Instruction Manual Charmec MF 605 DA
Instruction Manual Charmec MF 605 DA
Instruction Manual Charmec MF 605 DA
Original instructions
Normet Oy Tel. +358 (0)17 83 241
Ahmolantie 6 E-mail: info@normet.com
FI-74510 IISALMI Web: www.normet.com
FINLAND
Technical data sheet
100063155
Charmec MF 605 DA 06.06.2016
Features
Charmec MC 605 ANFO charger with diesel hydraulic drive is designed for face and production charging
in underground mines and tunnels up to 65 m2 cross sections where max face height is 8.4 m.
ANFO vessels options of 2 x 250 / 360 / 500 / 720 / 1000 litres provides enough explosive storage volume
for several faces without need for refuelling. Ready designed place for stick powder boxes, primers and
detonators makes it possible to bring all the needed materials to the workplace at once and eliminates
the need for an additional explosive service vehicle. Compressor option eliminates the need for external
pressure air line.
The liquid cooled turbo charged 120 kW Deutz or 110 kW MB TIER 3 approved engine provides clean and
efficient operation and gives maximum speed of 25 km/h and 8 km/h in upward 1:7 inclined tunnel.
The FOPS /ROPS approved safety canopy / cabin with pivotal operator's seat provides comfortable
compartment for the driver and his assistant. The enclosed cabin provides noise level < 75 dB.
Self extinguishing marine type wire harness with tinned wires and water tight conduits are specially
designed for safe and reliable operation in tough underground conditions. All daily checks can be done
from the ground level.
Normet reserves the right to change this specification without further notice.
Normet Oy 1/9 Tel +358 (0) 17 83 241
Ahmolantie 6 Fax +358 (0) 17 823 606
FI-74510 IISALMI, FINLAND info@normet.com www.normet.com
Technical data sheet
100063155
Charmec MF 605 DA 06.06.2016
Technical specification
Normet reserves the right to change this specification without further notice.
Normet Oy 2/9 Tel +358 (0) 17 83 241
Ahmolantie 6 Fax +358 (0) 17 823 606
FI-74510 IISALMI, FINLAND info@normet.com www.normet.com
Technical data sheet
100063155
Charmec MF 605 DA 06.06.2016
Normet reserves the right to change this specification without further notice.
Normet Oy 3/9 Tel +358 (0) 17 83 241
Ahmolantie 6 Fax +358 (0) 17 823 606
FI-74510 IISALMI, FINLAND info@normet.com www.normet.com
Technical data sheet
100063155
Charmec MF 605 DA 06.06.2016
LTC services
RECOMMENDED SPARE PARTS FOR EARLY LIFE TRAINING AND EXPERTISE SERVICES
Spare parts package: A complete package to make sure Available before and at the equipment delivery – and during
your machine runs with optimal uptime up to 1000 opera- the whole equipment life-time!
tion hours*.
Product training:
Includes periodical maintenance parts and most critical Operation and Maintenance
spare parts related to e.g.: Automation - NorSmart
- Engine (e.g. filters, belts) Foundation of electrics, hydraulics and mechanics
Trouble-shooting
- Chassis (e.g. wiper blades, throttle pedal connector)
- Hydraulics (e.g. filters) Process & operator improvement audit for:
- Electrics (e.g. sensors, work lights, solenoid coils, Concrete spraying
contactors) Charging
- Boom (e.g. sliding parts, bearings, cylinders, seals, pins) Scaling
1. Operator training
1.1 Classroom training
General introduction and operation of machine Comprehensive
Safety instructions Comprehensive
Use of manuals Comprehensive No classroom training
Technical introduction of equipment Comprehensive included in commissioning
Hands-on service and pre-operation checks Comprehensive
Controls and driving (starting, driving, stopping, parking) Comprehensive
Work method Comprehensive
1.2 Practical training
Pre-operation checks Comprehensive Basic
Driving, starting, stopping, parking Comprehensive Basic
Preparing the machine for specific operation conditions Comprehensive Not covered
Operation Comprehensive Basic
Washing the machine Comprehensive Basic
Troubleshooting Comprehensive Basic
Dimensions
SIDE VIEW
Basic machine
SIDE VIEW
Machine with options and enclosed cabin
Dimensions
TOP VIEW
TURNING RADIUS
Normet reserves the right to change this specification without further notice.
Normet Oy 6/9 Tel +358 (0) 17 83 241
Ahmolantie 6 Fax +358 (0) 17 823 606
FI-74510 IISALMI, FINLAND info@normet.com www.normet.com
Technical data sheet
100063155
Charmec MF 605 DA 06.06.2016
Dimensions
BOOM REACH
Normet reserves the right to change this specification without further notice.
Normet Oy 7/9 Tel +358 (0) 17 83 241
Ahmolantie 6 Fax +358 (0) 17 823 606
FI-74510 IISALMI, FINLAND info@normet.com www.normet.com
Technical data sheet
100063155
Charmec MF 605 DA 06.06.2016
Tractive efforts
Normet reserves the right to change this specification without further notice.
Normet Oy 8/9 Tel +358 (0) 17 83 241
Ahmolantie 6 Fax +358 (0) 17 823 606
FI-74510 IISALMI, FINLAND info@normet.com www.normet.com
Technical data sheet
100063155
Charmec MF 605 DA 06.06.2016
Tractive efforts
Normet reserves the right to change this specification without further notice.
Normet Oy 9/9 Tel +358 (0) 17 83 241
Ahmolantie 6 Fax +358 (0) 17 823 606
FI-74510 IISALMI, FINLAND info@normet.com www.normet.com
Declaration of conformity for machinery
Manufacturer: Normet Oy
Address: Ahmolantie 6
FI-74510 IISALMI
FINLAND
Name and address of the person authorised to compile the technical file.
Normet Oy
Design department
Ahmolantie 6
FI-74510 IISALMI
FINLAND
Herewith declares that anfo charging machine:
Charmec MF 605 DA, DJ305
CHARMEC MF 605 DA
Code: . . . . . . . . . . . . . . . . . . . . 100121643
Carrier No: . . . . . . . . . . . . . . . . DJ305
This manual is a guide to the proper and safe operation of the carrier. The information
contained in this manual is current for this carrier. In the interest of continually improving its
products, Normet reserves the right to update or modify information contained in this manual.
Illustrations shown in this manual were produced during the development stages and may
differ from the actual product.
Danger!
Warning!
Risk of injury.
Caution!
Note!
CONTENTS
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1. Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2. Carrier identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3. Frame Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3.1. Engine end Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3.2. Load end Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3.3. Oscillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4. Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4.2. Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4.3. Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4.4. Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4.5. Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.5. Hydrodynamic Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5.2. Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.5.3. Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.5.4. Transmission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.6. Mechanical Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.6.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.6.2. Driveshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.6.3. Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.7. Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.7.1. Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.7.2. Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.7.3. Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2. Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.1. General Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.2. Operating Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.3. Label locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Operator’s Manual
3. Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.1. Dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.1.1. Switches TB7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.1.2. TB7b . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.1.3. Norsmart Control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.1.4. Automatic Brake Application System . . . . . . . . . . . . . . . . . . . . . 34
3.1.5. Engine Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.2. Main Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.3. Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.4. Driving Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.5. Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.6. Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.7. Fire Suppression System(optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1. INTRODUCTION
1.1. Carrier
The carrier is a four wheel drive, centrally articulating frame steering carrier powered
by a diesel engine. The power from the engine is transmitted through a torque
converter to a three speed, full reversing, powershift transmission.
From the transmission, driveshafts with universal slip type joints transmit the power to
the deep reduction, inboard planetary drive axles. The wheel axles are equipped with
built-in brakes immersed in an oil bath and serve as both driving brakes and the carrier
safety/parking brake.
The steering system as well as the braking system are operated hydraulically.
Steering is full hydraulic power type, utilizing a flange-mounted, direct drive hydraulic
pump which provides hydraulic fluid to an orbital valve operated by the steering wheel.
This activates the two steering cylinders located at the articulating joint.
A 24 V electrical system supplies the carrier with voltage for carrier start-up, operation
and control panel monitoring functions. The instruments and controls to monitor and
operate all of the systems are located in the operator’s area. A description of each is
listed in this manual. Become familiar with the position and operation of each.
To obtain the best performance from your carrier, it is important that the carrier func-
tions as well as the operating procedures are well understood. Read this manual care-
fully, and then use it as a reference until complete proficiency is achieved.
Before initial operation and before each work shift, inspect and service the carrier.
2 3 4
1. Machine plate
2. Engine type plate
3. Powershift transmission type plate
4. Axle type plate
Fig. 1. Frame
1.3.3. Oscillation
The engine end axle oscillation allows the carrier to be turned along the longitudinal
axis. This arrangement makes it possible for the carrier to maintain full tractive power
on all four wheels on uneven surfaces.
1.4. Engine
1.4.1. General
Power between 60 and 170 kW at speeds between 1500 and 2400/min are available
for turbo charged four and six cylinder engines, whilst adhering to the standards of 97/
68 EU level III and EPA TIER III. The displacement is around 1.0 liters per cylinder.
The 2012 series has the designation TCD 2012 L4 / L6 2V and the 2013 series has
the designation TCD 2013 L4 / L6 4V for emission level III. The fundamental change
from the level II engine to the level III engine regarding emissions is the changeover
of the injection system from the current mainly mechanically controlled injection
system to electronically controlled systems. The current basic engine series are thus
equipped with the DCR (DEUTZ Common Rail) injection system.
In order to achieve emission level III, it was necessary to rework the inlet and exhaust
channels. The whole combustion process was optimized. An increase in ignition pres-
sure was also necessary, requiring the crankcase also to be optimized.
All existing characteristics of the 2012 and 2013 engines have, to a large extent, been
retained. With the TCD 2012 series a maximum torque of up to 850 Nm is available.
As previously, several gear-driven power take-off points are also available. Up to 100
% of the engine power output can be delivered to both ends of the crankshaft. An inex-
pensive V-belt is supplied as standard for the drive on add-on units. Alternatively, an
easy-to-maintain V-ribbed belt can be supplied.
Thanks to its low-level sound emission, this drive offers a high degree of comfort in
the driver’s cab and a low level of environmental pollution. In some special cases
noise capsules may be necessary, although the requirement for these is low. Low fuel
consumption and long maintenance intervals ensure high operational efficiency.
1.4.3. Cooling
TCD 2012/2013 power units are liquid-cooled engines. TCD 2012/2013 engines with
integrated cooling can accommodate both an engine cooling system and additional
torque converter or hydraulic fluid coolers within the engine envelope – no extra space
is required.
1.4.4. Benefits
– Good cost-effectiveness thanks to simple and inexpensive installation, good
durability and long service intervals.
– Low noise emission ensures further savings due to reduced sound proofing
measures.
– Lean engine structure and variable design of the engine’s front end offer max-
imum flexibility.
– Very low exhaust emissions actively contribute towards environmental protec-
tion.
– High running smoothness, thanks to mass balancing shafts in the 4-cylinder
engine, guarantee high operating comfort.
– The 2012 series complies with 2004/26/EU level III A emission standards and
EPA TIER III for mobile working carriers.
Silencer
Silencer is installed along the exhaust pipe as part of the exhaust system of an internal
combustion engine to reduce its exhaust noise. On internal combustion engines, the
engine exhaust blows out through the silencer.
1 2 3
1. Impeller
2. Turbine
3. Stator
Impeller
The engine power is transmitted from the engine flywheel to the impeller. This
element, constituting the pump portion of the hydraulic torque converter, is the primary
component that starts the oil flow to the other components, resulting in multiplication
of torque. The impeller gives the oil its movement, forcing it into the turbine.
Turbine
The turbine is mounted opposite the impeller and connected to the output shaft of the
torque converter. The turbine is the driven member of the torque converter. Fluid is
directed at the outer perimeter of this element. It discharges the fluid at its center and
also transfers the hydraulic force to the transmission.
Stator
The stator, the torque converter’s reaction member, is located between the impeller
and turbine. Its function is to redirect the fluid exiting the inner portion of the turbine to
the impeller element for recirculation.
The stator has strongly curved blades, and its hub features an overrunning clutch that
prevents the stator from turning against the engine’s direction of rotation. The stator
changes the direction of the oil flow such that the oil returns to the impeller in the direc-
tion of rotation of the impeller. The overrunning clutch prevents the stator from running
against the direction of rotation of the impeller and turbine by the force of the flow.
1.5.3. Transmission
The transmission has clutch discs that engage the gears. The multi-speed transmis-
sion can be engaged under load. The control system adjusts the speed and load and
directs the hydraulic oil to the clutch pack, which selects the optimal gear for each
operating situation.
The speed and direction clutch assembly is fixed to the transmission case and
connected to the output shaft of the converter. The purpose of the speed and direc-
tional clutches is to direct the power through the gear train to provide the desired
speed range and direction.
1.6.2. Driveshafts
The driveshaft assembly consists of a driveshaft, a slip joint, and one or more
universal joints. This assembly provides a flexible connection through which power is
transmitted from the transmission to the live axle.
There are two driveshafts in the power train. The two output shafts connect the lower
part of the powershift transmission case to the rear and front axles.
1.7. Hydraulics
This section contains general information concerning the carrier hydraulic system.
Detailed information is available in carrier schemas.
1.7.1. Pumps
General
The carrier has a common hydraulic system for steering and operation of accessories.
A hydraulic pump connected to a power outlet on the diesel engine supplies fluid to
the accessories system and also to the steering system. Simultaneous operation of
steering and accessories is possible.
Pumps
The hydraulic system comprises hydraulic pumps powered by a diesel engine. The
hydraulic fluid is distributed from the hydraulic pumps to the various parts of the carrier
by directional control valves.
Filtering
To provide good operational reliability and to maximize the lifespan of the components
included in the hydraulic system, a high degree of filtration has been implemented. All
of these filters are fitted with indicators to indicate when the filter cartridges should be
changed.
1.7.2. Brakes
General
Inside the axle assemblies, in the drive housing, oil bath type disc brake packs have
been fitted for both drive shafts.The brakes are hydraulically operated.
Pressure accumulator
A hydraulic accumulator is a pressure storage reservoir in which a non compressible
hydraulic fluid is retained under pressure from an external source. Its main function is
to store hydraulic energy and is necessary, make the energy available again to the
system.
The main reasons that an accumulator is used in a hydraulic system are so that the
pump doesn't need to be so large to cope with extremes of demand, so that the supply
circuit can respond more quickly to any temporary demand and to smooth pulsations.
1.7.3. Steering
General
The engine end and load end part of the centrally articulated carrier are joined in the
frame joint, which is movable about a vertical shaft for steering and is operated by two
hydraulic cylinders. Simultaneous operation of the steering and the accessories is
possible. Steering valve is Orbitrol type.
Load sensing
In load sensing steering systems both the steering system and the working hydraulics
can be supplied from just one pump. In addition LS steering systems make energy
saving possible by the use of an LS pump. Load sensing steering units have an extra
connection for load sensing (LS), so that a load pressure signal can be directed via
the steering unit to an LS pump. The load sensing signal controls the oil flow from the
LS pump to the steering unit.
Main components
– Hydraulic pump, which supplies the pressure fluid required.
– Steering device, to which the steering wheel is connected, controls the hydrau-
lic pump-supplied fluid flow to the cylinders so that a turning direction and
speed corresponding to the steering wheel movements is obtained for the car-
rier. The function of the steering device is also to act as a stand-by steering
pump in situations of reduced pressurized fluid supply to the steering system.
In this case, the required steering force is produced manually.
– Steering cylinders, which turn the carrier via its centre hinge upon the effect of
the pressure fluid.
2. SAFETY RULES
1. Keep the work site clear of personnel while the engine is running.
2. Shut off the engine when refuelling, servicing or carrying out repairs. The
engine may be left running for adjustment/tuning purposes only.
3. Read this manual thoroughly before operating the carrier.
4. Check the area around the carrier before entering the operator's cab.
5. With the exception of the co-operator, no other passengers are allowed in
the cab.
6. Before starting the carrier, make sure that the transmission is in neutral
and the safety/parking brake is applied.
7. Before starting to drive, always make sure that all equipment controls and
functions are in working order.
8. Maintain a safe operating distance between the carrier and other person-
nel.
9. Repair or report any irregular functions or damage immediately.
10. Never use the safety/parking brake to stop the carrier other than in emer-
gency situations.
11. Always reduce speed when travelling downhill.
12. Follow all auxiliary equipment instructions before operating.
13. Strictly observe all work site regulations regarding operation of the carrier.
14. Park on level ground wherever possible. Turn the wheels towards a bank
or berm, or block the wheels when parking on a slope.
15. Shift the transmission to neutral during idle periods.
16. Never stop the engine immediately after running at high revs if the engine
is hot.
17. Do not open the main switch while the engine is running.
18. Always make sure that the safety/parking brake is engaged before leaving
the carrier for any reason.
Fig. 8. Warning
1 2 3
6 5
1. Cabin
– Safety label - Fall over danger
– ROPS/FOPS label
– Safety label - Engine use
– Safety label - General
2. Warning - High pressure hydraulic oli
3. Warning - Danger of crushing
4. Fire suppression
5. Danger of crushing / Staying on area restricted
6. Pressurized vessel
3. OPERATOR CONTROLS
3.1. Dashboard
3.1.1. Switches TB7
1 2 3 4 5 6 7
14
15
8 9
16
10 11
17
12
13
1. Turn signal
Use
– Turning the switch to left or right causes a left-turn light or a right-
turn light to blink.
2. Rotating beacon
Purpose
– Warns persons being exposed under normal conditions of carrier
use to the hazards of impact or crushing and its movements.
Switch operation
– On / Off.
Switch operation
– High beam / Low beam / Off
Switch operation
– On / Off
Switch operation
– On / Off
Switch operation
– On / Off
7. Work light
Switch operation
– On / Off
Use
– Allows the carrier operator to override the automatic engine shut-
down when the switch is used during starting the engine.
– Must be used only in an emergency to start the engine and to drive
the carrier to a safe place.
Note!
Note!
Switch operation
– Audible signal will be heard.
– Visual signal will be seen.
– Engine stops.
Purpose
– Engine speed can be adjusted after switching the hand throttle ON.
Switch operation
– Right – increase the engine speed.
– Left – decrease the engine speed.
Purpose
– Used to set the engine speed during stationary operations.
– Use the “hand throttle + / -” switch to get the desired rpm.
Switch operation
– On / Off
Purpose
– Used to by-pass horn when starting the engine.
Switch operation
– On / Off
13. Horn
Purpose
– A warning device
To engage
– Push the safety/parking brake button.
Event sequence
– Safety/parking brake warning indicator lights up.
To reset
– Pull the safety/parking brake button up.
– Push the safety/parking brake release button.
Should be used when
– On-job parking is required.
– Leaving the carrier unmanned.
– The service brake fails.
– Emergency circumstances require its use.
Engine start
– Prevents accidental startup of the engine by unauthorized persons
when the operator is absent.
– Insert the switch key and turn clockwise.
– Turn the current key switch further to startup position.
– Horn sounds three seconds.
– Once the engine fires, release the current key switch.
Engine stop
– A solenoid stops the engine when turning the current key switch
anti-clockwise.
– Reduce speed to idling for a few minutes to allow the engine tem-
perature to equalize when stopping the engine.
– Engine shutdown is electrical.
Caution!
Purpose
– Stops the engine.
3.1.2. TB7b
1 2 3
4 5
Switch operation
– Move the lever up or down.
Switch operation
– Move the lever up or down.
Switch operation
– Move the lever up or down.
Switch operation
– Move the lever left or right.
Switch operation
– Move the lever left or right.
1. USB-connector
2. Remote display
3. Navigation keyboard
1. USB connector
Purpose
– To update the software.
– To take software backup.
Definition
– Main switch closed.
Purpose
– Provides all the necessary information.
3. Navigation keyboard
Purpose
– To control the system.
Definition
– The braking system is equipped with hydraulic accumulators.
– The system automatically applies the safety/parking brakes and stops the car-
rier before the hydraulic accumulators reach the critical level to stop the car-
rier.
Warning
– Warning system because of the hydraulic accumulators used for the applica-
tion of the service brake.
– Warning attracts the operator’s attention by providing a continuous visible
warning.
– System warns the operator that the hydraulic accumulator pressure is
approaching the critical level of the accumulator pressure so that the carrier
can be safely stopped or the operator prepares himself/herself for the applica-
tion of the safety/parking brakes.
Main switch
– The main switch in the carrier switches off and on the supply of electricity to
the carrier.
– It is vital that the main switch is opened before any electrical inspection or work
is carried out such as replacing a blown fuse.
– Isolates the battery from the rest of the circuit for fire protection when the
engine is stopped and the carrier is left unattended.
– Do not open the switch while the engine is running.
– After turning the current key switch anti-clockwise to shut down the engine,
wait at least 40 seconds before opening the main switch.
– Wait one minute before starting procedure.
Note!
Circuit breaker
– A circuit breaker is an automatically-operated electrical switch designed to
protect an electrical circuit from damage caused by overload or short circuit.
– The centre of the circuit breaker pops up in response to excessive temperature
or current rise.
– Can be reset manually to resume normal operation.
1 2
3
4
4
3
1. Steering wheel
2. Gear selector
3. Accelerator pedal
4. Service brake pedal
1. Steering Wheel
2. Gear shifter
Danger!
3. Accelerator pedal
3.5. Seat
3 4
2
1
5 6
1. Weight adjustment.
– to increase or decrease the suspension resistance.
2. Seat cushion angle adjustment.
3. Backrest regulation.
4. Seat belt.
– Always use the seat belt for all kinds of driving.
– A sudden application of the brakes could have serious consequences if the
belt is not used.
– Withdraw a sufficient length of strap from the retractor in a smooth and steady
movement.
– Insert the locking tongue into the buckle until a click is heard.
5. Fore-and-aft adjustment.
– Pull the lever.
– Slide the seat forward or backwards to required position.
– Release the lever after adjustment.
6. Seat rotating.
Danger!
7. Locking lever
Purpose
– To deflect or minimize the risk as quickly as possible.
– To provide safety for man and the carrier in emergency situations.
– In the event of operational malfunction.
– For fast stoppage of movement.
To engage
– Push the button down.
To reset
– Release the emergency stop button.
Danger!
Pressure accumulators
Hydraulic pressure accumulators are energy storage devices. They hold hydraulic
pressure in the hydraulic brake circuit only for emergency assistance if the hydraulic
pump fails or the engine quits altogether.
1. Start and run the engine for 1 minute to charge the accumulators.
2. Switch off the engine.
3. Turn the current on with the current key switch.
4. Apply and hold the service brake foot pedal for 10 seconds and release.
5. Repeat pressing and releasing.
– Service brake warning light lights up at 100 bar.
– This should take at least 3 applications.
Danger!
Safety/Parking Brakes
The holding effect of the safety/parking brakes depends both on the condition of the
brake discs and that there is no pressure acting on the safety/parking brake circuit.
1. Start the engine.
2. Push the safety/parking brake mushroom head button down.
3. Pull the safety/parking brake mushroom head button up.
Note: Don’t push safety/parking brake releasing button.
4. Set the gear shifter into 2nd gear.
5. Apply full throttle.
6. The carrier should not move. Do not operate if the carrier moves.
Service Brakes
The holding effect of the service brakes depends both on the condition of the brake
discs and on the pressure acting on the service brake circuit.
1. Start the engine.
2. Press the service brake pedal down.
3. Pull the safety/parking brake mushroom head button up.
4. Push the safety/parking brake pilot lamp button to release the brake.
5. Set the gear shifter into 2nd gear.
6. Apply full throttle.
7. The carrier should not move. Do not operate if the carrier moves.
Note!
If the carrier fails any of the above tests, tag and remove
from service. Report to maintenance personnel.
Danger!
Note!
Check the area around the carrier before entering the operator’s cab.
– Make sure that the frame joint safety bar is not connected.
– Use the steps and hand rails provided to enter the cab safely.
– Do not grab the steering wheel when entering the cab.
– Keep all foot controls free of obstruction.
– Keep the operator’s cab clean and tidy.
Warning!
Lock the frame joint by the safety bar when lifting and
shipping the carrier. Stop the engine before inserting
and removing the safety bar.
Caution!
Before starting, make sure the carrier's work danger area is free of personnel.
Check after repairs that all protective equipment is mounted and all tools have been
removed from the engine.
Do not use additional start aids (e.g. start pilot injection) when starting with heating
plugs/heating flange! Danger of accident!
1. Close the main switch.
2. Check that the carrier’s gear selector is in neutral.
3. Check that the safety/parking brake is engaged.
– Starting the engine is prevented if the safety/parking brake is not engaged.
4. Switch the current on with the current key switch on the instrument panel, where-
upon the indicator lights will light up.
5. Check all indicator lights are illuminated. If a light is not illuminated, change the
light. The engine must not be started if a warning light is not functioning.
6. Start the engine after the preheating indicator light extinguishes.
– Engine can be started right away if the light does not come on.
7. Start up the engine by turning the current key switch further round.
Danger!
Note!
1. Shift lever
2. Twist grip handle
Definition of terms
Selecting neutral
– Place the shift lever into its central detented position.
Selecting forward - engine end
– Lift the shift lever.
– Push the shift lever away from the driver.
– The forward position is a stable shift lever position.
Selecting reverse - load end
– Lift the shift lever.
– Pull the shift lever towards the driver.
– The reverse position is a stable shift lever position.
Upshift - selecting up
– Rotate the twist grip handle counter clockwise.
Downshift - selecting down
– Rotate the twist grip handle clockwise.
Gear selection
First gear
– Use to set the carrier in motion.
– Load and ground conditions prohibit driving in a higher gear.
Second gear
– The carrier speed approaches the limit of the first gear.
– Load and ground conditions allow a higher travelling speed.
Third gear
– The carrier speed approaches the limit of the second gear.
– Load and ground conditions allow travelling at maximum speed.
Lower gear change
– Observe the carrier speed.
– Do not change gear if the carrier speed is higher than the maximum speed of
the gear you intend to select.
Drive direction change
– The carrier must be brought to a complete stop before the change.
4.3.5. Steering
The carrier has hydrostatically controlled frame joint steering. Notice that the steering
reaction speed diminishes as the engine’s rotation speed decreases. Take this into
account particularly when turning and when driving in higher gears. Pull back slightly
when you reach the steering stop to prevent excessive fluid heating. Use the hand-
knob when steering.
Note!
1. Ensure that any possible outside couplings to the carrier are disconnected.
2. Release the safety/parking brakes.
3. Set the gear shifter to the desired driving direction position.
4. Use first gear to set the carrier in motion.
5. Apply even pressure to the accelerator until the carrier starts to move.
6. Check to ensure that all travel routes are clear of obstruction.
7. Check the function of the steering.
Danger!
4.3.9. Stopping
1. Stop the carrier by decreasing the engine revolutions and using the service
brake.
– Avoid heavy braking when driving a loaded carrier.
Caution!
Caution!
Note!
Caution!
To be noted
The carrier can not be started by towing. Attempts to start the carrier by towing
damages seriously the transmission circuit. Tow the carrier only in such cases where
it is judged necessary. Use always the tow bar.
Before towing is to start, remember to disengage the safety/parking brakes and
dismatle the cardan shafts. Make sure the towing carrier and the tow bar are robust
enough and dimensioned to tow the indended load.
Engine/pump combination is in working order.
– Towing can be carried out without any special measures.
– Start up the engine.
– Adjust the engine RPM to achieve normal transmission feed pressure.
– Towing can then be performed at normal driving speed.
Engine/pump combination is not functioning:
– Engine cannot be started.
– Steering does not function either.
– Release the safety/parking brakes mechanically
Note!
35 mm 35 mm
4.4.2. Lifting
Many countries have special laws and statutes related to lifting, hoisting cables and
lifting equipment. Always follow the safety regulations required by local laws.
Only a correct type of carrier with a sufficient lifting capacity can be used for lifting.
Fasten two hoists to the lifting points. Ensure that the carrier is properly fastened and
balanced by first lifting it a few centimeters from the ground. Continue the lifting only
after you are convinced that the carrier is in balance and safely fastened.
Warning!
Lock the frame joint by the safety bar when lifting the
carrier. All lifting points are painted red.
Fuel
Danger!
Risk of fire
• Fuel is highly flammable. For this reason, avoid fire and naked
flames and refrain from smoking when handling fuel.
• Use cold-resistant diesel fuel.
Jump-starting
Danger!
Risk of explosion
• The use of liquid or gaseous starting aids can cause explosions.
This may result in severe injuries.
• Do not use liquid or gaseous starting aids, such as ether or
Startpilot to start the engine.
Engine oil
When changing the engine oil, select an engine oil that is compatible with the SAE
classification and the ambient temperatures expected during the period of use.
Coolant
Warning!
Risk of injury
The cooling system is pressurised. Hot coolant can escape under pressure when the
cooling system is opened and scald your skin and eyes.
– Only open the cooling system at coolant temperatures below 90 °C.
– Unscrew the cap slowly and release any excess pressure completely before
opening the cap fully.
– Wear suitable protective gloves, protective clothing and safety goggles when
handling coolant.
Warning!
Risk of poisoning
Batteries
Have the batteries serviced and recharged more frequently during the cold months of
the year.
Warning!
Risk of injury
Warning!
Risk of explosion
• Gases leaking from batteries may explode and therefore cause
injury.
• Fire, naked flames, smoking and sparks are therefore not
permitted in the vicinity of the batteries.
Careful maintenance and low power consumption will help to maintain the full battery
charge. Starting capacity is greatly reduced in cold weather; at -10 °C, for example, it
is only around 60% of normal capacity. If the engine is not used for a long period of
time, store the batteries in a heated place if possible. Ensure good ventilation when
recharging.
Warning!
Risk of injury
The acid contained in batteries burns skin and eyes on contact.
Do not allow acid to come into contact with your skin, eyes or clothing.
Wear suitable protective clothing, as battery acid can burn through normal clothing. In
addition, protective gloves and safety goggles should be worn.
Rinse acid splashes off immediately with clean water and consult a doctor if neces-
sary.
Caution!
Risk of explosion
Gases leaking from batteries may explode and therefore cause injury.
Fire, naked flames, smoking and sparks are therefore not permitted in the vicinity of
the batteries.
Caution!
1. If a battery is dead or too low to crank the engine, you can jump start it using a
pair of jumper cables to connect the low/dead battery to a good battery in
another carrier.
2. Drive the other carrier as close as possible to the one with the dead/low battery,
but do not allow the carriers to touch.
3. Shut off the engine.
4. Jumper cables are colour coded, red for positive (+) and black for negative (—).
Do not mix up the cables or allow the metal ends to touch together because this
may damage the battery, charging system and/or electronics on a carrier.
5. Connect the positive terminals first and then the negative terminals of the bat-
tery.
6. Start the engine and run it for a short while.
7. Remove the jump leads in the reverse order.
8. If carrier is equipped with jump start terminal it is advisable to use it.
General
Engines are treated and equipped with the following corrosion protection:
– Interior corrosion protection
– Exterior corrosion protection
Note!
Fuel system
– Fill the fuel tank with a mixture of:
• 90 % distilled fuel
• 10 % corrosion protection oil SAE 20W-20
– Perform a corrosion protection run with no load for at least 5 minutes.
