Vacall AS & AC Series

Transcription

1 Vacall AS & AC Series Service Manual Part Number VA0000S4759 Revision A March 13 th 2012 Gradall Industries, Inc. 406 Mill Avenue SW New Philadelphia, OH Parts Dept: Phone: Fax:

2 Chassis Engine Engine Oil While the Vacall is parked on level ground and the engine is off, check the engine oil level with the supplied dipstick. Oil level should be up to full mark. If the oil level is low, add the proper grade oil to the full mark. Check engine oil level daily. Add the proper oil as required to maintain the proper oil level. Also, inspect engine and components for leaks. Change the oil approximately every 150 hours. Lube Oil Filter Change filter every 150 hours or every time engine oil is changed. Engine Coolant When the engine is cool, check the radiator water level. If the coolant is low, fill to proper level with soft water or antifreeze. Do not overfill. If the coolant is repeatedly low, check for the source of coolant loss. Periodic topping of the engine radiator with water will eventually dilute the antifreeze mixture. Maintain proper antifreeze/water ratio according to local weather conditions. Check coolant level daily. If coolant is repeatedly low, check for leaks. Flush and clean the cooling system every 1000 hours. Refill with soft water and a high quality antifreeze. Power Steering Fluid Check power steering drive pump for proper fluid level. If the fluid level is low, add the proper fluid level to full mark (see chassis owner s manual). If the fluid is repeatedly low, check the power steering pump for the source of fluid loss. Air Cleaner Filter Check the filter gauge located on the filter housing for condition of air cleaner. Remove the element and clean with compressed air at a low pressure. If needed, change air filter as directed in chassis owner s manual. Replace annually or more often, if needed. Battery Check liquid level on 12 volt battery. If level is low, add distilled water or battery acid as needed. Maintain proper fluid level. Engine Belts Check all belts for proper tension and inspect condition of belts for cracks and fraying. Change belts as needed. Windshield Washer Fluid Maintain proper fluid level in the washer fluid reservoir. Automatic Transmission Fluid While the engine is running, check the transmission fluid level with the supplied dipstick. Fluid level should be up to full mark. If the fluid level is low, add the proper grade transmission fluid to the full mark (see chassis owner s manual). If the fluid level is repeatedly low, check the transmission for the source of fluid loss. Change transmission fluid every 1500 hours as recommended in the owner s manual. Fuel Tank Keep fuel tank filled to reduce condensation. Use only recommended grade diesel fuel. See chassis owner s manual.

3 Fuel Filter The location of the fuel filter will depend on the chassis make you are operating. Locate the fuel filter and check for filter condition. Change filter every 300 hours or anytime the fuel system becomes contaminated. Debris Body Clean & prime or paint exposed metal surfaces to prevent the formation of rust. This is particularly important on the inside walls, floor, & deflectors of the body. Be sure tailgate support has been installed in the proper position.

4 Power Module Hydraulic Oil Check the hydraulic oil level sight glass on the reservoir located directly behind the chassis cab. Hydraulic oil level should be between the black full level mark and the red low level mark. If the oil level is low, add proper grade hydraulic oil. Change semi-annually to ensure the long life of all hydraulic components. Change the hydraulic oil anytime it becomes contaminated. Clean the air breather every week. Replace a breather that cannot be cleaned adequately. Contamination Many hydraulic problems may be traced directly to the fluid. It is important that all foreign matter be kept from the hydraulic fluid. Invisible quantities of abrasive type contamination may cause serious pump wear, malfunctioning of pumps & valves, & sludge accumulations within the system in relatively short periods of time. It is also essential that moisture & water be kept from the hydraulic fluids & system. Commercial Hydraulic Fluid Testing Hydraulic fluid samples should be taken periodically for laboratory analysis. The actual sampling method is critical. It should be done based on ANSI Standard B93.19M (R1980). This standard is available from the National Fluid Power Association, 3333 N. Mayfair Rd, Milwaukee, WI Samples should be taken from the center of the reservoir when the fluid is at operating temperature & placed in a clean, dry, glass bottle with a non-shedding, screw-on cap. The bottle should be labeled with the date, type of fluid, & model & serial number of the machine. Two identical samples should be taken. One for laboratory analysis & one for your own preliminary analysis while you are waiting for the lab report. We recommend the use of commercial laboratory services for analysis of routine fluid samples taken on a regularly scheduled basis. The most important analysis is particle count, Spectro-chemical analysis, water content, & viscosity. In House Hydraulic Fluid Testing After your sample has been allowed to stand for 20 to 30 minutes to eliminate all air bubbles, hold the bottle up to the light to check for debris in the fluid & also check whether the fluid is clear or cloudy. Any visible debris is an indication of a severe solid contamination problem, the source of which must be located & corrected immediately. Common sources of this kind of contamination may be component wear, unsealed reservoir cover, or dirty air breather filters. If the sample is the least bit cloudy it may be an indication of water contamination, the source of which must be located & corrected immediately. Common sources are inadequate outdoor storage, unsealed reservoir covers or condensation. A Blotter Spot Test may also be performed to test for oxidation. Place a drop of fluid on a piece of white blotter paper (P/N ). Note: The blotter test will provide an indication that a more complete test may be necessary. If the blotter remains colorless or develops only a light yellow ring, oxidation is under control. If color develops but is uniform throughout, the fluid is still serviceable but should be checked for correct additive content. If the sample shows distinct rings, the fluid should be changed. If a distinct dark spot remains in the middle, but a lighter color fluid migrates outward in the blotter paper the fluid is about to dump sludge or other by-products into the system. The time for replacement of this fluid has already passed.

