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  1. 1. Thank you for selecting Ground Force Manufacturing, L.L.C. as yoursupplier of mining and construction support equipment. Our business is based on providing quality equipment and the service tosupport it. Our Parts Department in Post Falls is stocked with the commonlyused parts on your machinery and will be glad to assist you in any way toprovide replacement parts when they are needed, as quickly as you needthem. In addition, trained field mechanics are available to assist your in-houseservice personnel should the need arise. If you have any questions or if we can be of assistance at any time,please don’t hesitate to call us at (208) 664-9291. We look forward to a long and mutually rewarding association. Sincerely, Ground Force Manufacturing Documentation DepartmentPlease refer to the following information when calling about service or parts:UNIT SERIAL NUMBERS: 145-04-001 / 145-04-002Delivery Date: January 2005Original Customer: Borusan Makina Kazakhstan
  2. 2. Operation, Service & Parts Manual FUEL / LUBE TRUCKS Borusan Makina Kazakhstan - Serial # 145-04-001 / 145-04-002© Copyright 2005, by Ground Force Mfg., L.L.C. All rights reserved. Nopart of this manual may be reproduced in any form or by any means(including electronic storage and retrieval or translation into a foreignlanguage) without prior agreement and written consent from Ground ForceMfg. as governed by United States and International copyright laws. Ground Force Mfg., L.L.C. E. 5650 Seltice Way Post Falls, Idaho 83854 (208) 664-9291Printing History: First Edition - July, 2001 Second Edition - November, 2002 Third Edition – February, 2005
  3. 3. ContentsPart One: GENERALPart Two: OPERATIONPart Three: MAINTENANCE / TROUBLE SHOOTINGPart Four: HYDRAULICS / PNEUMATICS / ELECTRICALPart Five: PARTS
  4. 4. 1. GENERAL
  5. 5. G3 General defects arising from the selection of materials or theINTRODUCTION processes of manufacture is limited to the repair ofYour lube truck was built to provide many years of such defects or to the repair or replacement (with aoperation. Durability, ease of operation and high similar item free from the defect in question) of anyspeed product delivery have been the goals in the accessory, equipment, or part which is defective indesign of the unit. any such respects. D. The extent of Ground Force Mfg.’s liabilityThis booklet will give you the basic operating under this warranty as to defects inherent ininstructions in the use of your new truck. As with design is limited to the correction at its expenseany piece of equipment, each unit will have its own of all such defects becoming apparent in theindividual operating characteristics which will become machine, accessory, equipment or partfamiliar to an operator with time. purchased here within six months or 1,000 hours of use, whichever shall first expire.Should any questions arise while you become familiar E. The warranty of Ground Force Mfg. does notwith your unit please dont hesitate to call us at cover, and Ground Force Mfg. makes noGround Force Mfg. Our goal is satisfied customers warranty with respect to:and we will do all we can to assure we meet that goal. 1. Defects not reported and defective items not returned to Ground Force Mfg. within the warranty period;LW General 2. Failure and damages due to misapplication, lack of properLIMITED WARRANTY maintenance, abuse, improperA. Ground Force Mfg. warrants that the specialty installation, or abnormal conditions of equipment it manufactures, including temperature, moisture, dirt or corrosive accessory equipment and parts manufactured matter; by Ground Force Mfg., shall be free from: 3. Failure due to operations, intentional or 1. Defects in material and workmanship otherwise, in any improper manner; furnished by Ground Force Mfg. and 4. Damage caused by components, or used in the fabrication thereof; parts, or accessories built by others or 2. Defects arising from the selection of which were not manufactured or materials or processes of manufacture; installed by Ground Force Mfg. 3. Defects in the design thereof in view of 5. Any item which has in any way been the state of the art on the date hereof. altered by anyone other than anThe foregoing warranty shall apply also to authorized representative of Ground Forceaccessories, equipment and parts manufactured to Mfg.Ground Force Mfg.’s detailed design and 6. Any item damaged in shipment orspecifications and supplied to Ground Force Mfg. by otherwise without the fault of Groundother manufacturers. Force Mfg.B. Ground Force Mfg. makes no warranty with Ground Force Mfg. shall in no way be liable for any regard to component parts not manufactured or expenses incurred by the purchaser in any attempt to fabricated by it, but agrees to assign to the repair, replace or rework any originally defective item purchaser all of its rights under any original of sale. Ground Force Mfg. shall in no way be liable manufacturers warranty covering such for any losses, costs, forfeiture or damages (including component parts, and agrees to assist the loss of profits, liabilities of the purchaser, purchaser in making such contacts with the or its customers, or third persons, and all other manufacturer of such component parts as may consequential damages), whether direct or indirect, be necessary to protect its right under the and whether or not resulting from or contributed to by warranty covering them. the default or negligence of Ground Force Mfg., itsC. In case of defects in materials or workmanship agents, employees and subcontractors, which might or defects arising from the selection of material be claimed as a result of the defect, use or failure of or processes of manufacture, such defects the item delivered. must become apparent in the machine, Except as stated, there is no warranty, express or accessory, equipment or part within six months implied, in connection with the design, manufacture, or 1,000 hours of operations, whichever shall sale or use of the machinery, accessories, equipment first expire after delivery of the machine to the and parts sold by Ground Force Mfg. Ground Force original purchaser. Mfg.’s liability on its warranty shall in no eventThe extent of Ground Force Mfg.’s liability under this exceed the cost of the item of sale.warranty as to defects in material or workmanship and
  6. 6. 2. OPERATION
  7. 7. PON1a Operation such as hydraulic oil tanks, gear boxes,IMPORTANT!!! compressor crankcase oil or “Lubricoolant” tanks, etc. If the unit involves oil-pumpingPRE-OPERATION NOTE equipment (such as lubrication trucks or skids),Because of strict regulations which govern the a minimal amount of product oil must be loadedoverseas shipment of equipment, any fluids or oils, into each particular tank to immerse the suctionwhich are not pertinent to or necessary for movement stand pipe. This will guarantee that when theof this unit, have most likely been removed or drained. oil product pumps are initially started, there willThis process may have been performed either at be enough oil to prevent running the pumpGround Force Mfg.s facility or prior to loading for dry.shipment. ♦ Remove stretch-wrap or shrink film fromAny and all gate valves or ball valves pertaining to equipment or assemblies. Many times if athe hydraulic oil tank have been closed to help particular component needs protection duringeliminate any interior contamination to the tank. shipment against rough handling, abrasions, or overall abusive contact, it will be protected byAny and all valves MUST BE OPENED prior to means of a wrapping compound or film. Thisoperation of this unit or severe damage to hydraulic film, either by itself or accompanied by “bubbleoil pump and hydraulic oil filters WILL occur. Gate wrap,” cardboard or wood should be removedvalves must be turned fully CCW to open and ball prior to operation, but not before the finalvalves are clearly marked on the handles as to which stage of commissioning of the equipment.position is open or closed.All other fluids and oils must be checked for proper NUB35 Operationlevels prior to operation. IMPORTANT!!! New Unit Break-InPSP1 Operation 1. Check hydraulic pump drive shaft set screws toIMPORTANT!!! be sure shipping vibration has not loosened them.POST-SHIPMENT PREPARATIONThis unit has been specially prepared to eliminate the 2. Check pump and air compressor drive shaftdetrimental effects, which occur to equipment in the coupling set screws daily until they set and noenvironment of ocean transport. There are a few longer loosen with operation.procedures that may need to be addressed prior tooperation of this unit. 3. Tighten any hydraulic fittings, which may loosen. Fittings will commonly loosen and drip♦ Remove any shipping film that has been the first few weeks of operation. applied to surfaces. This film is typically applied by means of a paint spray gun. This is 4. Check oil level on compressor daily. meant to provide protection directly on non- painted, machined surfaces such as control valves, shafts, couplings, cylinder piston rods, POC15 Operation etc. The film may be removed by simply wiping down the surface with a rag soaked with PRE-OPERATION CHECK LIST lacquer thinner or strong grade rubbing 1. Check hydraulic oil level. alcohol. 2. Check hydraulic oil tank outlet to be sure it is Because this film is very tacky and is not open. soluble with water or most oils, all surfaces must be cleaned thoroughly to prevent the 3. Check product oil tank outlets to be sure they malfunction of moving parts such as valve are open. spools. 4. Check general condition of truck.♦ Check all fluids pertaining to the operation of not only the truck chassis (if applicable), but 5. Check motor drive couplings. also the on-board system tanks or reservoirs