Air compressor
If an air compressor is fitted, corrosion protection agent should be sprayed into the air
compressor intake system after switching off the engine until the agent visibly
emerges from the adapter.
Cooling System
– Depending on the series, the engines are equipped with a cooling air, cooling
oil or cooling fluid system (cooling water with cooling system protection agent).
– Refer to exterior corrosion protection of the cooling air system presented in the
exterior corrosion protection section below.
– In oil-cooled series engines, the circulating lubricating oil simultaneously
serves as cooling oil. The cooling chambers are automatically protected
against corrosion by the lubricating oil system.
– If a coolant with corrosion protection properties is poured into liquid- cooled
engines, no further action is necessary after draining.
– If not, the coolant must be drained and, to ensure the formation of a protective
layer on the inner surfaces of the cooling system, a corrosion protection run
performed with a mixture of:
• 95 % distilled water
• 5 % corrosion protection agent
– The duration of the corrosion protection run and the concentration of the cor-
rosion protection agent are specified by the manufacturer of the corrosion pro-
tection agent.
– Then, drain the coolant.
Rubber parts
– Rubber parts (e.g. muffs) which are not painted over must be rubbed down
with talcum powder.
Belt drives
– Remove V-belts and V-rib belts and store them in closed packages.
– Spray V-belt pulleys and tension pulleys with corrosion protection agent.
– Toothed belts of the engine control may not be removed.
Engine openings
– All engine openings must be fitted with airtight and water-tight covers to delay
the liquefication process of the corrosion protection agents.
– If an air compressor is installed, the suction and pressure connection must be
sealed with a cap.
– The air inlet (air supply pipe) should be sealed off to avoid ventilation of the
engine (chimney effect).
Fuel system
– If the fuel tank was charged with a mixture of diesel fuel/corrosion protection
oil, drain it.
– Fill the fuel tank and fuel system with the proper fuel.
Coolant system
– If the implemented corrosion protection agent is compatible with the intended
coolant system protection agent, this can be filled directly into the coolant sys-
tem as specified.
– If it is uncertain whether the implemented corrosion protection agent is com-
patible with the coolant system protection agent, the cooling system should be
purged with fresh water for about 15 minutes before filling.
NOTES
Version: . . . . . . . . . . . . . . . . . . v.1.03
Date: . . . . . . . . . . . . . . . . . . . . . 08.02.2018
Language: . . . . . . . . . . . . . . . . English
This manual is a guide to the proper and safe operation of the control system. The
information contained in this manual is current for this control system. In the interest of
continually improving its products, Normet reserves the right to update or modify information
contained in this manual. Illustrations shown in this manual were produced during the
development stages and may differ from the actual product.
INDEX
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1. Purpose of the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2. Warnigs and notifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3. Definitions, terms and abbreviations used . . . . . . . . . . . . . . . . . . . . . 8
3. User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1. Navigation in the user interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2. Adjusting values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.3. Access rights of the user interface . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.4. Pop-up windows of the user interface . . . . . . . . . . . . . . . . . . . . . . . . 28
3.5. User interface alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.6. Drive display (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.7. Process display (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.8. Process control (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.9. Data Logging (4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.9.1. Process log window (4.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.9.2. Alerts window (4.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.9.3. Platform operating hours (4.3) . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.9.4. File transfer settings (4.4) (Commercial option) . . . . . . . . . . . . . 56
3.10. Display settings window (5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.11. Advanced settings window (6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.11.1. Access level selection (6.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.11.2. Commercial options (6.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.11.3. Factory & default parameters (6.3) . . . . . . . . . . . . . . . . . . . . . 68
3.11.4. System versions and settings (6.4) . . . . . . . . . . . . . . . . . . . . . 71
3.11.5. System backup (6.5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.12. Process maintenance (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.12.1. Calibrations (7.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3.12.2. Process parameters (7.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.12.3. Feeder options & parameters (7.3) . . . . . . . . . . . . . . . . . . . . . 104
4. FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
4.1. Starting up the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
4.2. System update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
4.3. System backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
4.4. System backup restoration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
4.5. Changing the access level using a code or a login key . . . . . . . . . . . 166
4.5.1. Changing the access level using a code . . . . . . . . . . . . . . . . . . 167
4.5.2. Changing the access level using a login key . . . . . . . . . . . . . . . 169
5. Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
APPENDIX 1. System alert and info texts . . . . . . . . . . . . . . . . . . . . . . . . . 170
APPENDIX 2. I/O-errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
APPENDIX 3. ANFO system alert and info texts . . . . . . . . . . . . . . . . . . . . 180
APPENDIX 4. ANFO process start up enabling conditions . . . . . . . . . . . . 182
APPENDIX 5. Warning symbol explanations . . . . . . . . . . . . . . . . . . . . . . . 183
1. GENERAL
This instruction manual contains instructions for using the control system user
interface of the NorSmart devices manufactured by Normet.
The system description is followed by the user interface functions.
The purpose of this instruction manual is to familiarize the user with the functions of
the user interface windows and the effects of their settings on the system as a whole.
Warning!
Warning!
Warning!
Caution!
3. USER INTERFACE
The system initialization window is the first thing that appears when the user interface
is launched.
Drive display
Important information related to driving the machine
Process display
Information on the process carried out by the machine
Process settings
Process settings
Data logging
Warnings, process log information, condition monitoring
Display settings
Brightness, language, time, date
Advanced settings
System settings, alert settings, updates, file management
Process maintenance
Calibration, parameter settings, factory parameters
Vehicle maintenance
Vehicle maintenance related functions
Boom maintenance
Boom related adjustments
Diagnostics
Whole-system diagnostics
Sub-view icon
The icon opens a new view
Sub-list icon
The icon opens a new sub-list
Pop-up
Pop-up window for choosing yes/no
Menu pop-up
The Menu icon can be accessed by using the direction buttons on the display, and the
Menu screen can be opened by pressing Enter above the Menu icon. When the
navigation focus in on the Menu icon, the icon is shown in blue. Otherwise, the Menu
icon is gray.
When the user interface has opened in the window, the navigation focus is already on
the Menu icon.
Fig. 8. Menu icon. The icon is blue when it is active. It can then be used
to access the Menu screen by pressing the Enter button at the bottom
of display.
The user interface is navigated using display buttons and the accompanying Menu
and Enter button or using the four direction buttons and the accompanying Enter
button. All display’s do not have separate direction buttons.
1. Menu button
2. Move left button
3. Move right button
4. Move up button
5. Move down button
6. Enter button
Fig. 13. User interface Menu screen. The screen opens in a separate pop-up window
with the display's Menu button or Menu icon.
Note!
The next level window view can be accessed via the row by pressing the
Enter button.
The next level window sub-list can be accessed via the row by pressing the
Enter button to move forward to new window views.
To navigate back from the next level window sub-list or view, use the
direction buttons to navigate to the Back button and then press Enter.
Fig. 14. The Back button is located in the left-hand corner of the window.
If the window includes a sub-list and the list contains more rows than can fit in the
window at a time, a black arrow symbol is shown at the bottom of the window. To view
the rest of the sub-list, use the direction buttons to navigate to the next page of the
window.
1. If the changed value is accepted as described earlier by pressing the Enter but-
ton, the changed value is immediately taken into use for the duration of the ongo-
ing session, but it is not permanently saved in the system and the change is no
longer valid when the program is relaunched.
2. If the changed value is saved also by using the window's Save button, the
change is saved in the system and will apply also when the system is
relaunched.
Fig. 19. The Save button is located in the right-hand corner of the window.
To use the Save button, navigate to the button using the direction buttons and press
the Enter button to accept the save. After pressing Enter, the system requests
confirmation of the save in a separate window.
Fig. 21. Virtual keyboard with numbers (left) and letters (right).
Use the direction buttons to select the desired character, and press Enter to accept it.
The chosen character can be deleted using the arrow key if necessary. Spaces are
entered using the Space key. Entered text is accepted with the OK key, which also
closes the keyboard automatically. To close the keyboard without saving, press
Cancel.
To switch the keyboard from number mode to letter mode, press the A key. To switch
back to number mode, press the 123 key.
The 19 most recently entered field texts are saved in the memory. When you move
from the writing field to the keyboard, the program suggests using the most recent text
entry. To access the list of saved texts, in the text writing field, press the Up direction
button and then the Enter button. The desired text can then be selected from the list
and accepted with the Enter button.
1. Basic user
– The basic user has the right to drive the machine and browse the user interface.
The basic user can view all parameters but cannot adjust them.
2. Site supervisor
– The site supervisor has same rights as the basic user and also the right to
delete reports from the system
3. Maintenance
– Maintenance access rights cover all access rights to the user interface
excluding activating commercial options, setting machine serial number,
clearing platform operating hours and setting Neutral position switch on/off.
4. Factory
– Factory access rights cover all access rights to the user interface.
Fig. 22. Popup window that appears when access level is too low.
The machine uses by default the access level 1 access rights, which do not require
log in. To perform functions that require access level 2, 3, or 4 access rights, the user
must log into the system using an access level code or a login key. Logging in is
presented in more detail in the Functions chapter.
Fig. 25. Pop-up window: Alert. Alert windows have a red margin.
Fig. 26. Active system alerts on the left-hand side. Window 4.2.1. System Alerts.
A maximum of 7 different alerts can fit in the column. If more alerts than this are active,
a yellow icon appears at the bottom of the column, which can be used to access the
rest of the alert list (window 4.2.1).
In the Alerts window all active alerts are visible at the same time. The content of the
Alerts window is discussed in detail in Chapter “Data logging (4)” on page 51.
If the Alerts window has been entered using, for example, the alert bar on the left of
the Drive display, you can return to that window via the Back button. The navigation
focus then returns to the yellow alert list icon at the bottom of the alert column.
Alerts are displayed on the alert bar in order of occurrence, the most recent being
highest on the list. Alerts can be browsed with the four direction buttons, and the
desired alert can be selected by pressing the Enter button. After this, the alert mes-
sage window opens, showing the alert ID number and a description of the alert.
Low gear
High gear.
Over temperature.
Over temperature.
Fuel level. The fuel level is indicated by a green bar beneath the symbol.
If the ignition switch is in the wrong position, the bars of diesel exhaust fluid, hydraulic
fluid, engine temperature, and transmission oil temperature are no longer visible and
the values are replaced by - - -.
Fig. 31. When DM1 alerts are active, “1” blinks in red. The Left/Right button of the
display changes the view. If there is no connection to the engine or information is
unavailable for used engine type, the values are replaced by --.
When the Up/Down buttons are pressed from the Drive display, the system cycles
among the following windows.
1. To move to the Camera view, press the Down button in the Drive display. If the
system has several cameras, the input data of the camera can be changed with
the Left/Right buttons.
2. The DM1 / J1939 message window can be accessed by pressing the Down
button in the Camera view.
The Emergency stop indicator light is red when the function is active.
Stop Engine indicator light is red when serious fault is active. Stop
engine immediately. The engine might shut down automatically
depending on engine controller configuration.
The Safety/parking brake indicator light is red when the parking brake
pressure is below 10 bar.
The Service brake indicator light is red when the charging pressure of
the pressure-accumulators in the brake circuit falls below the limit set.
The Battery charging indicator light is red when the charging voltage
sinks below the limit set.
The Water in fuel indicator light is yellow if the fuel contains more
water than the settings allow.
The Transmission oil pressure indicator light turns red when the
pressure sinks below the limit set.
The Hydraulic fluid level indicator light is red when the hydraulic fluid
level is low.
The Hydraulic fluid return filter indicator light is yellow if the return
filter is blocked.
The Engine air filter indicator light is yellow if the air filter is blocked.
The Engine oil temperature indicator light is red when the engine oil
temperature exceeds the limit set.
The Engine oil pressure indicator light is red when the engine oil
pressure is below the limit set.
Note!
The Diesel exhaust fluid low indicator light indicates, that the DEF
level has fallen below the initial warning level. This can be corrected by
filling the DEF tank with DEF.
Note!
When this light is illuminated, be sure the exhaust pipe outlet is not
directed at any surface or material that can melt, burn, or explode.
– Keep the exhaust outlet away from people and anything that can
burn, melt, or explode.
– Nothing within 0.6 m of the exhaust outlet.
– Nothing that can burn, melt, or explode within 1.5 m (such as
gasoline, wood, paper, plastics, fabric, compressed gas containers, or
hydraulic lines).
– In an emergency, turn the engine off to stop the flow of exhaust.
Warning!
The Service brake indicator light is red when the service brake is on.
Purpose
- To indicate that the support legs are not in the transport position.
Purpose
Fig. 35. Small tank button is shown in the upper part of the window if option two
charger environment is available on the machine. In the middle part of the window
can be seen the tank figure which one is activated.
Fig. 37. Process display window, if option two charger environment is not available.
In the upper part of the window, a symbol describes the machine's two explosive
charge vessels A and B.
The vessel being used is highlighted in blue. A pressurized vessel is indicated by gray
coloration and arrows pointing at both sides of the vessel.
To the left and right of the vessels are the symbols for the vessel vibrators. The
symbols can be used to activate the vibra function of the desired vessel. Vibra stays
on as long as the button is pressed. When the vibrator is on, the vessel symbol on the
button is shown in green.
If automatic vibration of the vessel is set ON in window 7.1.4, the outermost symbol is
shown green always when the vibrator is on.
Fig. 40. Symbol for vessel vibra. On left the vibra is OFF. On right the vibra is ON and
the symbol is shown in green.
Fig. 41. If the automatic vibration is set ON in window 7.1.4, the outermost symbol is
shown in green when the vibra activates.
When automatic vibration is set ON, the vibra function always activates during
charging.
This opens the Alerts window, from which either system or engine alerts can be
chosen and viewed. The window number is 4.2.
Deletion is performed by pressing Enter on the row. A separate pop-up window opens
and deletion is confirmed by pressing the Yes button.
Fig. 48. Delete system alert from the memory by pressing Yes.
Fault log deletion removes all non-active alerts. If there are active alerts in the system
at the time of the deletion their occurrences are integrated as one and the time of
occurrence is the time of the latest alarm.
Saving is performed by placing USB-memory into machine and pressing Enter on the
row.
This opens the Platform operating hours window for viewing the operating hours
information. The window number is 4.3.
For saving the maintenance times, access level 3 (maintenance) access rights are
required.
This opens the Platform operating hours editing enabled window for adjusting the
operating hours. The window number is 4.3.1.
For editing the maintenance times, access level 4 (factory) access rights are required.
This opens the File transfer settings window for adjusting the File transfer settings.
The window number is 4.4.
For setting the file transfer settings, access level 2 (site supervisor) access rights are
required.
Via the Network settings window enables setting DHCP on/off, saving IP-address,
subnet mask and default gateway. The window number is 4.4.1
For adjusting the file transfer settings, access level 2 (site supervisor) access rights
are required.
Via the Copy settings window can be set an encryption key and encryption on/off.The
window number is 4.4.2
For adjusting the Copy settings, access level 2 (site supervisor) access rights are
required.
The Email settings window enables adjusting following sending time period, sender
email address and three receiver email addresses, port, domain, host, email topic and
user information. The window number is 4.4.3
For adjusting the Email settings, access level 2 (site supervisor) access rights are
required.
The SCP settings window enables installing private key to the system via USB
memory stick, setting the port number and server’s IP address, setting SHH user
name and server’s copy path. The window number is 4.4.4
For adjusting the SCP settings, access level 2 (site supervisor) access rights are
required.
When changing the language, the change must be confirmed via a separate pop-up
window.
The code for the desired access level is entered in a separate window which opens
when Enter is pressed on the row.
Fig. 65. Current access level is shown in the text field and the open lock-symbol
shows that the access level is active.
The access level can be changed back to level 1 by pressing Enter on the row.
The response code for the challenge code is provided by the manufacturer.
The access level selection can also be done with a separate login key (USB). The
login key must be inserted into the machine when Enter is pressed on the access level
row. The program will automatically activate the access level corresponding to the
login key. This is discussed in detail in the chapter “FUNCTIONS” on page 163.
In the opening window there is a list of commercial options.The window number is 6.2.
Parameter backup and restoration can be performed in the window that opens. The
window number is 6.3.
1. Go to Advanced settings > Factory & Default parameters > Save/restore param-
eters to USB
2. Ensure that USB memory is inserted
3. Press Save parameters to USB and confirm with Yes
4. Wait until a notification window pops up and tells that parameters are saved
5. Press OK and remove USB memory
If a warning notification pops up it means that there was an error saving parameters.
In this case some or all parameters may be missing or have wrong values. Following
situations can cause warning:
– There are more parameters in a parameter list than there should be
If an error notification pops up it means that there was a critical error saving parame-
ters. In this case parameters are not saved. Following situations can cause error:
– Parameter list has invalid name
– USB memory is not found
Restoring parameters
1. Go to Advanced settings
2. Insert USB memory
3. Log in with USB memory (access level 3 required for restoring parameters)
4. Go to Advanced settings > Factory & Default parameters > Save/restore param-
eters to USB
5. Press Restore parameters from USB and confirm with Yes
6. Wait until a notification window pops up and tells that parameters are restored
7. Press OK and remove USB memory
If a warning notification pops up it means that there was an error restoring parameters.
In this case some or all parameters may be missing or have wrong values. Following
situations can cause warning:
– Parameter list has invalid name
– Parameters array or its name is invalid in JSON
– Value of a parameter is outside limits
– Index of a parameter is outside limits
If an error notification pops up it means that there was a critical error restoring param-
eters. In this case parameters are not restored. Following situations can cause error:
JSON file
Name of the JSON file have to be parlist.json and it must be placed in root directory
of USB memory.
Name/value pair “serial” can be removed from the JSON file so that the JSON file
applies to all machine serials. Just remove the line where the “serial” is.
In the opened System versions and settings window you can proceed forward to
Versions window or set the machine serial number. The window number is 6.4.
The window shows the machine number and the version numbers of the process (if
contained in the machine), platform, boom, feeder, and display. IP-address of the
display can be shown in the window and it can be renewed with the Renew Ip -button.
The image of the display can be generated by using the vnc-button. Custom iomux in
use (symbol is green) = Some signals are switched off and are not in use in this
machine type.
The window number is 6.4.1.
To set the machine serial number level 4 (maintenance) access rights are required.
The opened window enables viewing of signals related adjustments and adjustment
of their values as necessary. The window number is 6.4.4.
The opened window enables viewing of IoT related connections and tests. The
window number is 6.4.5.
The opened window enables to start and stop CAN recording. The window number is
6.4.5.1.
Start recorder:
1. Press Stop
2. Select “Yes” in popup
3. Box shows that copying is in progress
4. Wait for info popup and press OK
5. Box shows time stamp of last recording
6. Remove USB memory stick
7. BREC file can be found in the root directory of USB memory stick
The window that opens enables a backup of an individual module or the entire system
to be performed. The window number is 6.5.
The date of the last backup is shown on the same row. The emergency stop button
must be pressed before starting the backup. A USB memory stick must be inserted
into the machine for saving the backup file. Pressing the Enter button commences the
backup. After this, the program requests, in a separate window, confirmation to start
the backup.
Full system backup takes about 2 minutes maximum. When the backup is ready, the
date and time of the last backup are updated.
To perform copying connect USB memory to machine and press Enter on the row.
Via the opened Calibrations window various calibration functions can be carried out.
The window number is 7.1.
The window is used for calibration functions related to the hose main feeder. The win-
dow number is 7.1.1.
Fig. 86. Diagnostic information and functions in the upper edge of the window.
1. Feeder rotation device pulse number from the feeder pulse sensor.
2. Pulse number after starting the feeder (always resets at start up).
3. Controls for hose feed in and out. Functions by moving over the desired control
and pressing Enter.
4. Feeder travel distance (mm)
5. Measured distance in millimeters per hundred pulses.
Fig. 87. The two curves in this window show the hose feed speed in different direc-
tions during calibration, the upper curve is for feed speed out of the hole and the
lower one into the hole. Beneath the curve, the hose feed minimum and maximum
current (mA) is shown.
In the right-hand corner of the window, hose feeder related values are given:
Fig. 88. Hose feeder related values and settings.
Calibration
The hose main feeder calibration can be performed manually or automatically. The
calibration is performed separately for each feed direction.
The calibration is performed as follows:
1. The feeder maximum and minimum speed are set according to the needed hose
maximum and minimum speed.
2. Calibration method selection: manual or automatic calibration.
Fig. 89. The green indicator light shown next to Auto button and calibrated values.
3. The hand use percentage is changed back to zero.
4. The speed demand deviation is acquired by entering in the speed demand field
different values between the minimum and maximum demand. The value is com-
pared to the realized demand. After this, the deviation can be balanced with the
P and I controls. The gained deviation is entered as a value in the P and I control
adjustment ranges. The control adjustment values are acquired by experimental
testing.
Fig. 90. P control function. On the graph the red line indicates normal functioning of
the pump and the blue broken line indicates ideal pump functioning, i.e. where the
required output is reached in the shortest possible time. The P control helps the
pump to reach the demanded output faster. The remaining difference can be cor-
rected with the I control.
Fig. 91. I control function. On the graph the red line indicates normal functioning of
the pump and the blue broken line indicates ideal functioning. When the P control is
adjusted so that the output falls slightly short of the level required, it can be corrected
with the I control. The I control value is raised step-by-step by the time increments
set in the I interval until the output reaches the demanded level.
The window is used for calibration functions related to the hose middle feeder. The
window number is 7.1.2.
Fig. 93. Diagnostic information and functions in the upper edge of the window.
1. Actuator rotation device pulse number from the feeder pulse sensor.
2. Controls for hose feed in and out. Functions by moving over the desired control
and pressing Enter.
3. Measured distance in millimeters per hundred pulses.
Fig. 94. The two curves in the window show the hose feed speed in different direc-
tions during calibration, the upper curve is for feed speed out of the hole and the
lower one into the hole. Beneath the curve, the hose feed minimum and maximum
current (mA) is shown.
Fig. 95. Hose feeder related values and settings.
1. The feeder maximum and minimum speed are set according to the required
hose maximum and minimum speed.
2. Calibration method selection: manual or automatic calibration.
Manual calibration is performed using a hand use percentage.
The minimum current is determined by adjusting the hand use percentage to
1%. The minimum current is increased until the feeder starts to move in the
desired direction. The gained value is saved in the chart's Min mA field (left).
The maximum current is determined by adjusting the hand use percentage to
100%. The maximum current is increased until the maximum speed is reached.
The gained value is saved in the flow speed chart's Max mA field (right).
Intermediate points 25%, 50%, and 75% are determined by setting the hand
use percentage in question and saving the speed as the speed value (m/s) of
that control percentage. Note that the calibration curve is not linear, so it is not
possible to calculate the % control intermediate values directly. The intermedi-
ate value calibration is performed by augmenting each value by 1% of the con-
trol.
Automatic calibration automatically performs the manual calibration func-
tions. Automatic calibration is started with the Auto button. After pressing the
button, the green indicator light lights up next to the Auto button. After pressing
the button, the hose moving direction selected for calibration is selected via the
remote control. The remote control button is pressed until the calibration has
ended. During the calibration the green indicator light lights up and stays on
green next to already calibrated values. When all the values are calibrated and
the calibration is completed, the green indicator light next to the Auto button
switches off.
Fig. 96. The green indicator light shown next to Auto button and calibrated values.
3. The hand use percentage is changed back to zero.
The window is used for viewing values related to the hose feeder. The window number
is 7.1.3.
1. Main feeder control signal (value between -127 and 127, positive value into the
hole and negative value out of the hole).
2. Main feeder measured speed (m/s), measured frequency (hz), and measured
pulses.
3. Main feeder realized speed (m/s), realized frequency (hz), and realized pulses.
4. Hose travel distance (m) though the feeder, measured by the pulse wheel.
1. Middle feeder control signal (value between -127 and 127, positive value into the
hole and negative value out of the hole).
2. Middle feeder realized speed (m/s), realized frequency (hz), and realized pulses.
3. Measured hose travel distance (m) though the feeder.
1. P control value (at top), shows the process pulses to the main feeder.
2. P control adjustment range (at bottom), shows the process pulses to the middle
feeder.
Fig. 102. Reel control signal (value between -127 and 127, positive value into the
hole and negative value out of the hole).
In this window, the automatic vibra function can be set for vessels A and B and the
vibrator on and off times can be adjusted.
1. Vessel automatic vibra on/off. When the automatic vibra is set on, the vibrator
functions automatically during charging according to the times set in points 2 and
3. When the vibrator is on a green indicator light is lit in the Process display.
2. Automatic vibra on time.
3. Automatic vibra off time.
4. Manual on/off button for vessel A vibrator. The vibrator can be switched on and
off by pressing this button.
5. Manual on/off button for vessel B vibrator. The vibrator can be switched on and
off by pressing this button.
The window is used for viewing A and B tank level calibration parameters and
adjusting their values as necessary.
Values in this picture are not necessarily accurate and therefore must never be used
as example in adjusting.
1. Tank A values
2. Tank B values
3. Tank A: Minimum value is analog input adjustment. The input value is calibrated
and viewed as milliamperes (mA.)
4. Tank A: Maximum value is analog input adjustment. The input value is calibrated
and viewed as milliamperes (mA.)
5. Tank A: Value of RC filter. When adjusting the value, it filters signal. More bigger
value more peaks are removed from signal.
6. Tank A: Error range is analog input adjustment. The input value is calibrated and
viewed as milliamperes (mA).
7. Tank B: Minimum value is analog input adjustment. The input value is calibrated
and viewed as milliamperes (mA.)
8. Tank B: Maximum value is analog input adjustment. The input value is calibrated
and viewed as milliamperes (mA.)
9. Tank B: Value of RC filter. When adjusting the value, it filters signal. More bigger
value more peaks are removed from signal.
10. Tank B: Error range is analog input adjustment. The input value is calibrated and
viewed as milliamperes (mA).
11. Current measured value in the tank A (mA).
12. Current measured value in the tank B (mA).
13. Enable feature activates the feature On/Off
Fig. 107. Enable feature in the upper part of the window activates the feature.
Fig. 108. EMU Tank calibration. Five point conversion table is used to convert level
sensor readings to tank volume reading with the option to compensate irregular tank
shape.
1. Volume conversion point 1. Volume conversion points are used to define the
tank volume.
2. Volume conversion point 2.
3. Volume conversion point 3.
4. Volume conversion point 4.
5. Volume conversion point 5.
6. Minimum value when tank is empty (mA).
7. Anfo density (kg/m³)
8. A tank weight in kilograms (kg)
9. A tank volume in liters (l)
10. B tank weight in kilograms (kg)
11. B tank volume in liters (l)
The window is used to view the process parameters and adjust their values if
necessary. To adjust the values at least level 3 access rights are required. The
window number is 7.2.
The window is used to view the feeder related parameters and to adjust their values
if necessary. The window number is 7.3.
Note!
The opened window enables viewing of parameters related to platform functions and
adjustment of their values as necessary. The window number is 8.1.
The opened window enables viewing of settings related to the engine and drivetrain
and adjustment of their values as necessary. The window number is 8.3.
The opened window enables viewing and adjustment of engine related settings. The
window number is 8.3.1.
The opened window enables viewing of settings related to the drivetrain and
adjustment of their values as necessary. The window number is 8.3.2.
The power limitations set in points 7-10 are set as numerical values and by increasing
the value the reaction becomes slower.
1. Automatic braking start time (ms). When the throttle pedal is released, the
parking brake engages automatically after this time.
2. Automatic braking speed limit (km/h). When the speed falls below this limit, the
parking brake engages automatically.
1. The allowed drop in revolutions before changing gear ratio and speed
deceleration.
2. The gear ratio is zeroed when the engine speed drops below this rpm value.
The opened window enables to view and calibrate of brake circuit values. The window
number is 8.3.3.
Caution!
The opened window enables viewing of values related to transmission functions and
adjustment of their values as necessary The window number is 8.3.4.2.
In the right part of the window, inputs are described with the symbols:
Input, closed.
The opened window enables viewing of values related to lockup settings and
adjustment of their values as necessary The window number is 8.3.4.3.
The opened window enables to view and calibrate of hydraulic oil levels. The window
number is 8.3.3.
Five point conversion table is used to convert level sensor readings to tank volume
reading with the option to compensate irregular tank shape.
Volume conversion points are used to define the tank volume.
The opened window enables viewing of calibrations related to drive speed and
adjustment of their values as necessary. The window number is 8.4.
Fig. 146. The amount of pulses and drive speed km/h are shown in the window.
In the Drive speed window it is possible to adjust and save the amount of pulses and
required drive speed. The vehicle must be stopped during the adjustments
procedures.
Note!
At least level 3 (maintenance) access rights are required for performing the functions
available in this window.
If Boom maintenance is not in use, Normet for tough jobs window is opened. Back to
the Menu pop up can be accessed by pressing the Enter button of the display
Fig. 152. Normet for tough jobs window is opened if Boom maintenance window is
not in use.
The window that opens enables viewing of parameters related to different boom
movements and adjustment of their values as necessary. The window number is 9.1.
The window shows the different boom movements in separate rows. Boom
movements include lifting, turning, and zoom.
The + and – columns at the top describe the direction of the movement being adjusted
e.g. boom lift (+) and lower (-), boom turn to the left (+) and right (-), and boom zoom
out (+) and in (-).
The values in the figures do not necessarily correspond to reality, and they should not
be taken as an example when one is adjusting the values.
When the boom potentiometer is in the minimum position, the movement speed is
determined by the balance adjustment, i.e. the adjustment determines the current
range within which the movement is limited when using the boom potentiometer. The
higher the balance adjustment value, the greater the reduction in movement speed.
In other words, by making the value bigger the movement becomes slower.
Fig. 157. The example shows in blue the range limitation within the minimum-to-max-
imum current range for two different movements at different balance percentages.
When the balance adjustment is 25 %, the movement speed is 75 % of the maximum
current value when the crane potentiometer is turned to the minimum position. For
the second movement, the minimum speed is adjusted to 50% of the maximum
value.
The window is not in use in current system. The window number is 9.2.
The opened window shows a list of the different modules of the system according to
the connectors.
Not operational
Fig. 164. The pin information field shows at the top the pin number and the output
control signal (value between -127-127) and underneath the input current informa-
tion. An arrow on the left-hand side of the field describes the pin input and the arrow
on the right describes the pin output. The output or input in question is active when
the arrow is black.
The following information can be viewed from the connector diagnostics window:
Note!
If the Camera view has been accessed directly from the Drive display,
the program returns to the Drive display by pressing the Enter button in the Camera
view.
If the Camera view has been accessed directly from the Diagnostics window, the
program returns to the Diagnostics window (10) by pressing the Enter button in the
Camera view.
The opened window enables viewing of the status of both the front and rear end
support leg keys and the status of all leg valves and switches. The window also shows
the turn and lift limits of the boom when the support legs are on the ground. Window
number is 10.3.
Note!
1. Lower position limit switch. When the support leg is in the lower position the
upper symbol is open and the lower one is closed.
2. Support leg up/down movement. When the support leg raises, the upper sym-
bol is shown green. When the support leg lowers, the lower symbol is shown
green.
3. Upper position limit switch. When the support leg is in the upper position the
symbol is closed.