5 Hydraulic Return Filter Replace the filter semi-annually or anytime hydraulic oil is changed. Hydraulic System Inspect all hoses, fittings, central valves and cylinders for cracks, damage or leaks. Repair or replace as required. Transfer Case Oil When cool, check the transfer case oil level with the dipstick provided at the transfer case. The level should be to the full mark on the dipstick. Over the road service: Initial flush and oil change after 1000 miles of service, but not to exceed 4000 miles of service. Scheduled flush and oil change every miles of service after initial oil change. Water Pump Strainer Assembly On the suction side of the water pump, remove the hand nut on the strainer assembly and remove the basket screen. Clean as necessary with water. Grease Fittings Grease all fittings as indicated on grease point drawing. Fan Lubrication The amount & type of grease used for bearing lubrication contributes greatly to the fan s usable life. It is important to lubricate the fan after eight hours of use or at the end of the day. In extremely dusty environments, this interval should be increased to every four hours of operation. When lubricating the fan, the fan should be engaged & rotating at engine idle speed (700 to 800 RPM). This will allow for complete coverage within the bearing & also eliminate air pockets which may lead to condensation & displace any moisture that may have accumulated. It is important to use a hand held grease gun & grease both the inboard & outboard bearings with 15 to 20 strokes. The use of air pneumatic grease guns is not recommended. After greasing, immediately shut the unit down. The Lubricant used must be a premium quality NLGL #2 or #3 multipurpose ball bearing grease having corrosion inhibitors, anti-oxidation additives & mechanical stability for SUS at 100 F (38 C) & be suitable to operate continuously at 225 F (107 C). Do not use heavy, long fibered grease. It is also recommended that the bearings be filled with 30 pumps of grease (about 3 cubic inches) if the unit is left idle for more than one week or extended shutdown/storage. This will fill the bearing cavity & help prevent moisture condensing inside the bearing cavity. Again, this should be done with the blower rotating at engine idle speed & immediately shut down after lubrication. If the unit is in storage, repeat this process every three months.

6 Silencer The silencer assembly consists of an outer steel shell lined with acoustic foam retained by perforated metal. To maintain maximum effectiveness of the silencer, periodic inspection & cleaning must be performed. The frequency of cleaning will depend upon the number of hours in use & the amount & type of material ingested into the silencer. Cleaning Procedure: The acoustic foam must be removed from the silencer for cleaning. Remove the silencer cover & retaining nuts. Remove the screws from the seam of the internal perforated sheet metal retainer & remove the retainers & foam. Remove the lower perforated retainer & foam. The cleaning method used to clean the foam will depend on the trapped material. A mild soapy water solution can normally be used for washing the acoustic foam unless the material plugging the foam will harden when it comes in contact with water such as cement or fly ash. Alternate methods that can be used in these cases are blowing compressed air or vacuum cleaning. Clean the inside of the silencer shell by washing with water or vacuum cleaning. A wire brush or scraper may be needed to remove any caked dust. Repaint the inside of the silencer if bare metal is present. Silencer Assembly: Be sure the inside of the silencer is free from dirt & completely dry before installing the acoustic foam. To install, reverse the removal procedure. Acoustic Foam Replacement: If the foam has become unserviceable through deterioration, it must be replaced. When ordering replacement acoustical foam & retainers refer to the parts list to ensure correct parts.

7 Body Debris Body Clean and Inspect for cracking, leaks or wear. Repair as required. Clean & prime or paint exposed metal surfaces to prevent the formation of rust. This is particularly important on the inside walls, floor, & deflectors of the body. Be sure tailgate support has been installed in the proper position. Each week completely remove the filter screens from the body & wash both sides of the perforated surfaces along with the screen tracks. To lower the screens from the body remove the cotter pins in the latch arms which support the screen in the center track. Move the latch arm out while supporting the screen, only far enough to remove one side of the screen. Lower the screen to the floor & continue the process until all screens are removed from one side of the body. Continue in the same manner on the opposite side of the body until all screens are removed. Replace in reverse order as previously described. Dump Body Hinge Grease the body hinge at the rear of the unit at all grease fittings. Visually inspect the hinges and pins for damage or wear. Repair or replace as required. Tailgate Latches and Hinges Lubricate the tailgate latches at the grease fittings and visually inspect the hinges and lock areas for wear or other mechanical problems, Repair or replace as needed. Tailgate Gasket Inspect the tailgate gasket for any cuts or damages. It is important to keep the tailgate gasket clean and free of all debris. Operating the system with a worn tailgate gasket may cause load leakage or loss of vacuum. Clean Out Doors Clean and inspect the separator doors for gasket damage. Check the door latches and hinges for wear or damage. Check the door adjustment to ensure proper sealing to the body. Repair or replace as required. Hoist Cylinder Keep the exposed stroke on the hoist cylinder form weathering by hand greasing daily or as required. Grease the body hoist cylinder pivot pins at the grease fittings. Visually inspect the pivot points for cracks or wear and the cylinder itself for seal leakage or physical damage. Inspect upper & lower trunnion ends of cylinder, at cylinder & lifting lever cross shafts, at frame, at valve & at pump. Inspect all hose lines for damage & hose ends for tightness. Check valve control for proper shifting. Inspect seals in control valve. Check cylinder packing (a light film of fluid on the piston rod is acceptable). Boom Clean and inspect for cracking, leaks or wear. Repair or replace as required. Hand grease bi-weekly to prevent rusting and insure smooth operation. Boom Bearing Grease all fittings. Inspect for damage or mechanical problems. Repair or replace as required. Boom Lift Inspect the boom lift mechanism and hydraulic cylinders for damage or mechanical problems. Repair or replace as required. Electrical System Visually inspect all wires, timers, relays, fuses and connections for burns, cracks, damage or corrosion. Clean thoroughly and replace any damaged parts.

