a confidential document and must not be Drawn Scale Drawing No. reproduced without ADE038999 consent of the owner.
  • Page 39 1 2 3 4 5 6 7 8 9 10 11 12 J1939 BACKBONE EXTENSION GROUP (OPTIONAL) J1939 GPS IF ADDITIONAL OPTIONS ARE TO BE ADAPTOR HARNESS INSTALLED ADE039919 SEE GROUP ADE042667 IF ONLY SINGLE ADE CANNON J1939 J1939 J1939 J1939 TERMINATION INSTALLED TO ADE CANNON JOYSTICK RESISTOR...
  • Page 40 Date Description Client Description The furnishing of this drawing does not convey Electrical Schematic any manufacturing rights. Project ADE Spray 4.0 It is to be considered a confidential document and must not be Drawn Scale Drawing No. reproduced without ADE038999 consent of the owner.
  • Page 41 CANOPEN SYSTEM Third angle If in doubt - ASK !! projection ADE SPRAY SYSTEM CONTROL CABINET CANOPEN ADE SPRAY SYSTEM CONTROL CABINET ADE039300 CANOPEN CAN ADAPTOR HARNESS ADE039938 PLC - S PLC - P OUTPUT MODULE I/O PID CONTROLLER ADE039246...
  • Page 42 Date Description Client Description The furnishing of this drawing does not convey Electrical Schematic any manufacturing rights. Project ADE Spray 4.0 It is to be considered a confidential document and must not be Drawn Scale Drawing No. reproduced without ADE038999 consent of the owner.
  • Page 43 Date Description Client Description The furnishing of this drawing does not convey Electrical Schematic any manufacturing rights. Project ADE Spray 4.0 It is to be considered a confidential document and must not be Drawn Scale Drawing No. reproduced without ADE038999 consent of the owner.
  • Page 44 CAN_GND 6 GNDcan GNDcan ADE042067 - 10m CAN ADAPTOR HARNESS ADE039952 (OPTIONAL) CANOPEN 1 2 3 4 FROM ADE SPRAY SYSTEM CAN_GND CONTROL CABINET CAN_H (Sheet 5) CAN_L 1 2 3 4 5 6 SHEET 8 OF 8 Rev Grid...

  • Page 45: Hydraulic Schematics

    Appendix Hydraulic Schematics Installation Guide Page | 41...
  • Page 46 Appendix 6.5.1 ADE039334 –500 L/min Oil Page | 42 Installation Guide...
  • Page 47 05-05-22 UPDATED HIGH FLOW PROPORTIONAL DIVERTER any manufacturing rights. 30/08/22 Updated spray head block labelling Project ADE Spray 4.0 - 500 L/min It is to be considered a 13/02/23 Optional Extras Schematics Added confidential document and must not be...
  • Page 48 Client Description The furnishing of this Hydraulic Schematic drawing does not convey any manufacturing rights. Project ADE Spray 4.0 - 500 L/min It is to be considered a confidential document and must not be Drawn Scale Drawing No. reproduced without ADE039334 consent of the owner.
  • Page 49 Client Description The furnishing of this Hydraulic Schematic drawing does not convey any manufacturing rights. Project ADE Spray 4.0 - 500 L/min It is to be considered a confidential document and must not be Drawn Scale Drawing No. reproduced without ADE039334 consent of the owner.
  • Page 50 Client Description The furnishing of this Hydraulic Schematic drawing does not convey any manufacturing rights. Project ADE Spray 4.0 - 500 L/min It is to be considered a confidential document and must not be Drawn Scale Drawing No. reproduced without ADE039334 consent of the owner.
  • Page 51 Appendix 6.5.2 ADE039337– 980 L/min Oil Installation Guide Page | 47...
  • Page 52 Hydraulic Schematic drawing does not convey 30/08/22 CHANGED SPRAY HEAD VALVE DESIGNATIONS any manufacturing rights. 13/02/23 Optional Extras Schematics Added Project ADE Spray 4.0 - 980 L/min It is to be considered a confidential document and must not be Drawn Scale Drawing No.
  • Page 53 Client Description The furnishing of this Hydraulic Schematic drawing does not convey any manufacturing rights. Project ADE Spray 4.0 - 980 L/min It is to be considered a confidential document and must not be Drawn Scale Drawing No. reproduced without ADE039337 consent of the owner.
  • Page 54 Client Description The furnishing of this Hydraulic Schematic drawing does not convey any manufacturing rights. Project ADE Spray 4.0 - 980 L/min It is to be considered a confidential document and must not be Drawn Scale Drawing No. reproduced without ADE039337 consent of the owner.
  • Page 55 Client Description The furnishing of this Hydraulic Schematic drawing does not convey any manufacturing rights. Project ADE Spray 4.0 - 980 L/min It is to be considered a confidential document and must not be Drawn Scale Drawing No. reproduced without ADE039337 consent of the owner.
  • Page 56 Appendix 6.5.3 ADE041105 –500 L/min Oil specifically for HD605-8 Page | 52 Installation Guide...
  • Page 57 Client Description The furnishing of this Hydraulic Schematic drawing does not convey any manufacturing rights. Project ADE Spray 4.0 - 500 L/MIN It is to be considered a ADE SPRAY 4.0 confidential document and must not be Drawn Scale Drawing No.
  • Page 58 Appendix Hydraulic Motor Comparison (ADE039030) Page | 54 Installation Guide...
  • Page 59 ADE039030 Hydraulic Motor Comparison Return Port Pressure Port 2" Code 61 2" Code 61 1/2" UNC Bolts 1/2" UNC Bolts Drain Port (3/4" UNO or 1/2" BSPP) Pressure Port 2" Code 61 1/2" UNC Bolts Drain Port (1/2" NPT) Return Port 2"...
  • Page 60 Appendix Suggested Hose Sizing Table 6.7.1 Recommendations for 500 L/min block House Routing Hose Size Suggested Hose Machine supply oil to motor control manifold ‘INLET’ port: At least 1 1/2” AEROQUIP GH493-? Motor control manifold ‘OUTLET’ port to machine return At least 1 1/2”...
  • Page 61 Appendix 6.7.2 Recommendation for 980 L/min block The 980 L/min motor control manifold is equipped with two inlet ports (‘INLET1’ & INLET2’) and two outlet ports (‘OUTLET1’ & ‘OUTLET2’). Both inlet ports and outlet ports are used when the specific machine has two separate oil supplies that are necessary to achieve the required flow.
  • Page 62 Appendix Tank Recommendations Page | 58 Installation Guide...