4. Extension extreme position limit switch. When the support leg extension is in
the extreme position the upper symbol is open and the lower one is closed.
5. Extension inner position limit switch. When the support leg extension is in the
inner position the symbol is open.
6. Extension movement. When the support leg moves outwards, the left-hand
symbol is shown in green. When the support leg moves inwards the right-hand
symbol is shown in green.
1. Lower position limit switch. When the support leg is in the lower position, the
upper symbol is open and the lower one is closed.
2. Support leg up/down movement. When the support leg raises, the upper sym-
bol is shown green. When the support leg lowers, the lower symbol is shown
green.
3. Upper position limit switch. When the support leg is in the upper position the
symbol is closed.
4. Extension extreme position limit switch. When the support leg extension is in
the extreme position the upper symbol is open and the lower one is closed.
5. Extension inner position limit switch. When the support leg extension is in the
inner position the symbol is open.
6. Extension movement. When the support leg moves inwards the left-hand sym-
bol is shown in green. When the support leg moves outwards the right-hand
symbol is shown in green.
The arrow is shown in black when the movement representing the arrow in question
is active.
Boom lift limit while the support legs are on the ground:
1. Boom drive position lift limitation limit switch. When the boom is raised the
upper symbol is open and the lower one is closed.
2. Boom lift. When the boom is raised the symbol is shown green.
1. Boom turn limitation limit switch to the left. When the boom is turned to the left
the upper symbol is open and the lower one is closed.
2. Boom turn limitation limit switch to the right. When the boom is turned to the
right the upper symbol is open and the lower one is closed.
3. Boom turn to the left. When the boom is turned to the left the symbol is shown
green.
4. Boom turn to the right. When the boom is turned to the right the symbol is
shown green.
1. Lower position limit switch. When the support leg is in the lower position the
upper symbol is open and the lower one is closed.
2. Support leg up/down movement. When the support leg raises, the upper sym-
bol is shown green. When the support leg lowers, the lower symbol is shown
green.
3. Upper position limit switch. When the support leg is in the upper position the
symbol is closed.
1. Lower position limit switch. When the support leg is in the lower position the
upper symbol is open and the lower one is closed.
2. Support leg up/down movement. When the support leg raises, the upper sym-
bol is shown green. When the support leg lowers, the lower symbol is shown
green.
3. Upper position limit switch. When the support leg is in the upper position the
symbol is closed.
The arrow is shown in black when the movement representing the arrow in question
is active.
The opened window shows the status of certain switches and functions and some of
the system temperatures and use times. Window number is 10.4.
Input, closed.
Note!
1. Safety brake on
2. Safety brake off
The opened window shows information related to CAN bus. Window number is 10.5.
The opened window shows diagnostics information of the two charger environment
and radio controller. The window is useful when diagnosing a system fault. The
window number is 10.6.
1. Remote A
2. Charging on
3. Blowing on
4. Winding the hose onto the reel
5. Charging off
6. Blowing off
7. Unwinding the hose from the reel
8. Remote on (Length reset, if the power is on)
9. Lamp indicates the status of the remote controller.
1. Remote B
2. Charging on
3. Blowing on
4. Charging off
5. Blowing on
6. Power on (or Length reset, if the power is on)
7. Lamp indicates the status of the remote controller.
4. FUNCTIONS
Fig. 190. The update starts 30 seconds after the update program has started.
Fig. 191. If the USB memory stick is removed during the 30 second waiting period,
the update is interrupted and the main power must be switched off.
Fig. 192. The update has been completed successfully. The machine must now be
fully restarted.
Module backup
After adjustment, the module parameters can be backed up on the application
controller (MID070S). The backup is performed in window 6.5.1.
The latest parameters are always sent to the modules during start up. The files are
checked with a check sum to avoid erroneous parameters. If the system tries to load
an erroneous parameter file on a module, the system makes a report of the error and
the module will not be started.
System backup
Full system backup creates an identical copy of the machine's settings on a USB
memory stick. Emergency stop must be engaged before starting the backup. A
backup directory must be created in the USB memory for saving the backup. The
backup can be made on any USB memory, but not on the same update memory stick.
The backup is performed in window 6.5.
The backup file format is .tar. The file can be opened with standard compression
programs (e.g. winzip). In addition to the tar file, the following directories and files are
created:
– Chk; contains the check sums of the parameter files
– Parameters; contains the system parameters
– Backup; contains the parameter files of the modules
– Temp; directory for storing temporary files
– Usagemonitoring; contains operating monitoring files (if in use)
– Log; contains the process log
– Config.gui; user interface file
– Config_language1.gui; language file (usually English)
– Config_language2.gui; language file (Finnish)
– Config_language3.gui; language file (other language)
– Maini; Norsmart application file
– text_presets; memory file for the entered texts
The access code for the desired access level is entered in a separate window. To
open this window, press Enter when in the row.
Fig. 196. Current access level 3 is shown in the text field and the open lock-symbol
tells that the access level is active.
The access level can be changed back to level 1 by pressing Enter on the row.
The response code for the challenge code is provided by the manufacturer.
When the login key is in the machine and the Enter button is pressed on the first row
of the Advanced settings window, the program will automatically apply the access
level corresponding to the login key. The program gives successful login notification
in a separate window.
Fig. 197. The program gives successful login notification in a separate popup win-
dow.
Fig. 198. The access level row shows the number of chosen access level and the
name of the person to whom the login key is registered.
The access level can be changed back to level 1 by pressing Enter on the access level
row.
5. APPENDICES
Table 1:
Platform alerts
No. Alert text
1023 Low hydraulic oil level
1024 Coolant level critically low
1025 Engine air filter clogged
1026 Boom turn lift limitswitch failure
1027 Right supportleg limit switch failure
1028 Left supportleg limit switch failure
1035 Engine red stop alarm
1036 Engine amber warning
1037 Compressor overheat
1039 Compressor airfilter clogged
1040 Compressor hydraulics return filter clogged
1041 Platform hydraulics return filter clogged
1044 Fire suppression activated
1046 H2KN18 24V system
1047 H2KN20 24V system
1048 H2KN22 24V system
1049 H2KN24 24V system
1050 H2KN26 24V system
1051 H2KN28 24V system
1052 H2KN30 24V system
1053 H3K1N48 24V system
1054 H3K1N50 24V system
1055 H3K1N50 24V system
1056 H3K1N54 24V system
1057 H3K1N56 24V system
1058 H3K1N58 24V system
1059 H3K1N60 24V system
1065 Low fuel level
1066 Alternator failure
1067 Battery voltage low
1068 Battery voltage critical low
1069 Battery voltage high
1070 Transmission high temperature
1071 Transmission low pressure
1072 Critical low fuel level
1073 Water in fuel prefilter
Table 1:
Platform alerts
1074 Engine end axle high temperature
1075 Load end axle high temperature
1076 Hydraulic oil high temperature
1077 Hydraulic oil critical high temperature
1080 Basket overload
1082 J1939 connection to diesel engine lost
1084 Compressor motor overheat
1088 Boom turn left limitation output short circuit to supply voltage
1089 Boom turn right limitation output short circuit to supply voltage
1090 Boom lift limitation output short circuit to supply voltage
1091 Hydrostat oil level low
1092 Hydrostat oil filter clogged
1093 Compressor critical temperature
1095 Powerpack motor protector
1096 Compressor motor protector
1097 Too many hydraulic oil contamination particles
1098 Brake accumulator pressure low
1099 Hydraulic oil temperature high switch closed
1102 Powerpack motor overtemp
1103 Wrong powerpack phase sequence
1104 Drive hydraulics return filter clogged
1105 Safety brake pressure exist while should not
1106 Safety brake pressure missing
1107 Emergency stop test failed
1108 Engine protect alarm
1109 Engine malfunction alarm
1118 Platform parameters corrupted
1118 Platform parameters corrupted
1124 Platform parameters missing
1130 Out of RAM
1134 Engine oil temp switch alarm
1135 Engine temperature high
1136 Engine oil pressure switch alarm
1144 Hydraulic oil high temperature
1147 Axle high temperature
1151 M1K1N97 24V SYSTEM
1152 Boom down limit switch failure
1153 Boom extensions in limit switch failure
1155 Load end axle high temperature
1156 Engine end axle high temperature
Table 1:
Platform alerts
No. Alert text
1460 Engine oil pressure alarm
1461 Emergency stop test failed
1462 Drive speed sensor failure too much difference in readings
1463 No pulses from drive speed sensor
1464 No pulses from drive speed sensor
1465 Analog boom turn sensor channel readings deviate
1466 Analog boom turn sensor test failed
1467 Analog boom turn sensor calibration not correct
1475 CAN RX errors cumulating
1476 CAN TX errors cumulating
1477 Boom transport position limit switch failure
1478 Speed limit brake control valve error
1479 Speed limit brake control valve error
1480 Speed above limit for too long
1481 Transmission low pressure
1482 Steer valve error
1483 Compressor overheat
1484 Powerpack motor overtemp
1486 Compressor airfilter clogged
1487 Compressor critical temperature
1488 Compressor motor overheat
1489 Compressor motor protector
1490 Lift sensor signal sum does not match
1491 MEWP pressure sensor difference too high
1492 MEWP load sensor test failed
Table 2:
Boom alerts
No. Alert text
1045 Joystick toggle information not detected
1083 Control place selection error
Table 3:
Table 3:
Table 3:
Table 3:
Table 3:
Table 4:
Table 5:
APPENDIX 2. I/O-errors
System I/O errors are always in form:
Table 6:
ANFO alerts
No. Alert text
1042 Tank A over pressure
1043 Tank B over pressure
1122 ANFO parameters corrupted
1128 ANFO parameters missing
1130 Out of RAM
Table 7:
Table 8:
Process control modules must be on Not all necessary control modules are
the bus present on bus
Danger!
Warning!
Risk of injury.
Caution!
Note!
Every 1 Years
Every 2 Years
As required
12000 h
1000 h
1500 h
2000 h
3000 h
6000 h
125 h
250 h
500 h
● = Maintenance interval (which comes first)
○ = First maintenance for a new carrier Note!
Engine
1 Check the air cleaner. ●
2 Check the engine oil level. ●
3 Check the coolant level. ●
4 Check the engine for leaks. ●
5 Check the fuel pre-filter. ●
6 Check the fuel level. ●
7 Replace the engine oil filter. ○ ●
8 Check the ribbed V-belt. ●
9 Change the engine oil. ○ ●
10 Check the coolant additive concentration. ●
11 Check the battery and clean battery terminals. ●
12 Clean the catalytic exhaust gas purifier ●
13 Replace the fuel filters. ●
14 Replace the fuel pre-filter insert. ●
15 Clean the radiator. ●
16 Replace the air cleaner filter. ●
17 Check the glow plugs. ●
18 Check the engine monitoring system. ●
19 Check the wear limit of V-rib belt. ●
20 Check the engine suspension. ●
21 Check the fastenings and hose connections. ●
22 Adjust the valve clearance. ●
23 Replace the V-rib belt. ●
24 Replace the injection valves. ●
25 Carry out a basic engine overhaul. ●
26 Change the coolant. ●
Powershift Transmission
1 Check transmission oil level ●
2 Replace the transmission oil filter. ○ ●
3 Change transmission oil ○ ●
Mechanical Transmission
1 Check the tyres visually. ●
2 Check drive line bolts. ●
3 Lubricate the propeller shaft greasing fittings. ●
4 Check tyre pressure and condition. ●
5 Check the oil level in axle differential. ●
6 Check the wheel nuts. ●
7 Check the axle planetary gear oil level. ●
8 Check the brake plate wear. ●
9 Change the axle differential oil. ○ ●
10 Change the axle planetary gear oil. ○ ●
11 Air bleed the service brakes. ●
12 Air bleed the safety/parking brakes. ●
Hydraulic System
1 Check the hydraulic fluid level. ●
2 Check there are no leaking or hanging hoses. ●
3 Check the pressure accumulators ●
4 Replace the hydraulic return fluid filter. ○ ●
5 Change the hydraulic fluid. ●
6 Accumulator gas pressure test. ●
7 Check the steering hydraulic pressure. ●
8 Check and adjust the charging pressure. ●
Every 1 Years
Every 2 Years
As required
12000 h
1000 h
1500 h
2000 h
3000 h
6000 h
125 h
250 h
500 h
● = Maintenance interval (which comes first)
○ = First maintenance for a new carrier Note!
9 Check the service brake pressure. ●
10 Check and adjust the safety/parking brake pressure. ●
Frame
1 Lubricate the carrier greasing fittings. ●
2 Check the oscillation axle bushings. ●
3 Check the frame joint bearings. ●
4 Check the steering cylinder joint pin, pin locking and bearing. ●
MEWP
1 Make a visual inspection. ●
2 Check the tilting cylinder pin and work platform joint pin. ●
3 Keep the working area clean. ●
4 Lubricate the grease fittings. ●
5 Check the boom mounting attachment. ●
6 Inspect the hydraulic cylinder, cylinder joint pin, pin locking and bearing. ●
7 Check the boom extension clearance. ●
8 Check the hydraulic pressures. ●
9 Inspect the turning joint lug welding. ●
10 Inspect the tilting cylinder fixing lug welding. ●
11 Inspect the condition of the boom beams. ●
12 Inspect the function of the load-lowering valve. ●
13 Inspect the boom mounting bolt connections. ●
14 Change the tilting cylinder joint pin and bearing. ●
15 Change the tilting cylinder. ●
16 Adjust the boom lowering speed. ●
17 Adjust the boom slewing speed. ●
18 Adjust the load sensing system. ●
Compressor
Every 1 Years
Every 2 Years
As required
12000 h
1000 h
1500 h
2000 h
3000 h
6000 h
125 h
250 h
500 h
● = Maintenance interval (which comes first)
○ = First maintenance for a new carrier Note!
1 Check the condition of electric motor and clean it if necessary. ●
2 Check oil level and the condition of oil hoses. ●
3 Check the condition of prefilter mat and clean it if necessary. ●
4 Check the oil cooler and clean it if necessary. ●
5 Check bolts and clamps and retighten if necessary. ●
6 Clean the oil cooler ● ●
7 Check oil level ●
8 Change oil filter ○
9 Change oils ●
10 Check the condition of oil hoses and replace with new ones if necessary. ●
11 Change air filter. Air filter sensor lights up a signal light if the filter is clogged and
● ●
needs to be replaced.
12 Change oil filter ●
13 Clean oil return filter. ●
14 Change prefilter mat. ●
15 Change oil separator elements. ●
16 Change oil return filter. ●
17 Change air inlet valve maintenance kit. ●
18 Change minimum pressure valve maintenance kit. ●
19 Change control valves. ●
20 Change air inlet valve repair kit ●
21 Change minimum pressure valve repair kit. ●
Note!
The intervals given are for normal usage. For tougher working conditions, consult
the responsible service person for information on the appropriate intervals.
CARRIER
Code: . . . . . . . . . . . . . . . . . . . . 100121643
Carrier No: . . . . . . . . . . . . . . . . DJ305
This manual is a guide to the proper and safe maintenance of the carrier. The information
contained in this manual is current for this carrier. In the interest of continually improving its
products, Normet reserves the right to update or modify information contained in this
manual. Illustrations shown in this manual were produced during the development stages
and may differ from the actual product.
Danger!
Warning!
Risk of injury.
Caution!
Note!
CONTENTS
1. Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1. Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2. Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3. Other precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2. Oil samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Maintenance Manual
3. Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1. Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2.1. Quality grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2.2. Lubricating oil change intervals . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2.3. Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2.4. Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2.5. Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.3. Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.3.1. Daily or once per shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Check the air cleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Check the engine oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Check the coolant level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Check the engine for leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Check the fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Check the fuel level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.3.2. Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Replace the engine oil filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Change the engine oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Check the ribbed V-belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Check the coolant additive concentration. . . . . . . . . . . . . . . . . . . . . . . . . . 41
Check the battery and clean battery terminals. . . . . . . . . . . . . . . . . . . . . . 43
Clean catalytic exhaust gas purifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.3.3. Every 1000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Replace fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Replace the fuel pre-filter insert. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Clean the radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Replace the intake air cleaner filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Check the glow plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Check the engine monitoring system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Check the wear limit of the ribbed V-belt. . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Check the engine suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Check the fastenings and hose connections. . . . . . . . . . . . . . . . . . . . . . . . 60
3.3.4. Every 1500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Adjust the valve clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.3.5. Every 3000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Replace the ribbed V- belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.3.6. Every 6000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Replace the injection valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.3.7. Every 12000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Carry out a basic engine overhaul. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.3.8. Every 2 Years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Change the coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Maintenance Manual
4. Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.1. Lubricant recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.2. Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.2.1. Daily or once per shift (10 hours) . . . . . . . . . . . . . . . . . . . . . . . . 78
Check the transmission oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.2.2. Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Replace the transmission oil filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.2.3. Every 1000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Change the transmission oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.3.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.3.2. Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.3.3. Troubleshooting guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5. Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.1. Lubricant Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.2. Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.2.1. Daily or once per shift (10 hours) . . . . . . . . . . . . . . . . . . . . . . . . 91
Check the tyres visually. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.2.2. Weekly (50 hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Lubricate the propeller shaft greasing fittings. . . . . . . . . . . . . . . . . . . . . . . 93
Check tyre pressure and condition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Check the drive line bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.2.3. Every 125 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Check the axle differential oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.2.4. Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Check the wheel nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Check the axle planetary gear oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.2.5. Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Check the brake plate wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Change the axle differential oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.2.6. Every 1000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Change the axle planetary gear oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.2.7. As required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Air bleed the service brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Air bleed the safety/parking brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5.3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Maintenance Manual
7. Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
7.1. Lubricant Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
7.2. Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
7.2.1. Weekly (50 hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Lubricate the carrier greasing fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
7.2.2. Every 1000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Check the oscillation axle bushings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Check the frame joint bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Check the steering cylinder joint pin, pin locking and bearing. . . . . . . . . . . 133
1. SAFETY PRECAUTIONS
1.1. Service
1. When servicing or repairing the carrier, shut down the engine unless it is
required to be running for adjustment purposes.
2. Keep your head, hands, feet and loose clothing away from power-driven
parts.
3. Lock the frame joint by the safety bar when working near the frame joint.
Stop the engine before inserting and removing the safety bar.
4. Do not grab the steering wheel when mounting the carrier.
5. Ensure that all tyre and rim parts are undamaged and correctly assembled
before inflating the tyre.
6. Always inflate the tyres with the correctly designed inflation device. Do not
exceed the tyre manufacturer’s recommended maximum pressure.
7. Use caution when draining hot fluids from the carrier, splashing hot fluid
can cause serious burns.
8. Accumulated grease or oil on the carrier is a fire hazard. Remove debris
whenever a significant quantity of oil is spilled on the carrier.
9. Do not arc weld on the carrier without first disconnecting the alternator.
10. Before performing maintenance or repair work on any equipment, consult
the manufacturer’s instruction manual and follow the recommended proce-
dures.
11. Inspect equipment daily for signs of failure.
12. Perform all recommended checks.
13. Before you start cleaning the carrier with water, high-pressure washer,
steam jet or other washing methods cover all such openings, places and
components which may cause danger or break.
Do not use the high pressure washer to clean components such as:
• Service brake valve
• Electric motors, switch cabinets, electric components and boxes.
• Rubber parts.
14. Report all defects.
15. Use the proper tools for servicing.
16. Never attempt to clean, lubricate or adjust the carrier while it is in motion.
17. Always comply with your company’s regulations and practices for the safe
servicing of this carrier.
1.2. Hydraulics
2. OIL SAMPLES
Take an oil sample and check the oil quality.
Take oil samples and send part out for analysis. These oil samples should include a
simple, quick ”patch test” and a more complete lab analysis. A patch test considers
only oil color and the presence of particles visible with a low power microscope or
hand-held magnifying glass. The patch test gives an indication of the general condi-
tion of the oil. An interpretation of the color and the nature of the foreign material might
indicate pending component failure. A chart is available to aid in this interpretation.
Do not overlook the importance of an oil analysis as a regular part of every mainte-
nance program and the direction the results lead. A complete oil analysis confirms
information already found in addition to providing other data needed to establish the
total condition of the oil and machinery.
An analysis of the lubricants will supply you with a multitude of data and findings and
it is an important source of information in proactive servicing. Early detection of
damage cannot be done without a lubricant analysis. This will not prevent break-
downs, but is an accurate guide to the actual condition of the carrier and provide infor-
mation that can be used for decisions what action is to be taken.
3. ENGINE
Danger!
Note!
The filters must always meet the requirements of the manufacturer. This can be
ensured by using original spare parts.
Caution!
Additional venting of the fuel system by a 5-minute trial run at idle speed or on low load
is absolutely essential.
Because of the high production accuracy of the system, utmost cleanliness must be
observed.
The fuel system must be tight and closed.
Make a visual inspection for leaks and damage to the system.
Clean and dry the engine and the engine compartment thoroughly before starting
work.
Cover parts of the engine compartment from which dirt could be loosened with a new,
clean foil.
Work on the fuel system may only be carried out in an absolutely clean environment.
Air contamination such as dirt, dust, moisture etc. must be avoided.
Danger!
Danger!
Note!
Pay attention to utmost cleanliness when working on the lubricating oil system.
Carefully clean the area around the affected parts.
Blow damp areas dry with compressed air.
Observe the safety regulations and national specifications for handling oils.
Dispose of leaking lubricating oil and filter elements properly.
Do not allow used oil to seep into floor.
Perform a trial run after all work.
Pay attention to tightness and oil pressure and then check the engine oil level.
For fuels with a sulfur content higher than 1 % ask your responsible service represent-
ative.
Danger!
Danger!
Caution!
Danger!
Caution!
Pay attention to utmost cleanliness when working on the intake system, close intake
openings if necessary.
Dispose of old filter elements properly.
3.2. General
Modern diesel engines place very high demands on the lube oil used. Engine perfor-
mances are increasing constantly, leading to an increased thermal load on the oil and
increased exposure of the oil to contamination due to reduced oil consumption and
longer oil change intervals. For these reasons, the requirements and recommenda-
tions described in this instruction manual should be followed in order to maximize the
life of the engine.
Lube oils always consist of a basic oil and an additive package. The most important
tasks of a lube oil (e.g. wear protection, corrosion protection, neutralization of acids
from combustion products, prevention of coke and soot deposits on engine parts) are
assumed by the additives. The properties of the basic oil are also decisive for the
quality of the product, e.g., with regard to thermal load.
In principle, all engine oils can be mixed. However, mixing of engine oils should be
avoided because the worst properties of the mixture are always dominant.
The lube oil quality has a considerable influence on the life, performance and thus also
on the cost-effectiveness of the engine. The better the lube oil quality, the better these
properties.
The lube oil viscosity describes the flow behaviour of the lube oil relative to its temper-
ature. Lube oil viscosity has no effect on the lube oil quality.
Synthetic lube oils are increasing in use, and do offer some advantages. These oils
have better temperature and oxidation stability as well as relatively low cold viscosity.
Some process factors that determine the lube oil change intervals are not directly
dependent on the quality of the lube oil (such as soot and other contamination). For
this reason, when using synthetic lube oils the lube oil change interval given in the
lubrication schedule may not be changed.
Biodegradable lube oils may be used in DEUTZ engines if they meet the requirements
of this operating manual.
Deutz Others
Note!
3.2.3. Viscosity
The ambient temperature at the installation site or area of application of the engine is
decisive for the choice of the right viscosity class. Too high a viscosity can lead to
starting difficulties, too low a viscosity can endanger the lubrication effect and cause
high lube oil consumption. At ambient temperatures below -40 °C the lube oil must be
pre-heated (e.g. by storing the carrier in a heated shed). The viscosity is classified
according to SAE. Multipurpose oils should be used as standard. Single purpose oils
can also be used in closed, heated rooms at temperatures >5 °C. The specified lube
oil qualities must, naturally, also be single purpose oils.
We recommend the following common viscosity classes depending on the ambient
temperature.
3.2.4. Fuel
Permissible fuels
The following fuel specifications are permitted:
– Diesel fuels according to DIN EN 590
– US diesel fuel according to ASTM D 975 Grade No. 1-D and 2-D
– Japanese diesel fuel JIS K 2204 Grade 1 Fuel and Grade 2 Fuel with lubricat-
ing properties according to diesel fuel EN590 (HFFR max. 460 micrometer
according to EN ISO 12156)
Use commercially available diesel fuels with a sulphur content below 0.5 %. If the
sulphur content is higher, the lube oil change intervals must be reduced.
If other fuels are used which do not meet the requirements of this manual, the
warranty will be voided.
The certification measurements to satisfy the legal emission limits are performed with
the test fuels defined by law. These correspond to the diesel fuels according to EN
590 and ASTM D 975 described in this operating manual. No emission values are
guaranteed for the other fuels described in this manual.
Caution!
Only carry out mixing in the tank! First pour in the neces-
sary amount of kerosine, then the diesel fuel. Addition of
normal and super petrol is not permitted.
At low ambient temperatures fuel discharges can lead to blockages in the fuel system
and cause operating faults. Begin using winter fuel, as available from standard petrol
stations, in outside temperatures below 0 °C (to -20 °C) in good time before the cold
season begins.
– Kerosine should be added at temperatures below -20 °C. The mixing ratios
required are as per the diagram.
– Special diesel fuels can be used for arctic climates to -44 °C.
If it is necessary to use summer diesel fuel below 0 °C, kerosine can also be added
up to 30 % as per the diagram.
Usually a sufficient cold resistance can be achieved by adding a flow improver. For
questions regarding this please contact your DEUTZ partner.
3.2.5. Coolant
General
Caution!
Water quality
The correct water quality is important for conditioning the coolant. Clear, clean water
with the following properties must be used:
Warning!
Note!
This cooling system protection agent is free from nitrites, amines and phosphates and
adapted to the materials in our engines. Order from your DEUTZ partner.
If the DEUTZ cooling system protection agent is not available, please contact your
DEUTZ partner.
The cooling system must be monitored regularly. This includes checking the concen-
tration of the cooling system preservative, as well as inspecting the coolant level.
The inspection of the concentration of cooling system preservative can be carried out
with standard testing devices (e.g. refractometer).
At temperatures below -35 °C, please consult your responsible DEUTZ Service. It is
possible to use other cooling system preservatives (e.g. chemical corrosion preserv-
atives) in exceptional cases.
3.3. Procedures
Every 2 years
26. Change the coolant
Danger!
Note!
ITEM 2
Check the engine oil level.
Caution!
Danger!
Fig. 3. Dipstick
ITEM 3
Check the coolant level.
Danger!
ITEM 4
Check the engine for leaks.
Carry out a visual inspection. Inspect the engine for loose fasteners, oil leaks and
general wear and damage. This inspection should be performed in conjunction with
each one of the maintenance procedures rather than treated as a separate procedure.
Each time a maintenance procedure is carried out, spend a couple of minutes to check
for damaged or deteriorating hoses and electrical wiring. Check also for loose hard-
ware, fluid leaks and structural damage.
Preventive maintenance of this type often enables an operator to spot potential
trouble and thereby prevent many hours of engine downtime.
ITEM 5
Check the fuel pre-filter
1. Position a collecting receptacle beneath the filter.
2. Drain the water out.
3. Bleed the fuel system.
Fig. 6. Filter
1. Drain plug
ITEM 6
Check the fuel level.
1. Check the engine fuel level.
2. Clean the area around the fuel filler cap before removing it.
3. Remove the fuel filler cap.
4. Fill the reservoir with the proper grade diesel fuel each day.
– At the end of the work shift.
– To prevent condensation in the reservoir during shutdown.
Note!
ITEM 8
Change the engine oil.
Danger!
ITEM 9
Check the ribbed V-belt.
Danger!
Only carry out work on the belt drive when the engine is
not running!
Only test / tighten / replace ribbed V-belt when the engine is not running.
If necessary, remount ribbed V-belt guard.
Re -tension ribbed V-belt after it has run for 15 minutes.
1. Visually inspect entire V-belt for damage.
2. Replace damaged V-belts.
3. Remount protective devices if necessary.
4. Pay attention to correct fit of new belts and check the tension after running for 15
minutes.
3
2
1. Indicator arm
2. V -belt
3. Guide
4. Pad
5. Scale
ITEM 10
Check the coolant additive concentration.
1. Ensure that the carrier is on level ground.
2. Operate the engine until it is warm enough to open the filler cap. Continue to run
the engine until the coolant has circulated the cooling system.
3. Stop the engine.
4. Allow the engine to cool until the temperature of the coolant is below 60 °C.
5. Remove the filler cap of the cooling system.
Danger!
6. Use a special coolant hydrometer that will check the temperature and the spe-
cific gravity of the coolant, follow the manufacturer’s instructions.
7. Adjust the strength of the mixture as necessary.
Note!
ITEM 11
Check the battery and clean battery terminals.
A.) Safety precautions
B.) Checking the acid level
C.) Checking the voltage
D.) Removing the battery
E.) Charging the battery
F.) Installing the battery
G.) Checking acid density
Note!
Danger!
Danger of explosion!
• Explosive gases released by battery!
• Fire, sparks, smoking and naked lights are prohibited!
• Danger of acid burns!
• Wear protective gloves and glasses!
• Avoid contact with skin and clothing.
• Danger of short circuit!
• Do not place tools on the battery!
Caution!
Electrolyte density
ITEM 12
Clean catalytic exhaust gas purifier.
Caution!
Caution!
Caution!
Danger!
Note!
ITEM 14
Replace the fuel pre-filter insert.
1. Position a fuel collecting vessel beneath filter.
2. Loosen the drain plug and drain the water/fuel completely.
3. Unscrew the filter cartridge together with water collecting vessel in anti-clock-
wise direction and remove.
4. Loosen water collecting vessel from old filter cartridge in anti-clockwise direction
and remove.
5. Empty remaining fuel into the fuel collecting vessel and clean water collecting
vessel.
– Dispose of collected fuel and old filter cartridge properly.
6. Screw water collecting vessel onto the new filter cartridge in clockwise direction.
7. Clean any dirt from the sealing surface of the new filter cartridge and the reverse
side of the filter head.
8. Fill the filter with clean fuel.
9. Wet the sealing surfaces of the filter cartridge slightly with fuel and screw back
onto the filter head in clockwise direction (17-18 Nm).
2
4
1. Drain plug
2. FIlter cartridge
3. Mechanical pump
4. Electric pump switch
2. Pump fuel with hand pump until fuel without air bubbles starts to come out of the
filter.
3. Close the air bleeding screws.
4. Continue pumping until pressure raises up in fuel line.
5. Carry on pumping for 2 more minutes.
6. Start the engine and run for about 5 minutes at idling or low load.
– Check the fuel system for leaks
Electric pump
1. Actuate the fuel pump for 2 minutes.
2. Start the engine and run for about 5 minutes at idling or low load.
– Check the fuel system for leaks.
Note!
ITEM 15
Clean the radiator.
Caution!
For all cleaning work, make sure that no parts are dam-
aged (e.g. bent cooler mesh).
Cover electrical/electronic parts and connections to clean the engine (e.g. control
units, generator, solenoid valves etc.)
Do not aim water/steam directly at electrical parts.