8 Indicator Lights Inside the cab, check the operation of travel mode, sweep mode and hydraulic indicator lights located on the cab control console. Note: Failure to maintain these lights in working order could result in operator error. If indicator light failure occurs, investigate possible cause.

9 Browning Split Taper Bushing Mounting Instructions for Split Taper Bushings in Split Taper Bushed Products. Warning: Read all instructions carefully. Disconnect and lock out power before installation and maintenance. Working on or near energized equipment can result in severe injury or death. Do not operate equipment without guards in place. Exposed equipment can result in severe injury or death. Before Installation: 1. Make sure the shaft, bushing barrel and bore, Browning split taper bushed product bore, keys and keyways are free of burrs, paint, etc. For idler bushings, make sure the bushing barrel and Browning split taper bushed product bore are free of burrs, paint, etc. 2. For proper operation, make sure the shaft size is within the size limits shown in Table 1. Some applications may benefit from tighter shaft tolerances. Caution: Mounting a Browning split taper bushing on a shaft smaller than the size limits shown in Table 1 may result in faulty assembly. The assembly may come off the shaft or undesirable assembly run out may result. Installation: 1. For light weight products, the bushing may first be loosely installed into the Browning split taper bore product, hereafter referred to as product, and then the assembly slid onto the shaft (illustration 1A and B). For heavier products, it is usually easier to either first slide the bushing onto the shaft and then slide the product onto the bushing (illustration 2A), or first position the product over the shaft, next slide the bushing onto the shaft, and then pull the product onto the bushing (illustration 2B). The light weight products method is common, however if the bushing barrel has collapsed, it must be wedged open (described below), and the heavy product procedure may be easier. Heavier product may require a hoist or other means of holding the product in position until the bushing is installed into the product. When mounting on a vertical shaft, make sure the bushing and the product do not drop during installation. 2. It may be necessary to slightly wedge open the saw slot on some bushings in order to start the bore and position the bushing onto the shaft. A narrow edged regular screw driver may be used. Caution: Excessive wedging forces in bushing saw slot may damage or break bushing. Avoid.

10 3. Align the shaft keyset with the bushing bore keyway and install the key. Make sure the key runs the entire length of the bushing bore. For type 2 bushings except G and H, a key, which protrudes through the bushing and into the product, is provided. Some type 1 bushings with shallow keyways are also supplied with shaft keys. For proper operation use the key(s) supplied with the bushing. No keys are required for Browning idler bushings. 4. Position the product so the keyway in the bore of the product is aligned with the external (barrel) key in the bushing (G, H and idler bushings do not have an external key). Whether the bushing has an external key or not, the threaded holes in the product must be aligned with the non-threaded holes in the bushing flange. Insert the capscrews through the non-threaded holes in the bushing flange. Insert the capscrews through the non-threaded holes in the bushing flange and thread them by hand into the product three or four turns. 5. Position the bushing product assembly axially on the shaft such that it is aligned with its running mate. Be sure to check for adequate clearance between the assembly and other nearby components if applicable. If the bushing has a set screw over the keyway, tighten it to the torque value in Table 2. Caution: Tightening the set screw to a torque higher than shown in Table 2 may lead to bushing damage or breakage. Avoid. 6. If the bushing-product assembly is not between the shaft bearings, then locating the assembly closer to a bearing will reduce the load and increase the life of both bearings. Check for adequate clearance. 7. Using a torque wrench and appropriate socket, tighten the capscrews sequentially until each is tightened to the torque shown in Table 2. When the capscrew torque is at or near the recommended torque, make at least two more sequential rounds to assure all capscrews are at the Table 2 capscrew torque value. Caution: Tightening the capscrew to a torque higher than shown in Table 2 may lead to product faiure. Avoid. 8. If capscrews were provided with the product, use them instead of the ones provided with the bushing.