  • Page 63: Water Tank

    Design Recommendations To optimise the performance and longevity of ADE Spray and its components, the recommendations contained in this document are intended for new tank designs. While this document lists best practices, it is acknowledged that these practices are not always easily achieved; particularly with regards to retrofitting systems onto existing tanks.
  • Page 65 TANK RECOMMENDATIONS ......2 ... 2 YDRAULIC OTOR AND ATER ..........3 TONE ILTER ........... 4 PRAY ........5 ANNON IPEWORK ....6 ATER EVEL ENSOR ....... 6 YDRAULIC ILTER OUNTING ....7 LECTRICAL ABINET OUNTING Page | i ADE Spray...

  • Page 66: Tank Recommendations

    Tank Recommendations Hydraulic Motor and Water Pump ADE recommends the use of a 150 x 125 x 250 ISO pump. Please refer to Figure 2 for typical pump dimensions. Consider the following when manufacturing the adjacent spray bar pipe work: •...

  • Page 67: Stone Filter

    Stone Filter ADE recommends the use of a stone filter on the suction side of the pump to filter out debris bigger than ø4.8mm. Excessive wear, damage and/or clogging of the spray heads will result if an appropriate stone filter is not installed.

  • Page 68: Spray Bar

    • The ADE spray kit provides for the spray heads to be mounted on AS 2129 DN80 (3”) Table E flanges at the end of the spray bar, where the spray bar outlet flange faces are vertical and are parallel to the centreline off the truck as shown in Figure 4.

  • Page 69: Cannon Pipework

    ANSI B16.5 DN125 (5”) Class 150 flange for the water cannon connection, oriented vertically as shown in Figure 5 unless otherwise specified. Adaptors to adapt the DN125 water cannon flange to DN80 are available for purchase from ADE. • Tapped plates for the mounting of water cannon support structure, located as show in Figure 5 unless otherwise specified.

  • Page 70: Water Tank Level Sensor Port

    Water Tank Level Sensor Port A 1” BSPP socket is required to mount the water level tank sensor. ADE recommends this socket be positioned in a location slightly higher than and with at least 2 m clearance from the pump suction pickup point. Tapped bosses or mounting tabs are recommended along the tank for hose &...

  • Page 71: Electrical Cabinet Mounting

    Recommendations Electrical Cabinet Mounting One electrical cabinet is supplied as standard with ADE Spray systems. Provisions for mounting bracketry to suit the mounting bolt pattern in Figure 7 is required. Taking into consideration harness routing and length, the electrical cabinet is recommended to be no further than 6m away from the furthest spray head assembly. Extension harnesses are available for purchase from ADE if this distance is greater.

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