Run the engine warm afterwards.
Danger!
General
The following causes of soiling require cleaning of the engine:
– High dust content in the air.
– Debris in and around the engine.
– Coolant leakage
– Lubricating oil leakage
– Fuel leakage
Due to differences in application conditions, cleaning depends on the degree of
soiling.
1. Engine intercooler
2. Engine coolant
3. Transmission oil cooler
ITEM 16
Replace the intake air cleaner filter.
1. Release the filter seal gently.
The filter fits tightly over the outlet tube, creating the critical seal on the inside diameter
of the filter end cap.
– The filter should be removed gently to reduce the amount of dust dislodged.
– There will be some initial resistance, similar to breaking the seal on a jar.
– Gently twist the end of the filter to disengage the seal.
2. Avoid dislodging dust from the filter.
Gently pull the filter off the outlet and out of the housIng, straight and not at an angle.
– Take care not to remove the safety element with the main element.
– Avoid knocking the element against the housing.
– Remove and change the safety element at every third replacement of the main
element.
ITEM 17
Check the glow plugs.
In low temperatures, factors such as cold intake air and cold cylinder walls hinder the
attainment of the necessary starting temperature. In these situations, glow plugs func-
tion as an additional heat source to bring the intake air up to the temperature neces-
sary to initiate the combustion cycle.
It is recommended to replace all the glow plugs at the same time if one glow plug fails.
The following signs are the clearest indicators that the glow plugs should be replaced.
If any of these conditions exist, be sure to check the carrier’s glow plugs and if neces-
sary, replace them with a new set of glow plugs.
– Carrier won’t start.
– Carrier starts only after excessive cranking. Excessive cranking can cause the
engine oil to be diluted with fuel, which could adversely affect the life of the
engine.
– Carrier idles roughly during initial start-up
– Excessive exhaust emissions during initial set-up.
ITEM 18
Check the engine monitoring system.
The instruments and controls to monitor and operate all of the systems are located in
the operator’s area. A brief description of each is described in the Operator Manual.
Gauges provide indications of engine performance. Ensure that the gauges are in
good working order. Determine the normal operating range by observing the gauges
over a period of time.
Noticeable changes in gauge readings indicate potential gauge or engine problems.
Problems may also be indicated by gauge readings that change even if the readings
are within specifications. Determine and correct the cause of any significant change
in the readings.
If any of the readings do not read within the normal operating ranges, stop the engine
and investigate the problem.
Once all the gauges have been checked and found to be reading within the normal
operating ranges, the carrier is ready to operate.
The engine will reach normal operating values after a few minutes operation at
moderate load and varying speed.
• Engine oil pressure . . . . . . . . . . . . . . . . . . min. 0.8 bar
• Engine coolant temperature . . . . . . . . . . . max. 100 °C
• Transmission feed pressure . . . . . . . . . . . min. 16.5 bar
• Transmission oil temperature . . . . . . . . . . max. 90 °C
• Voltmeter. . . . . . . . . . . . . . . . . . . . . . . . . . 24...28 V
ITEM 19
Check the wear limit of the ribbed V-belt.
The wear limit of the ribbed V-belt is checked as follows:
1. Check the distance between the projection of the moving tension arm and the
contact with the fixed tensioner housing.
2. If the distance ”a” is less than 3 mm, the ribbed V-belt should be replaced.
ITEM 20
Check the engine suspension.
1. Visually inspect the engine suspensions for damage.
2. Replace damaged suspensions.
ITEM 21
Check the fastenings and hose connections.
The connections of the intake manifolds to the cylinder heads should be checked for
tightness, and retightened where necessary. The connections of the fuel piping should
be checked also.
1 4
3 2
4 1
2 3
1 6
5 2
3 4
6 1
2 5
4 3
Note!
2 1
4
1. Tension roller
2. Ribbed V-belt
3. Ratchet
4. Locking pin
Danger!
Do not drain the coolant while the engine is still hot and
the system is under pressure – danger of hazardous
coolant discharge.
1. Ensure that the carrier is on level ground.
2. Remove the filler cap of the radiator.
3. Remove the drain plug from the side of the radiator in order to drain the radiator.
If the radiator does not have a drain plug, disconnect the hose at the side of the
radiator. Drain the coolant.
4. If necessary, flush the system with clean water.
5. Fit the drain plug or connect the radiator hose.
6. Fill up with coolant.
7. Fit the radiator filler cap.
8. The cooling system is bled automatically after filling.
9. After the first engine run, check coolant level on cold engine.
3.4. Troubleshooting
Faults are often the result of incorrect engine operation or maintenance.
For all faults, check whether all operation and maintenance instructions have been
followed.
If you cannot identify the cause of the fault or fix it yourself, contact your authorised
service representative.
Danger!
Note!
4. POWERSHIFT TRANSMISSION
Requirements:
Transmission lubricant must be qualified by one of the following specifications in order
of preference.
– Caterpillar TO-4
– John Deere J20 C,D
– MIL-PRF-2104G
– Dexron® IID or Dexron III quality level*
GL-5 and engine oils are not approved. The lubricant must be designed for transmis-
sions.
Multi-viscosity lubricants are approved.
Preferred oil viscosity:
– Select a lubricant with a viscosity grade that fully covers the prevailed ambient
temperature on the Oil Application Chart.
For example
Ambient temperature from 14 to 68ºF / -10 to 20ºC.
Select 10W30.
– When multiple viscosity grades are suitable, select the grade where the ambi-
ent temperature is closest to the middle of the viscosity range.
For example
Ambient temperature from 68ºF / 20ºC.
SAE30 is preferred over SAE40 or SAE50.
4.2. Procedures
Note!
Note!
4.3. Troubleshooting
4.3.1. General
The following information serves as an aid in isolating and determining the specific
cause of a possible transmission malfunction.
When troubleshooting a “transmission” problem, it should be kept in mind that the
transmission is only the central unit of a group of related powertrain components.
Proper operation of the transmission depends on the condition and correct functioning
of all components in this group. Therefore, to properly diagnose a suspected trans-
mission problem, the transmission fluid, charging pump, torque converter, transmis-
sion assembly, oil cooler, filter, connecting lines, and controls, and also the engine,
must be considered as a complete system.
By analysing the transmission operation principles together with the information
presented in this section, it should be possible to identify and correct any malfunction
which may occur in the system.
Power shift torque converter transmission troubles fall into three general categories:
1. Mechanical problems.
2. Hydraulic problems.
3. Electrical problems.
In addition to mechanical and electrical components, all of which must be in proper
condition and functioning correctly, the correct functioning of the hydraulic circuit is
also vital. Transmission fluid is the “life blood” of the transmission. It must be supplied
in an adequate quantity and delivered to the system at the correct pressures to ensure
converter operation, to engage and hold the clutches from slipping, and to cool and
lubricate the working components.
4.3.2. Procedures
Stall Test
A stall test to identify transmission, converter, or engine problems. Use the following
procedure:
1. Position the carrier against a solid barrier, such as a wall, and/or apply the park-
ing brake and block the wheels.
2. Put the gear selector in forward or reverse, as applicable.
3. Select the highest speed. With the engine running, slowly increase the engine
speed to approximately one-half throttle and hold until the transmission (con-
verter outlet) oil temperature reaches the operating range.
Caution!
Hydraulic checks
Also, before checking the transmission clutches, torque converter, charging pump,
and hydraulic circuit for pressure and oil flow rate, it is important to make the following
transmission fluid check:
1. Check the oil level in the transmission. The transmission fluid must be at the cor-
rect, full level.
2. All clutches and the converter and its fluid circuit lines must be fully filled at all
times.
Note!
Caution!
Overheating
– Worn oil sealing rings.
• Remove, disassemble, and rebuild converter assembly.
– Worn charging pump.
• Replace charging pump.
– Low oil level.
• Fill to proper level.
– Dirty oil cooler.
• Clean cooler.
– Restriction in cooler lines.
• Change cooler lines.
Noisy converter
– Worn charging pump.
• Replace charging pump.
– Worn or damaged bearings.
• Complete disassembly will be necessary to determine which bearing is
faulty.
Lack of power
– Low engine RPM at converter stall speed.
• Tune engine check governor.
– See ”Overheating” and perform the same checks.
• Make corrections as explained in ”Overheating”.
5. MECHANICAL TRANSMISSION
Axle lubricant must be qualified by one of the following specifications in order of pref-
erence*:
– API GL-5/MT-1/
– SAE J2360
– Axles with wet disc brakes or limited-slip (LS) differentials must have “LS”
additives
LS = Additive
– Limited Slip
– Additive for oil-bath brakes, for units presenting hypoid crown wheel and pin-
ion and /or self-locking differential gear.
API Category MT-1
– Designates lubricants intended for non-synchronized manual transmissions
used in heavy-duty trucks.
– Lubricants meeting API MT-1 provide protection against the combination of
thermal degradation, component wear, and oil seal deterioration which is
not provided by lubricants meeting only the requirements of API GL-4 and
API GL-5.
Extreme pressure gear lubricant is recommended for use in all drive-steer and rigid
drive axles except where explicitly stated differently by Dana Off-Highway Application
Engineering.
Preferred oil viscosity – Select highest oil viscosity compatible with the prevailing
ambient temperature on the Oil Application Chart.
Steep grade applications – Grades of 15% or more for extended distances of 0.3 miles
[0.5km] must consult the Dana Off-Highway Application Engineering.
Friction modifiers for Posi-torq (limited slip) differentials can be used to minimize oper-
ational noise or in liquid-cooled brakes to reduce brake noise. 2% to 5% by
weight is recommended.
Danger!
After the additives are placed into the oil, verify service
brake and safety/parking brake performance after a few
hours of work. Also verify brake noise has been elimi-
nated. If brake performance is insufficient or noise is still
occurring, flush with washing oil, refill with new oil and
check again.
It is important to consult the applicable axle Service Manual as it may have unique
lubrication requirements not outlined in this manual.
Any deviation from the above requirements must have written approval from the
Dana Off-Highway Application Engineering.
*Axles with Hypoid Gears must use API GL5 and no Universal Tractor Transmission
Oil [UTTO]
Axles with Non-Hypoid Gears can use API GL4 or API GL5
Axles with USA serial numbers must use gear oil (no UTTO)
Axles with wet disc brakes or limited-slip (LS) differentials must have “LS” additives (If
UTTO is being used, the “LS” additive is not necessary).
5.2. Procedures
As required
11. Air bleed the service brakes.
12. Air bleed the safety/parking brakes.
Note!
ITEM 3
Check tyre pressure and condition.
Tyres use high pressures (8 - 10 bar). Make sure that there is clearly higher pressure
in the filling line (12 - 15 bar) than required in tyres for appropriate inflation pressures.
Air pressure gauge shall be calibrated at least once a year. The gauge can be
damaged and show wrong values, if:
– the gauge drops to ground.
– exceeding the upper limit of the gauge.
Take off the gauge and check again the pressure when the needed inflation pressure
has been reached.
Interval for inflation pressure measurements is at least 2 weeks. Normal drop is 0.3 -
0.5 bars during service period. Cross-ply tyres will grow a bit after first filling and use,
so the first drop is greater than next to follow.
Note!
Danger!
ITEM 4
Check the drive line bolts.
The drive line connects the transmission and differential through universal joints,
turning the axles which turn the wheels. It’s important to have the universal joints and
flanges inspected to ensure there are no cracks that can damage the carrier.
Check all drive line and flange bolts to ensure:
1. No bolts are missing.
2. All bolts are tight
3. Use a torque wrench to torque the bolts to the recommended specification.
– Refer to section “Tightening Torques”
Warning!
ITEM 7
Check the axle planetary gear oil level.
1. Ensure that the carrier is parked on level ground when performing the oil check.
2. Check the oil immediately after driving when the oil is warm.
3. Allow a few minutes for the oil level to settle.
4. Turn the wheel hubs until the word ”OIL LEVEL” can be read in the horizontal
position.
5. Remove the oil plug and fill until the correct level is reached as shown by the
”OIL LEVEL” line on the planet carrier.
6. Reinstall the oil plugs when the filling is completed.
Danger!
ITEM 9
Change the axle differential oil.
1. Ensure that the carrier is parked on level ground when performing the oil
change.
2. Change the oil immediately after driving when the oil is warm and flows easily.
3. Clean the area around the filler plugs, and remove them.
4. Remove the axle differential drain plugs, and drain the oil into a container.
5. When the differentials are empty, reinstall the drain plugs.
6. Fill the differential with fresh oil through the filler plug openings until the level in
each axle reaches the bottom of the filler plug opening.
7. Use a recommended oil type.
8. Reinstall the filler plugs.
1. Ensure that the carrier is parked on level ground when performing the oil
change.
2. Change the oil immediately after driving when the oil is warm and flows easily.
3. Turn each wheel so that the oil plugs are positioned downwards.
4. Drain the oils.
5. Turn the wheel again until the word ”OIL LEVEL” on the planet carrier is in the
horizontal position.
6. Refill with fresh oil of the correct grade.
7. Fill until the correct level is indicated by the ”OIL LEVEL” line on the planet car-
rier.
8. Reinstall the oil plugs when the filling is completed.
5.2.7. As required
ITEM 11
Air bleed the service brakes.
The brakes must be bled if air has entered the system and the braking effect has
diminished.
Make sure the carrier is levelled, and that the wheels are blocked against movement
before venting.
1. Push a clear plastic hose over the bleeding screw.
– To catch the oil and to help detect air bubbles.
2. Start up the diesel engine.
3. Loosen the bleeding screws by about a 1/2 turn.
4. Press the foot brake to the floor in one movement, do not pump.
5. Close the bleeding screws as soon as the oil emerges fee of air bubbles.
Danger!
ITEM 12
Air bleed the safety/parking brakes.
For trouble-free operation of the safety/parking brake, it is important that the hydraulic
system is entirely free of air. Air can enter the system, for example, in connection with
component replacements or repairs and as a result of possible leaks. The brake is
released by hydraulic pressure. If the system contains air, this causes the pressure to
decrease and the brake to not release properly, or to engage after a delay. For this
reason, the brake circuit must be bled after each repair operation or whenever
malfunctions occur.
Danger!
5.3. Troubleshooting
Malfunctions are often due to improper operation or maintenance of the axle.
In the event of a malfunction, always check whether the operating instructions have
been strictly followed.
Insufficient braking.
– Brake discs worn out.
• Inspect disc thickness and replace if necessary.
6. HYDRAULIC SYSTEM
Temperature:
tF = Fahrenheit
tC = Celsius
tF = 9/5 tC + 32
tC = 5/9 (tF - 32)
Ambient Classification
Carrier/Capacity
temperature ISO 3448
M8
M7
6.3. Procedures
As required
7. Check and adjust the steering hydraulic pressure.
8. Check and adjust the charging pressure.
9. Check the service brake pressure.
10. Check and adjust the safety/parking brake pressure.
Note!
1
2
ITEM 2
Check there are no leaking or hanging hoses.
1. Visually inspect the exterior of the carrier for loose, leaking, hanging, or broken
hoses.
– This inspection should be performed in conjunction with each one of the main-
tenance procedures rather than treated as a separate procedure.
2. Check lines, tubes and hoses carefully.
– Do not use your bare hand to check for leaks.
– Use a board or cardboard to check for leaks.
– Leaks can cause fires.
– Tighten all connections to the recommended torque.
3. Each time a maintenance procedure is carried out, spend a couple of minutes to
check for damaged or deteriorating hoses and electrical wiring.
– Check also for loose hardware and structural damage.
– Preventive maintenance of this type often enables an operator to spot poten-
tial trouble and thereby prevent many hours of engine downtime.
4. Repair any lines that are loose or damaged.
– Do not install any lines that are bent or damaged.
5. Inspect the carrier for loose fasteners, oil leaks and general wear and damage.
6. Make sure that all clamps, guards, and heat shields are installed correctly.
– During engine operation, this will help to prevent vibration, rubbing against
other parts, and excessive heat.
7. Check for loose electrical wires and check all wires for wear.
Warning!
ITEM 4
Replace the hydraulic return fluid filter.
1. Unscrew the filter assembly lid.
2. Slowly remove the element assembly from the hydraulic fluid tank.
3. Remove the filter element from the hydraulic fluid return tube.
– No tools are needed.
– The element is installed hand-tight only.
4. Replace the old filter element with a new one.
5. Reinstall in reverse order.
Note!
1. Lid
2. Filer element
3
4
1. Cover
2. Filer element
3. Setscrews
4. Filler sieve
ITEM 5
Change the hydraulic fluid.
Note!
Warning!
Check
Push
Adjust
ITEM 8
Check and adjust the charging pressure.
Conditions
– Hydraulic fluid is at normal working temperature.
– Pressure gauge connected to the pressure check point M7.
A) Check the pressure.
1. Start the engine.
2. Check the pressure gauge.
– The pressure should rise rapidly to max. 150 bar.
3. Adjust the pressure if it is too low or high.
B) Adjust the pressure.
Adjust the pressure by turning the adjustment screw.
– Adjustment screw at the charging valve.
– Pressure differs from the given value.
– Turn the adjustment screw in the desired direction.
Adjust
M7
ITEM 9
Check the service brake pressure.
Conditions
– Hydraulic fluid is at normal working temperature.
– Pressure gauges connected to the pressure check points
A) Check the pressure.
1. Start the engine.
2. Check the pressure gauge.
3. Press the service brake pedal down fully.
– The pressure should be 80 bar max.
ITEM 10
Check and adjust the safety/parking brake pressure.
Conditions
– Hydraulic fluid is at normal working temperature.
– Pressure gauge connected to the pressure check point M1.
A) Check the reducing valve pressure.
1. Start the engine.
2. Check the pressure gauge.
– The pressure should be 21....25 bar.
3. Adjust the pressure if it is too low or high.
1
4
2
1. Adjustment screw
2. Jam nut
3. Check point M1
4. Check point M2
6.4. Troubleshooting
Trouble
Location
– Probable cause
• Remedy
6.4.1. Steering
7. FRAME
7.2. Procedures
Note!
Warning!
Warning!
ITEM 3
Check the frame joint bearings.
Danger!
2 4
3
1
6
ITEM 4
Check the steering cylinder joint pin, pin locking and bearing.
The following points regarding inspections are:
– proper installation
– excessive wear
– cracks or distortion appear
– bruises or corrosion damages appear
– permanent deformations
– bad wear
– there should not be any visible fractures or cracks in the welding seams.
Nuts
Bolts
8. TIGHTENING TORQUES
8.1. Screws
Tightening torques Nm
Tightening torques Nm
Bolt size Class 8.8 Class 8.8 Class 10.9 Class 12.9
Galvanized Galvanized Non-plated Non-plated
or zinc plated or zinc plated screws screws
Oiled Dry Oiled Oiled
M3 1,3 1,3 1,8 2
M4 3,1 3,1 4,1 4,6
M5 6 6 8,1 9,1
M6 10,5 10,5 14,1 15,8
M8 25 25 34 38
M10 49 50 67 75
M12 85 85 115 128
M14 135 136 183 204
M16 205 208 279 311
M18 288 291 391 437
M20 402 408 547 610
M22 548 557 745 831
M24 693 703 942 1052
M27 1010 1028 1375 1533
M30 1379 1401 1875 2091
M33 1855 1889 2526 2815
M36 2394 2436 3259 3633
M39 3087 3145 4203 4683
M42 3820 3890 5202 5799
NOTES
Code: . . . . . . . . . . . . . . . . . . . . 100087044
This manual is a guide to the proper and safe operation, maintenance, minor repair and
adjustment of the MEWP. The information contained in this manual is current for this unit. In
the interest of continually improving its products, Normet reserves the right to update or
modify information contained in this manual. Illustrations shown in this manual were
produced during the development stages and may differ from the actual product.
Danger!
Warning!
Risk of injury.
Caution!
Note!
CONTENTS
1. Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2. Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3. Work platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.4. Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.5. In Case Of Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.6. Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5. Operator's controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.1. Work platform controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2. Lower controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.3. Terminal box TB3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.4. Work platform terminal box TB4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.5. Alarm unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.6. Safety canopy locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.1. Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.2. Use of the MEWP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.3. Daily checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.4. Operation definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.5. Safety harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.6. Extreme conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.2. Greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8.3. Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.4. Maintenance items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.4.1. Daily or once in shift (10 hours) . . . . . . . . . . . . . . . . . . . . . . . . . 44
Visually check the hydraulic hoses, couplings and the structure. . . . . . . . . 44
Check the tilting cylinder pin and work platform joint pin. . . . . . . . . . . . . . . 45
Keep the working area of the work platform clean. . . . . . . . . . . . . . . . . . . . 45
8.4.2. Weekly (50 hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Lubricate the grease fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Check the boom mounting attachment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Inspect the hydraulic cylinder, cylinder joint pin, pin locking and bearing. . 47
8.4.3. Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Check the boom extension clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.4.4. Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Check the hydraulic pressures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Inspect the tilt cylinder fixing lug welding. . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Inspect the condition of the boom beams. . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Inspect the function of the load-lowering valve. . . . . . . . . . . . . . . . . . . . . . 54
Inspect the boom mounting bolt connections. . . . . . . . . . . . . . . . . . . . . . . . 56
8.4.5. Every 2000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Change the tilting cylinder joint pin and bearing. . . . . . . . . . . . . . . . . . . . . . 57
8.4.6. Every 6000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Change the tilting cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
8.4.7. When necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Adjust the boom lowering speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Adjust the boom slewing speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Adjust the load sensing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
9. Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.1. Speed values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.2. Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9.2.1. General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9.2.2. Daily checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
NBB 3XS Operator’s Manual
1. FOREWORD
These instructions are intended for both the MEWP owner and persons who operate,
service and repair the MEWP.
These instructions provided by the manufacturer must be kept in a safe, easily acces-
sible place at the work site.
All operators are obliged to familiarize themselves with the safety and operating
nstructions of the MEWP and apply them in practice.
The MEWP is fully compliant with current technical standards and safety regulations.
Despite this, faulty operation, service and repair may cause danger.
The precondition for all operation is that the operator is familiar with the operating
instructions and follows them. It is therefore recommended that the instructions are
read through several times and that the operator familiarises him/herself thoroughly
with the MEWP before taking it into use.
In addition to the operating instructions, the operator must follow the regulations of the
local labour protection authorities as well as the laws and statutes of the country in
which the MEWP is in use.
Using the MEWP for any other task than that for which it has been designed, or
exceeding its operating capacity is considered inappropriate usage. The manufac-
turer/supplier does not assume liability for damage resulting from such usage.
2. INTRODUCTION
2.1. General
The MEWP is intended for mining and tunnelling lifting purposes including, e.g.,
manual charging and scaling and other mounting tasks performed at height.
The MEWP can be fitted as an accessory onto a carrier that is specially designed for
MEWP use.
The MEWP is a so-called telescopic construction boom, consisting of a basic boom
and one hydraulically operated extension telescope in addition.
The MEWP also contains a work platform which automatically remains parallel during
raising and lowering of the MEWP. This is performed hydraulically with assistance of
the stabilization cylinder and work platform tilting cylinder.
2.2. Boom
The MEWP is a so-called telescopic construction boom, consisting of a basic boom
and a hydraulically operated extension.
The extension cylinder incorporates pressure-opened non-return valves that prevent
uncontrolled boom movements in the event of possible hose breakage.
Lifting of the boom is affected hydraulically by means of a cylinder. The boom lift
cylinder incorporates a load-lowering valve for both directions of motion. The valves
ensure that the boom does not drop in an uncontrolled maner in the event of possible
hose breakage. Additionally, they protect the boom from overloading in either direc-
tion. The basket tilt cylinder is also fitted with a similar load-lowering valve.
3. SAFETY INSTRUCTIONS
3.1. General
1. Read and understand all instructions before operating.
2. Make sure that personnel are familiar with the contents of this manual.
3. Ensure the safety of all personnel.
4. Use the MEWP correctly and appropriately.
5. It is forbidden to operate a faulty MEWP.
6. All safety and warning plates on the MEWP must be legible and intact.
7. Personal safety equipment must be worn inside the entire operating area of the
MEWP.
8. Pressure hoses must never be bent when while the pump is in operation.
– Obstruction caused by hose bending increases the risk of accident.
9. Connect different circuits, such as pressure and water lines, carefully and safe-
guard them as necessary.
10. The operator must always have an unobstructed overview of the working area.
– If this is not possible, an assistant must be appointed.
11. Stop the MEWP movement immediately if any risk of causing a safety hazard is
identified or suspected.
12. Always protect the MEWP against unauthorized use and unintentional operation
when left unmanned.
13. It is prohibited to increase the working height of the MEWP by using additional
equipment, such as ladders.
14. It is prohibited to increase wind load of the work platform, e.g. by attaching sign-
boards to the railings.
15. Never exceed maximum inclination values.
3.2. Operation
1. Only use the MEWP for the purpose informed by the manufacturer.
2. While operating the MEWP always follow the operating instructions, safety regu-
lations and warning plates and pay attention to generally accepted regulations to
prevent damage.
3. Safety measures and precautions before lifting the MEWP:
– Turn the gear selector to the neutral position.
– Engage the safety/parking brake.
– Lower the support legs (option) and ensure that the MEWP is positioned in
accordance with the permitted inclination values.
– Ensure that the support legs (option) are lowered onto firm ground.
– The carrier must be positioned straight and level.
– Lower the work platform as low as possible in order to enter the platform.
• Do not enter the work platform by climbing the MEWP.
– Close the work platform gate carefully, and make sure it is thoroughly locked.
– Make sure there are no obstacles in the working area.
– Exercise special caution when working in tight places or close proximity to
power cables, pipelines etc.
– Do not swing the MEWP before it is clear of the ground.
4. Make sure that everybody at the working place knows where emergency stop
switch is.
– Daily check function of the emergency stop switch.
5. Use the emergency stop button to quickly stop the motion of the MEWP.
– Brings all hydraulic operations to a halt.
– After being used, the button must be returned to its original position.
6. Unauthorized persons must be prevented from entering the working area.
7. Being under the raised MEWP prohibited.
8. Do not exceed the maximum load permitted.
9. Clean the work platform daily.
10. Move the MEWP to the transport position when driving the carrier.
– Before moving the carrier, make sure that the support legs (option) are fully
raised.
11. When in operation, the position of the MEWP must be in accordance with the
inclination values given.
– longitudinal 3°
– lateral 3°
12. The work platform must be free of load and personnel while the carrier is being
driven.
13. The MEWP is equipped with various safety equipment.
– These must not be changed or removed.
14. The work platform must not be used for transporting materials.
– The MEWP must not be used as a lifting device.
– When lifting personnel however, tools and equipment can also be lifted in the
work platform.
– It is forbidden to lift materials that extend beyond the edges of the work plat-
form.
15. Do not direct water- or steam jets towards electric cables.
16. After using the MEWP, lower the MEWP as low as possible.
17. Make sure that regular safety tests and corresponding inspections are carried
out.
18. Operation and use of a faulty or damaged MEWP is forbidden.
19. Constantly keep an eye on
– mounting bolts
– balance of the carrier
– oil leakages
– function of controls
3.3. Maintenance
1. Only qualified and specially trained persons are allowed to use, service or repair
the MEWP.
2. Service the MEWP regularly at the prescribed intervals, and observe all sched-
uled safety inspections.
3. Support the boom correctly or use a hoist when carrying out the service.
– Turn off the engine and the powerpack.
• Engine running only for adjustment purposes.
– Empty the work platform.
4. Do not repair or change the structures without the manufacturer's permission.
Structural changes may affect the MEWP durability.
5. Clean all explosive material from the work platform before the repair work.
6. Lubricate the bearings regularly.
7. Replace clogged or damaged grease nipples.
8. Pay special attention to the condition of the entire MEWP.
– The tightness of the bolt joints.
– The condition and tightness of the hydraulic hoses and connectors.
– The locking of the joint pins.
9. Air bleed the system if the hoses or other components are changed.
– Air in the hydraulic system can cause malfunction and safety hazard.
10. Spare parts must meet the requirements of the manufacturer.
– Always use genuine spare parts.
11. Do not make changes without the manufacturer's permission.
– Extension of pressurized pipes and hoses.
– Factory settings such as pressures, speeds and capacities.
– Replacements with a material of different specs to the original.
– Pressure limits.
12. The pipe joints must not be opened when there is operating pressure in the
pipes.
– The pressure must be released before opening the pipe system.
13. Only authorized persons are permitted to repair damaged electrics and hydrau-
lics.
Purpose
– To deflect or minimize the risk as quickly as possible.
– To provide safety for man and the carrier in emergency situations.
– In the event of operational malfunction.
– For fast stoppage of movement.
To engage
– Push the button down.
To reset
– Release the emergency stop button.
3.6. Environment
Special care must be taken to ensure that the equipment, carriers, lifting equipment,
stock, tools, safety equipment, galleries, passages and mine areas remain in an
appropriate condition.
1. Explain the meaning of the warning plates, signs etc of the MEWP to all person-
nel working on the site.
2. The working area must be kept clear of waste and other unnecessary material.
Tools, such as belts, chains, hoses , etc., must be checked regularly for wear,
looseness, breakage, rubbing or chafing, and damaged items must be replaced
or repaired immediately.
3. The surroundings of the operator's panel must be kept clean so that the emer-
gency stop button can be reached unobstructed.
4. Working may become dangerous due to operating conditions. It is always dan-
gerous to work on a slope. If necessary, the working area must be levelled. The
inclination values informed must not be exceeded.
5. If the work is carried out near to an underground drain, power cable, gas-, oil-, or
water pipe, always contact the owner / responsible for the installation in question
before starting work. Necessary safety measures can be decided in co-operation
with the owner / responsible. The operator and the designated site representa-
tives are responsible for implementing the necessary safety precautions.
6. The working environment must be arranged so as to promote safety taking into
consideration the quarrying methods, quarrying work and equipment, blasting
technique and preparatory work, loading and transportation, concrete spraying,
crushing of blasted rock, lifting methods, supporting and enforcing methods, pos-
sible construction work, electric, water and air equipment, ventilation, labor, fire
safety and other possible safety measures.
7. Always follow the local environmental norms and laws.
4.2. Responsibility
1. Only use the MEWP for the purpose informed by the manufacturer.
2. It is to be noted that the manufacturer of the MEWP is not liable for damages and
accidents caused by:
– incorrect, careless, and inappropriate use.
– changes made without the manufacturer's permission.
– spares that are not original.
– normal wear.
– bringing the MEWP into a country, without taking the manual's limitations and
instructions into account when considering the regulations of the country in
question.
– operating errors caused by personnel.
5. OPERATOR'S CONTROLS
1 2 3 4
Fig. 3. Controls
1. Workplatform tilt
Lever operation
– Push the lever forward to tilt the workplatform upward.
– Pull the lever backward to tilt the workplatform downward.
– Use the lever to adjust the work platfrom horizontally level.
2. Boom slew
Lever operation
– Push the lever forward to slew the boom counterclockwise.
– Pull the lever backward to slew the boom clockwise.
Lever operation
– Push the lever forward to drive the telescope extension in.
– Pull the lever backward to drive the telescope extension out.
Lever operation
– Push the lever forward to lower the boom.