11 Caution: Failure to use the capscrews that came with the assembly may lead to an unsafe assembly. Avoid. 9. Since tightening the capscrews may affect the axial position of the product, confirm that it is still properly aligned with its running mate. If not, determine how much the assembly must be moved to be in proper alignment. 10. If axial adjustment is required, (follow removal procedure), reposition the assembly, and repeat step 11. Check installation gap There must be a gap between the bushing flange and the product face. If there is no gap between them, disassemble the parts, (following the removal procedure), and determine the reason(s) for the faulty assembly. Removal: 1. Heavier product may require a hoist or other means of supporting the product during the removal procedure. When removing from a vertical shaft, make sure the bushing and product do not drop during removal. 2. Insert all capscrews sequentially. If the bushing has a keyway setscrew, loosen it. 3. Insert capscrews in all threaded bushing flange holes. Tighten the capscrews against the (hub) face of the product until the screw force releases the product from the bushing. 4. Remove the bushing and product from the shaft using appropriate means.

12 Rexnard Falk Steelflex Couplings Installation and Maintenance How to use this section: This manual provides detailed instructions on maintenance, lubrication, installation, and parts identification. Use the table of contents below to locate required information. CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS MANUAL FOR OPTIMUM PERFORMANCE AND TROUBLE FREE SERVICE Introduction: This manual applies to sizes 1020T thru 1140T and 20T thru 140T10 Falk Steelflex Tapered Grid Couplings. Unless otherwise stated, information for sizes 1020T thru 1140T applies to sizes 20T thru 140T respectively, e.g. 1020T = 20T, 1100T = 100T, etc. These couplings are designed to operate in either the horizontal or vertical position without modification. Beginning in the year 1994 through 2003, these couplings were being supplied with one set of inch series fasteners and one set of Metric fasteners. Beginning in year 2004 only Metric fasteners are being supplied. Refer to Parts Identification and Parts Interchangeability. The performance and life of the couplings depend largely upon how you install and service them. Caution: Consult applicable local and national safety codes for proper guarding of rotating members. Observe all safety rules when installing or servicing couplings. Warning: Lockout starting switch of prime mover and remove all external loads from drive before installing or servicing. Lube Fittings: Cover halves have 1/8 NPT lube holes. Use a standard grease gun and lube fitting as instructed in Annual Maintenance, Re-lube and Disassembly. Limited End Float: When electric motors, generators, engine, compressors and other machines are fitted with sleeve or straight roller bearings, limited axial end float kits are recommended for protecting the bearings. Falk Steelflex couplings are easily modified to limit end float. Contact Rexnard for further instructions. Lubrication: Adequate lubrication is essential for satisfactory operation. Below is a list of typical lubricants and specifications for general purpose and long term greases. Because of its superior lubricating characteristics and low centrifuge properties, Flak Long Term Grease (LTG) is highly recommended. Sizes 1020T to 1090T10 are furnished with a pre-measured amount of grease for each coupling. The grease can be ordered for larger size couplings. The use of general purpose grease requires re-lubrication of the coupling at least annually.

13 Type T10 Steelflex Coupling Long Term Grease (LTG): The high centrifugal forces encountered in couplings separate the base oil and thickener of general purpose greases. Heavy thickener, which has no lubrication qualities, accumulates in the grid-groove area of Steelflex couplings resulting in premature hub or grid failure unless periodic lubrication cycles are maintained. Falk Long Term Grease (LTG) was developed specifically for couplings. It resists separation of the oil and thickener. The consistency of Falk LTG changes with operating conditions. As manufactured it is an NLGI #1/2 grade. Working of the lubricant under actual service conditions causes it to become semifluid while the grease near the seals will set to a heavier grade, helping to prevent leakage. LTG is highly resistant to separation, easily out performing all other lubricants tested. The resistance to separation allows the lubricant to be used for relatively long periods of time. Steelflex couplings initially lubricated with LTG will not require re-lubrication until the connected equipment is stopped for servicing. If a coupling leaks grease, is exposed to extreme temperatures, excessive moisture, or experiences frequent reversals, more frequent lubrication may be required. Although LTG grease is compatible with most other coupling greases, the mixing of greases may dilute the benefits of LTG.