  8. 8. 6. Check charge on fire extinguishers. Both methods of mounting incorporate an operating speed of 1400-1800 rpm engine speed. Consult the7. Be sure all operating controls are "OFF" "Operating Instructions" in section 2 of this manual before starting truck. for your particular application. ESO1c Operation8. Check compressor crankcase oil level. EMERGENCY SHUT -OFFPOC15 Operation(Continued) PRODUCT PUMPS9. Check product levels in tanks - make certain This unit is equipped with an emergency shut-off that there is enough oil or product in tank to valve which enables the operator to disengage the immerse the pump suction if tank is not in use. low volume product oil product pumps (by pushing one valve knob) but ONLY in the case of anDO NOT RUN PRODUCT PUMPS DRY!!! emergency. Such emergencies would include a low volume oil product delivery hose failing, or if equipment tank being filled was not monitored andHPU1a Operation allowed to overflow. In many cases, the emergencyENGAGING THE HYDRAULIC shut-off is easier and quicker to push than trying to figure out in a split second which product control toPUMP shut off. Keep in mind that the purpose of this valveThis unit is equipped with a variable volume hydraulic IS NOT for daily operation and MUST not be used aspump. There are two distinct methods which Ground (what some operators have, in the past, beenForce Mfg. uses to mount and couple these pumps to considering) a main On/Off control.the chassis or drive system. These two methods alsodetermine the procedure to engage the pump. WARNING!!!Direct Front MountThe first mounting method is pump installation ahead This Emergency Valve has been installed ONLY forof radiator (front mount) between the chassis frame the above mentioned reason in an EMERGENCYrails. The pump is then connected to the engine situation. This valve does not turn Off all systemscrankshaft dampener via a flexible u-joint driveline. on the unit. If used as a main shut-off during dailyThis driveline also includes a slip-spline for any operations, the potential for damage to otherextreme movement of engine due to torque. Since the pumping systems is extremely high. This damagedirect drive line connection means that the pump is will NOT be covered under warranty.turning continuously with the engine or power unit, aball valve has been installed within the pumpdischarge line to disengage the pump. By closing this This emergency shut-off system is operated with aball valve and stopping the flow of oil from the pump, single valve and needs simply to be pushed in to thethe pump will remain in a "neutral state". When "off" position IF NECESSARY. The valve is installedhydraulic pressure is needed to run systems, simply in the hose reel compartment and is clearly marked.turn on the ball valve. Operators must familiarize themselves with not only this but all controls.IMPORTANT!!!Note: At no time should this vehicle be operated at IMPORTANT!!!higher than 1500 rpm with hydraulic pump engaged. Note: This valve does not effect the diesel deliveryThe pump is designed to run with no load system or any high volume oil product delivery(disengaged) at speeds up to 2400 rpm without system. Each of these systems have their owndamage. The ball valve must be turned off while unit separate on-off controls.is being operated at these higher speeds. OPW1 OperationPTO or Direct-Couple PTOThe second mounting method consists of a P.T.O. WARNING!!!using either a drive line or a direct coupled Oil Product Pumpconfiguration to drive the pump. Typically the pump The oil product pumps on this unit utilize a selfis mounted separate from the P.T.O. on a heavy contained hydraulic control system. This system willmount which is suspended from truck frame or main automatically control the hydraulic circuit that turnsstructure of carriage. the pump/motor on and off. The system relies on a series of sensing lines and check valves to sendTo engage this system is simply to flip the P.T.O. proper signals which determine the demand of anyswitch to "Engage" position. one product delivery system.
  9. 9. The most danger to these systems occurs when the 10. If so equipped, using appropriate reel controlsupply tanks are run low on product. Once the valve, pull out knob to "UNWIND" positionproduct pump looses its prime, the product line is not and pull hose from appropriate reel. (See alsoOPW1 Operation "Ground Force Hose Reel Operating(Continued) Instructions".)allowed to build pressure and will not properly signalthe hydraulic control system. Without signal, the 11. Dispense required amount of product.pump will continue to run dry and will eventually bedamaged. 12. Return hoses to reel by pushing in on the knob of the appropriate rewind control valve.At NO time should these pumps be allowed to rundry. Damage due to dry-running is typically self- 13. When dispensing of product is complete, turnevident and is not covered by warranty. Operators the appropriate pump control off.must be aware of product levels in tanks to preventthis type of damage. 14. When delivery processes are completed allow truck engine to idle. Disengage hydraulicIn the case of a product tank being inadvertently run pump.dry during oiling procedures, the “Emergency PumpShut-Off” may be utilized to turn off the dry pump. Oil Delivery SystemTank must be immediately refilled before engaging the The oil pumping systems on your new lube truck“Emergency Pump Shut-Off” again and running the utilize a self-contained hydraulic control system. Thisproduct pump. system automatically turns the pump hydraulics on and off as the truck operator opens the oil dischargeOI237 Operation nozzle. The truck operator is not required to manually turn the oil pump systems on. Once the dischargeOPERATING INSTRUCTIONS nozzle is attached to the receiving equipment, theFuel/Lube Truck operator simply needs to turn on the control valve at1. Do pre-operation checklist. the end of the delivery hose.2. Be sure all operating controls are in The oil pump delivery rates depend on whether the oil "OFF" position before starting truck. system is equipped for low volume, fixed delivery, or for high volume delivery. The high volume system3. Start truck engine and allow to idle. Make has a variable output rate with which the truck certain that parking brakes are set. operator can adjust from minimum flow to maximum flow (approx. 20-30 gpm). The delivery speed control4. Engage the hydraulic pump. Engine must run is affected by moving the pump speed control lever at approximately 1500 RPM. CW to decrease flow, CCW to increase flow. The output rate of the low volume system is a fixed rate5. If compressed air is needed, locate (not adjustable). Pump delivery can be throttled back compressor control, turn on compressor however, by partially opening the hose-end delivery and allow it to charge tank(s) fully. control valve.6. Product delivery functions may be operated from rear compartment. Grease Pumps Pull out the appropriate control valve for grease reel7. Reset product totalizer or meter. to engage either the high or low volume grease pumps. Grease hoses will be charged until the control8. Engage selected product by pulling valves are turned off (pushed in). appropriate selector valve handle out to "ON" position. Waste Oil Pump Pull out the appropriate control valve to engage theNote: Low volume oil product pumps have no waste oil pump. If so equipped, a selector valve isselector valve (see “Emergency Shut-Off Product included in the waste oil plumbing system to allowPumps” instructions). both on-loading and offloading. The selector valve is clearly marked for flow position.9. All product delivery rates on this truck have been preset to the maximum allowable, so no adjusting of pump speeds will be necessary.