– Pull the lever backward to raise the boom.
Purpose
– Compressed air outlet.
1 2 3
Fig. 4. Controls
1. Boom slew
2. Boom extension in / out.
3. Boom raising / lowering
1. Boom slew
Lever operation
– Push the lever forward to slew the boom counterclockwise.
– Pull the lever backward to slew the boom clockwise.
Lever operation
– Push the lever forward to drive the telescope extension in.
– Pull the lever backward to drive the telescope extension out.
Lever operation
– Push the lever forward to lower the boom.
– Pull the lever backward to raise the boom.
1 2 3
4 5
6
7 8 9 10
11 12
13
Purpose
– Frame side control - 0 - work platform control
Use
– Frame side control and cabin control when the handle turned left.
– Turn the handle to "0" position when driving.
– Work platform control when the handle turned right.
Lights up
– Indicates if carrier is exceeding inclination limits.
• longitudinal 8°
• lateral 3°
At same time
– Control system user interface gives alert message.
– Alarm unit warns user.
This feature is not active when MEWP is in trasport position.
Purpose
– To deflect or minimize the risk as quickly as possible.
– To provide safety for man and the carrier in emergency situations.
– In the event of operational malfunction.
– For fast stoppage of movement.
To engage
– Push the button down.
To reset
– Release the emergency stop button.
Purpose
– To indicate that the support legs are not in the transport position.
Lights up
– Support leg extensions are out.
– Support legs are lowered.
– Boom has slewed.
Purpose
– To indicate that the work platform is not in the transport position.
Lights up
– Work platform has raised.
Purpose
– Only for testing the emergency pump. Not for continuous use.
– Use only to lower down the work platform.
Definition
– Main switch must be closed.
– Current key switch must be on.
– Emergency stop is not actuated.
– Load sensing system is not active.
Use
– Actuate the switch.
– At the same time actuate the work platform lowering function.
10.Emergency pump
Purpose
– To use in a situation which poses an immediate risk to health, life,
property or environment.
– Use only to lower down the work platform if the:
• hydraulic pressure is lost.
• emergency stop is actuated.
• load sensing system stops the movement of the work platform.
Definition
– Main switch must be closed.
– Pump can be used until the carrier's battery is discharged.
– Overrides the emergency stop function.
– Overrides the control place selector switch.
Use
– Actuate the switch.
– At the same time actuate the work platform lowering function.
Switch operation
– Move the lever left or right.
Remote display
– Indicator light lights up on the screen when the support legs are
not in the transport position.
Switch operation
– Move the lever left or right.
Remote display
– Indicator light lights up on the screen when the support legs are
not in the transport position.
Indicator lamp
– Indicates compressor is on/off.
Switch
– To start and stop compressor.
1 2 3 4 5
8
6 7
Purpose
– Used to set the engine speed during stationary operations.
– Use the “hand throttle + / -” switch to get the desired rpm.
Switch operation
– On / Off
3. Hand throttle + / -
Purpose
– Engine speed can be adjusted after switching the hand throttle ON.
Switch operation
– Right – increase the engine speed.
– Left – decrease the engine speed.
4. Horn
Purpose
– A warning device
5. Emergency pump
Purpose
– To use in a situation which poses an immediate risk to health, life,
property or environment.
– Use only to lower down the work platform if the:
• hydraulic pressure is lost.
• emergency stop is actuated.
• load sensing system stops the movement of the work platform.
Definition
– Main switch must be closed.
– Pump can be used until the carrier's battery is discharged.
– Overrides the emergency stop function.
– Overrides the control place selector switch.
Use
– Actuate the switch. Max 20 s.
– At the same time actuate the work platform lowering function.
– Let she pump cool down. Wait 30 s.
Switch operation
– Move the lever up or down..
Use
– Move the lever up to lift the safety roof.
– Move the lever down to lower the safety roof.
Switch operation
– Move the left or right.
Use
– Move the lever to move the safety roof.
Purpose
– To deflect or minimize the risk as quickly as possible.
– To provide safety for man and the carrier in emergency situations.
– In the event of operational malfunction.
– For fast stoppage of movement.
To engage
– Push the button down.
To reset
– Release the emergency stop button.
Indicator lamp
– Indicates compressor is on/off.
Switch
– To start and stop compressor.
Fig. 8. Lock the protective safety equipment to operating position before use.
– Safety canopy must be lifted at its working position and locked properly before
using the MEWP.
– Sliding safety canopy must be slided above the user before using the MEWP
6. OPERATION
6.1. Preparations
1. Turn the carrier's gear selector to the neutral position.
2. Engage the safety/parking brake.
3. Check whether the ground is slippery.
– Place blocks in front of the wheels if necessary.
4. Use the MEWP when the carrier is well-supported and as level as possible.
– Position the carrier as straight and level as possible.
5. Check the carrying capacity of the ground.
– Lower the support legs (option).
– Use extra plates underneath the support legs (option).
• E.g. an asphalt surface can give way if water has eroded the soil beneath
the asphalt.
6. Close and lock the gates of the work platform.
7. Make sure that its operating area is unobstructed.
– Exercise caution when working near power cables, pipelines etc.
– Do not turn the MEWP until the work platform is clear of the ground.
8. There is an emergency stop button in the work platform.
– To quickly stop the motion of the MEWP e.g. in an emergency situation.
9. The work platform must not be used for transporting materials.
– The MEWP must not be used as a crane.
– When lifting personnel, tools and equipment can be lifted in the work platform.
– It is forbidden to lift materials that extend beyond the edges of the work plat-
form.
Caution!
Fig. 9. Lock the protective safety equipment to operating position before use
Warm conditions
Beware of the hydraulic fluid overheating in exceptionally warm conditions.
– Too high > 80 °C fluid temperature
• degrades the fluid.
• damages the seals.
Hard wind
7.1. Driving
1. Read the driving instructions of each carrier carefully.
– Owing to the carrier, driving requires special measures.
2. Do not disengage the safety/parking brake before you have checked that:
– the steering functions correctly.
– the MEWP is in a correct position for moving.
– all equipment and operations are in order.
– operating the carrier does not cause any danger to people or property.
3. The carrier must never be driven or operated until it has been ensured that doing
so entails no danger to personnel.
4. Never attempt to drive the carrier from any place other than the operator's cabin.
5. Only trained personnel are allowed to drive the carrier.
6. It is forbidden to enter or leave the carrier while it is moving.
7. Beware of narrow passages and low underpasses.
8. Always position the MEWP in its driving position.
– This brings the centre of gravity as low as possible and makes the carrier more
stable to drive.
9. When transporting the carrier, adjust the driving speed according to the terrain.
– This prevents the MEWP from swaying and wobbling, which causes strain on
the pins, bushings and the mechanical structure.
10. The support legs (option) must be fully raised and retracted.
11. No personnel are permitted on the work platform while driving.
7.2. Storage
If the MEWP is to be stored for extended period, it is necessary to take protective
measures to prevent rust formation. The protective measures described here will
protect the MEWP for a period of up to 6 months. Before reusing the MEWP, the
protection must be removed. Use anti-corrosive agent for external protection only.
7.3. Lifting
Many countries have special laws and statutes related to lifting, hoisting cables and
lifting equipment. Always follow the safety regulations required by local laws.
Only a correct type of carrier with a sufficient lifting capacity can be used for lifting.
Fasten two hoists to the lifting points. Ensure that the MEWP is properly fastened and
balanced by first lifting it a few centimeters from the ground. Continue the lifting only
after you are convinced that the MEWP is in balance and safely fastened.
Note!
8. MAINTENANCE
8.1. General
The boom contains both slide and ball bearings whose lubrication should be carried
out regularly at intervals of about 50 operating hours. Blocked or damaged grease
nipples must always be replaced immediately. If the holes in the joint pins get blocked,
the pin must be removed and the hole opened to ensure proper lubrication.
Because the MEWP is used for lifting people, special attention should be paid to the
condition of the equipment as a whole. The things to be checked weekly are the tight-
ness of the bolt connections, the condition and tightness of the hydraulic hoses and
fittings, and the joint pin locking.
Hydraulic pressures should be checked if malfunctions occur in the operation. The
specified pressure values must not be exceeded without the manufacturer's permis-
sion. If hoses or other components are changed, the involved movement needs air
bleeding by driving the relevant a few times to the extreme position. Air in the hydraulic
system can cause malfunctions and dangerous situations.
The rest of the inspections are regular checking of joints, pins and bearings etc, and
changing the worn/damaged parts if necessary. The worn components must be
replaced with new ones as soon as possible, to avoid further damage to other compo-
nents.
Warning!
8.2. Greasing
Lithium based greases:
– NLGI grade . . . . . . .2
– Penetration . . . . . . .265/295
– Dropping point . . . . .180 °C
– Base oil viscosity . . .150 - 250 mm2/s @ 40°C
Warning!
8.3. Schedule
In addition to these instructions, always follow the local regulations, laws and stand-
ards concerning periodical inspections.
When necessary
15. Adjust the boom lowering speed.
16. Adjust the boom slewing speed.
17. Adjust the load sensing system.
ITEM 2
Check the tilting cylinder pin and work platform joint pin.
1. If the work platform has hit an obstacle;
– detach the tilting cylinder pins.
– detach the work platform joint pin.
2. Check the bearing.
3. Check the joint pin.
4. Check the locking of the pin.
5. Check that the work platform does not start to descend when positioned horizon-
tally.
ITEM 3
Keep the working area of the work platform clean.
Keep the working area of the work platform clean and free of oil, ice, mud and loose
objects.
– Use a high pressure washer.
Warning!
ITEM 5
Check the boom mounting attachment.
Slackened or stretched bolts must be replaced with new ones.
ITEM 6
Inspect the hydraulic cylinder, cylinder joint pin, pin locking and bearing.
1. Check all cylinders, nuts, pins, pin lockings and bearings for proper installation.
2. Check for excessive wear, cracks or distortion.
3. Check closely for permanent deformation, extreme wear, dents or corrosion
damage.
4. Welding seams should be visibly free of fractures or cracks.
Side clearance
1. Loosen the fixing bolts.
2. Position the inner boom in the middle of the intermediate boom.
– The intermediate boom in the middle of the outer boom.
3. Tighten the covers fully and firmly.
4. Loosen the covers 1/4 turn.
5. Tighten the fixing bolts.
Base clearance
1. Check the clearance gap.
– Clearance gap between the steel plate and the inner/intermediate boom.
– Check the clearance gap using a feeler gauge.
– Maximum 2,0 mm clearance gap.
2. Change the worn base wear plates.
3. Fasten a hoist to lift the boom end.
– In order to get space for the change.
4. Loosen the fixing bolts.
5. Remove the cover.
6. Install new wear plates.
1. Clearance gap
2. Hoist
3. Fixing bolt
4. Cover
5. Wear plate
1. Fixing bolt
2. Cover
3. Wear plate
1. Fixing bolt
2. Cover
3. Wear plate
1. Check the pressure when the hydraulic oil is at normal operating temperature.
2. Connect the pressure gauge (0 - 200 bar) to the measurement point.
3. Drive the desired function of the boom to its extreme position by the control lever.
4. The pressure should be 200 bar max.
5. Pressure values shown in the hydraulic scheme are absolute top limits, which
must not be altered without manufacturer's permission.
ITEM 9
Inspect the tilt cylinder fixing lug welding.
There should not be any visible fractures or cracks in the welding seams.
ITEM 10
Inspect the condition of the boom beams.
Check boom structure, boom members and their connections for absence of frac-
tures, cracks, permanent deformations, bad wear, bruises or corrosion damages.
Inspect paint and overall appearance.
ITEM 11
Inspect the function of the load-lowering valve.
ITEM 12
Inspect the boom mounting bolt connections.
1. Check the bolt connections.
– Use a torque wrench.
2. Replace all bolts if any of the bolts has slackened or stretched.
– Size M 12
– DIN 912 Grad 12.9
– Tightening torque 78 Nm with grease on the threads.
2 3
1. Tilt cylinder
2. Protective structure
3. Joint pin
Danger!
Removal
1. Lower the work platform on ground or proper on proper supports.
– Remove the protective structure.
2. Clean the parts before opening any hydraulic connections.
3. Turn the tilt mechanism so that the tilt cylinder joint pins are not under load.
4. Mark hoses and make notes about locations and routing of the hydraulics.
5. Position collecting vessel beneath cylinder
– Dispose oil in accordance with local environmental regulations.
6. Ensure that system is unpressurised.
7. Disconnect hydraulic hoses
8. Remove the joint pins.
– Detach joint pin locking and use sliding hammer or hydraulic pin puller/ pusher
to remove the pins.
9. Remove the tilt cylinder.
Installing
10. Connect hoses to new cylinder.
11. Drive the cylinder in and out several times to get air out from cylinder.
12. Drive the cylinder to same length as the old one was.
13. Install the cylinder with new joint pins an pin locking mechanisms.
– Install the protective structure.
Danger!
Caution!
ITEM 16
Adjust the boom slewing speed.
The boom slewing speed is set to a certain value at the factory. This speed is based
on the main block valve setting.
To stabilize the slew movement, the slew cylinder is fitted with a one-way flow control
valve.
1. Adjust the valve if necessary.
– Make the adjustment while the hydraulic fluid is warm.
– Adjustment may be necessary on account of the conditions and the applica-
tion.
2. Open the locking of the one-way flow control valve adjustment knob.
– Use a hexagon socket spanner.
3. Adjust the boom slew speed to the desired value with the valve adjustment knob.
– Turn the knob clockwise to decrease the slew speed.
– Turn the knob counterclockwise to increase the slew speed.
4. Lock the valve adjustment knob after making the adjustment.
ITEM 17
Adjust the load sensing system
The load sensing system is a safety device which prevents any normal movement of
the work platform from a stationary working position after the rated load is reached
and before 120 % of the rated load is exceeded.
A flashing red warning light together with an acoustic alarm signal is activated when
normal movement is prevented at the pre-selected control position. Normal movement
can only be resumed once the overload is removed.
Adjust the load sensing system to activate no later than 10% overload.
1. Lock nut
2. Adjustment screw
9. SPECIFICATION
To check the speed values, measure the work platform movement distances and time
values. Check the table below in order to determine the correct boom movement
speeds.
Operate the boom until the oil reaches normal operating temperature.
1. Drive the boom to its most extended position.
2. Measure the distance using the work platform centre point movement while
checking the boom slewing speed.
3. Measure the distance using the work platform bottom movement while checking
the boom lowering speed.
Speed 0,4 m/s 0,7 m/s Speed 0,4 m/s 0,7 m/s
9.2. Sticker
9.2.1. General instructions
10. TROUBLESHOOTING
Trouble
– Possible cause
• Remedy
NOTES
Code: . . . . . . . . . . . . . . . . . . . . 100121643
Carrier No: . . . . . . . . . . . . . . . . DJ305
The information contained in this manual is current for this unit. In the interest of continually
improving its products, Normet reserves the right to update or modify information contained
in this manual. Illustrations shown in this manual were produced during the development
stages and may differ from the actual product.
Danger!
Warning!
Risk of injury.
Caution!
Note!
CONTENTS
1. Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1. Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2. Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3. ANFO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2. Charging Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1. Pneumatic Loaders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2. Charging Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3. Mobile Elevating Work Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4. Compressed Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5. Charging The Round . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6. Smooth Wall Blasting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3. Safety Aspects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1. Static Electricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2. Electrical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3. Chemical Reaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5. Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.1. Charging Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.2. Charging Hand Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.3. Charging Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.4. Selecting the Pressure Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.5. Terminal Box TB5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.6. Connector Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.7. Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.8. Pressure Release Valves For Charging Hose . . . . . . . . . . . . . . . . . . 32
5.9. Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7. Preparatory Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.1. Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.2. Charging Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
ANFO Charging Module
8. Blowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.1. Borehole Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.2. Charging The Borehole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.3. Charging Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9. Lubricant Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
9.1. Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
11. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
11.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
11.2. Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
11.2.1. Daily or once per shift (10 hours) . . . . . . . . . . . . . . . . . . . . . . . 60
Drain water from the modular type air filter. . . . . . . . . . . . . . . . . . . . . . . . . 60
Drain water from the water separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Check the lubricator drippage amount and oil level. . . . . . . . . . . . . . . . . . . 62
Keep the pressure vessel and charging unit clean. . . . . . . . . . . . . . . . . . . . 63
Check the interior and exterior condition of the vessel. . . . . . . . . . . . . . . . . 63
Check the wear of the charging hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Check the total resistance between earthing strap and free end of the charging
hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Check the resistance between earthing strap and ANFO charger quick acting
coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Check the vacuum pump oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
11.2.2. Every 500 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Clean the modular type air filter element. . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Measure the earthing strap resistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Clean the vacuum pump oil reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
11.2.3. As Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Change the water separator filter element . . . . . . . . . . . . . . . . . . . . . . . . . 71
Fix the connections of the earthing straps and earthing points. . . . . . . . . . 72
Replace the earthing straps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Clean the cyclone separator filter element. . . . . . . . . . . . . . . . . . . . . . . . . . 74
ANFO Charging Module
1. TECHNICAL INFORMATION
1.1. Foreword
The charging unit can be used for drift as well as up-hole and down-hole stope
charging.
Normet mining carriers equipped with either a lifting platform or basket boom are
designed for easy site-to-site transfer. The carrier referred to in this manual is
equipped with a basket boom. The lifting platform or basket boom is hereafter referred
to as a mobile elevating work platform, or MEWP.
Pneumatic charging of bulk ANFO provides an economical and time-saving method
of blasting in relatively dry borehole conditions. For such applications,
Normet manufactures complete units with ANFO chargers and other accessories
installed.
As an option, the carriers are available with fire resistant hydraulic fluid and a fixed fire
suppression system.
The basic requirements for successful blasting are:
– Safe working method.
– Desired fragmentation and throw of the rock.
– Blasting economy.
– Smooth tunnel profile and minimum disturbance of surrounding rock in order
to reduce support costs and assist ventilation.
– Rapid charging of boreholes
ANFO
Prilled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.9 – 1.0 kg/dm3
50/50 crystalline/prilled. . . . . . . . . . . . . . . . . . . . . . 1.1 – 1.15 kg/dm3
Crystalline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 – 1.2* kg/dm3
* maximum value for ANFO
1.3. ANFO
Pneumatic loaders are intended for charging of boreholes with ready-made ammo-
nium nitrate/fuel oil (NH4NO3/oil). The use of ammonium nitrate/fuel oil explosive has
become widespread due to its economical price per kilogram and its suitability for
labour--saving pneumatic charging, instead of the conventional method of tamping
cartridges into the boreholes.
– Is the most widely used civil explosive in the world.
– Is classed as a blasting agent and requires initiation by a primer.
– Consists of a mix of ammonium nitrate and fuel oil.
– Special ANFOs include various additives.
– Explosives are used mainly in large open-cast blasting in non-urban areas and
in underground mines.
The limitation of the method is the low water resistance of bulk ANFO. The risk of
ammonia emissions should be considered if the likelihood of exposure to fresh
concrete exists.
Special ANFO products have been developed for specific applications:
– enhanced moisture tolerance ANFOs.
– “sticky” ANFOs for better up-hole adherance.
– lighter density ANFOs.
Fig. 2. Prills
2. CHARGING TECHNIQUE
3. SAFETY ASPECTS
B) Charging carrier
1. The charging carrier must be earthed to the ground during operation.
2. The support legs of the charging carrier must be directly against the ground or
mine sole, or must have some other metallic contact with it.
3. A stainless steel chain must be fixed to the charging carrier frame if the carrier is
on rubber tyres.
– At least 10 cm of the total chain length should drag along the bottom of the drift
or along the ground.
4. A corresponding contact between the carrier and the earth must be installed, and
likewise between the charging unit and the carrier if the charging unit is mounted
on a fork lift or other carrier.
C) Borehole
1. The resistance of the casing pipe should not exceed 30 kΩ/m if the borehole
must be lined with casing pipe.
– E.g. if the rock is cracked.
B) Instructions
1. The information contained in this operator’s manual is intended for charging unit
operators.
– The charging unit may be handled and operated only by persons with the
appropriate technical skills, training and operating permission.
2. The operator must obtain detailed work instructions from the responsible work
supervisor, and must be fully familiarised with the contents of this operator’s
manual before operating the unit.
3. The instructions contained in the operator’s manual must be followed in detail.
4. The operator must be familiar with the carrier and mobile elevating work platform
functions in order to operate the charging unit.
5. Each user is responsible for being aware of the details contained in the opera-
tor’s manual and of the proper scope of application of the charging unit with
respect to its specific intended use.
6. While Normet makes every effort to ensure that the details contained in the oper-
ator’s instructions are as accurate as possible, the conditions under which the
charging unit is used are not within its control.
7. Contact Normet for assistance if technical advice is required within the specified
scope of application of the charging unit.
8. Always comply with the instructions in this operator’s manual and with your com-
pany’s regulations and practices when operating the charging unit.
C) Explosives
1. The explosives used with this charging unit are classified as dangerous goods
and can cause severe personal injury and damage to property if used incorrectly.
2. Explosives must be handled, transported and stored in accordance with all rele-
vant regulations.
3. Ensure that the explosive is loaded through a semi-conductive hose or tube with
a minimum resistance of 15 kΩ and a maximum resistance of 2 mΩ along its
entire length.
4. Handle explosives carefully and be aware of their specific hazards.
5. Use only approved explosives.
6. Rotate the stock so that older explosive is used first.
7. Protect the detonator against damage during the charging operation.
– Use protected type detonators when pneumatic loading and electrically firing.
8. Charge only after the entire face has been fully drilled
– to avoid accidental detonation by drilling into explosives
9. Keep away from the blast area.
– Switch off the ventilation completely before blasting.
– Switch on the ventilation at full capacity after blasting.
– The entire work crew must withdraw to a protective shelter during blasting.
– In small tunnels, the protective shelter can be installed in a niche.
– Keep at a safe distance from flying debris and toxic fumes resulting from blast-
ing.
B) Instructions
1. Follow the work instructions and remember which tasks require a work permit.
2. Ask your supervisor for further instructions if anything is unclear.
3. In addition to work-site-specific instructions, familiarize yourself with the operat-
ing, lubrication, maintenance, and safety instructions provided by the equipment
and component manufacturers.
4. Ask your supervisor for detailed work instructions.
– Read and make sure you fully understand these operating instructions.
5. When operating the charging unit, always follow the instructions in this manual
and the instructions and policies of your company.
– Follow the operating instructions in every detail.
6. Study the material safety data sheet for each substance before use.
C) Earthing
1. Before handling and connecting electric detonators, remove your gloves and
ensure that you are properly earthed to discharge any electrostatic charge.
2. Do not use water lines, compressed air lines, wire covered hoses, rail or perma-
nent electrical earthing systems as a means of earthing.
D) Work routines
1. Ensure that you know the location and proper use of safety devices and fire-
extinguishing equipment, alarm systems, and emergency exits.
2. Report any deficiencies in the safety arrangements to your supervisor.
3. Keep the work site clean and in good order.
4. Work in a deliberate, systematic manner.
5. Collect rubbish and explosive waste in the appropriate locations.
6. Familiarize yourself with the basic operation of the carrier and the mobile elevat-
ing work platform
– to ensure safe operation of the charging unit.
7. Follow these rules if you are going to drive the charging carrier on public roads.
– Remove all explosives from the charging carrier.
– Obtain a transport permit.
8. Do not make any modifications or perform any trials without your supervisor’s
permission.
9. Use the charging carrier only for the purposes stated in the instructions.
10. Always put the lid on the grid while driving.
– Not required if equipped with ANFO filling system (fixed lid).
E) Charging
1. Do not operate unless the charging unit, charging hose and earthing arrange-
ments are safe and effective and in accordance with the manufacturer’s recom-
mendations.
2. Carry out charging work only under the supervision of an authorised and quali-
fied blasting specialist.
3. Keep unauthorized persons out of the working area during operation.
4. Protect the detonator/primer against damage during charging.
5. Stand to the side of the borehole, not directly in front of it when charging.
6. Supervise the charging process and monitor the condition of the charging unit.
7. In the event of a fault or malfunction, shut down the charging unit.
– Do not operate a faulty charging unit.
8. Perform maintenance and inspections of the charging carrier in accordance with
the maintenance plan.
9. Report any unusual observations or occurrences to your supervisor.
10. Keep a record of the inspections and procedures performed.
– Store the records carefully.
11. When filling the vessel, make sure no loose, hard objects, such as rocks or tools,
can fall into it.
12. Normet bears no risk, responsibility or liability arising from incorrect use of the
charging unit.
5. OPERATOR CONTROLS
2 3
1. Process activation
2. Vessel “B” pressurised
3. Vessel “A” pressurised
4. Compressor
5. Emergency stop
1. Process activation
Use
– Move the lever up to use the charging unit.
Action
– Process activation indicator light lights up.
Green light
– Indicates that the vessel is selected.
Green light
– Indicates that the vessel is selected.
4. Compressor
Use
– Start the compressor.
– Stop the compressor.
Action
– Compressor ON indicator light lights up.
Purpose
– To deflect or minimize the risk as quickly as possible.
– To provide safety for man and the carrier in emergency situations.
– In the event of operational malfunction.
– For fast stoppage of movement.
To engage
– Push the button down.
To reset
– Release the emergency stop button.
1 2
1. Blow
Use
– If necessary, blow the boreholes clean with pressurized air.
• Spring returned
2. Charge
Use
– Press the button to start feeding explosive to the borehole.
• Manually returned
– Press slightly the blow button to stop charging.
2 1
1. Blow
Use
– If necessary, blow the boreholes clean with pressurized air.
• Spring returned
2. Charge
Use
– Press the pedal to start feeding explosive to the borehole.
• Spring returned
1 2
1. Back blowing
2. Vessel selector
1. Back blowing
Use
– To open a blockage.
Warning!
Use
– Select vessel “A”
– Select vessel “B”
Note!
1
2
1. Housing
2. Hood
2
1
1. Pressure air shut off valves and claw couplings for air take-out.
2. Pressure air shut off valves and claw couplings for air in.
Purpose
– To deflect or minimize the risk as quickly as possible.
– To provide safety for man and the carrier in emergency situations.
– In the event of operational malfunction.
– For fast stoppage of movement.
To engage
– Push the button down.
To reset
– Release the emergency stop button.
6.1. Procedure
1. Turn the gear selector switch in the drive cabin to the N (neutral) position
2. Engage the safety/parking brake before starting to operate.
3. Release the pressure from the explosive tank by pushing the tank control valve
lever. Check that the hydraulic oil pressure gauge shows 70 bar.
5. Fill the explosive tank with the explosive substance by pushing the vacuum
pump control valve lever. The tank air pressure gauge pointer gradually drops to
- 0,5...-1 bar when actuating the valve lever.
6. The explosive tank is full when the gauge pointer shows close to -1 bar. Release
the vacuum pump control valve lever when the vessel is full.
Danger!
2. Pressurize explosive tank a certain extent by pushing the tank control lever.
Warning!
1 2
1. Back blowing
2. Vessel selector
7. PREPARATORY TASKS
7.1. Adjustments
1. Adjust the vessel air pressure by turning the pressure regulator knob
– To a pressure of 3.5 bar (0,35 MPa) when using NH4NO3/oil.
– Lock the knob.
2. Adjust the extra air flow as required by turning the flow control valve hand wheel.
Drift charging
– Open the hand wheel 1/2 - 1 turns or more if needed.
Stope charging
– Open the hand wheel 2 - 5 turns(@ 6 m3) or more if needed.
3 4
Danger!
8. BLOWING
Detonator/primer
– Interrupt the charging cycle to the desired detonator/primer site.
– Feed the primer cartridge with a detonator or other approved ignition sub-
stance to the borehole.
– A sufficient quantity of primer is needed to properly ignite the loaded borehole.
– The detonator conductors, whether cord or Nonel type, must follow the bore-
hole during charging hose feeding.
Note!
Note!
Too slow a charging hose speed will increase spillage and dust formation.
Too high a speed can result in an inconsistent charge in the borehole.
Keep the speed a just above the speed at which spillage occurs.
The speed of charging is affected negatively if the loading hose is permitted to lie with
sharp bends. This also increases the wear of the hose.
It is important to keep the correct distance between the charge column in the borehole
and the mouth of the hose. If this distance is increased or reduced, the charge density
is negatively affected.
The detonator must be protected against damage during the charging operation. The
detonator can be inserted in an explosives cartridge or protection shell.
When using cartridges, so-called tube loads, a single cartridge may be sufficient. This
is used as the primer cartridge, with the detonator placed away from the bottom of the
borehole.
All remaining explosive must be charged from the hose when charging the final bore-
hole, or prior to a lengthy break in charging work.
Caution!
Check that there always is enough explosive in the charging unit during charging. If
the hose runs empty, it can be ejected from the borehole, causing potential injury to
the operator.
Initial Data
Drift charging
– Vessel air pressure 2.0 – 3.5 bar.
Stope charging
– Vessel air pressure 2.0 - 5.0 bar.
Definition
Increased extra air
– Increases ANFO speed in the charging hose.
– Decreases ANFO volume in the charging hose.
– Decreases the charging capacity.
Increased vessel pressure
– Increases ANFO speed in the charging hose.
– Increases the charging capacity.
a. Open the vessel lid and clear the blockage with a rod.
Note!
9. LUBRICANT RECOMMENDATIONS
Oil recommendation
It is recommended to use the following lubrication oils.
– Do not use multigrade oils.
Caution!
Caution!
11. MAINTENANCE
11.1. General
1. Empty all remaining ANFO in the vessel into the storage container after charging
work is finished for the day.
– Put the charging hose into the storage container.
– Charge the remaining ANFO into the storage container.
2. Blow the charging hose clean.
– Keep the charging hose end in the storage container to prevent the explosive
from being blown around.
– It is important that the charging hose is blown clean, as any remaining explo-
sive can become encrusted on the hose, rendering subsequent charging diffi-
cult or impossible.
– Clean the hose using the same method used to clear charging hose block-
ages.
3. Always clean the charging unit carefully to remove any remains of explosive after
finishing charging work and before carrying out repair work on the unit.
– Clean the unit also when it is not in daily use.
– Clean at minimum by wiping down.
– Oil all valves and couplings.
– Flush clean with water.
4. Valves may not function initially if the charging unit has been out of use for some
time.
Note!
Warning!
As Required
13. Change the water separator filter element
14. Fix the connections of the earthing straps and earthing points.
15. Replace the earthing straps.
16. Clean the cyclone separator filter element.
Warning!
ITEM 2
Drain water from the water separator.
Discharge the drain before the drain fluid surface reaches the center of the sight glass.
– Use the drain valve.
ITEM 3
Check the lubricator drippage amount and oil level.
1. Check the drippage daily.
– Drip failure can cause damage to components requiring lubrication.
2. Adjust the amount of lubricant using the needle on the front face.
– Turning the needle clockwise increases the amount of lubricant.
– Turning the needle counter-clockwise until fully opened shuts off the lubricant.
3. Depressurize the unit before removing the bowl.
4. Clean the bowl with neutral detergent.
5. Fill the bowl with ISO VG 32 Industrial fluids.
– Filling amount 1,35 dl.
Warning!