14 USDA APPROVAL: LTG has the United States Department of Agriculture Food Safety & Inspection Service approval for applications where there is no possibility of contact with edible products. (H-2 ratings). Caution: Do not use LTG in bearings. SPECIFICATIONS FALK LTG: The values shown are typical and slight variations are permissible. AMBIENT TEMPERATURE RANGE _ -20 F (-29 C) to 250 F (121 C). Min Pump = 20 F (-7 C). MINIMUM BASE OIL VISCOSITY_ 3300SSU 100 F (38 c). THICKENER_Lithium and soap/polymer. CENTRIFUGE SEPARATION CHARACTERISTICS_ ASTM #D4425 (Centrifuge Test) K36 = 2/24 max., very high resistance to centrifuging. NLGI GRADE (ASTM D-217) ½ CONSISTENCY (ASTM D-217)_ 60 stroke worked penetration value in the range of 315 to 360 measured at 77 F (25 C). MINIMUM DROPPING POINT_ 350 F (177 C) minimum. MINIMUM TIMKEN O.K. LOAD_ 40 lbs. ADDITIVES_ Rust and oxidation inhibitors that do not corrode steel or swell or deteriorate synthetic seals. PACKAGING: 14 oz. (0,4 kg) CARTRIDGES Individual or case lots of 10 or lb. (16 kg) pail, 120 lb. (54 kg) keg and 400 lb. (181 kg) drums. GENERAL PURPOSE GREASE: Annual lubrication The following specifications and lubricants for general purpose grease apply to Falk Steelflex couplings that are lubricated annually and operate within ambient temperatures of 0 F to 150 F (-18 C to 66 C). For temperatures beyond this range (see Table 1), consult the factory. If a coupling leaks grease, is exposed to extreme temperatures, excessive moisture or experiences frequent reversals, more frequent lubrication may be required. SPECIFICATIONS GENERAL PURPOSE COUPLING LUBRICANTS: The values shown are typical and slight variations are permissible. DROPPING POINT_ 300 F (149 C) or higher. CONSISTENCE_ NLGI No. 2 with 60 stroke worked penetration value in the range of 250 to 300. SEPARATION AND RESISTANCE_ Low oil separation rate and high resistance to separation from centrifuging.

15 LIQUID CONSTITUENT_ Possess good lubricating properties equivalent to a high quality, well refined petroleum oil. INACTIVE_ Must not corrode steel or cause swelling or deterioration of synthetic seals. CLEAN_ Free from foreign inclusions. GENERAL PURPOSE GREASES MEETING REXNORD SPECIFICATIONS: Lubricants listed below are typical products only and should not be construed as exclusive recommendations. Table 1 General Purpose Greases 0 F to 150 F (-18 C to 66 C) -30 F to 100 F (-34 C to 38 C) Manufacturer Lubricant Lubricant Amoco Oil Co. Amolith Grease #2 Amolith Grease #2 BP Oil Co. Energrease LS-EP2 Energrease LS-EP1 Chevron USA Inc. Dura-Lith EP2 Dura-Lift EP1 Citgo Petroleum Corp. Premium Lithim Grease EP2 Premium Lithim Grease EP1 Conoco Inc. EP Conolith Grease #2 EP Conolith Grease #2 Exxon Company USA Unirex EP2 Unirex EP2 E.F. Houghton & Co. Cosmolube 2 Cosmolube 1 Imperial Oil Ltd. Unirex EP2 Unirex EP2 Kendall Refining Co. Lithium Grease L421 Lithium Grease L421 Keystone Div. (Pennwalt) 81 EP-2 81 EP-1 Lyondell Petrochemical Litholine H EP 2 Grease Litholine H EP 2 Grease (ARCO) Mobil Oil Co. Mobilux EP111 Mobilith AW1 Petro-Canada Products Multipurpose EP2 Multipurpose EP1 Phillips 66 Co. Philube Blue EP Philube Blue EP Shell Oil Co. Alvania Grease 2 Alvania Grease 2 Shell Canada Ltd. Alvania Grease 2 Alvania Grease 2 Sun Oil Co. Ultra Prestige 2EP Ultra Prestige 2EP Texaco Lubricants Starplex HD2 Multifak EP2 Unocal 76 (East & West) Unoba EP2 Unoba EP2 Valvoline Oil Co. Multilube Lithium EP Grease - * Grease application or re-lubrication should be done at temperatures above 20 F (-7 C). If grease must be applied below 20 F (-7 C), consult the factory. * Lubricants listed may not be suitable for use in the food processing industry. Check with lube manufacturer for approved lubricants. Installation of Type T10 Steelflex Tapered Grid Couplings: Installation: Only standard mechanics tools, wrenches, a straight edge and feeler gauges are required to install Falk Steelflex couplings. Coupling sizes 1020T thru 1090T are generally furnished for CLEARANCE FIT with setscrew over the keyway. Sizes 1100T and larger are furnished for an INTERFERENCE FIT without a setscrew.

16 CLEARANCE FIT HUBS Clean all parts using a non-flammable solvent. Check hubs, shaft and keyways for burrs. Do not heat clearance fit hubs. Install keys, mount hubs with flange face flush with shaft ends or as otherwise specified and tighten screws. INTERFERANCE FIT HUBS Furnished without setscrews. Heat hubs to maximum of 275 F (135 C) using an oven, torch, induction heater or an oil bath. To prevent seal damage, DO NOT heat hubs beyond a maximum temperature of 400 F (205 C). When an oxy-acetylene or blow torch is used, use an excess acetylene mixture. Mark hubs near the center of their length in several places on hub body with a temperature sensitive crayon, 275 (135 C) melt temperature. Direct flame towards hub bore using constant motion to avoid overheating an area. Warning: If an oil bath is used, the oil must have a flash point of 350 F (177 C) or higher. Do not rest hubs on the bottom of the container. Do not use an open flame in a combustible atmosphere or near combustible materials. Heat hubs as instructed above. Mount hubs as quickly as possible with hub face flush with shaft end. Allow hubs to cool before proceeding. Insert setscrews (if required) and tighten. Maximize Performance and Life: The performance and life of couplings depend largely upon how you install and maintain them. Before installing couplings, make certain that the foundations of equipment to be connected meet manufacturer s requirements. Check for soft foot. The use of stainless steel shims is recommended. Measuring misalignment and positioning equipment within alignment tolerances is simplified with an alignment computer. These calculations can also be done graphically or mathematically. Alignment is shown using spacer bar and straight edge. This practice has proven to be adequate for many industrial applications. However, for superior final alignment, the use of dial indicators (contact Rexnord for details), lasers, alignment computers or graphical analysis is recommended. 1. Mount Seals and Hubs: Lock out starting switch of prime mover. Clean all metal parts using a nonflammable solvent. Lightly coat seals with grease and place on shafts BEFORE mounting hubs. Heat interference fit hubs as previously instructed. Seal keyways to prevent leakage. Mount hubs on their respective shafts so the hub face is flush with the end of its shaft unless otherwise indicated. Tighten setscrews when finished.