  10. 10. Coolant Pump gravity) until control valve is moved to anotherPull out the appropriate control valve to engage the function position.coolant pump. The coolant pump will run as long asthe control valve is in the “ON” position. This 2. Lock: this function is accomplished bycoolant system will deliver new coolant. “bumping” the control valve handle slightly from the unwind position to the “center” position. In this position, the valve will closeOI237 Operation off the flow of hydraulic fluid to the reel drive(Continued) motor and create a “lock” in the hydraulicDiesel Fuel Pump circuit, which will allow virtually no reelPull out the appropriate control valve to engage the movement.diesel pump. The pump will run as long as the controlvalve is in the “ON” position. DO NOT let this pump This position may also be used after rewinding byrun continually!! Run the pump only as long as simply allowing control valve handle/spool to returndelivery is required. Damage to pump may occur if to the center (lock) position.allowed to run indefinitely. 3. Rewind: this function is accomplished by using the control valve handle to the fully “in” CAUTION!!! position. This is a spring loaded valve position which when released will return to the Any time the pump control valves are pulled out, “lock” position. In the “rewind” position, the the product hoses will be pressurized. DO NOT hydraulic valve controls the powered rewind open the discharge nozzle or valve unless you are function of the reel. The hydraulic fluid which ready to have product pumped out!!! drives the reel motor is regulated both in pressure and flow. Even though this function is regulated, during this function the operator must maintain a moderate tension on the product hose (by physically holding the hose)OI164 Operation to eliminate the “freewheeling” effect that willOPERATING INSTRUCTIONS occur if hose is left unattended.Ground Force Hose Reels “Freewheeling” can cause serious personalThis unit is equipped with Ground Force hydraulically injury and/or equipment damage if notcontrolled product hose reels. Each hydraulic control monitored. Damage encountered because offor these reels consist of one single spool directional this freewheeling is considered misuse and iscontrol valve and one hydraulic drive motor which not covered by warranty.also acts as the live center for the drum (sheave) ofthe reel. When the rewinding procedure is completed, simply release the valve handle, allowing valve to return toThe control valve has three positions being: 1) the “lock” position.unwind, 2) lock, and 3) rewind. Each of these threepositions will determine the function of the reel. Hose Reels Each of the Ground Force hydraulic rewind reelsNote: The hydraulic systems on Ground Force includes the use of a specific size and type of hose,equipment are typically of the load sensing type and which has been installed to accommodate the typein order for proper operation of the reel controls, one and flow requirements of that particular productor more product delivery functions may need to be delivery system. Many different fluid flow rates andengaged. The easiest system to accomplish this is working pressures may be present, so mixing of hosesthe diesel delivery. By engaging this system the main from one reel to another may have detrimental affects.hydraulic system will maintain its maximum pressure If servicing of reels or replacement of reel hoses isand provide more control for hose reel circuits. required, make certain that the hoses installed on reels are of original size and type.1. Unwind: this function is accomplished by pulling out on the control valve handle. When engaged in this position the reel will be allowed Hose Stops to “float” or coast so that the operator may pull Each Ground Force reel is equipped with a hose stop any desired amount of hose from the reel. to alleviate the problem of pulling the product hose Although having a slight tension, this function through the reel fair lead during rewinding does not allow hose to be held in position by procedures. This hose stop should be occasionally itself. Hose will continue to feed off of reel (by checked for tightness and positioning, and should be replaced immediately if any damage shows evident. If
  11. 11. the hose stop is missing or damaged, extreme caution To Operateshould be exercised during reel use, until hose stop After initial warm-up procedures have been followed,can be replaced. the hydraulic pump must be engaged (see also “Engaging the Hydraulic Pump” section) and thePressure and Flow Regulation “compressor” switch must be turned On.The hydraulic circuits which control the functions ofthe Ground Force hose reels have incorporated relief Note: Compressor switch is sometimes accompaniedOI164 Operation by an On indicator light. If compressor indicator light(Continued) does not illuminate when switch is turned on, do notvalves and flow controls which have been factory set assume that the compressor is not functioning, checkto accommodate the needs of this particular unit. for faulty bulb.These controls must not be tampered with. Allow the compressor to run long enough to fully charge the receiver tanks (until system shuts down to CAUTION!!! “standby” mode). Air system is now ready for use. Severe damage to equipment and/or personal injury Drain tank condensation with each use (see below). could result if relief valves and flow controls are readjusted by anyone other than a qualified IMPORTANT!!! Ground Force technician. This damage will not be covered as a part of the warranty. SAFETY NOTE!!!OI87d Operation Do not assume that the compressor is turned offOPERATING INSTRUCTIONS simply because it is not running. This system will intermittently start and stop without warning.Air Compressor Keep hands and loose clothing clear of all movingThis truck is equipped with an on-board hydraulic- parts and make certain that all guards and shieldsdrive air compressor. This compressor develops an are properly in place at all times.air supply which may be used to fill tires, drive airtools and remote pumps or motors, etc. Included withthis air compressor is one or more receiver tanks, an After use of compressor is complete, turn off“F.R.L.” package (explained later), and a supply of ½” “compressor” switch (located either in truck cab or ator ¾” I.D. hose which is loaded on a hose reel. control console). This system should never be left “on” while not in use. During any “Down-Time” ofThe loading of this compressed air supply is an “on- this truck (whether it be for a short period, shiftdemand” system. Once the “compressor” switch change, or for prolonged service or maintenance) the(located either in truck cab or rear control panel) is air compressor as well as all system controls shouldturned on, the hydraulic system will drive the be in the “Off” position. Any functions left in “On”compressor which will run until a pre-set air pressure position could cause potential dangers whenis reached, and then the system will shut down hydraulic system or air system is re-engaged.leaving the compressor in a “standby” mode. Thecompressor will then stay idle until additional air is Air Tank Drainneeded to replenish the supply, or until the Most air receiver tanks for these air systems are“compressor” switch is turned off. equipped with a drain valve for bleeding residual condensation. This valve should be opened dailyF.R.L. (Optional) and should be considered part of the normalInstalled within the airline system is a “filter-regulator- maintenance for this unit.lubricator” assembly. This assembly is used to filterand trap airline contaminants, regulate the airlinepressure, and automatically lubricate the dischargeline air.The filter must be cleaned and drained on a regularbasis and the lubricator kept relatively full with a highquality, moisture repelling air system lubricant. Donot allow lubricator to run dry.
  12. 12. 3. MAINTENANCE / TROUBLE SHOOTING
  13. 13. M16 MaintenanceINTRODUCTIONYour lube truck was constructed with care and withquality materials. Simple routine maintenance willassure that it will continue to operate with minimalproblems. This section of this manual will help youestablish a routine maintenance schedule and willdetail components which may need service at sometime.Note: This section of the manual has the suggestedschedule of maintenance operations for your newtruck body. Some or all of the schedules will apply toyour individual truck. These schedules are intendedas a guideline only. As long as attention is paid tolubrication and maintenance a minimum of times asrecommended, your own mine maintenance schedulecan supersede the recommended schedule.SP1 MaintenanceSAFETY PROCEDURES1. THINK!!2. Use EXTREME CAUTION when working on or servicing any machinery.3. Before doing any work on equipment, follow three easy steps: A. Lock It Out B. Tag It Out C. Put The Keys In Your Pocket4. Before starting equipment after servicing, check to see that all personnel are clear. When you are positive all are clear, check again!HS11 MaintenanceHYDRAULIC SYSTEMInspectionInspect your truck daily for worn hoses or loosefittings. When hoses appear worn (especially if wirewrappings are showing through), replace the hosebefore a failure occurs. Tighten any loose fittings.Note: When equipment is new, leaks will frequentlyoccur. This is normal and will cease after the unit hasbeen in operation for a while when fittings aretightened and seated.