Do not introduce air from the outlet side as this can dam-
age the damper. Prevent the unit from soiling with syn-
thetic oils, organic solvents, chemicals, cutting oils,
screw tightening agent, etc. Protect from ultraviolet light.
Needle
ITEM 4
Keep the pressure vessel and charging unit clean.
1. Thoroughly clean all explosive from the unit.
– Explosives have a corroding effect on machinery.
2. Lubricate the O-rings of all valves with moving parts.
– Once or several times each month.
– In addition to cleaning the valves, lubrication will prevent the valves from jam-
ming.
– Cleaning is recommended by the explosive suppliers.
ITEM 5
Check the interior and exterior condition of the vessel.
1. Check the pressure vessel periodically as part of normal maintenance opera-
tions
– To observe fouling, which interferes with the explosive flow.
– To ensure safe operation prior to vessel inspection, repairs and charging.
2. Inspect especially for rust, dirt and other debris formed or entered into the unit
during fabrication, shipment, or erection that are likely to cause damage after
start-up.
– There should be no visible fractures or cracks in the vessel.
ITEM 6
Check the wear of the charging hose.
A) Check the wear
1. Check the charging hose at each workshift.
– In addition to outer mechanical wear, the lifetime of the charging hose is also
limited by internal wear.
– Internal wear cannot be visually inspected.
2. Replace the charging hose before unforeseeable failures occur, e.g. due to
cracking or hose rupture:
– Inspect visually.
– Bulges are a sign of a failing hose.
– If in doubt, replace the hose.
3. Hose conductivity is known to vary with age and usage.
– Periodic replacement or testing is necessary to ensure safe values are main-
tained.
Danger!
ITEM 7
Check the total resistance between earthing strap and free end of the charging hose.
– Measure the resistance of the earthing straps (engine end/load end/support
legs) separately.
• Between points 1-4, 2-4 and 3-4.
– Use classified measurement device.
– Use MΩ scale in the measurement device.
– Measured value must be under 5 MΩ.
– Fix the earthing connections if measured resistace is over 5 MΩ.
1
2
Note!
ITEM 8
Check the resistance between earthing strap and ANFO charger quick acting
coupling.
– Measure the resistance of the earthing straps (engine end/load end/support
legs) separately.
• Between points 1-4, 2-4 and 3-4.
– Use classified measurement device.
– Use MΩ scale in the measurement device.
– Measured value must be under 1 MΩ.
– Fix the earthing connections if measured resistance is over 1 MΩ.
1
2
Note!
ITEM 9
Check the vacuum pump oil level.
1. Check the oil level in the oil reservoir daily via the dipstick.
– The oil must be topped up immediately whenever the oil level drops to the
lower notch.
– Never allow the oil level to drop below the minimum level.
2. Remove the oil filler cap and top up the oil reservoir.
3. Close the oil filler cap firmly after filling the reservoir.
ITEM 11
Measure the earthing strap resistance.
– Measure each earthing strap separately.
– Use only classified measurement device.
– Use Ω scale in the measurement device.
1. Connect a measurement wire to one end of the earthing strap.
2. Connect the second measurement wire to the another end of the earthing strap.
– Measured value must be under 0.5 Ω.
– Replace the earthing strap if measured resistance is over 0.5 Ω.
Note!
ITEM 12
Clean the vacuum pump oil reservoir.
1. Clean the oil reservoir every 500 hours.
2. Drain off the lube oil with the pump on standstill.
– Open the hexagonal plug and drain the oil.
3. Flush the oil tank with flushing oil.
4. To prelubricate, inject about a ¼ litre of oil into the intake socket.
– Repeat every 15 minutes during the initial 1-2 operating hours.
Note!
1 2
1. Hexagonal plug
2. Sealing ring
11.2.3.As Required
ITEM 13
Change the water separator filter element
1. Replace the element every 2 years or when the pressure drop reaches 0.1MPa,
whichever comes first, to prevent damage to the element.
2. Replace the old element with a brand new element.
– Replace also the O-ring and gasket.
ITEM 14
Fix the connections of the earthing straps and earthing points.
Check the earthing links if the measured resistances are too high.
Make sure that:
– there is no corrosion on the earthing straps or cables.
– contact between earthing straps, cables and carrier frame are in good condi-
tion.
– earthing straps and cables are secured.
1 2 3
4 5 6
ITEM 15
Replace the earthing straps.
Replace the earthing strap if the measured resistance is too high (>0.5 Ω).
Procedure:
1. Open the earthing strap mounting nut or bolt.
2. Replace the earthing strap with a new one.
– Remove dirt and corrosion from the connection point.
3. Tighten the earthing strap mounting nut or bolt.
– Tightening torque 47 Nm.
ITEM 16
Clean the cyclone separator filter element.
The condition of the ANFO used (moisteness, powderiness etc.) determines the filter
cleaning cycle. Clean the filter element when:
– Vacuum pump output reduces.
– Vacuum pump sound changes.
Maintenance sequence
– Clean the filter element using a high pressure washer.
– Replace the filter element.
4
2
1
3
1 2
NOTES
Safety Instructions
SAFETY INSTRUCTIONS
Code: . . . . . . . .
Carrier No. . . .
Equipment: . . .
This manual is a guide to the safety instructions of the vehicle. In respect of opera-
tion the equipment outfit over the vehicle causes changes and additions which must
be considered separately. The information contained in this manual is current for the
standard vehicle. Continued product improvement, and different versions of the
equipment may result in changes to the vehicle which are not covered.
Safety Instructions
CONTENTS
1. Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page . . . 3
2. Terms and symbols used in the operating instructions . . . . . . . . . . . . . . . 4
3. General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Safety instructions in manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1. Safety instructions of the operating instructions . . . . . . . . . . . . . . . . . . . . 6
4.2. Safety instructions of the workshop manual . . . . . . . . . . . . . . . . . . . . . . . . 6
5. Instructions and warnings in the equipment . . . . . . . . . . . . . . . . . . . . . . . . . 7
6. Instructions for the owner and operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.1. Working environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.2. Operation of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.3. Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.4. Distribution of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.5. Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7. Operator suitability and responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7.1. Operator suitability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7.2. Operator responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.3. Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8. Summary of the most important instructions
to prevent damage and maintain safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
9. Operation of the machine or equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
9.1. Safety instructions prior to operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
9.2. Starting up the equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
9.3. Safety instructions for the operation of the equipment . . . . . . . . . . . . . . . 19
9.3.1. Safety instructions for boom operation . . . . . . . . . . . . . . . . . . . . . . 20
9.3.2. Safety instructions for lifting platform operation . . . . . . . . . . . . . . . 21
9.4. Operation in cold conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
9.5. Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9.5.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9.5.2. Correct operation of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9.5.3. Incorrect operation of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9.6. Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.7. Working methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.8. Stopping the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.9. Ending of shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.10. Dowage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.11. Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Page 1 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
Page 2 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
e--mail: . info@normet.fi
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
1. FOREWORD
These safety instructions are intended for both the owner of a Normet
machine and the persons who operate, service and repair the machine or
equipment.
The machine is in accordance with the technical requirements and the existing
and necessary safety regulations. Despite this, faulty operation, service and
repair may cause danger.
The requirement for all operation is that the operator is familiar with the
operating instructions and follows them. It is therefore recommended that the
instructions are read through several times and that the operator becomes
familiar with the machine before it is taken into use.
In addition to the operating instructions, the operator must remember to act in
accordance with the regulations of the local labour protection authorities, and
the laws and statutes of the user country.
Using the equipment for any other task than for which it has been designed or
to exceed its operating capacity is considered inappropriate usage. Any other
kind of use of the equipment or machine is not acceptable. The manufacturer/
supplier does not assume liability for a damage resulting from such usage.
Page 3 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
! DANGER
When there is an immediate danger, which
may cause a dangerous bodily injury or
death.
! WARNING
When there is a danger, which may cause a
bodily injury.
! CAUTION
When there is a danger or misuse, which may
damage property.
Page 4 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
e--mail: . info@normet.fi
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
Page 5 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
Page 6 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
e--mail: . info@normet.fi
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
OPERATOR’S SAFETY
D Diagram of places of risk
D Warning of the frame joint
D Symbols of gauges, warning lights and control levers
CONDITIONS AND THE ENVIRONMENT
D Unobstructed starting
D Parking
D Transporting personnel
D Emergency stop
D Warning equipment, beacon, warning plates
OF THE EQUIPMENT
D Type plate
D Operating plate of the main switch
D Tyre pressure plate
D Operating instruction plate of the gearing
D Starting
D Inspection of the brakes
D Operating instruction plate of the parking brake
D Daily and weekly service instruction
D Symbols of the signal lights
D Instruction for the extinction equipment
D Instruction for extras as necessary
D Symbols of the safety equipment
The warning and safety equipment installed in the machine must neither be
changed nor removed, and they must be used correctly.
All safety and warning plates in the machine must be legible and undamaged.
A damaged plate must be replaced.
Page 7 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
Page 8 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
e--mail: . info@normet.fi
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
Page 9 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
Page 10 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
e--mail: . info@normet.fi
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
Page 11 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
Page 12 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
e--mail: . info@normet.fi
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
Page 13 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
Page 14 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
e--mail: . info@normet.fi
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
Page 15 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
Page 16 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
e--mail: . info@normet.fi
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
Page 17 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
Page 18 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
e--mail: . info@normet.fi
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
Page 19 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
Safety Instructions
Page 21 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
Page 22 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
e--mail: . info@normet.fi
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
Page 23 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
Page 24 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
e--mail: . info@normet.fi
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
Page 25 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
Page 26 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
e--mail: . info@normet.fi
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
Page 27 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
Page 28 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
e--mail: . info@normet.fi
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
Page 29 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
Page 30 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
e--mail: . info@normet.fi
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
7. Ensure that the load is properly fastened and balanced by first lifting it a
few centimeters from the ground. Continue the lifting only after you are
convinced that the load is in balance and safely fastened.
8. Hoisting cables, which consist of several parts must not be wound. The
hoisting cables must be fastened in accordance with the instructions pro-
vided by the manufacturer.
NO YES
Page 31 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
NO YES
10. The load must never be lowered so much that there are less than two
rounds of cable on the reel. In this way, we ensure that the weight of the
load to be lifted is evenly distributed on the cable and on the fastening
point.
11. Check the capacity and length of the cable, if the length of the cable or
mast is changed.
12. Never stand or work underneath a load hanging from the lifter.
13. Never use the machine balance as a measurement for capacity.
14. Never lift a load above people.
15. Make sure that lifting can be carried out unobstracted.
16. Never use any other machine for lifting people than a special passenger
hoist.
17. Lifting people on top of the load is strictly forbidden.
Page 32 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
e--mail: . info@normet.fi
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
Page 33 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
Page 34 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
e--mail: . info@normet.fi
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
Page 35 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
Page 36 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
e--mail: . info@normet.fi
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
12.1. GENERAL
Keep a record of the service of the equipment and its wearing parts. Regular
maintenance carried out at prescribed intervals and at the correct time adds
to the operating reliability, economy and safety of the equipment.
Maintenance work can be dangerous if not carried out by executing special
caution. Everyone should understand the possible danger factors involved
and use safe working methods. Before commencing the service or
maintenance work, familiarize yourself with the instructions provided by the
manufacturer, and follow them.
Clearly define the responsible person for the service and maintenance work.
1. Do nothing you are not entitled to do.
2. Inform the operators about the timetable of special service and mainte-
nance work.
3. Reserve a sufficient service area around the machine.
4. If the machine or its part has been stopped for service or repair, make
sure that it will not restart or that it is impossible to start it up by mistake.
--- Turn off the main switch.
--- Remove the ignition key.
--- Place a warning sign on the main switch. The sign can only be removed
by a person who is aware of the situation and knows when the sign can
be removed without danger.
5. Clean and wash the equipment regularly and always before service and
maintenance work.
6. Before you start cleaning the equipment with water, high---pressure wash-
er, steam jet or other washing methods cover all such openings and
places which may cause danger or break. Special attention should be
paid to the protection of electric motors, switch cabinets and boxes.
7. If required, use suitable and safe ladders or working platforms for repair
and maintenance work
8. Do not use any parts of the machine as stepping stones. If the service
must be carried out in a high or dangerous place, use safety equipment
that prevents you from falling.
9. All working platforms, steps, handles, rails, ladders and other places
where you can slip or meet with an accident must be kept clear of oil, dirt,
snow and ice.
Page 37 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
Page 38 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
e--mail: . info@normet.fi
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
Page 39 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
Page 40 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
e--mail: . info@normet.fi
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
Page 41 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
Page 42 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
e--mail: . info@normet.fi
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
Page 43 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
Page 44 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
e--mail: . info@normet.fi
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
Page 45 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
Page 46 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
e--mail: . info@normet.fi
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
Page 47 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
Page 48 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
e--mail: . info@normet.fi
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
Page 49 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
Page 50 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
e--mail: . info@normet.fi
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
Page 51 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
Page 52 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
e--mail: . info@normet.fi
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
Page 53 (55)
Normet Oy
Ahmolantie 6
FI--74510 IISALMI
FINLAND
1 --- 1 GB 0996 US
Safety Instructions
Page 54 (55)
Tel. . . . . +358 (0)17 83 241
Fax. . . . +358 (0)17 8324 308
e--mail: . info@normet.fi
www. . . normet.fi
1 --- 1 GB 0996 US
Safety Instructions
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Technical Bulletin
0199 - 99 - 3005/9 EN
This Circular supersedes: TR 0199-99-3005/8
DEUTZ engines
● All above-mentioned DEUTZ engines
● Product number(s) EKZ:
All product code numbers
● Assemblies:
99
Fuels
The 9th replacement was introduced due to more detailed specifications of:
● introduction of engines with new emission stages Tier 4 interim and stage IIIB.
● Extension of biodiesel releases
● Revision of fuel standards
General
This bulletin defines for which compact engines of the DEUTZ brand the following fuels are
approved:
● Diesel fuels
● MDF distillate fuels
● Light heating oils
● Jet fuels
● Biofuels
Note:
The part numbers indicated in this document are not subject to updating.
Binding for the identification of spare parts is exclusively the spare parts documentation.
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Distillate fuels with residue oil percentages or mixed fuels may not be used in DEUTZ com-
pact engines.
The DEUTZ vehicle engines are designed for diesel fuels in accordance with EN 590 with
a cetane number of at least 51. DEUTZ engines for mobile work machinery are designed
for a cetane number of at least 45. When using fuels with a low cetane number, a disturbing
formation of white smoke and ignition stutter is to be expected under some circumstances.
This Technical Bulletin applies for all air-cooled and liquid-cooled compact engines of the
DEUTZ brand. For engines which are no longer in production, this TB applies accordingly.
This TB only applies up to year of production 2000 for engines of the 226 series.
A cetane number of at least 40 is approved for the US market, therefore special engine ver-
sions were developed to avoid starting difficulties, extreme white smoke or increased hy-
drocarbon emissions. If the use of fuels with a very low cetane number is also known in
advance in other countries, we recommend ordering the engines in EPA versions. It is gen-
erally recommened to use fuels with a higher cetane number than the minimum require-
ment of 40 in winter.
Fuels must be used which are regulated in the respective national regulations (e.g. in Ger-
many by the 10th BimSchV). No fuels which deviate from these national regulations may
be used (e.g. no fuel may be used in Europe if it only meets the limit values of the US stand-
ard purely by chance).
The certification measurements for compliance with the legal emission limit values are car-
ried out with the test fuels specified in the laws. These correspond with the diesel fuels ac-
cording to EN 590 and ASTM D 975 described in the following section. No emission values
are guaranteed with the other fuels described in this bulletin. The owner is obliged to check
the permission for the use of fuels according to the regional regulations.
Engines which are equipped with exhaust gas after-treatment by particle filters (DPF), die-
sel oxidation catalytic converters (DOC), particle oxidation catalytic converters or an SCR
system (Selective Catalytic Reduction) may only be operated with sulphur-free diesel fuels
(EN 590, DIN 51628, ASTM D975 Grade 2-D S15, ASTM D975 Grade 1-D S15 or heating
oil in EN 590 quality). Otherwise compliance with the emission requirements and durability
is not guaranteed.
In a warranty case the customer must prove by a certificate from the fuel supplier that a re-
leased fuel was used.
The following list specifies the released fuels for the different series and emission stages,
the following text contains further data about these releases:
OBJ_DOKU-22583-001.fm 2 / 36 © 2010
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0199 - 99 - 3005/9 EN
up to from up to up to from
Jet fuels - - - - -
up to from up to from
Jet fuels
- - - -
3 4
Biodiesel (up to 100 % EN14214,
up to 20 % ASTM D7467) - -
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Restrictions
1 Release only for heating oils with EN 590 quality but less strict limit values for density, viscosity
and sulphur content, see chapter Non-road fuels and light heating oils.
2 Release only for heating oils with EN 590 quality, see chapter Non-road fuels and light heating oils.
3 Release up to 30 %(V/V) EN14214 at replacement interval of the SCR catalytic converter of
200,000 km, see chapter Biofuels.
4 Release for engines as of 01.07.2010, retrofitting possible in earlier engines.
US biodiesel release up to 50 % (V/V) for MSHA engines
5 Release for US diesel fuel according to ASTM D975 S15 only
6 Does not apply for the 1015M series
Diesel fuels
Diesel fuels are released and can be used according to the following specifications:
Fuel Specifications
DIN EN 590 (biodiesel content max. 7 %(V/V)) Appendix 2
DIN 51628 (biodiesel content max. 7 %(V/V)) Appendix 3
ASTM D 975-09b Grade 1-D S15 Appendix 4
ASTM D 975-09b Grade 1-D S500 Appendix 4
ASTM D 975-09b Grade 2-D S15 Appendix 4
ASTM D 975-09b Grade 2-D S500 Appendix 4
JIS K 2204 No. 1, No. 2, No. 3 Appendix 5
NATO F-54, equivalent to diesel fuel in accordance with EN 590 Appendix 2
US fuels in accordance with ASTM D 975 1-D S500 and ASTM D 975 2-D S500 are not
released for engines from Tier 4 interim or Stage IIIB.
Japanese diesel fuels according to JIS K 2204 Grade 1 Fuel und Grade 2 Fuel are only re-
leased if the lubricating properties correspond with diesel fuel EN 590 (HFRR max. 460 mi-
crometer according to EN ISO 12156-1).
The EN 590 standard has the status of a national standard in the countries of the EU, e.g.
DIN EN 590. The NATO fuel F-54 is equivalent to diesel fuel in accordance with EN 590.
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Mixing with petrol is not permissible for safety and technical reasons (cavitation in the in-
jection system).
Diesel fuels up to -44 °C are available for an Arctic climate. Mixing flow improvers with the
diesel fuel is possible. The choice of a suitable additive and the necessary dosing and mix-
ing procedure must be discussed with the fuel supplier.
If only summer diesel fuel is available, petroleum can be added to the diesel fuel up to 30
% (V/V) at low temperatures as shown in the diagram below.
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The mixing should take place in the engine tank: First fill in the necessary amount of petro-
leum and then add the diesel fuel.
For engines with common rail injection, the mixing of petroleum and adding of extra low ad-
ditives is not permissible. Fuels in accordance with ASTM D 975 Grade 1-D or DIN EN 590
- Arctic-Diesel may have no petroleum added.
Fuel Specifications
DIN ISO 8217 DMX Appendix 6
DIN ISO 8217 DMA (restriction: sulphur content max. 1,0 %(m/m) Appendix 6
NATO F-75 Appendix 7
NATO F-76 Appendix 8
● The cetane number must be at least 40, otherwise starting difficulties, extreme white
smoke or increased hydrocarbon emission may occur.
● At a density of > 0.860 g/cm3 a return blocking on the injection pump is necessary (may
only be done by personnel authorised by DEUTZ).
● The possible high sulphur content 0.5 %(m/m) requires a shorter lubricating oil
change interval. Fuels with a sulphur content > 1.0 %(m/m) are not permissible due to
higher corrosion and considerable shortening of the engine life. It must also be pointed
out that fuels in accordance with ISO 8217 DMA are only permissible when the maxi-
mum sulphur content is 1.0 %(m/m).
● Low-ash oils (low SAPS) are not permissible already at sulphur contents >50 mg/kg,
i.e. are not usually suitable for marine fuels.
● Because of the possible heavy contamination, great emphasis must be placed on fuel
cleaning and possibly the installation of an additional fuel filter with a water trap to avoid
biological contamination especially.
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● For engines up to Tier 2 / Stage II and engines up to Tier 3 / Stage IIIA with mechanical
injection, the following light heating oil may be used:
Fuel Specifications
DIN 51603-1 Appendix 9
● For all engines up to Tier 3 / Stage IIIA, other light heating oils and non-road fuels may
be used if they comply with all the limit values of EN 590 except for the fuel density, the
cetane number, and the sulphur content. The following limit values apply for these pa-
rameters:
● For engines from Tier 4 interim / Stage IIIB, light heating oils may only be used if they
comply with all the limit values of EN 590.
● The cetane number must be at least 40 otherwise starting difficulties, extreme white
smoke or increased hydrocarbon emission may occur.
● Light heating oils and non-road fuels are not generally released for commercial vehicle
engines.
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Jet fuels
The following jet fuels can be used:
Fuel Specifications
F 34/F 35 (kerosene, NATO designation) Appendix 10
F 44 (kerosene, NATO designation)
F-63 (kerosene, NATO designation, equivalent to F-34/F-35 with additives)
F-65 (kerosene, NATO designation, 1:1 mixture of F-54 and F-34/F-35) Specifications
available on re-
JP-8 (kerosene, US military designation)
quest
JP-5 (kerosene, US military designation)
Jet A (kerosene for civil aviation)
Jet A1 (kerosene for civil aviation)
● There are some problematical fuel properties amongst the listed jet fuels (viscosity, lu-
bricating capacities and low boiling point). A slight increase in wear in the injection sys-
tem is to be expected which can lead to a statistically shorter life of these components.
The engine guarantee is maintained when these fuels are used.
● Jet fuels can be mixed with each other. Mixing of kerosene with diesel fuel in accord-
ance with EN 590 in order to improve the flow properties in winter operation is permit-
ted.
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Bio fuels
The generic term biofuels includes biodiesel and pure vegetable oils.
Bio-diesel
Biodiesel is Fatty Acid Methyl Ester (FAM) of the vegetable oil. It is produced on a large
scale by re-estering of vegetable oil and methanol to glycerine and fatty acid methly ester.
It is possible to use different vegetable oils such as soya oil, palm oil, rape seed oil or sun-
flower seed oil.
In Europe biodiesel must comply with the EN 14214 standard. Because the biodiesel qual-
ities available on the market do not always meet the requirements, DEUTZ customers in
Germany are recommended to ensure the quality by buying biodiesel with an AGQM cer-
tificate (Association for Biodiesel Quality Management). The customers should also have
compliance with the quality demands confirmed by the supplier by submission of a current
analysis certificate of an ISO 17025 certified laboratory.
The use of US biodiesel, based on soya oil methly ester, is only permissible in mixtures with
diesel fuel with a maximum biodiesel content of 20 %(V/V). The US biodiesel used for the
mixture must comply with the ASTM D6751-09a (B100) standard. Users are recommended
to use biodiesel qualities with a quality certified in accordance with BQ 9000.
Fuel Specifications
Biodiesel according to EN 14214 Appendix 11
US biodiesel blends according to ASTM D7467 - 09a (B100) Appendix 12
(only for biodiesel mixtures with diesel fuel of 6-20 %(V/V))
US biodiesel according to ASTM D6751 - 09a (B100) Appendix 13
(only permissible for mixtures with diesel fuel of 20-50 %(V/V))
Released engines
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0199 - 99 - 3005/9 EN
tive mixture for up to 20 %(V/V) US biodiesel in accordance with the ASTM D7467-09a
standard. For engines operated within the jurisdiction of the Mine Safety and Health
Administration (MSHA), additive mixtures of up to 50 %(V/V) US biodiesel in accord-
ance with ASTM D6751-09a are permissible.
Mixtures of US-biodiesel with diesel fuel are not very suitable for cold conditions so that
their use in winter is not recommended.
Engines with an earlier production date can be retrofitted. Head office can provide in-
formation about the scope of the retrofit.
● Turbocharged engines are excepted from the release for applications which are nor-
mally operated with a high load above 80% nominal power; these are, for example, en-
gines in block type heating power stations.
● Engines for Tier 4 interim / Stage IIIB are not released for biodiesel at present. Howev-
er, suitable tests are being planned.
● Because of the low heating value, a power loss of 5-9 % and an extra fuel consumption
of 7-8 % in comparison with diesel fuel according to EN 590 is possible. Increasing of
injection fuel quantity to compensate the lack of power is not allowed.
● The lubricating oil change interval must be halved in comparison with operation with
diesel fuel according to EN 590.
● Standstill times of longer than 4 weeks must be avoided with biodiesel. Otherwise the
engine must be started and shut down with diesel fuel.
● Engines with a low annual running time, e.g. emergency generators, are excluded from
operation with bio-diesel.
● In series engines, the fuel pipes, the fuel manual supply pumps, and the LDA dia-
phragms (series 1012/1013/2012/2013/TCD 2012 2V mechanical and TCD 2013 2V
mechanical) are not resistant to biodiesel and must be changed annually.
● To avoid the annual replacement, a piston with an LDA diaphragm resistant to biodie-
sel fuel was introduced. This piston can be ordered from DEUTZ Service with part
number 02113543 if required. Since the fuel pipes can dissolve prematurely at increas-
ing fuel temperature and high running performance, they may have to be replaced be-
fore one year is up. The fuel pipes must be checked for damage (swelling) in the course
of daily maintenance E 20. The use of biodiesel-resistant fuel pipes (Viton) is recom-
mended; in this case the annual replacement can be dispensed with.
● Biodiesel can be mixed with normal diesel fuel but the basic conditions described in
this section apply for mixtures. Mixtures containing up to 7 %(V/V) biodiesel (B7) as
they are permitted in EU countries according to national laws are excepted. However,
the biodiesel mixtures must comply with EN 14214 in any case.
● Approx. 30-50 oh after changing over from diesel fuel to bio-diesel, the fuel filter should
be changed as a precaution to avoid a drop in performance due to clogged fuel filters.
Deposited fuel ageing products are dissolved by bio-diesel and transported into the
fuel filter. They should not be changed immediately, but after approx. 30 to 50 hours,
because the dissolving of dirt takes a certain amount of time.
● All parts carrying fuel which are installed later (by OEM or end customers, e.g. fuel pre-
filter and fuel pipes) must be suitable for operation with biodiesel.
● To increase the oxidation stability of the used biodiesel and to improve the storability
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and reduce deposits and clogging in the injection system, it is recommended to use the
DEUTZ additive "DEUTZ Clean-Diesel InSyPro" in the recommended concentration
(see Technical Bulletin 0199-99-1210).
Plant oil
Pure plant oils (e.g. rape seed oil, soy oil, palm oil) are not classified as bio-diesel and ex-
hibit problematic properties for engines which were not designed for operation with plant
oils (strong tendency to coke, risk of piston seizure, extremely high viscosity, poor evapo-
ration behaviour).
● Because of the lower heating value, a power loss of 5-10 % and an extra fuel consump-
tion of 4-5 % in comparison with diesel fuel according to EN 590 is possible. Blocking
up of the injection pump is not allowed.
● The engine is a two-tank system with switching between diesel fuel and rape seed oil.
Alternatively biodiesel can be used instead of rape seed oil or diesel fuel.
● At temperatures below 5 °C, rape seed oil should be replaced by diesel fuel or biodie-
sel.
● Shutdown periods of longer than 4 to 6 weeks must be avoided with bio-diesel and rape
seed oil. Otherwise the engine must be started and stopped with diesel fuel.
● The lubricating oil change interval must be halved in comparison with operation with
diesel fuel according to EN 590.
● Important fuel properties such as water content, oxidation stability, calcium, magnesi-
um and phosphorus content and the total contamination are influenced especially by
the harvest time, the pressing process in the oil mill, the storage of the rape seed oil
and the further logistics chain. Because of the frequent exceeding of the limit values at
distributed oil mills, the user is recommended to have the quality of the rape seed fuel
delivery confirmed by an analysis certificate. In cases of doubt, the quality can be cer-
tified by an analysis carried out by a laboratory accredited according to ISO 17025,
(e.g. ASG Analytik GmbH, D-86356 Neusäß, Tel. ++49 (0)821-450-423-0).
● Mixtures with other plant oils such as sunflower seed oil, soya oil or palm oil are not
permissible. Pure vegetable oils (e.g. rape seed oil, soya oil, palm oil) are not classified
as biodiesel and have problematical properties in engines which were not developed
for vegetable oil operation (great tendency for coking, danger of piston seizure, ex-
tremely high viscosity, poor evaporation behaviour.
● To increase the oxidation stability of the used biodiesel and to improve the storability
and reduce deposits and clogging in the injection system, it is recommended to use the
DEUTZ additive "DEUTZ Clean-Diesel InSyPro" in the recommended concentration
(see Technical Bulletin 0199-99-1210).
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Notes for the storage of rape seed oil in fuel stations for own use:
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Symptoms
The following symptoms may indicate that a fuel tank is contaminated by micro-organisms:
Cause
Micro-organisms (bacteria, yeast, fungus) can multiply into biosludge under favourable
conditions (especially favoured by heat and water).
The water entry is usually caused by condensation of the water contained in the air. Water
dissolves poorly in fuel so that the water which enters sinks to the bottom of the tank. The
bacteria and fungi grow in the watery phase at the boundary with the fuel phase from which
they draw their nutrition. There is an increased risk especially with biodiesel (FAME).
In suspicious cases biological contamination according to DIN 51441 (determination of the
number of colonies in mineral oil products in the boiling range below 400 °C) can be ana-
lysed by laboratories certified according to ISO 17025 (e.g. Petrolab GmbH, D-67346 Sp-
eyer, Tel.: ++49 (0) 6232-33011).
Remedial measures
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Fuel additives
The DEUTZ Clean-Diesel InSyPro additive is released exclusively for use in DEUTZ en-
gines. See Technical Bulletin 0199-99-1210 for notes on use and dosing.
The previously mentioned flow improvers (not for DEUTZ Common Rail engines) are an-
other exception. The use of other fuel additives is prohibited. Voiding of the warranty is to
be expected when unsuitable, unapproved additives are used.
Fuel filters
Modern diesel engines, especially with high-pressure injection and common rail injection
system make very high demands on the fuel quality. The Deutz original fuel filters are
adapted and tested for these demands. Continuous, trouble-free operation of the engines
is only guaranteed when the original filters are used. In case of damage to the injection sys-
tem within the warranty period and proof that no original filters were used, the warranty will
be voided.
Please contact the following persons if you have any questions about the listed topics.
Contact:
DEUTZ Engines
E-mail: lubricants.de@deutz.com
or
E-mail: service-kompaktmotoren.de@deutz.com
Service Information
This document has been created digitally and is valid without a signature.
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Appendix 1
General information on fuel properties, exhaust gas after-treatment systems and emission regulations
Density
The density is usually specified in g/cm3 or kg/m3 at 15 °C and is important for converting
the fuel consumption from volume to weight unit. The higher the density, the greater the
weight of the injected fuel. At the same control linkage setting, the engine output increases
with higher density.