17 2. Gap and Angular Alignment: Use a spacer bar equal in thickness to the gap specified in Table 2 in Installation and Alignment Data. Insert bar as shown above, to same depth at 90 intervals and measure clearance between bar and hub face with feelers. The difference in minimum and maximum measurements must not exceed the ANGULAR installation limits specified in Table Offset Alignment: Align so that a straight edge rests squarely (or within the limits specified in Table 2) on both hubs as shown above and also at 90 intervals. Check with feelers. The clearance must not exceed the PARALLEL OFFSET installation limits specified in TABLE 2. Tighten all foundation bolts and repeat steps 2 and 3. Realign coupling if necessary. 4. Insert Grid: Pack gap and grooves with specified lubricant before inserting grid. When grids are furnished in two or more segments, install them so that all cut ends extend in the same direction (as detailed in the exploded view image above); this will assure correct grid contact with non-rotating pin in cover halves. Spread the grid slightly to pass over the coupling teeth and seat with a soft mallet.

18 5. Pack with Grease and Assemble Covers: Pack the spaces between and around the grid with as much lubricant as possible and wipe off excess flush with top of grid. Position seals on hubs to line up with grooves in cover. Position gaskets on flange of lower cover half and assemble covers so that the match marks are on the same side (see above). If the shafts are not level (horizontal) or coupling is to be used vertically, assemble cover halves with the lug and match mark UP or on the high side. Push gaskets in until they stop against the seals and secure cover halves with fasteners, tighten to torque specified in Table 2. Make sure gaskets stay in position during tightening of fasteners. Caution: Make certain lube plugs are installed before operating. Annual Maintenance: For extreme or unusual operating conditions, check coupling more frequently. 1. Check alignment per steps above. If the maximum operating misalignment limits are exceeded, realign the coupling to the recommended installation limits. See Table 2 for installation and operating alignment limits. 2. Check tightening torques of all fasteners. 3. Inspect seal ring and gasket to determine if replacement is required. If leaking grease, replace. 4. When connected equipment is serviced, disassemble the coupling and inspect for wear. Replace worn parts. Clean grease from coupling and repack with new grease. Install coupling using new gasket as instructed in this manual.

19 Periodic Lubrication The required frequency of lubrication is directly related to the type of lubricant chosen, and the operating conditions. Steelflex couplings lubricated with common industrial lubricants, such as those shown in Table 1, should be re-lubed annually. The use of Falk Long Term Grease (LTG) will allow relube intervals to be extended to beyond five years. When re-lubing, remove both lube plugs and insert lube fitting. Fill with recommended lubricant until an excess appears at the opposite hole. CAUTION: Make certain all plugs have been inserted after lubricating Coupling Disassembly and Grid Removal Whenever it is necessary to disconnect the coupling, remove the cover halves and grid. A round rod or screwdriver that will conveniently fit into the open loop ends of the grid is required. Begin at the open end of the grid section and insert the rod or screwdriver into the loop ends. Use the teeth adjacent to each loop as a fulcrum and pry the grid out radially in even, gradual stages, proceeding alternately from side to side. Type T Coupling Installation & Alignment Data Maximum life and minimum maintenance for the coupling and connected machinery will result if couplings are accurately aligned. Coupling life expectancy between initial alignment and maximum operating limits is a function of load, speed and lubrication. Maximum operating values listed in Table 2 are based on cataloged allowable rpm. Values listed are based upon the use of gaps listed, standard coupling components, standard assemblies and cataloged allowable speeds. Values may be combined for an installation or operating condition. Example: 1060T maximum operating misalignment, refer applications details to factory. Angular misalignment is dimension X minus Y as illustrated below.