  14. 14. Hint: When re-sealing pipe thread fittings, use $30 filter is an inexpensive preventative maintenanceanaerobic hydraulic thread sealant (Felpro #51452). for a $6,000.00 hydraulic system.Do not use Teflon tape (its use voids somecomponent manufacturers warranties). Suction Filter This filter is included to capture any large particlesGeneral Fitting Sizes: which may get into the oil reservoir. This filter is theo 1/4" hose - JIC #4 (37o) screw-on canister filter which is plumbed to the hydraulic oil tank in the suction oil line.o 3/8" hose - JIC #8 (37o)o 1/2" hose - JIC #10 (37o) CAUTION!!!o 3/4" hose - JIC #12 (37o) Your hydraulic reservoir is equipped with a pressure holding vent cap. This pressurizes theo 1" hose - JIC #16 (37o) reservoir to approximately 3 psi to assure adequate oil feed to the hydraulic pump. DO NOT replaceHydraulic Oil this cap with a non-pressurized model!!!Your new truck has been shipped without hydraulicoil. Utilize preferably a premium grade AW46hydraulic oil.Return Oil FilterThese filters are the screw-on canister filters whichare plumbed to the hydraulic oil tank in the return oilline. Ground Force replacement filters MUST be usedto maintain the factory warranty.We recommend changing the hydraulic system returnoil filters monthly if your truck is used frequently. AMS60 Maintenance MAINTENANCE SCHEDULE DESCRIPTION DAILY WEEKLY MONTHLY ANNUALLY Lubricate reel fair lead rollers X Lubricate hydraulic valves and actuators X Change hydraulic oil X Change hydraulic oil filter X Clean in-tank suction strainer (with oil change) X Check hydraulic oil level X Check chassis motor oil X Check hydraulic control valves X Check hydraulic hoses and fittings X Check drive couplings and inserts X Check body mounting bolts X Check hydraulic pump driveshaft bolts/coupling X set screws
  15. 15. Check hydraulic pump mount bolts XCheck compressor crankcase oil level XCheck compressor drive couplings XChange compressor crankcase oil See Compressor “Maintenance Schedule”Clean compressor air filter element See Compressor “Maintenance Schedule”FRL package - drain condensation fromfilter/separator - add lubricant oil to lubricator asneeded XClean coolant suction strainer (if applicable) XReplace diesel fuel filters (if applicable) XDrain condensation from air receiver tanks X
  16. 16. TSG10 Trouble Shooting system, simple tests will narrow down potentialINTRODUCTION problems.Periodically some problem may occur with your lube Test instruments which are needed to diagnose yourtruck. Most problems are minor and can be easily truck are:solved. This section of this manual is provided tohelp you in diagnosing and solving problems you o High pressure and flow test meter.may encounter. o Digital electronic multi-meter (Must be digitalNote: Before replacing any major components, isolate with 0-10 amp DC current range).the problem! As with any hydraulic or electricalTS11a Trouble Shooting TROUBLE SHOOTING GUIDE PROBLEM PROBABLE CAUSE ITEMS TO CHECK Hydraulic system PTO not engaged or main Cable Shift PTOs: Check cable. will not operate. pump ball valve not turned on. Air Shift PTOs: Adequate air pressure to shift? Air Tank Emergency Valve: Valve functioning? Control valve working properly? Shift cylinder on PTO operating? Check position of ball valve on pump (direct mount only). Hydraulic pump not Check PTO-pump driveshaft. running. Check keyways in pump, PTO driveshaft. Check pump shaft. Check if pump is free or "frozen up." Hydraulic pump turning, no Check oil level in hydraulic tank. apparent oil output. Check pump driveshaft. Hydraulic pump turning, oil Check pressure build when a circuit is used. output apparently O.K. a. No/low Pressure: Check circuit or main relief valve. b. High Pressure Relieving: Check to be sure the operating system is not "frozen up." (Pressure Compensated Check pressure compensator, reset to 1800 psi. Pumps Only) Pump output pressure too low. Check relief valves.
  17. 17. TS11a Trouble Shooting TROUBLE SHOOTING GUIDE (Continued) PROBLEM PROBABLE CAUSE ITEMS TO CHECK Product pump will Motor flow control closed. Check inlet flow control to motor; closed, reset for not run. desired output. No hydraulic oil at drive Check main hydraulic pump ball valve to be sure it motor or low oil pressure. is fully opened. High pressure in system, Pump binding: Check oil flow to be sure pump pump will not turn. turns with hydraulic motor uncoupled. Motor turns, pump will not. Check drive coupling. Hydraulic motor bad. Check motor. Hose reel will not PTO not engaged. Check PTO. function. No hydraulic oil or low Check hydraulic pump. pressure to control valve. Relief valve on valve block Check system pressure, if OK and hose reel does set too low. not develop pressure when running, reset reel control valve relief. Hydraulic motor getting oil, Replace motor. but not functioning.
  18. 18. TS44 Trouble Shooting HYDRAULIC LOAD SENSING SYSTEM TROUBLE SHOOTING GUIDE PROBLEM PROBABLE CAUSE ITEMS TO CHECK Hydraulic system will not Plugged load sense bleed valve Remove cartridge, check for debris return to a standby cartridge. creating obstruction of orifice. Clean pressure of 300-500 psi and reinstall. after all circuits have been disengaged. Faulty pump compensator. Replace compensator block. Hydraulic circuit(s) not totally Perform single circuit diagnostics to disengaged - load sense circuit still determine which circuit remains receiving signal pressure. open. Repair circuit components. Hydraulic system will not Plugged signal port on pump Remove load sense signal line from develop high pressure (will compensator control block. compensator block. Engage one not raise above typical 300- circuit (such as “product delivery,” 500 psi standby pressure). compressor, or down riggers). Signal hose should discharge a steady stream of oil. Remove compensator block and thoroughly clean (see pump service instructions). Wrong sized orifice in load sense Check for proper load sense bleed bleed valve cartridge. Pressure is valve cartridge. If questionable, not being allowed to build in load replace with 0.1 g.p.m. cartridge. sense signal circuit. Leak in load sense signal line Check for leaks, repair as needed. circuit. Circuit control valve not being Check for mechanical failure such engaged properly. as pneumatic pilot not actuating a hydraulic valve. Faulty load sense check valve or Systematically run each separate possible plug. circuit. Determine which circuit does not bring pump up to pressure. Replace or repair load sense check valve on that circuit. Faulty pump compensator. Replace compensator block. Hydraulic system pressure Too high of volume of load sense Check for leaks, repair as needed. will not increase even with circuit signal pressure lost by bleed all system and circuit relief to tank or by line leaks. Check for proper load sense bleed valves set. valve cartridge. If questionable, replace with 0.1 g.p.m. cartridge.