Boiling curve
The boiling curve indicates how many volume% of the fuel is overdistilled at a certain tem-
perature. The greater the boiling residue (amount remaining after evaporation), the more
combustion residue may occur in the engine, especially in partial load operation.
Viscosity
The kinematic viscosity in mm2/s at a certain temperature (1 mm2/s = 1 cSt [centistoke]) is
specified. The viscosity must be within certain limits for engine operation. Too high viscosity
requires pre-heating.
Flashpoint
The flashpoint has no significance for the engine operation. It applies as a value for the fire
hazard and is important for classification in one of the hazard classes (decisive for storage,
transport and insurance).
Sulfur content
High sulfur content and low component temperature can cause increased wear due to cor-
rosion. The sulfur content influences the lubricating oil change intervals. Too low a sulfur
content may impair the lubricity of the fuel if this has not had lubricity improvers added.
Coke residue
The coke residue serves as a reference value for the tendency for residue to form in the
combustion chamber.
Water
Too high a water content leads to corrosion and, in connection with corrosion products and
sediments, to sludge. Disturbances in the fuel and injection system are the result.
Ash
Ash is carbon-free combustion residue which can lead to wear due to deposits in the engine
and turbocharger.
Sediments/total contamination
Sediments are solids (dust, rust, scale) which can cause wear in the injection system and
combustion chamber as well as leaks in the valves.
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Behaviour in cold
The following parameters indicate the suitability of the fuel for low temperatures:
● The solidification point indicates at what temperature the fuel no longer flows under its
own weight.
● The pour point is approx. 3 °C above the solidification point.
● The cloud point indicates at what temperature solid emissions (paraffin) are visible.
● The limit of filtrability (CFPP) indicates at what temperature filters and pipes may be
blocked.
Heating value
The lower heating value (Hl) indicates the amount of heat which is released when burning
1 kg of fuel.
Neutralisation number
The neutralisation number is a measure of the content of free acids in the diesel fuel or bio-
diesel fuel. It describes the amount of potassium lye required for neutralising the acids. Acid
compounds in the fuel lead to corrosion, wear and formation of residue in the engine.
Copper corrosion
Diesel fuel can act corrosively especially during prolonged storage with fluctuating temper-
ature and formation of condensation on the tank walls. To test the limit values specified in
DIN EN 590 and DIN 51628, a polished copper strip is brought into contact with diesel fuel
at 50 °C for 3 hours. Appropriate additives ensure protection of the metals which come into
contact with the fuel even under difficult conditions.
Oxidation resistance
Fuels may oxidise and polymerise partly during long storage. This can lead to the formation
of insoluble (varnish like) ingredients and the associated filter blockage.
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Lubricity
The lubricity decreases with the degree of desulphurisation and can drop to a level that
leads to considerable wear in the distributor injection pumps and common rail systems. Ex-
tremely desulphurised fuels contain special lubricity additives. The HFRR test (High Fre-
quency Reciprocating Wear Rig) was developed for evaluating the fuels (EN ISO 12156-1).
This test simulates the sliding wear in the injection pump by rubbing a ball on a polished
steel plate with constant contact force. The flattening of the ball after 75 minutes is meas-
ured as an average wear diameter (limit value 460 µm).
Bio-diesel
Biodiesel is made by re-estering of greases or oils (triglyceride) with methanol. The correct
chemical name is fatty acid methyl ester, often abbreviated to FAME. In Europe it is usually
produced by re-estering of rape seed oil (rape seed oil methyl ester = RME). In the USA,
biodiesel comes almost exclusively from soya oil (soya methyl ester = SME). Other vege-
table oils (sunflower seed oil, palm oil, jatropha oil) or animal fats are also possible.
Due to national and EU regulations biodiesel (FAME) percentages are now possible or pre-
scribed in most diesel fuels. In the new EN 590 max. 7 %(V/V) are permissible for example,
in the US-ASTM D975 max. 5 %(V/V). According to the biofuel quota law, at least 5 %(V/
V) FAME must be mixed with the normal, commercially available diesel in Germany.
Conversion ppm
The term parts per million (ppm) is often used in fuel analyses.
The term ppm alone is not a unit of measure. It usually describes the weight concentration
(1 ppm (m/m) = 1 mg/kg). 1 ppm = 10-6 = parts per million = 0,0001 %
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Emission laws for mobile work machinery (including building machinery, tractors, compressors, mobile elec-
tricity units)
Europe and the USA have largely similar emission legislations so that the stages specified
for EU and the USA in one line in the following table are both satisfied by an engine devel-
oped for this. The dates for introduction and limit values differ for different performance cat-
egories. The dates for the category >130 kW are the first respectively for a certain stage.
Fuel laws have also been introduced appropriate to the emission laws. For the work ma-
chinery, the limit values from stage IIIB or Tier 4 interim are so low that exhaust gas after-
treatment systems such as particle filters or SCR have to be introduced in most cases. Sul-
phur-free fuels are largely required for this and these are legally prescribed for the specified
dates. Exhaust gas after-treatment has been introduced for commercial vehicle engines as
of EURO IV.
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Appendix 2
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Appendix 3
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Appendix 4
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Appendix 5
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Appendix 6
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Appendix 7
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Appendix 8
– collected at 350 ℃
Kinematic viscosity at 40 ℃ mm2/s 1.7 - 4.3 IP 71
Flashpoint °C min. 61 IP 34
Cloud point °C max. -1 IP 219
Pour point °C max. -6 IP 15
Ash content %(m/m) max. 0.01 IP 4
Neutralisation number mg KOH/g max. 0.3 IP 139
Neutralisation number mg KOH/g 0.0 IP 182
(water soluble acids)
Sulphur content %(m/m) max. 1.0 ** IP 336
Corrosion effect on copper Degree of cor- max. 1 IP 154
rosion
(3 h at 100 ℃ )
Coke residue %(m/m) max. 0.2 IP 14
(from 10 % distillation residue)
Cetane number min. 45 ASTM D 613
Sediments mg/l max. 10
* national specifications
EN = DEF. STAN 91-4
US = MIL-F-16884 J
FR = STM 7120 B
NL = KN 10323
** Observe national requirements, max. 1.0 %(m/m)
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Appendix 9
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Appendix 10
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Appendix 11
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Appendix 12
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Appendix 13
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Appendix 14
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Appendix 15
Limit values for countries in which none of the named diesel fuels released by DEUTZ exist
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Technical Bulletin
0199-99-1210/0 EN
This Circular supersedes:
DEUTZ engines
All current DEUTZ engines
Product number(s) EKZ:
All product codes of the DEUTZ engines named above
Assemblies:
99
General
Greater percentages of biodiesel (FAME) are now contained in diesel fuels in accordance
with EU directives and many other national regulations. The current diesel fuel standards
in Germany (DIN 51628 / DIN EN 590) and in Europe enable biodiesel percentages up to
7 %(V/V).
There are also special diesel/biofuel blends of up to 30 %(V/V) (B30, B20) which national
regulations in France or Italy allow for example.
Outside Europe (USA, Soth America, Asia) fuel blends based on soya oil methyl ester
(SME) are often produced. SME is of a much poorer quality in its chemical properties, es-
pecially the oxidation stability, than biodiesel in accordance with EN 14214 which is normal-
ly produced based on rape seed methly ester.
These bio components in the fuel behave differently to fuels without bio components added,
especially during storage.
The biodiesel components in the fuel can decompose under the influence of temper-
ature, air oxygen and time. This produces deposits in the injection system during op-
eration which can lead to sticking of the injectors and pumps especially in the
current Common Rail injection systems. The results are ignition failure, black
smoke, starting problems and increased fuel consumption.
Note:
The part numbers indicated in this document are not subject to updating.
Binding for the identification of spare parts is exclusively the spare parts documentation.
0199-99-1210/0 EN
Deposits from a pump plunger after longer standstill with a diesel fuel containing bi-
odiesel.
To avoid these negative influences, DEUTZ AG has now developed a fuel additive specially
adapted to the DEUTZ engines which prevents premature ageing of the biodiesel parts and
can effectively eliminate deposits which have already been left.
The fuel additive is released for all current engine series up to EPA TIER 3 / EU Stage IIIA.
0199-99-1210/0 EN
Main properties
"Keep Clean"
Increase in the oxidation stability of the used fuel when using biogenic fuels (biodiesel
(FAME) or plant oils).
Protects against deposits and sticking.
Therefore prolongs the storage time of these fuels.
Reduces incidences of filters becoming contaminated and clogged.
For preservation of engines which are out of operation for a long time.
Devices with longer storage periods without operation (e.g. new devices in the deliv-
ery).
Operation with biodiesel (FAME).
Operation with pure vegetable oil (only applies for DEUTZ Natural Fuel Engine ®).
“Clean-Up”
Dissolves deposits in injectors, injection pumps and lines and makes them as good as
new provided there is no mechanical damage.
Increased smoke values are normalised.
Reduces fuel consumption with improved engine performance.
Protects against corrosion.
Improves poor lubricating properties.
The above properties were proven both in laboratory tests and in practical use.
Only "DEUTZ Clean Diesel InSyPro" has the release for use in DEUTZ engines, other prod-
ucts available on the market do not have this release!
0199-99-1210/0 EN
The additive is suitable for all internationally approved diesel and biodiesel fuels as well as
diesel/biodiesel blends.
In addition, tests on injection components in use in the field have revealed that these can
be returned to a functioning state in case of problems by treating with "DEUTZ Clean Diesel
InSyPro" and therefore save cost-intensive exchange.
Machine downtimes are also avoided in addition to saving costs.
For the above reasons we urgently recommend the use of "DEUTZ Clean Diesel InSyPro"
when the following conditions are satisfied:
1 Devices which are not put into operation at the OEM or for more than 3 months after
production.
"Keep Clean"
2 Devices which are operated in regions with poor quality fuel.
“Clean-Up”
3 If problems in the injection system (start problems and increased smoke values) are
reported, at least one or better still two tank fillings should be operated with the additive
in the fuel before exchanging expensive components.
“Clean-Up”
4 Operation with biodiesel (FAME) or with vegetable oil (only applies for DEUTZ Natural
Fuel Engine ®), see Technical Bulletin 0199-99-3005 for fuels.
"Keep Clean"
5 Preservation of engines. (See Technical Bulletin 0199-99-1170).
"Keep Clean"
6 Engines which are shut down at the end customers for more than 3 months (e.g. har-
vesting machinery).
"Keep Clean"
0199-99-1210/0 EN
Available under:
- Part no.:
01017967
- Container size:
1 litre
0199-99-1210/0 EN
Application instructions
For good mixing first put in the additive and then top up with diesel fuel.
Avoid overdosing!
Dosing
- 1:400 for "Keep Clean"
Please contact the following persons if you have any questions about the listed topics.
Contact:
DEUTZ Engines
E-mail: service-kompaktmotoren.de@deutz.com
Service Information
This document has been created digitally and is valid without a signature.
2
2 Monitor installation/Surveiller l’installation/
Monitor-Installation/L’installazione del monitor/
Vigilar la instalación/Monitor installatie
3
3 Connections/Connexions/Verbindungen/
Connessioni/Conexiones/Aansluitingen
4
4 Controls/Contrôles/Kontrollen/Controlli/Controles/
Controles/
1
2
3
4
5
1 2
1 2
3 MENU 4 UP 5 DOWN
5
1 Controls/Contrôles/Kontrollen/Controlli/Controles/
Controles
x1=
3 MENU
3 MENU x 0.5sec =
5 DOWN = UP =
6
2 Operation/Opération/Betrieb/Operazione/Operación/
Werking
Auto Power
4 MENU x 20sec =
4 MENU x 20sec =
7
3 Set up menu/Menu setup/Setup Menü/Menu setup/Menú
setup/Setup menu
4 MENU x 0.5sec =
1. CAMERA SETTING
2. TRIGGER SETTING
3. AUTO SCAN SETTING
4. DAY/NIGHT SETTING
5. ADVANCED MENU
1. LANGUAGE: [ENGLISH;DEUTCH;
FRANCAIS;ITALIANO;ESPANOL]
2. AUTO POWER: [ON]
3. FACTORY RESET
MENU =
8
4 Specifications/Spécifications/ Spezifikationen/
Specifiche/Especificaciones/Specificaties
ENGLISH FRANCAIS
Specifications Specifications
Monitor BE-970WM Moniteur BE-970WM
TV system NTSC/PAL Système TV NTSC/PAL
Picture 7" TFT LCD colour monitor with Image 7" TFT LCD moniteur couleur avec
on-screen display function affichage de fonction (OSD)
Display size 7" diagonal Dimension de l’ecran 7" diagonal
Field of view Top: 50°, Bottom: 60°, Left: 65°, Champ de vision Haut: 50°, Bas: 60°, Gauche: 65°,
Right: 65° Droite: 65°
Resolution (800x3(RGB)x480) Résolution (800x3(RGB)x480)
Picture image Factory set to reverse image Image vidéo Réglage d’usine sur image inverse
Power 12~24Vdc input Alimentation 12~24Vdc input
Inputs 2 x camera Entrées 2 x caméra
Dimensions 194(w) x 124(h) x 48(d)mm Dimensions 194(w) x 124(h) x 48(d)mm
7.6(w) x 4.9(h) x 1.9(d) inches 7,6(w) x 4,9(h) x 1.9(d) inches
Operating -40°C ~ +70°C Température -40°C ~ +70°C
temperature -40°F ~ +158°F d'utilisation -40°F ~ +158°F
ITALIANO DEUTSCH
Specifiche Spezifikationen
Schermo BE-970WM Monitor BE-970WM
Sistema TV NTSC/PAL TV-System NTSC/PAL
Immagine 7" TFT LCD colour monitor with Bild 7" TFT LCD Farbmonitor mit Funk-
on-screen display function tionsanzeige (OSD)
Formato display 7" diagonale Bildschirmgröße 7" diagonal
Campo visivo Top: 50°, Bottom: 60°, Left: 65°, Sichtfeld Oben: 50°, Unten: 60°, Links: 65°,
Right: 65° Rechts: 65°
Risoluzione (800x3(RGB)x480) Auflösung (800x3(RGB)x480)
Immagine a video Immagine reversibile program- Videobild Werkseinstellung Reversebild
mabile Stromversorgung 12~24Vdc input
Alimentazione 12~24Vdc input Eingänge 2 x kamera
Prese 2 x telecamera Abmessungen 194(w) x 124(h) x 48(d)mm
Dimensioni 194(w) x 124(h) x 48(d)mm 7.6(w) x 4.9(h) x 1.9(d) inches
7.6(w) x 4.9(h) x 1.9(d) inches Betriebstemperatur -40°C ~ +70°C
Temperatura di -40°C ~ +70°C -40°F ~ +158°F
servizio -40°F ~ +158°F
9
7 Specifications/Spécifications/Spezifikationen/
Specifiche/Especificaciones/Specificaties
ESPANOL NEDERLANDS
Especificaciones Specificaties
Monitor BE-970WM Monitor BE-970WM
Sistema de TV NTSC/PAL TV-systeem NTSC/PAL
Imagen Monitor a color de 7" TFT LCD Beeld 7" TFT LCD colour monitor with
con visualización de las funciones on-screen display function
(OSD) Displayformaat 7" diagonaal
Tamaño de pantalla 7" diagonal Gezichtsveld Boven: 50°, Onder: 60°, Links:
Campo visual arriba: 50°, abajo: 60°, a la izqui- 65°, Rechts: 65°
erda: 65°, a la derecha: 65° Resolutie (800x3(RGB)x480)
Resolución (800x3(RGB)x480) Videobeeld Fabrieksinstelling reversebeeld
Imagen de vídeo Ajuste de fábrica de la imagen Stroomvoorziening 12~24Vdc Ingang
inversa
Ingangen 2 x camera
Suministro de 12~24Vdc entrada
corriente Afmetingen 194(w) x 124(h) x 48(d)mm
7.6(w) x 4.9(h) x 1.2(d) inches
Entradas 2 x cámara
Bedrijfstemperatuur -40°C ~ +70°C
Dimensiones 194(w) x 124(h) x 48(d)mm -40°F ~ +158°F
7.6(w) x 4.9(h) x 1.2(d) inches
Temperatura de -40°C ~ +70°C
servicio -40°F ~ +158°F
Dénégation
Les systèmes de moniteurs des caméras sont une aide précieuse pour le conducteur, mais
celui-ci doit toutefois prendre toutes les précautions nécessaires pendant les manœuvres.
Brigade ou ses distributeurs n’assument aucune responsabilité résultant de l’utilisation ou d’un
défaut du produit.
Verzichterklärung
Die Kamerabildschirmsysteme sind eine wertvolle Hilfe für den Fahrer, entbinden ihn jedoch
nicht von der notwendigen Sorgfalt beim Manövrieren des Fahrzeuges. Brigade und seine Ver-
triebshändler haften nicht für Schäden aus der Nutzung oder einer Fehlfunktion des Produktes.
Disconoscimento
I sistemi di monitor della telecamera sono un aiuto prezioso per il conduttore, ma non lo eson-
erano dall’obbligo di prendere le precauzioni necessarie durante le manovre del veicolo. Brid-
age e i suoi distributori non si assumono nessuna responsabilità per danni risultanti dall’utilizzo
o da un malfunzionamento del prodotto.
Negante
Los sistemas de pantalla de cámara son una valiosa ayuda destinada a los conductores; en
todo caso no les resta la responsabilidad de proceder con precaución a la hora de maniobrar
con el vehículo. Brigade y sus distribuidores comerciales no se responsabilizan de los daños
derivados de un mal funcionamiento del producto.
Verwerping
De camera-monitorsystemen zijn een waardevolle hulp voor de bestuurder, ontheffen hem
echter niet van de nodige zorgvuldigheid bij het manoeuvreren van het voertuig. Brigade en zijn
distributeurs zijn niet aansprakelijk voor schade door gebruik of een gebrek van het product.
11
OPERATION AND
MAINTENANCE
MANUAL
SCREW COMPRESSOR
PTR-40-HV
INTRODUCTION
This operation and maintenance manual for PTR-40-HV informs you about all details required
to install, start, operate and maintain the compressor unit. In addition to operation manual, fully
illustrated manuals concerning lubrication, manual, parts as well as workshop manual are also
included.
This operating manual describes how the machine must be handled and operated in order to achieve
safe operation, maximum efficiency and long service live.
Read the operating manual before starting the machine, so that appropriate handling, operation and
maintenance is ensured from the very beginning. The maintenance plan contains all measures required
to keep the machine in good condition. Maintenance must be executed regularly.
Keep the operating manual available for the operators and take care that operation and maintenance is
performed according to the instructions. Enter all operating data, executed maintenance measures in
an operating log book. Repair and maintenance work should be performed by qualified personnel only.
When ordering spare parts it is very important to mention complete compressor name and mode, serial
number as well as order number of the spare part needed.
If you do not observe this operating instruction and/or arbitrarily change the unit or components
supplied by Paineteho, you forfeit any claim under warranty. Please contact customer service
department if initial troubles or breakdowns occur.
The manufacturer assumes no responsibility for any damage or injury caused by ignoring these safety
provisions or the usual carefulness and precaution during handling, operation, maintenance and repair,
even if they are not expressly mentioned in this operating manual.
The manufacturer reserves the right to make technical changes without prior notice.
3
PTR-40-HV JBPTR40HV03082 1.1
TABLE OF CONTENTS
INTRODUCTION ................................................................................... 3
4
PTR-40-HV JBPTR40HV03082 1.1
ANNEXES
Annex A Maintenance intervals
Annex B Procedures done prior to, during and after operation
5
PTR-40-HV JBPTR40HV03082 1.1
Compressor type plates are found in the frame outside and inside.
2 WARRANTY TERMS
2.1 General
PTR -compressors are thoroughly tested at the production plant. Correctly operated and installed,
they are fail-safe. The PTR- warranty includes all components (as long as the term of warranty
applies). Claims that fall under this warranty are ones where delivered product does not comply with
specifications defined in order agreement.
Respecting the indicated working temperatures avoids the formation of condensate in the screw
compressor. Warranty does not apply in case of damages caused by condensation.
Compressor oils
Only those types of oil may be filled in, which have been classified by the oil producer as appropriate
for screw compressors. In case of doubt, please consult Paineteho prior to filling in the oil in order
to determine the appropriate type of oil. In case defects occur having used inappropriate types of oil
results in the loss of the warranty.
Compressor components are designed for ambient temperatures of +0°C to + 35°C / 28°F to 104°F.
Operation at other ambient temperatures is only permitted after having consulted Paineteho.
6
PTR-40-HV JBPTR40HV03082 1.1
The company‘s obligation under this warranty is limited to repairing or, at its option, replacing,
during normal business hours at an authorized service facility of the company, any part which in its
judgement proved not to be as warranted within the applicable warranty period as follows.
Compressor units
Compressor unit, consisting of all parts within and including the compressor cylinder and gear
housing, are warranted for 24 months from the date of initial use or 27 months from the date of
shipment to the purchaser, whichever occurs first.
Any disassembly or partial disassembly of the air end, or failure to return the „unopened“ air end per
Company instructions, will be cause for denial of warranty.
Compressor package
All other components in the compressor package are warranted for 12 months from the date of initial
use or 15 months from the date of shipment to the purchaser, whichever occurs first.
Spare parts
The genuine spare parts delivered by the Company are warranted for 6 months from the date of
shipment to the purchaser.
Costs
All costs of transportation, freight, importation or insurance or local taxes or customs clearances
of product or parts claimed not to be as warranted and, of repaired or replacement parts to or from
such service facility shall be borne by the Purchaser. The Company may require the return of any
part claimed not to be as warranted to one of its facilities as designated by Company, transportation
prepaid by Purchaser, to establish a claim under this warranty.
Replacement parts provided under the terms of this warranty, are warranted for the remainder of the
Warranty Period of the Product upon which installed to the same extent as if such parts were original
components.
2.3 Disclaimer
The foregoing warranty is exclusive and it is expressly agreed that, except as so title, the Company
makes no other warranties, expressed, implied or statutory, including and implied warranty of
merchantability.
The remedy provided under this warranty shall be the sole, exclusive and only remedy available to the
Purchaser and in no case shall the Company be subject to any other obligations or liabilities. Under
no circumstances shall the Company be liable for any special, indirect, incidental or consequential
damages, expenses, losses or delays howsoever caused.
Under no circumstances and in no conditions, the Company’s liability, whether in respect of one claim
or in the aggregate, arising out of any contract shall not exceed the purchase price payable under the
contract for such part in which Company’s liability shall arise.
This warranty shall not be effective as to any claim which is not presented within 30 days after the
date upon which the Product is claimed or should have been claimed not to have been as warranted.
Any action for breach of this warranty must be commenced within one year after the date upon which
the cause of action occurred.
7
PTR-40-HV JBPTR40HV03082 1.1
No claim will be considered, and the warranty will be considered null and void, if other than genuine
parts are used in the Product.
The obligations under this warranty are limited at Company’s option, to:
- replace the part, free of charge, Ex Works Kuopio (Incoterms 1990) or
- repair the part free of charge, Ex Works Kuopio (Incoterms 1990) or
- refund the part at Company’s order price.
The Purchaser shall retain the claimed part or Product for six (6) months for Company’s inspection
and on request the alleged defective part shall be sent to a destination designated by the Company at
the Purchaser’s costs. After warranty handling, the title to the defective parts shall be transferred to the
Company.
Any adjustment made pursuant to this warranty shall not be construed as an admission by the
Company that any Product was not as warranted.
The warranty shall not be suspended on the grounds of non-use, intermittent use or for any other
reason.
8
PTR-40-HV JBPTR40HV03082 1.1
3 TECHNICAL SPECIFICATIONS
Compressor unit
Model..…………………………………............. TEMPEST 12
Speed of rotation………………………….......... Max. 6500 rpm and min: 1000 rpm
Working pressure..……………………............... 7.0 bar
Calculated capacity............…………………...... 4.00 m³/min
Weight..……………………………………….... 180 kg
Direction of rotation……………………............. Check the arrow on top of the compressor unit
Hydraulic motor
Rated power…………………………………..... 19 cm³
Rated rotation speed.......……………………...... 3600 rpm
Pressure...……………………………………..... 250 bar
Oil flow...........………………………….............. 68 l/min
Safety valve
Activating pressure……………………….......... 14.5 bar
Operating requirements
Minimum ambient temperature……………….... + 0 °C
Maximum ambient temperature………………... + 35 °C
Maximum angle of tilt......................................... See chapter 3.2 Angles of tilt, page 10
Oil capacity
Total oil capacity………..........……………........ 20 Liters.
9
PTR-40-HV JBPTR40HV03082 1.1
Compressor can be tilted as indicated in the angle of tilt -sign that is located on top of the compressor.
It is forbidden to exceed those values. If the compressor is tilted more than advised, oil can flare
up and mix with the exhaust air. When the amount of oil in the compressor is reduced, compressor
overheats and is shut down.
PTR-40-HV compressor can be tilted 7 degrees maximum towards the oil separator unit and 25
degrees to other directions.
There are links on the corners of the compressor top to esure safe lifting. These lifting points are
pointed with signs (see figure below).
10
PTR-40-HV JBPTR40HV03082 1.1
This chapter deals with safety issues in general. It is suggested to study safety instructions introduced
in other chapters as well. All the safety instructions must be studied before starting to work with the
compressor. In addition to these instructions and regulations, local regulations must be taken into
consideration.
ATTENTION - IMPORTANT!
These provisions shall apply for screw-type compressor components of the PAINETEHO company.
The relevant manufacturers’ provisions shall apply for components of other manufacturers or
suppliers, respectively. Please read them carefully and act accordingly when you install, start or repair
the machine or its components.
If any of the provisions contained in this list (especially concerning safety) does not comply with local
provisions of law, the safer provision must be applied.
4.2.1 Installation
In addition to the general technical operation according to the regulations of the local authorities, the
following guide lines must be strictly observed:
1. Use an appropriate hoist complying with the local safety regulations to lift a screw-type compressor.
Secure all loose and swinging parts such that they cannot be moved before lifting the machine. It
is strictly forbidden to be in the danger area of a lifted load. The acceleration and deceleration of
transportation must stay within permissible limits.
2. Remove all blind flanges, plugs, caps and bags containing drying agents before assembling the
tubes. Unions and tube connections must have the right size and be fit for the relevant operating
pressure. Screw connections must be torqued to the indicated values, unless otherwise indicated.
11
PTR-40-HV JBPTR40HV03082 1.1
3. The unit must be installed in a place where the ambient air is as cool and clean as possible. Never
obstruct admission of air. Make sure that moisture in the intake air is kept to a minimum.
4. The intake air must not contain any inflammable vapors, such as paint solvents, which may cause an
internal fire.
5. Air cooled machines must be installed such that an adequate flow of cooling air is provided and that
the outlet air does not recirculate into the inlet.
6. Use pneumatic hoses that are rated to withstand the working pressure. Pay special attention to the
hose mountings. A whipping hose may cause unpredictable damage.
7. There might be some oil in the water condensate. Notice the regulations concerning the oil remove!
8. Prevent the exhausted air from recirculating to the intake. Make sure that foreign objects cannot get
into the compressor with the intake air. Arrange the air intake such that loose clothes cannot be drawn
in.
9. Make sure that the pressure pipe from the compressor to the after cooler or air delivery main can
expand due to the heat and does not come into contact with inflammable material.
10. If a remote control is provided, the unit must be equipped with a clearly visible plate with the
following lettering: Warning: This unit is operated by remote control and could start without any
warning. As an additional protective measure, persons who start a unit by remote control must make
sure that no person is checking or operating the unit. For this purpose, a corresponding plate must be
provided at the remote control unit.
11. Screw-type compressors must in principle be set up on a level surface and levelled with a spirit
level as necessary. In exceptional cases, for example in the case of portable systems, the latter must be
operated within maximum angle of tilt limits. See chapter 3.2 Angles of tilt, page 10.
4.2.2 Operation
4.2.3 Maintenance
Maintenance and repair work may only be executed under the supervision of a person qualified for
this work.
1. Use only the right tools designed for maintenance and repair work.
2. Use only original spare parts. When ordering spare parts it is necessary to indicate model, machine
number and spare part number.
3. Execute any repair or maintenance work other than current repair work only when the unit is
switched off and the mains supply is disconnected. Make sure that the unit cannot be switched on
unintentionally. The shut-off valve to the pressurized air network should also be closed.
12
PTR-40-HV JBPTR40HV03082 1.1
4. Shut off the unit from all pressure sources and discharge the entire unit from pressure before
removing a part under pressure. It may take 1 to 2 minutes to depressurize the whole compressor.
Make sure that the air/oil receiver is pressureless before you start maintenance.
5. Do not use inflammable solvents or carbon tetrachloride to clean parts. Take precautions against
toxic vapors of cleaning solvents.
6. Take care that extreme cleanliness is observed during maintenance or repair work. Keep away dust.
Cover parts or bare openings with a clean cloth, paper or adhesive tape.
7. Do not repair the container by welding. Do not weld or perform any other work requiring heat near
the oil system.
8. Make sure that no tools, loose parts or cleaning rags are left in or on the unit.
9. Before releasing the unit for operation after it has been maintained or overhauled, check whether
the operating pressure temperatures and time adjustments are correct and the control and switch-off
devices in perfect working order.
10. Protect the motor, the air filter, electrical components, control system against moisture, when
cleaning them by means of steam jet.
12. Do not use corrosive solvents, which could affect the materials of the air delivery main, such as
poly carbonate bowls.
13. All alterations must conform to the regulations concerning pressure vessels.
14. Starting of compressors with remote control must be prevented while maintenance work is in
progress.
15. Do not neglect the regular check-ups and maintenance of the compressor.
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PTR-40-HV JBPTR40HV03082 1.1
Read manual before Electric voltage Compressor oil type
operating
Air exhaust
14
PTR-40-HV JBPTR40HV03082 1.1
5 OPERATING MANUAL
PTR-compressors are used to produce compressed air. The air in compressed in compressor unit,
which is powered by electric motor. PTR-compressors can also be powered by hydraulic motors.
Meshed rotors suck air between rotor cogs while at the inlet opening. When rotors rotate, the
connection to the inlet opening closes and the space between cogs gets smaller. In the end of
compression the desired pressure is achieved and connection to the oil separator unit opens.
Oil is injected to the screw unit to cool the unit and the compressed air. It also lubricates bearings and
seals clearances of rotors and housing.
Main parts of the screw unit are the frame of the unit (1), two rising rotors (2, 3), pressure flange (4)
and bearing shield (6). Rotors are connected to the frame (1) and to the pressure flange (4) through
bearings. Drive shaft and the fan axel (7). In cases where there is separate air module, the screw unit
comes without fan axel.
15
PTR-40-HV JBPTR40HV03082 1.1
The frame (1), in which the oil separator unit is located. Main
part of the oil is separated in the oil separator unit and the rest in
the oil separator cartridge (3). The meshed rotors that produce
compressed air are located in the screw unit (2).
3. Oil cooler
4. Prefilter mats
5. Fans
Fan takes air through the prefilter mat and cools the oil cooler.