20 Parallel misalignment is distance P between the hub center lines as shown below. End float (with zero angular and parallel misalignment) is the axial movement of the hub(s) within the cover(s) measured from 0 gap. Table 2 Misalignment & End Float SIZE MAX inch 1020T T T T T T T T T T T T T.011 INSTALLATION LIMITS PARALLEL OFFSET-P MAX mm 0,15 0,15 0,15 0,20 0,20 0,20 0,20 0,20 0,25 0,25 0,28 0,28 0,28 ANGULAR (x-y) MAX inch HUB GAP ± 10% OPERATING LIMITS PARALLEL OFFSET-P MAX mm inch mm MAX inch MAX mm MAX inch 0, , , , , , , , , , , , , , , , , , , , , , , , , , ANGULAR (x-y) MAX mm 0,25 0,30 0,33 0,41 0,46 0,51 0,61 0,71 0,84 0,91 1,02 1,19 1,35 END FLOAT PHYSICAL LIMIT (Min) 2 x F COVER FASTENER TIGHTENING TORQUE VALUES INCH OR METRIC SERIES FASTENERS ALLOW SPEED (rpm) LUBE WEIGHT inch mm (lb-in) (Nm) lb kg ,33 5,03 5,36 5,38 6,55 6,58 7,32 7,26 10,90 10,90 14,12 14,00 14, ,3 11,3 11,3 22,6 22,6 22,6 22,6 22, ,03 0,04 0,05 0,07 0,09 0,11 0,17 0,25 0,43 0,51 0,74 0,91 1,14 MAM0150

21 Table 3 Coupling Cover Fastener Identification SIZE INCH SERIES FASTENERS OLD STYLE NEW STYLE METRIC FASTENERS T10 SAE GRADE 8 * SAE GRADE 8 PROPERTY CLASS T10 SAE GRADE 8 SAE GRADE PROPERTY CLASS T10 SAE GRADE 5 SAE GRADE PROPERTY CLASS 8.8 * OLDER STYLE COVERS, SIZES 1020T10 THRU 1070T10 MUST UTILIZE SOCKET HEAD CAPSCREWS & LOCKNUTS HELD BY THE COVER MAM0160 Parts Identification All coupling ports have identifying part numbers as shown below. Parts 3 and 4 (hubs and grids), are the same for both type T10 and T20 couplings. All other coupling parts are unique to type T10. When ordering parts, always SPECIFY SIZE and TYPE shown on the COVER. Parts Interchangeability Parts are interchangeable between sizes 20T and 1020T, 30T and 1030T, etc. except as noted. Grids Size 1020T thru 1140T Steelflex couplings use blue or non-painted grids. Older models, 20T thru 140T, use orange grids. Caution: Blue or non-painted grids may be used in all applications, but DO NOT substitute orange grids for blue or non-painted. Covers Caution: DO NOT mix cover halves of different designs. Sizes 1020T thru 1070T10 covers have been manufactured in several different two-rib designs and 80T thru 140T covers have been manufactured with two and three ribs. Hardware Older style covers, sizes1020t10 thru 1070T10, utilized socket head capscrews with captured locknuts. The new style covers use hex hd capscrews (either inch or metric from year 1994 thru 2003 and only metric beginning in 2004). Specify the style cover when ordering replacement parts

22 Part Number Location Part Description Order Information 1. Seal (T10) 1. Identify part(s) required by name above. 2. Cover (T10) 2. Furnish the following information 3. Hub (Specify bore and keyway) EXAMPLE: 4. Grid Coupling size: Gasket (T10) Coupling Type: T10 6. Metric Fasteners (T10) Model: B 7. Lube Plug Bore: Keyway:.375 X Contact your Rexnord distributor or Rexnord for price and availability

23 Lovejoy Grid Couplings Spacer Grid Installation Instructions Pre-Assembly Inspection Hubs, covers and grids come in a variety of sizes and types. First, determine the size and type of components being used. Remove all components from their boxes and packaging. Check maximum rpm values in Table 1 against operating speed. Inspect all coupling components and remove any protective coating or lubricants from bores, mating surfaces and fasteners. Clean all parts using a non-flammable solvent. Make sure that shaft, hubs and keyways are clean and smooth. Assembly Instructions 1. When installing coupling hubs onto each shaft, use keys where required. Keys should fit snugly. Seal the keyways to prevent grease leakage. 2. The shaft hubs are a clearance fit with the shaft and are supplied with set screws. Do not heat the clearance fit hubs. Position the hubs on the shafts so that the hub teeth are flush with shaft ends. It is usually best to have an equal length of shaft extending into each hub. Tighten the set screws. Position equipment to achieve the appropriate distance between shaft ends. If an interference fit with the shaft was required the hubs are not supplied with set screws. It is necessary to heat hubs, using a torch, oven, induction heater or an oil bath, to a maximum temperature of 275 F. To avoid overheating the hubs, direct flame towards the bore using a constant motion. If an oil bath is used it must have a flash point of at least 350 F. DO NOT rest hubs on the bottom of container or apply heat directly to the teeth. Heat hubs as specified above. Mount hubs immediately with the hub teeth flush with the shaft end unless otherwise specified. Allow the hubs to cool before proceeding to the next step. Position equipment to achieve the appropriate distance between shaft ends. 3. Lightly smear seals with grease and carefully roll seal over hub teeth of each space hub. Fit appropriate spacer hub onto each shaft hub and insert fasteners. Torque fasteners to flange fastener specifications given in Table Check the angular misalignment by setting the gap using a spacer bar equal in thickness to the nominal gap specified in Table 1. With the spacer bar inserted to the same depth, measure clearance between the bar and hub face at 90 intervals using feelers. Determine the maximum and minimum dimensions without rotating the coupling. The difference of these two measurements must be less than the angular value in Table Check the parallel alignment by placing a straight edge across the two coupling hubs, and measuring the maximum offset at various points around the periphery of the coupling without rotating the coupling. If the maximum offset exceeds the parallel value in Table 1, realign the shafts. 6. Tighten all set screws using the tightening torque values specified in Table 3. Repeat steps 5 and 6 and if necessary re-align the coupling.