  19. 19. 4. HYDRAULICS / PNUEMATICS / ELECTRICAL
  20. 20. VVH5 Hydraulics out with the compensator/pump set at high pressure,VARIABLE VOLUME or system damage could occur if the compensator setting is too high.HYDRAULIC PUMPADJUSTMENT For further information, see the adjustmentFor Part #3286PM3XX, 3286PM4XX, procedures in the appropriate “Overhaul Manual.”3286PM6XX, Series PumpsThis Ground Force hydraulic system is designed to HSP4 Hydraulicsoperate at less than 1800 psi hydraulic pressure.Therefore, it is important that the pressure HYDRAULIC SYSTEMcompensator (which sets the maximum available Pressure Relief Adjustmenthydraulic pressure of the hydraulic pumps) be set Procedures (With Hydraulic Pumpproperly or damage to the hydraulic system could Series 3286 PM 3XX, 4XX, andpotentially occur. 6XX/Without Spool Valve Relief)The pressure compensator is a cast housing which isattached to the main body of the hydraulic pump. Reference Drawing No. 96019/B32This cast housing includes two adjustment screws.One being the load sense pressure adjustment, and Prior to adjusting any relief valves, please verifythe other being the load pressure limiter adjustment. which particular valves are involved with thisThe load pressure limiter should be the only procedure. Follow directions precisely and carefully.adjustment immediately necessary. A= Main Hydraulic Pump - Flow and PressureSome portions of Ground Force hydraulic systems are Compensateddesigned to "overdrive" the hydraulic pressure B= Load Sense Adjustment Screwneeded to operate the system, i.e. on air compressors. C= Pressure Compensator AdjustmentThis means that when that function of the truck is Screwengaged, the hydraulic pump will automaticallydeliver its maximum pressure rather than just the D= Main System Relief Valve (only one)pressure needed to operate the system. This aids in E= Cap, Adjustment Screw Coveradjusting the compensator. Follow the listed F= Adjustment Screwprocedures to adjust the compensator. G= Cartridge, Relief Adjustment Note: Do not start engine or engage hydraulicBulk Explosive Trucks With Variable system(s) until called for!!!Volume PumpEngage the auger delivery circuit to bring the truck to Adjustment Preparationmaximum pressure. It will be O.K. to leave the product 1. Locate "A" (Hydraulic Pump) and controlselector (ANFO or Blend) off and run the truck as block which includes “B” (Load Sensethough it is in a "clean out" mode; this will still bring Adjustment Screw) and “C” (Pressurethe truck up to full operating pressure. When the Compensator Adjustment Screw).system is turned on, adjust the pressure limiteradjusting screw on the pressure compensator control 2. Using a 1/2" wrench, loosen the jam nuts onup to the desired 1800 psi, and set the lock nut. “B” and “C,” making sure that “B” and “C” do not turn in the process. A 5/32" Allen wrenchService Trucks (Mechanics, Lube, may be used to hold “B” and “C” in place.etc.)The air compressor on all Ground Force service trucks 3. Using a 5/32" Allen wrench, turn “C” (Pressureis designed to overdrive the hydraulic system. Turn Compensator Adjustment Screw) CCW untilon the compressor controls, and while the air spring pressure is no longer observed. Thencompressor is running adjust pressure to 1800 psi and turn the same “C” screw CW approximately 2set the lock nut. full turns. This will adjust the pump output to a fairly low pressure.On All UnitsWhen replacing the main hydraulic pump or the 4. Locate "D" (Main System Relief Valve) andcompensator; be sure to back off the pressure associated components "E", "F", and "G".compensator adjustment counter clockwise when firstinstalling the part. Engage the hydraulics and bringthe pressure up and set at 1800 psi. DO NOT start
  21. 21. HSP4 Hydraulics(Continued) 7. Turn "F" slowly CW until "squealing" stops.5. Use a 1" wrench to hold "G" (Relief Valve Cartridge) in place while using a 15/16" wrench 8. Replace "E" (Cap). Do not over tighten, needs to loosen and remove "E" (Adjustment Screw only to be slightly more than hand tight. Main Cap). Make certain that during this procedure System Relief Valve is now set and should the Relief Valve Cartridge "G" does not loosen need no further adjustments. from its seated position within the main block of the relief valve (assembly). Place "E" in a 9. Return to main pump and while monitoring the safe location (to be reinstalled later). pressure gauge, turn "Pump Compensator Pressure Adjustment Screw" CCW slowly until6. Make certain ALL controls are "OFF" or in pressure gauge reads 1800 psi pressure. "NEUTRAL" position, including the "Product Delivery" control. 10. While holding the adjustment screw with a 5/32" Allen wrench, tighten the jam nut with aAdjustment Procedures ½" wrench.Note: Do not attempt any adjustments without firstfollowing steps 1 through 6 of "Adjustment 11. Recheck pressure at gauge. If pressure hasPreparation." changed, pump compensator must be readjusted.1. Start engine, engage hydraulic pump, raise to approximately 1000 rpm. Note: Please keep in 12. Disengage the main hydraulic circuit which had mind that even the slightest adjustments made been engaged for pressure adjustments. must be monitored visually on the "Hydraulic System Pressure Gauge." 13. Locate “B” (Load Sense Pressure Adjustment). While monitoring the system pressure gauge,2. Making sure that ALL other operating controls use a 5/32" Allen wrench and adjust the are "OFF" or in "NEUTRAL" position, turn “Standby” pressure to 400-500 psi. "ON" one of the main hydraulic circuits: CW = Increase Pressure u Stemming/ANFO Trucks = CCW = Decrease Pressure Product Delivery Note: After releasing all of the function circuits to u Mechanic/Service/Lubrication “Neutral” on this system, the “Standby” pressure Units = Air Compressor or Fuel Pump should drop to 400-500 psi within 30-45 seconds maximum. If the system does not react in this manner,3. Locate "C” (Pressure Compensator see the “Load Sense Trouble Shooting” section in Adjustment) on main pump control block. this manual.4. Turn “C” (Adjustment Screw) CW while 14. Once the “Standby” pressure has been monitoring the pressure gauge. Continue to adjusted and rechecked (by engaging and turn until pressure reads 2000 psi or until "D" disengaging a hydraulic circuit) tighten the jam (Main System Relief Valve) starts to make a nut on “B” to secure in place. whistling or squealing sound, whichever comes first. 15. Disengage the hydraulic pump.3. If 2000 psi cannot be obtained without the main 16. Allow engine to idle for "cool down" period system relief valve making noise (which signifies and then stop engine. that the oil is relieving), then "F" (Relief Valve Adjustment Screw) must be turned CW no more than ½ (one-half) turn at a time, along with continued CW adjustment of the "Pressure Compensator Adjustment Screw," until a 2000 psi pressure is reached. Once the pressure gauge reads 2000 psi, locate "D" and turn "F" (Adjustment Screw) CCW until the valve begins to "squeal."