Fan is attached to the shaft of the ait end.
16
PTR-40-HV JBPTR40HV03082 1.1
Air filter is located in the filter housing (1). Air filter and
cyclone (2) are located on top of the compressor. Air filter filters
the intake air of the compressor.
7. Coupling housing
8. Coupling
17
PTR-40-HV JBPTR40HV03082 1.1
1. Pressure gauge
Pressure gauge (bar) is located in the meter board and shows the
pressure of the compressor.
18
PTR-40-HV JBPTR40HV03082 1.1
5. Safety valve
Minimum pressure valve makes sure the pressure will not drop
under minimum pressure.
1. Hydraulic motor
3/2 Direction valve makes sure that the motor cannot be rotated
to the wrong direction.
19
PTR-40-HV JBPTR40HV03082 1.1
20
PTR-40-HV JBPTR40HV03082 1.1
21
PTR-40-HV JBPTR40HV03082 1.1
22
PTR-40-HV JBPTR40HV03082 1.1
23
PTR-40-HV JBPTR40HV03082 1.1
5.1.8 Hoses
Table 2. Hoses
Figure 35.Hoses 1
24
PTR-40-HV JBPTR40HV03082 1.1
Figure 36.Hoses 2
25
PTR-40-HV JBPTR40HV03082 1.1
26
PTR-40-HV JBPTR40HV03082 1.1
27
PTR-40-HV JBPTR40HV03082 1.1
Coil
1. Whether compressor temperature rises to 100 °C, signal light H38 light up indicating danger of
compressor overheating
2. Whether compressor temperature rises up to 115 °C, is compressor overheated and shuts down.
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PTR-40-HV JBPTR40HV03082 1.1
29
PTR-40-HV JBPTR40HV03082 1.1
1. Start:
Air inlet valve (1) is closed. After starting compressor intakes air from non-return valve (2).
Compressor achieves adjusted minimum pressure (4 to 4.5 bar) using minimum pressure valve (3).
.
2. Output
Shut-off valve is open. Maximum pressure valve (6) closes 3/2 direction valve (5). Adjusting air
directs air inlet valve (1) according to air consumption/pressure.
3. Maximum pressure
No air intake, shut-off valve closed. Maximum pressure valve (6) closes air inlet valve and opens 3/2
direction valve (5). Compressor runs idle at maximum pressure. Maximum pressure is controlled with
maximum pressure valve (6).
4. Shut down
When compressor is shut down, air inlet valve (1) and minimum pressure valve (3) are closed. 3/2
direction valve (5.1) opens and compressor minimum pressure is exhausted.
5. Pressure difference
Pressure difference is seen in pressure gauge by pressing pressure difference button (5.2). Pressure
difference is measured before and after oil separator and shown by pressure gauge. If the pressure
difference is 0.5 to 1 bar, oil separator elements must be replaced. Pressure difference with new
separator elements is 0.2 bar.
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PTR-40-HV JBPTR40HV03082 1.1
31
PTR-40-HV JBPTR40HV03082 1.1
In addition to the general technical operation according to the regulations of the local authorities, the
following guide lines must be strictly observed:
1. Use an appropriate hoist complying with the local safety regulations to lift a screw-type compressor.
Secure all loose and swinging parts such that they cannot be moved before lifting the machine. It
is strictly forbidden to be in the danger area of a lifted load. The acceleration and deceleration of
transportation must stay within permissible limits.
2. Remove all blind flanges, plugs, caps and bags containing drying agents before assembling the
tubes. Unions and tube connections must have the right size and be fit for the relevant operating
pressure. Screw connections must be torqued to the indicated values, unless otherwise indicated.
3. The unit must be installed in a place where the ambient air is as cool and clean as possible. Never
obstruct admission of air. Make sure that moisture in the intake air is kept to a minimum.
4. The intake air must not contain any inflammable vapors, such as paint solvents, which may cause an
internal fire.
5. Air cooled machines must be installed such that an adequate flow of cooling air is provided and that
the outlet air does not recirculate into the inlet.
6. Use pneumatic hoses that are rated to withstand the working pressure. Pay special attention to the
hose mountings. A whipping hose may cause unpredictable damage.
7. There might be some oil in the water condensate. Notice the regulations concerning the oil remove!
8. Prevent the exhausted air from recirculating to the intake. Make sure that foreign objects cannot get
into the compressor with the intake air. Arrange the air intake such that loose clothes cannot be drawn
in.
9. Make sure that the pressure pipe from the compressor to the after cooler or air delivery main can
expand due to the heat and does not come into contact with inflammable material.
10. If a remote control is provided, the unit must be equipped with a clearly visible plate with the
following lettering: Warning: This unit is operated by remote control and could start without any
warning. As an additional protective measure, persons who start a unit by remote control must make
sure that no person is checking or operating the unit. For this purpose, a corresponding plate must be
provided at the remote control unit.
11. Screw-type compressors must in principle be set up on a level surface and levelled with a spirit
level as necessary. In exceptional cases, for example in the case of portable systems, the latter must be
operated within maximum angle of tilt limits. See chapter 3.2 Angles of tilt, page 10.
Following instructions apply to PTR-compressors in general. One must always study each compressor
and its manual thoroughly before installation and operations.
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PTR-40-HV JBPTR40HV03082 1.1
ATTENTION!
Oil tank is to be filled with recommended coolant. Before initial start-up 0,5 liter oil is poured
to into compressor screw unit (intake opening). This procedure is repeated every time the
compressor has been unused more than a months period of time. See instructions chapter 6.3
Compressor lubrication before initial start-up on page 37.
1. Air conditioning must me adequate around the compressor and the cooling air must be of
temperature between +0°C and +35°C.
2. Around the compressor there must be enough space to perform maintenance duties.
3. Compressor is installed always on level position. Compressor can be tilted, but only according to
given values. See chapter 3.2 Angles of tilt, on page 10.
4. Between compressor and compressed-air network must be flexible connector and shut-off valve.
5. The direction of rotation must be checked and corrected before initial start-up as well as every time
the compressor is reconnected to electric network.
5.3.3 Start up
Every PTR-compressor is thoroughly tested at the factory before delivery. Testing ensures that
compressor meets the technical needs set for it and that it functions properly. It is however
advised to keep an eye on the compressor during initial operating hours to discover any possible
disfunctionalities.
When the compressor is running, let it run idle about one (1) minute unloaded or as long as it
needs the pressure to reach normal level. See reading from pressure gauge. If the compressor is
loaded right away, it is possible for oil to foam.
Avoid repeatedly opening and closing the shut-off valve. If however it is opened and closed in
small intervals, it may cause oil to foam and leak to the air filter and output air.
1. Compressor must be connected only to appropriate voltage. See type plates of the electric motor.
Make sure that the direction of rotation is correct.
2. Compressor must not be loaded over maximum pressure. See compressor type plate.
3. Compressor is to be installed so that the ambient temperature is between 0° and 35°C.
4. One must never shut compressor down by using the main electric switch.
5. Check oil level.
6. The direction of rotation must be checked before initial start-up and every time it is reconnected to
electrical network. Direction of rotation is checked by starting the motor up for a moment.
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PTR-40-HV JBPTR40HV03082 1.1
34
PTR-40-HV JBPTR40HV03082 1.1
6 LUBRICATION MANUAL
Only the suitable oils can be used in operating PTR- compressors. Oil must be approved by the
manufacturer. The oil must also be suitable for use in unfavorable conditions such as contamination
of the intake air by gases, solvent vapors, exhaust gases as well as in conditions with high ambient
temperature.
Suitable types and brands of oil can be specified on request. Suitable oils can be mineral oils, synthetic
oils as well as biological degradable oils. The substances and materials used in compressors such as
seals must be taken into account when selecting the oil type. Corrosion or other material degradation
must not occur.
Oil refill:
Use the same product and the same oil type. Different types of oil must no be mixed.
Pipeline materials:
The oil used in compressor may attack compressed-air pipeline networks made of plastic.
Caution:
Absolutely observe the oil viscosity, otherwise the life of the bearings is at risk.
Cold starts:
When effecting compressor cold starts, it is equally important that upon the start the viscosity of the
oil, taking into account that the pressure drop is higher when the oil circuit is still cold, facilitates a
sufficient and immediate lubrication of the compressor. The higher demand for energy of cold starts
may not overload the compressor machinery.
Oil separation:
In the upper range, the fine separation of oil decreases as the compressor outlet temperature increases.
Multigrade oils:
The problem with some multigrade oils is that after a certain period of time the molecular chains of
their viscosity improvers can get what you could call “cut into small pieces” (sheared off). When this
happens, the upper viscosity grade is endangered and therefore the oil does no longer offer complete
temperature stability. For this reason multigrade oils are not to be used for PTR-compressors.
35
PTR-40-HV JBPTR40HV03082 1.1
From the screw compressor unit pressured air/oil mist is goes to the oil separator unit in which they
are separated. There are two phases in oil separating process. The most of the oil is separated in the
cyclone of the separator unit employing centrifugal force. Remaining oil is separated in oil separator
cartridge (1).
From the oil separator cartridge the separated oil is lead back to the oil circulation through oil return
lead (2). In the return lead there is an orifice plate (3) to prevent excessive air flow back to the unit.
From the oil separator unit the hot oil is lead through the cooler (7) and oil filter (4) back to cool the
screw unit. There is a thermostat (5) in the container, which leads the oil pass the cooler if the oil
is already cold. Oil circulation is forced and is maintained by the pressure difference between the
container and the screw unit.
To ensure oil circulation all times while air is produced is the compressor equipped with an minimum
pressure valve (6). Minimum pressure valve controls the pressure in the container and ensures that it
does not drop under minimum value (3 bar).
Safety valve (8) protects the oil separator cartridge from excessive pressure. Valve prevents the
pressure rising to dangerous levels by opening at certain pressure.
36
PTR-40-HV JBPTR40HV03082 1.1
It is of great importance to lubricate the compressor unit before initial start-up and every time the
compressor has not been used for a months period of time or longer. Pour 0,5 liter oil into the intake
opening.
37
PTR-40-HV JBPTR40HV03082 1.1
1. Keep an eye on the hour meter and follow instructions concerning lubrication intervals.
2. Before oil change, drain or refill the compressor must be fully shut down, depressurized and in level
position. After shut down compressor should be depressurized after one to two minutes.
Confirm zero pressure from the pressure gauge!
3. In case of oil refill right after operation, one must wait at least 15 minutes to make sure that oil
foam has vanished to indicate correct oil level.
6. Check the condition of the sealing gaskets (do not forget to put them back)
7. When an engine is drained, clearly mark it so that it is not operated before it is refilled.
38
PTR-40-HV JBPTR40HV03082 1.1
7 MAINTENANCE MANUAL
Maintenance and repair work may only be executed under the supervision of a person qualified for
this work.
1. Switch off all the operations of the compressor from the main switch before starting any
maintenance work and make sure it is not switched on unintentionally.
2. Execute maintenance and repair work only when the unit is completely discharged.
3. Use only original spare parts and the right tools designed for maintenance and repair work.
4. Execute any repair or maintenance work only when the unit is switched off and the mains supply is
disconnected. Make sure that the unit cannot be switched on unintentionally. The shut-off valve to the
pressurized air network should also be closed.
5. Shut off the unit from all pressure sources and discharge the entire unit from pressure before
removing a part under pressure. Make sure that the air/oil receiver is pressureless before you start
maintenance.
6. Do not use inflammable solvents or carbon tetrachloride to clean parts. Take precautions against
toxic vapors of cleaning solvents.
7. Take care that extreme cleanliness is observed during maintenance or repair work. Keep away dust.
Cover parts or bare openings with a clean cloth, paper or adhesive tape.
8. Make sure that no tools, loose parts or cleaning rags are left in or on the unit.
9. Before releasing the unit for operation after it has been maintained or overhauled, check whether
the operating pressure temperatures and time adjustments are correct and the control and switch-off
devices in perfect working order.
10. Protect the motor, the air filter, electrical components, control system against moisture, for
instance when cleaning them by means of steam jet.
12. Do not use corrosive solvents, which could affect the materials of the air delivery main, such as
poly carbonate bowls.
13. All alterations must conform to the regulations concerning pressure vessels.
14. Starting of compressors with remote control must be prevented while maintenance work is in
progress.
15. Do not neglect the regular check-ups and maintenance of the compressor.
16. When switching the unit back on again, make sure there is no person working on the machine.
Make sure that all connections are properly tightened and all safety installations are in perfect working
order.
39
PTR-40-HV JBPTR40HV03082 1.1
DANGER! - Surfaces inside the compressor cabinet are hot immediately after shutting
down the compressor!
40
PTR-40-HV JBPTR40HV03082 1.1
41
PTR-40-HV JBPTR40HV03082 1.1
42
PTR-40-HV JBPTR40HV03082 1.1
See pages 39 and 40 for safety instructions and procedures prior to operation.
ATTENTION! Drain the condensate regularly when the screw compressor unit is cold, for
instance before start-up. It is of advantage if the unit has been standing still for a
longer time.
The condensate content in the oil affects operating safety and life of the screw compressor unit. If
you operate the screw compressor unit for a short period of time and consequently at low operating
temperature, for instance below the switch temperature of the thermal oil bypass valve, condensate
will possibly accumulate in the oil separator receiver. The relative humidity in the intake air
determines the quantity of condensate.
Possible Malfunctions:
-Insufficient lubrication of the screw unit.
-Insufficient air/oil separation and high differential pressure in the purifier cartridge.
-Corrosion and rust formation due to condensate in the oil.
Drain the condensate regularly when the screw compressor unit is cold, for instance before start-up. It
is of advantage if the unit has been standing still for a longer time.
Maintenance Procedure:
1. Switch off unit with main switch and position switch (prevent it from being switched on
unintentionally).
2. Slowly unscrew cover screw of oil filling pipe. Figure 51.
3. Oil drain points are located underneath the compressor. After placing a container underneath the
drain hoses, open drain valves.
4. Drain the condensate unti oil comes out, than close drain valves.
5. Fill receiver with oil up to maximum, then close oil filling pipe manually with the cover screw.
6. Switch on compressor unit and let it run for approximately three (3) minutes.
7. Stop the compressor and let it cool down approximately two (2) minutes.
8. Check oil level: if oil is missing, fill up to maximum.
9. Dispose of condensate in accordance with regulations.
Figure 51. Oil filling pipe Figure 52. Oil sckecking glass
43
PTR-40-HV JBPTR40HV03082 1.1
See pages 39 and 40 for safety instructions and procedures prior to operation.
DANGER! - Use recommended oil types only; do not mix different oils!
- Oil is hot when the compressor has just been stopped!
- Do not open the oil filling plug if the receiver is pressurized!
- Dispose of used oil according to current local regulations on handling of waste oil!
Adding oil
1. Open the plug of oil filling pipe (Fig. 53) and the hose connection (Fig. 54) and add oil up to top
mark of the measuring glass. Fig. 55.
2. Close the plug and hose connection. Figs. 53-54.
4. Close the safety valve and open shut-off valve.
Oil change
1. Run the compressor until the oil temperature is +40...50 °C.
2. Open the oil filling plug and place a contaner underneath the oil drain valves. Open the drain valves
and plugs and let the oil drain.
3. Close the drain valves and add oil up to the maximum of the oil measuring rod. Figure 55.
4. Close the oil filling pipe plug. Figure 53.
5. Close the safety valve and open the net work shut-off valve.
Check also the condition of oil hoses and if necessary change defected ones. Oil filter is also usually
changed while the compressor is drained. See chapters 7.4.3 Changing oil hoses, on page 45 and 7.4.4
Changing oil filter, on page 46.
Figure 53. Oil filling pipe Figure 54. Hose connection Figure 55. Oil measuring glass
44
PTR-40-HV JBPTR40HV03082 1.1
See pages 39 and 40 for safety instructions and procedures prior to operation.
Checking and/or changing the oil hoses are done at the same time as oil change.
45
PTR-40-HV JBPTR40HV03082 1.1
See pages 39 and 40 for safety instructions and procedures prior to operation.
ATTENTION! - Allow the compressor to cool down before starting the work.
- Dispose the used filter according to regulations on toxic waste.
- Use only the original oil filters.
1. The oil filter (1) is located in the compressor unit. Use protective cloth, as some oil will drain out
when the filter is being removed.
2. To remove the filter, turn it counterclockwise with a oil filter wrench.
3. Lubricate the oil filter sealing ring of the new filter with clean oil.
4. Screw the new oil filter cartridge on the fitting by hand, without using any tool.
5. Check whether the oil filter is tight when the unit is running.
46
PTR-40-HV JBPTR40HV03082 1.1
See pages 39 and 40 for safety instructions and procedures prior to operation.
For the operational safety of the screw compressor unit, clean the cooler weekly and more often if it
is necessary. Keep the cooling ribs of the cooler clean. This is a prerequisite for achieving optimum
cooling power. Adequate cooling means low oil temperature and thus longer service life.
We recommend cleaning with compressed air, steam jet or cleansing agent. Should the intake
air (cooling air) be strongly contaminated, clean the cooler in shorter intervals, especially if the
compressor outlet temperature is above the normal value.
In case a prefilter mat is fitted before the screw compressor, shake out the dust or replace mat daily.
Maintenance procedure:
1. Switch off system and protect it against unauthorized re-starting.
2. Remove the bolts and other fasteners and remove the covering metal shield of the cooaler end.
3. Clean the oil cooler.
4. After cleaning, put back the prefilter mat and close the stand.
47
PTR-40-HV JBPTR40HV03082 1.1
See pages 39 and 40 for safety instructions and procedures prior to operation.
DANGER! - Allow the compressor to cool down before starting the maintenance work!
- Dispose used separator element according to regulations on handling toxic
waste!
1. Detach air hoses and remove bolts (4 pieces) of the cover of the recceiver (1).
2. Remove the body of the minimum pressure valve/the cover of the receiver (1).
3. Remove the oil separator elements (2). Use tool to assist. See figure 67.
4. Clean the sealing surfaces on the receiver and the minimum pressure valve body (1).
5. Clean the orifices (3) inside the pipe.
6. Clean the oil return filter and assemble in reverse order. See chapter 7.4.9 Cleaning and changing
oil return filter on page 50.
7. Grease the O-rings of the separator elements and install new separator elements (2) into place.
8. Change the O-ring (5) between the receiver and the minimum pressure valve.
9. Place the cover of the receiver/body of the minimum pressure valve back on. Make sure that the
plugs of the receiver cover match with the holes in the separator elements.
10. Tighten the screws alternately to even tightness.
48
PTR-40-HV JBPTR40HV03082 1.1
Fig. 59. Bolts 4 pieces. Fig. 60. Tool used to remove elements
Fig. 61. Cover and O-ring removed Fig. 62. Removing separator elements
Fig. 63. Oil separator element removed Fig. 64. Elements replaced. Installling the cover.
49
PTR-40-HV JBPTR40HV03082 1.1
See pages 39 and 40 for safety instructions and procedures prior to operation.
50
PTR-40-HV JBPTR40HV03082 1.1
51
PTR-40-HV JBPTR40HV03082 1.1
See pages 39 and 40 for safety instructions and procedures prior to operation.
Figure 72. Air inlet valve bolts Figure 73. Removable hex. socket screws
Figure 74. Thread bars, nuts and screws Figure 75. Spring and piston
52
PTR-40-HV JBPTR40HV03082 1.1
Reference numbers in the table correspond with numbers in the air inlet valve explosion diagram!
See the diagram on the next page!
53
PTR-40-HV JBPTR40HV03082 1.1
Figure 76. Explosion diagram, Air inlet valve (fig © Gardner Denver)
54
PTR-40-HV JBPTR40HV03082 1.1
See pages 39 and 40 for safety instructions and procedures prior to operation.
See pages 39 and 40 for safety instructions and procedures prior to operation.
Control valves include 3/2 direction valves and maximum pressure valve. The following instructions
apply to all the valves listed.
Figure 78. 3/2 direction valves Figure 79. Maximum pressure valve Figure 80. 3/2 direction valve
55
PTR-40-HV JBPTR40HV03082 1.1
See pages 39 and 40 for safety instructions and procedures prior to operation.
Changing the maintenance kit (See pictures from the next spread)
1. Detach minimum pressure valve hoses.
2. Tighten the nut and release the spring.
3. Remove the retaining ring.
4. Lift the cover up.
5. Change parts 3, 4, 8, 9, 13, 14.
6. Assemble in reverse order.
Changing the repair kit (See pictures from the next spread)
1. Detach minimum pressure valve hoses.
2. Tighten the nut and release the spring.
3. Remove the retaining ring.
4. Lift the cover up.
5. Change parts 3-5, 7-17, 19.
6. Assemble in reverse order
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PTR-40-HV JBPTR40HV03082 1.1
Fig. 81. Explosion diagram, minimum pressure valve (Fig. © Gardner Denver)
57
PTR-40-HV JBPTR40HV03082 1.1
Fig. 82. Minimum pressure valve Fig. 83. Tightening the nut
Fig. 84. Removin lock ring Fig. 85. Removing minimum pressure valve
Fig. 86. Minimum pressure valve detached Fig. 87. Minimum pressure valve
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PTR-40-HV JBPTR40HV03082 1.1
See pages 39 and 40 for safety instructions and procedures prior to operation.
ATTENTION! Make sure that no dust get into the compressor’s intake air!
DANGER! Never clean the filter with gasoline or any fluids!
Main element of the air cleaner (2) is cleaned when service indicator light is on.
Main element is changed after four times of cleaning and if necessary. However, at least once a year.
If the intake air is very dusty are the cleaning and changing intervals shorter that in normal conditions.
Underneath the main element (2) there is a safety cartridge (3) (secondary element), which is replaced
after the main element has been changed four times or after 500 operating hours, or when necessary
for instance in case of main element failure. Safety cartridge is to be changed after two years of use at
the latest.
Maintenance operations:
1. Switch off system and protect it against unauthorized re-starting.
2. Clean the dust discharge valve by compressing it sideways to remove the dust. Dust discharge valve
is located on the bottom of the filter lid. See picture 108.
3. Open filter lid (1) and carefully remove dust.
4. Remove the main element (2), clean or change it. Underneath the main element there is a secondary
element (3) (Safety cartridge).
a) Cleaning by knocking out: Knock the face of the cartridge several times against the ball of your
thumb so that dust falls off. Do not use force, avoid damaging the cartridge. Clean seating of
gaskets.
b) Cleaning by blowing: Blow cartridge surface with dry compressed air of no more than 5 bar at
an angle from the outside and the inside.
Figure 88. Air filter Figure 89. Main elenent Figure 90. Safety cartridge
(secondary element)
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PTR-40-HV JBPTR40HV03082 1.1
See pages 39 and 40 for safety instructions and procedures prior to operation.
ATTENTION! Make sure that no dust get into the compressor’s intake air!
Figure 91. Cyclone parts and air filter Figure 92. Cyclone bracket removed
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PTR-40-HV JBPTR40HV03082 1.1
See pages 39 and 40 for safety instructions and procedures prior to operation.
DANGER! - All the maintenance and adjustment procedures regarding safety valve are to
be done by professionals only!
The safety valve is spring-weighed. The blow-off pressure is 1 - 2 bar (14-28 psig) above the relevant
operating pressure (final pressure) of the unit. The valve is type-tested.
Safety valve is equipped with a testing device. The opening pressure of the pressure relief valve must
be tested in a separate pressurized air line.
! LOOK OUT FOR THE PRESSURE UNLOADING FROM THE SAFETY VALVE!
1. Turn the knurled screw (cap) (1) on the top 1-2 turns counterclockwise.
2. Reset the valve again by turning it clockwise until it stops.
3. Always tighten up the pressure relief valve cap properly to avoid damage caused by vibration.
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PTR-40-HV JBPTR40HV03082 1.1
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PTR-40-HV JBPTR40HV03082 1.1
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PTR-40-HV JBPTR40HV03082 1.1
Motor shuts Faulty motor Check wheter the shaft rotates, if not
down motor is broken and needs to be repaired
or replaced.
Faulty compressor unit Check the whether the screw unit
functions properly, if not must the unit be
repaired or replaced.
Inadequate oil flow to the motor Check the pressure and liters coming to
the motor. See technical information on
page 9.
Faulty coupling Check coupling, whether broken, replace
or repair.
Faulty or worn-out coupling Replace coupling element.
element
Too high working pressure Lower working pressure. See technical
details on page 9.
Low air output Dirty or clogged air filter Change air filter.
Faulty or clogged air inlet valve Repair valve, change seal kit.
Faulty or clogged 3/2 direction Check valve and replace if faulty.
valve
Clogged oil filter Change oil separator elements.
High air consumption Check hoses and fasteners for leakage,
repair if leaks found.
Incorrectly adjusted minimum Check pressure adjustments and readjust if
and maximum pressures necessary.
No air output Shut-off valve is closed Open shut-off valve.
Faulty or clogged 3/2 direction Check valve and replace if faulty.
valve
Faulty or clogged air inlet valve Repair valve, change seal kit.
High air consumption Check hoses and fasteners for leakage,
repair if leaks found.
Compressor is Too high angle of tilt Check angles of tilt and follow
leaking oil instructions.
Seal, connection or oil hose Check seals, hoses and connections and
leaks change or retighten if necessary.
Shut-off valve has been Do not open and close the valve in short
repeatedly opened and closed. intervals.
Oil hose leaks Check hoses and change if necessary.
When problem is located, add oil to meet the correct oil level.
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PTR-40-HV JBPTR40HV03082 1.1
8.1 General
This manual includes clear identification of all spare parts, components through explosion diagrams,
photographs and drawings. Also part lists of major components are included. When ordering spare
parts, it is important to mention compressor model, type, serial number and order number of the part
in question. Locations of the serial numbers are found on the type plates.
Quantity Description
0,14 Prefilter mat
0,23 Prefilter mat
1 Thermometer
1 Pressure gauge
2 3/2 Direction valve
1 Oil cooler
1 Hydraulic motor
1 Coupling
1 Coupling
1 Coupling
1 3/2 Direction valve (hydraulic)
1 Fan impeller
1 Coupling housing Tempest 12
1 Hour meter
1 Oil filter
1 Safety valve
1 Compressor unit
1 Air inlet valve
1 Minimum pressure valve
1 Air filter service indicator
1 Maximum pressure valve
2 Oil separator element
1 Air filter housing bracket
1 Air filter Europiclon 400
1 Cyclone
1 Intake hose
1 Intake hose
1 Non return valve
65
PTR-40-HV JBPTR40HV03082 1.1
8.3 Part lists and explosion diagrams of the compressors main components
8.3.1 Tempest 12
66
PTR-40-HV JBPTR40HV03082 1.1
7 1 Suction pipe
8 1 Measuring rod
9 1 Fitting
10 3 Filling plug
11 1 Oil checking glass
12 2 Bushing
13 1 Cyclone pipe
15 2 Oil separator
16 1 Oil thermostat element (Incl. spring)
17 1 Oil filter
18 1 Safety valve
19 1 Plug
21 1 Plug
22 1 Seal
23 4 Plug
24 1 Screw
25 1 O-ring
26 1 O-ring
27 1 O-ring
28 2 O-ring
29 1 O-ring
30 1 O-ring
31 1 O-ring
32 1 Seal
33 8 Screw
34 4 Screw
35 2 Screw
36 2 Screw
37 3 Screw
38 2 Spring washer
39 6 Screw
40 4 Screw
42 1 Part kit for discharge valve
43 See discharge valve
44 2 Screw
48 1 Fitting
50 2 Fitting
51 Orifice
52 1 Tube
52_1 3 Support bushing
55 1 Check valve
56 4 Seal
57 1 Oil pipe
58 1 O-ring
99 1 Spring
67
PTR-40-HV JBPTR40HV03082 1.1
Fig. 98. Explosion diagram, compressor unit Enduro 12 TS (Fig. © Gardner Denver)
68
PTR-40-HV JBPTR40HV03082 1.1
69
PTR-40-HV JBPTR40HV03082 1.1
Figure 99. Explosion diagram, minimum pressure valve (Figure © Gardner Denver)
70
PTR-40-HV JBPTR40HV03082 1.1
71
PTR-40-HV JBPTR40HV03082 1.1
Figure 100. Explosion diagram, air inlet valve (Figure © Gardner Denver)
72
PTR-40-HV JBPTR40HV03082 1.1
73
PTR-40-HV JBPTR40HV03082 1.1
74
PTR-40-HV JBPTR40HV03082 1.1
8.3.6 Hoses
No. Description
L1 Hydraulic motor pressure
L2 Hydraulic motor return
L3 Hydraulic motor leak
L4 Compressor drain
L5 Cooler drain
L6 Cooler in
L7 Cooler out
L8 Air out
L9 Hydr. 3/2 tank
L10 Hydr. 3/2 pressure A
L11 Hydr. 3/2 B
L12 Hydraulic cell in
L13 Block - cell 2Bar
L14 Hydraulic cell out
L15 Air out lead-through
L16 3/2 valve lead-through
L17 3/2 valve lead-through
L18 Cooler lead-through
L19 Cooler lead-through
L20 Motor lead-through
L21 Motor lead-through
L22 Fluid level gauge bottom
L23 Fluid level gauge top
L24 Block - cell
75
PTR-40-HV JBPTR40HV03082 1.1
ANNEXES
76
PTR-40-HV JBPTR40HV03082 1.1
Timing Procedure
Prior to operation Check the condition of electric motor and clean it if necessary.
Check oil level and the condition of oil hoses.
Check the condition of prefilter mat and clean it if necessary.
Check the oil cooler and clean it if necessary.
Check bolts and clamps and retighten if necessary.
Make sure that the direction of rotation is correct. This is to be
done at least when the compressor is reconnected to electric
network.
Whether ambient atmosphere is very damp, check the amount of
condensate and drain if necessary.
Check the ambients temperature and make sure it is between + 0
to +35 degrees Celsius.
Check the condition of the belts.
Check the overall condition of the compressor and act
accordingly.
During operation Monitor meter readings.
Make sure that intake air is fresh.
Check whether any of the signal light are on and act accordingly.
Listen to the compressor, if any unusual noises are discovered,
locate the sound origin and act accordingly.
Monitor the compressor, whether any malfunctioning is
discovered, locate the problem and act accordingly.
Avoid situations in which the shut-off valve is repeatedly
opened and closed. If however, it is opened and closed in small
intervals, it may cause oil to foam and leak to the air filter and
output air.
After operation Let the compressor run unloaded for two (2) minutes before
shutting down.
The compressor should cool down for fifteen (15) minutes
before starting any maintenance or repair work.
Compressor can be restarted after shut down when the pressure
has gone down to zero. This will take about one to two minutes
time. Monitor the pressure gauge reading.
Remember that compressor surfaces are hot after shut down.
77
Using the portable fire extinguisher
A dry powder fire extinguisher is suitable for extinguishing most types of fires (not suitable
for grease fires; risk of injury when sprayed at close distances). A fire extinguisher of this
type is not optimal for extinguishing fires affecting computers and other electronic
equipment, though.
Familiarize yourself with the fire extinguisher and its operating instructions before a fire
occurs.
Every year
1. Check the pressure.
2. Check the valve system.
3. Check the hoses.
4. Check the tank.
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