  22. 22. HP22 Parts HYDRAULIC SYSTEM PARTS UNIT SERIAL NUMBERS 145-04-001 & 145-04-002 REFERENCE HYDRAULIC DIAGRAM145-02-001_2/H ITEM PART # DESCRIPTION QTY 1 3286PM604 MAIN HYDRAULIC PUMP 1 2 1227HY301 MAIN RELIEF VALVE 1 3 9475FI010 SUCTION STRAINER, IN TANK 1 4 9475HY003 FILLER/BREATHER CAP - 3 PSI 1 5 9475FI011 FILTER HOUSING, RETURN OIL 1 6 9777FI004 FILTER ELEMENT DO NOT SUBSTITUTE 2 7 9400HY003 CARTRIDGE, LOAD SENSE BLEED VALVE 1 7A 9400HY004 BODY, FLOW CONTROL 1 8 3400VA008 GATE VALVE, 2-1/2" TANK SUCTION 1 9 3451VA054 CHECK VALVE, 3/4" BRONZE 1 10 1812HY001 SIGHT GLASS 2 11 9400HY031 BODY FLOW CONTROL 5 12 9400HY078 CARTRIDGE, FLOW CONTROL - 2.0 GPM 1 13 9400HY007 PRESSURE REDUCING VALVE 1 14 9414HY257 MOTOR, HYDRAULIC - REELS 8 14A 9414HY253 MOTOR, HYDRAULIC - REEL 2 15 9411HY001 VALVE, SINGLE SPOOL - REELS 10 16 6156GG001 PRESSURE GAUGE - 3000 PSI 1 17 2519HY351 VALVE, SELECTOR - 1/2" 3 18 9400HY070 CARTRIDGE, FLOW CONTROL 2 19 9400HY074 CARTRIDGE, RELIEF VALVE 2 20 9424HY001 CHECK VALVE, LOAD SENSE 3 21 9900HY131 MANIFOLD, COMPRESSOR CONTROL 1 22 9400HY083 SOLENOID CARTRIDGE 1 23 9400HY084 SOLENOID COIL - 12 VDC 1 24 9500HY063 CARTRIDGE, LOAD SENSE CHECK 1 25 9400HY052 CARTRIDGE, FLOW CONTROL - 25 GPM 1
  23. 23. HP22 Parts HYDRAULIC SYSTEM PARTS UNIT SERIAL NUMBERS 145-04-001 & 145-04-002 REFERENCE HYDRAULIC DIAGRAM (Continued) 26 9414HY247 MOTOR, HYDRAULIC 1 27 9400HY078 CARTRIDGE, FLOW CONTROL 1 28 9400HY078 CARTRIDGE, FLOW CONTROL 1 29 9414HY272 MOTOR, HYDRAULIC - COMPRESSOR COOLING FAN 1 30 10082PM301 MOTOR, HYDRAULIC - GREASE PUMP 2 31 10082PM303 PUMP TUBE, GREASE - HIGH PRESSURE 1 32 10082PM302 PUMP TUBE, GREASE - HIGH VOLUME 1 33 9900HY130 MANIFOLD, PRODUCT PUMP - SEE ALSO DRAWING NO. 94080/B91 5 34 9400HY013 CARTRIDGE, FLOW CONTROL 5 35 9424HY004 CHECK VALVE, PRODUCT OIL 5 36 2617PM303 PUMP/MOTOR COMBO - SEE ALSO DRAWING NO. 94080/B91 5 37 2519HY352 SELECTOR VAVLE, 3/4" 1 38 9400HY012 CARTRIDGE, FLOW CONTROL 1 39 9400HY016 BODY, FLOW CONTROL 1 40 9414HY209 MOTOR, HYDRAULIC - WATER PUMP 1
  24. 24. 5. PARTS
  25. 25. Parts Parts WARRANTY PARTS TO PURCHASE PARTS:When Ground Force manufactures Order ALL parts for the items shown inmachinery, we utilize parts and supplies this book through Ground Force not themade by many vendors. It is an part manufacturer!!!unfortunate fact of life that a percentage ofthese parts that we purchase to assemble Ground Force is a master distributor allour machinery will be bad. Component the components used to build yourparts all have their respective equipment and can furnish them cheapermanufacturers warranties. Since youve and faster than the componentpurchased Ground Force manufactured manufacturer.machinery, we will do everything in ourpower to assure you that your equipment When ordering, use the Ground Forcestays in top operating condition and will Part Number to assure receiving the rightback you in any warranty claims. part quickly!Should any parts on your new unit prove Ground Force maintains an inventory ofto become defective, we can usually ship the common parts which are part of thea replacement part from our stock normal maintenance and repair of yourovernight if you so desire. What we need equipment.to do at Ground Force to receive ourwarranty credit for parts proven to bedefective is to have parts returned by you,the owner of the machine, to us, so thatwe may apply to parts suppliers forwarranty credit. To do this, it isimperative that we receive the faulty partwhen you replace it with a new one.Our warranty procedure at Ground Forceis that when we ship a replacement partfor your unit, either on warranty orstandard replacement, we will send aninvoice with that part. When we receivethe defective part back from you, we willsubmit that to our suppliers for a warrantycredit. As soon as warranty credit isreceived for that part, we will issue acredit invoice for the amount charged onyour replacement. (Freight charges arenot covered under warranty).If you have any questions about GroundForces warranty system, please contactChad Wilson at (208) 664-9291.
  26. 26. DP4a DOOR PARTS CATCHGAS SPRING LATCH LEVERSIDE COMPARTMENTS PART # 13500WH501(LIFT-UP DOORS) (INCLUDES CATCH)PART # 15088HW1252 EACH PER DOOR EDGE TRIM PART # 4200WH015 (PER FOOT)(SIDE-SWING DOORS)PART # 15088HW0351 EACH PER DOOR "D" DOOR SEAL (SELF BONDING) PART # 10600WH939 (ORDER PER FOOT)
  27. 27. ITEM DIM ARESCO DESCRIPTION QTY A PART # 1266DC401 COUPLING HALF, 1-1/4 x 5/16 AR 1266DC402 COUPLING HALF, 1-1/2 x 3/8 AR 1 4.0 1266DC404 1266DC405 COUPLING HALF, 50 mm x 14 mm COUPLING HALF, 1 x 1/4 AR AR 1 1266DC407 COUPLING HALF, 1-7/8 x 1/2 AR 1266DC408 COUPLING HALF, 1-3/4 x 3/8 AR 1266DC412 COUPLING HALF, 1-1/4 AR 14 TOOTH SPLINED 2 1266DC403 INSERT, HYTREL AR 1266DC503 COUPLING HALF, 1-1/4 x 5/16 AR 1266DC504 COUPLING HALF, 2-3/8 x 5/8 AR 1266DC505 COUPLING HALF, 2-1/8 x 1/2 AR AR 2 1266DC506 COUPLING HALF, 2-1/2 x 5/8 1 1266DC507 COUPLING HALF, 1-1/2 x 3/8 AR 4.8 1266DC508 COUPLING HALF, 1-7/8 x 1/2 AR 1266DC509 COUPLING HALF, 1-15/16 x 1/2 AR 1266DC510 COUPLING HALF, 2-1/4 x 5/8 AR 1 1266DC511 COUPLING HALF, 55 mm x 16 mm AR 1266DC512 COUPLING HALF, 50 mm x 14 mm AR 1266DC513 COUPLING HALF, 2-1/4 X 3/8 AR 1266DC501 INSERT, HYTREL AR2 1266DC502 INSERT, NEOPRENE AR 1266DC301 COUPLING HALF, 1 6 TOOTH SL E PI D N AR 1266DC302 COUPLING HALF, 1-1/4 x 5/16 AR DIM A 1266DC304 COUPLING HALF, 3/4 x 3/16 AR OUTSIDE DIAMETER 1266DC306 COUPLING HALF, 1 x 1/4 AR 1266DC307 COUPLING HALF, 1-1/8 x 1/4 AR 1266DC308 COUPLING HALF, 1-1/2 x 3/8 AR 1266DC309 COUPLING HALF, 1-5/8 x 3/8 AR 1266DC310 COUPLING HALF, 38 mm x 10 mm AR 1 3.45 1266DC311 COUPLING HALF, 28 mm x 8 mm AR 1266DC312 COUPLING HALF, 35 mm x 10 mm AR 1266DC313 COUPLING HALF, 42 mm x 12 mm AR NOTE : PART NUMBERS 1266DC314 COUPLING HALF, 7/8 x 1/4 AR HIGHLIGHTED ARE 1266DC315 COUPLING HALF, 1-3/8 x 5/16 AR APPLICABLE TO 1266DC316 COUPLING HALF, 9/16 x 1/8 AR YOUR TRUCK. 1266DC317 COUPLING HALF, 7/8 13 TOOTH SPLINED AR 2 1266DC303 INSERT, HYTREL AR 1266DC102 COUPLING HALF, 1 x 1/4 AR 1266DC105 COUPLING HALF, 3/4 x 3/16 AR 1266DC109 COUPLING HALF, 16.5 mm x 5 mm AR1 2.6 1266DC111 COUPLING HALF, 7/8 x 1/4 AR 1266DC112 COUPLING HALF, 5/8 x 3/16 AR 1266DC113 COUPLING HALF, 1/2 x # 404 WOODRUFF AR G o n r u d F r e Mg o c f . 1266DC114 COUPLING HALF, 3/8 BORE AR DRAWING NUMBER : 9-1 2- 3 2 0-5 B 1266DC115 COUPLING HALF, 24 mm x 8 mm AR 1266DC116 COUPLING HALF, 5/16 BORE AR DRIVE COUPLING 2 1266DC104 INSERT, HYTREL AR S RE 1 0 3 0 4 0 & 5 0 E I S 0 , 0 , 0 0 . O V
  28. 28. JB1 JUNCTION BOX ITEM PART# DESCRIPTION 1 7813LT012 JUNCTION BOX/COMPLETE
  29. 29. L1 TRUCK LIGHTS ITEM PART # DESCRIPTION 1 7813LT012 JUNCTION BOX 2 7813LT007 LAMP, CLEARANCE, AMBER 3 7813LT006 LAMP, CLEARANCE, RED 4 7813LT005 IDENTIFICATION BAR 5 7813LT009 LAMP, STOP, OR TURN
  30. 30. L2 TRUCK LIGHTS 1 2 ITEM PART # DESCRIPTION 7813LT009 LAMP, STOP OR TURN/COMPLETE 1 1156 BULB 2 7813LT025 LENS, REPLACEMENT - RED
  31. 31. L4 ICC LIGHTS ITEM PART # DESCRIPTION 1 7813LT005 IDENTIFICATION BAR 2 7813LT001 LENS 3 T-67 BULB
  32. 32. L5b FLOOD LIGHT ASSEMBLY ITEM PART # DESCRIPTION 7813LT014 FLOOD LIGHT, AMBER/COMPLETE 7813LT008 FLOOD LIGHT, CLEAR/COMPLETE 7813LT013 FLOOD LIGHT, HALOGEN/COMPLETE 1 7813LT017 BULB, HALOGEN 2 7813LT018 BULB, CLEAR FLOOD 3 7813LT022 BULB, AMBER
  33. 33. L7a CLEARANCE LIGHT ASSEMBLY ITEM. PART # DESCRIPTION 1 7813LT006 LAMP,CLEARANCE RED/COMPLETE 2 7813LT007 LAMP, CLEARANCE AMBER/COMPLETE 3 7813LT002 LENS, AMBER 4 7813LT003 LENS, RED 5 56 GROMMET 6 T67 BULB
  34. 34. WIRING LOOM AND FITTINGS 90 ELBOW (3/8" - 635-053) (1/2" - 635-065) 3/8" TUBING - PT24006 1/2" TUBING - PT24008 STRAIGHT FITTING (3/8" - 600-053 (1/2" - 600-063)WIRING JUNCTION BOX (BOX - #4900EL125) (PANEL - #4900EL126)
  35. 35. 1615AP002 PART # 6500-04-02 1615AP001 PART # 6500-04-02 PART # 6500-04-02 PART # 6500-04-02PART # 6500-04-04PART # 6500-04-04 PART # 222P-4-4PART # 6500-04-04PART # 6500-04-04 PART # 6500-04-04 3936AP006 PART # 222P-4-4PART # 6500-04-04 3936AP007Ground Force Mfg. PLUMBING AIR VALVESDRAWING NUMBER : 3 9 3 6 A P ( 6 5 P 0 ,1 1 A 0 2 9 6 P 0 / 0 ) 1 1 A 0 1 6 5P 0 , 3 A 0 6 0 7 3 ov
  36. 36. G3 G5 2 1 8 7 4 4 5 10 3 6 9 ITEM PART # DESCRIPTION QTY 1 9483HY028 STACKING BOLT, G3 AR 2 9483HY029 CLAMP BOLT, G3 AR 3 9483HY030 CLAMP WELD PLATE, G3 AR 4 9483HY031 CLAMP INSERT, G3 AR 5 9483HY032 CLAMP, 1/4 TUBING, G3 AR 9483HY033 CLAMP, 1/2 TUBING, G3 AR 9483HY035 CLAMP, 5/8 TUBING, G3 AR 9483HY037 CLAMP, 3/4 TUBING, G3 AR 9483HY038 CLAMP, 7/8 TUBING, G3 AR 9483HY039 CLAMP, 1 TUBING, G3 AR 6 9483HY040 CLAMP, RAIL WELD PLATE, G3 AR 7 9483HY048 STACKING BOLT, G5 AR 8 9483HY049 CLAMP BOLT, G5 AR 9 9483HY050 CLAMP WELD PLATE, G5 AR 10 9483HY054 CLAMP 1 PIPE, G5 AR 9483HY056 CLAMP 1-1/4 PIPE, G5 ARGround Force Mfg. RIGID HYDR. TUBE MOUNTINGDRAWING NUMBER : 9-1 2- 1 2 0-4 B PARTS
  37. 37. DL25dc DRIVELINE - COMPLETE 1 2 3 4 5 7 6 6 7 Highlighted Items Apply to This Unit Note: Quanity "A/R" = As Required LENGTH USED IN INCHES ITEM PART # DESCRIPTION ITEM PART # QUANTITY DESCRIPTION 4 2-40-1701DS SPLINE STUB 1 2-2-329 1 FLANGE YOKE 2-40-1711DS SPLINE STUB 2-2-479 1 FLANGE YOKE 5 2-3-5221KX SLIP YOKE 3-2-119 1 FLANGE YOKE 3-3-1501KX SLIP YOKE 2 2-28-1757 TUBE YOKE 1 6 1-0153HD U-JOINT ASSEMBLY 3-28-47 TUBE YOKE 2 2-0053 U-JOINT ASSEMBLY 3 DOM 2 X .120 DRIVELINE TUBING 2 5-280X U-JOINT ASSEMBLY DOM 2-1/2 X .083 DRIVELINE TUBING 2 7 2-4-433 END YOKE, 3/4" X 3/16" KEY A/R 2-4-473 END YOKE, 1" X 1/4" KEY A/R 2-4-1741 END YOKE, SPLINED A/R 2-4-533 END YOKE, 1-1/4" X 5/16" KEY A/R 2-4-1233 END YOKE, 1-1-/2" X 3/8" KEY A/R 2-4-3331 END YOKE, 7/8" SPLINED A/R 8 50-2502 SET SCREW A/R NOT SHOWN 1-0099 U-BOLT KIT FOR 2-0053 A/R 3-4-24 YOKE, TAPER A/R 6-4-7541X YOKE A/R 6-4-7561X YOKE A/R
  38. 38. Instructions – Parts List PartsALUMINUM AND STAINLESS STEELHuskyt 1040 Air-OperatedDiaphragm Pumps 308479ADAluminum Model Shown120 psi (0.8 MPa, 8 bar) Maximum Fluid Working Pressure120 psi (0.8 MPa, 8 bar) Maximum Air Input Pressure*Model No. D73____ Aluminum Pumps*Model No. D83____ Aluminum Pumps, Remote*Model No. D74____ Stainless Steel Pumps*Model No. D84____ Stainless Steel Pumps, Remote*Model No. D7C____ Aluminum BSPT Pumps*Model No. D8C____ Aluminum BSPT Pumps, Remote*Model No. D7D____ Stainless Steel BSPT Pumps*Model No. D8D____ Stainless Steel BSPT Pumps, Remote*Model No. DR4____ Stainless Steel Plus Pumps*Model No. DS4____ Stainless Steel Plus Pumps, Remote*Model No. DRD____ Stainless Steel BSPT Plus Pumps*Model No. DSD____ Stainless Steel BSPT Plus Pumps, RemoteModel No. 232501 Private–Label Aluminum 1040 Pump (See page 24.) (not certified )Model No. 234124 Private–Label Aluminum 1040 Pump (See page 24.)*NOTE: Refer to the Pump Matrix on page 24 to determinethe Model No. of your pump.NOTE: Plus models include stainless steel center sections.US and Foreign Patents Pending Read warnings and instructions. See page 2 for table of contents 02632CGRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441Copyright 1994, Graco Inc. is registered to I.S. EN ISO 9001
  39. 39. Table of Contents SymbolsSafety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Warning SymbolSymbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 WARNINGOperation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 This symbol alerts you to the possibility of seriousTroubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 injury or death if you do not follow the instructions.Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Pump Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Caution SymbolRepair Kit Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 CAUTIONDimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . 31Technical Data and Performance Chart . . . . . . . . . . . 32 This symbol alerts you to the possibility of damage toGraco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . 34 or destruction of equipment if you do not follow theGraco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 instructions. WARNING EQUIPMENT MISUSE HAZARD Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury. INSTRUCTIONS D This equipment is for professional use only. D Read all instruction manuals, tags, and labels before operating the equipment. D Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor. D Do not alter or modify this equipment. Use only genuine Graco parts and accessories. D Check equipment daily. Repair or replace worn or damaged parts immediately. D Do not exceed the maximum working pressure of the lowest rated component in your system. This equipment has a 120 psi (0.8 MPa, 8 bar) maximum working pressure at 120 psi (0.8 MPa, 8 bar) maximum incoming air pressure. D Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings. D Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment. Such use could result in a chemical reaction, with the possibility of explosion. D Do not use hoses to pull equipment. D Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not ex- pose Graco hoses to temperatures above 82_C (180_F) or below –40_C (–40_F). D Do not lift pressurized equipment. D Comply with all applicable local, state, and national fire, electrical, and safety regulations.2 308479
  40. 40. WARNINGTOXIC FLUID HAZARDHazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on theskin, inhaled, or swallowed.D Know the specific hazards of the fluid you are using.D Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local, state and national guidelines.D Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and solvent manufacturer.D Pipe and dispose of the exhaust air safely, away from people, animals, and food handling areas. If the diaphragm fails, the fluid is exhausted along with the air. See Air Exhaust Ventilation on page 9.FIRE AND EXPLOSION HAZARDImproper grounding, poor ventilation, open flames or sparks can cause a hazardous condition andresult in a fire or explosion and serious injury.D Ground the equipment. Refer to Grounding on page 4.D If there is any static sparking or you feel an electric shock while using this equipment, stop pumping immediately. Do not use the equipment until you identify and correct the problem.D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid being sprayed.D Pipe and dispose of the exhaust air safely, away from all sources of ignition. If the diaphragm fails, the fluid is exhausted along with the air. See Air Exhaust Ventilation on page 9.D Keep the work area free of debris, including solvent, rags, and gasoline.D Electrically disconnect all equipment in the work area.D Extinguish all open flames or pilot lights in the work area.D Do not smoke in the work area.D Do not turn on or off any light switch in the work area while operating or if fumes are present.D Do not operate a gasoline engine in the work area. 308479 3
  41. 41. InstallationGeneral Information GroundingD The Typical Installations shown in Figs. 2–4 are only guides for selecting and installing system WARNING components. Contact your Graco distributor for FIRE AND EXPLOSION HAZARD assistance in planning a system to suit your needs. This pump must be grounded. Before operating the pump, ground the system as explained below. Also, read the sec-D Always use Genuine Graco Parts and Accessories. tion FIRE AND EXPLOSION HAZARD, Refer to Product Data Sheet 305588. on page 3.D Reference numbers and letters in parentheses refer To reduce the risk of static sparking, ground the pump to the callouts in the figures and the parts lists on and all other equipment used or located in the pumping pages 26–28. area. Check your local electrical code for detailed grounding instructions for your area and type of equip-D Aluminum Husky 1040 Pump Model No. 239823, ment. Ground all of this equipment. with straight-thread manifolds, is available and can be ordered separately. D Pump: Connect a ground wire and clamp as shown in Fig. 1. Loosen the grounding screw (W). Insert one end of a 12 ga (1.5 mm@) minimum ground wire (Y) behind the grounding screw and tighten the screw securely. Connect the clamp end of the WARNING ground wire to a true earth ground. Order Part TOXIC FLUID HAZARD No. 222011 Ground Wire and Clamp. Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin, inhaled, or swallowed. Y 1. Read TOXIC FLUID HAZARD on page 3. 2. Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Technical Data section of all equipment manu- als. Read the fluid and solvent manufacturer’s warnings. W 02646B Fig. 1Tightening Screws Before First Use D Air and fluid hoses: Use only grounded hoses withAfter you unpack the pump, and before you use it for a maximum of 500 ft (150 m) combined hosethe first time, check and retorque external fasteners. length to ensure grounding continuity.Retorque the fluid cover screws first, then the manifoldscrews. This keeps the manifolds from interfering with D Air compressor: Follow the manufacturer’s recom-tightening the fluid covers. See the Service section for mendations.torque specifications. D All solvent pails used when flushing: Follow the local code. Use only metal pails, which are conduc-After the first day of operation, check and retorque the tive. Do not place the pail on a non-conductivefasteners again. Although the recommended fre- surface, such as paper or cardboard, which inter-quency for retorquing fasteners varies with pump rupts the grounding continuity.usage, a general guideline is to retorque fastenersevery two months. D Fluid supply container: Follow the local code.4 308479
  42. 42. InstallationMountings c. The air line filter (F) removes harmful dirt and moisture from the compressed air supply. CAUTION 2. Install a grounded, flexible air hose (A) between The pump exhaust air may contain contaminants. the accessories and the 1/2 npt(f) pump air inlet Ventilate to a remote area if the contaminants (N). See Fig. 5. Use a minimum 3/8” (9.5 mm) ID could affect your fluid supply. See Air Exhaust air hose. Screw an air line quick disconnect cou- Ventilation on page 9. pler (D) onto the end of the air hose (A), and screw the mating fitting into the pump air inlet snugly. Do not connect the coupler (D) to the fitting until youD Be sure the mounting surface can support the are ready to operate the pump. weight of the pump, hoses, and accessories, as well as the stress caused during operation. Installation of Remote Pilot Air LinesD For all mountings, be sure the pump is bolted directly to the mounting surface. 1. Refer to Parts Drawings. Connect air line to pump as in preceding steps.D For ease of operation and service, mount the pump so the air valve cover (2), air inlet, and fluid inlet and outlet ports are easily accessible. 2. Connect 1/4 in. O.D. tubing to push type connec- tors (14) on air motor of pump.D Rubber Foot Mounting Kit 236452 is available to reduce noise and vibration during operation. NOTE: by replacing the push type connectors, other sizes or types of fittings may be used. The new fittingsAir Line will require 1/8 in. npt threads. 3. Connect remaining ends of tubes to external air WARNING signal, such as Graco’s Cycleflo (P/N 195264) or A bleed-type master air valve (B) is required in Cycleflo II (P/N195265) controllers. your system to relieve air trapped between this valve and the pump. Trapped air can cause the NOTE: the air pressure at the connectors must be at pump to cycle unexpectedly, which could result in least 30% of the air pressure to the air motor for the serious injury, including splashing in the eyes or on pump to operate. the skin, injury from moving parts, or contamination from hazardous fluids. See Fig. 3. Fluid Suction Line 1. Use grounded fluid hoses. The pump fluid inlet (R)1. Install the air line accessories as shown in Figs. is 1” npt(f). See Fig. 5. Screw the fluid fitting into 2–4 on pages 7 and 8. Mount these accessories the pump inlet securely. on the wall or on a bracket. Be sure the air line supplying the accessories is grounded. 2. If the fluid inlet pressure to the pump is more than a. Install an air regulator (C) and gauge to control 25% of the outlet working pressure, the ball check the fluid pressure. The fluid outlet pressure will valves will not close fast enough, resulting in be the same as the setting of the air regulator. inefficient pump operation. b. Locate one bleed-type master air valve (B) 3. At inlet fluid pressures greater than 15 psi (0.1 close to the pump and use it to relieve trapped MPa, 1 bar), diaphragm life will be shortened. air. See the WARNING above. Locate the other master air valve (E) upstream from all air line accessories and use it to isolate them 4. See the Technical Data on page 32 for maximum during cleaning and repair. suction lift (wet and dry). 308479 5

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