24 7. Before inserting the grid segments, thoroughly pack the grooves with specified lubricant. When grids are supplied with two or more segments assemble so that the cut ends of a segment join extend in the same direction. Spread the grid slightly so that it will pass over the coupling teeth, and tap all the rungs into the respective slots with a soft mallet. Table 1 - Misalignment and End Float COUPLING SIZE HORIZ SPEED RPM G. MISALIGNMENT DIM ± 10% PARALLEL ANGULAR INCH INCH MAX TOTAL END FLOAT INCH GREASE WEIGHT oz. kg MAM Pack the spaces around the grid with lubricant and wipe off the excess, flush with the top of grid. Position seals on spacer hubs so that they line up with the grooves in the cover. Position gaskets on lower cover half and assemble covers so that match marks are on the same side. If using the coupling in any position other than horizontal, assemble covers halves with the lug and match mark up, or on high side. Install the fasteners through the cover halves and torque to the horizontal cover fastener specifications in Table 2. Make certain all plugs are inserted and secured before operating the equipment. Note: Install coupling guard per OSHA or ASME requirements.

25 Annual Maintenance 1. To prevent the possibility of unexpected motion, ensure that the power source is isolated before attempting to service the system components. 2. Adequate lubrication is essential to prolong the life of the coupling and obtain trouble free service. It is recommended that the couplings be re-lubed annually when using the common industrial lubricants shown in our catalog. If using Lovejoy Coupling Grease, lube intervals can be extended. However, a coupling exposed to extreme temperatures, excessive moisture, frequent reversals or grease leakage may require more frequent lubrication. Remove covers and check lubricant condition, alignment and general condition of grid members and teeth every year. Also, check tightening torque of all fasteners and set screws. Coupling used in high ambient temperatures (greater than 158 F), at high speed and/or frequent reversing applications may require more frequent inspection and re-lubing. 3. If lubricant is required, remove both lube plugs and insert the appropriate lubrication fitting in one of the tapped holes. Fill with the recommended lubricant until excess appears at the opposite lube hole. Replace both lube plugs. 4. For best results, clean coupling of all lubricant and replenish every two years. Grid Removal When it is necessary to remove the grid, remove the cover. Use a round rod or screwdriver that fits into the open loop ends of the grid. Using the teeth on the hub as a support, pry the grid out radially in even, gradual stages, proceeding alternately from side to side. Removal and Installation of Spacer Assembly 1. To remove spacer assembly, remove pipe plugs and all but two fasteners per hub 180 apart from each other. Loosen remaining fasteners approximately ¼ and tap fasteners with a soft mallet to disengage spacer assembly from the shaft hubs. Remove remaining fasteners and spacer assembly. 2. To reinstall spacer assembly, insert fasteners so that they do not protrude beyond flange face. Remove pipe plugs to vent and press spacer hubs together to remove gap. Insert spacer assembly between shaft hubs. Carefully engage the spacer hubs to shaft hubs and then alternately tighten fasteners. Torque fasteners to specifications in Table 2. Install pipe plugs.

26 Table 2 Fastener Tightening Torque COUPLING SIZE HORIZONTAL COVER FASTENER FLANGE FASTENER TIGHTENING TORQUE TIGHTENING TORQUE SIZE VALUES SIZE VALUES INCH METRIC in-lb Nm INCH in-lb Nm /4-20 M / /4-20 M / /4-20 M / /16-18 M / /16-18 M / /16-18 M / /16-18 M / /16-18 M / MAM0200 COUPLING SIZE FOR INCH SCREWS FOR METRIC SCREWS TIGHTENING TORQUE SET SCREW SIZE SET SCREW SIZE TIGHTENING VALUES TORQUE VALUES INCH LENGTH in-lb Nm mm in-lb Nm / M / M / M / M / M /4-20 5/ M /4-20 5/ M / / M MAM0210

27 VacAll Industries, Inc. Operator Training DATE: SERIAL NO. This training form covers the following unit. ALLJETVAC Combination Machine. Answer the following questions by circling the appropriate answer. If you have any questions on proper operation of any component on your ALLJETVAC, please contact VacAll Industries, Inc. Service Department at FILTRATION/AIRFLOW: A. I understand that the cyclonic ring or deflector plate is the first stage of material separation. YES NO B. I understand that the air/water cyclonic separator is the second stage of filtration. YES NO C. I understand the basics of the blower and how it produces airflow through-out the unit. YES NO D. I understand that airflow is discharged through the vacuum pump silencer and why it is used to quiet the vacuum pump. YES NO TAILGATE: A. I know how to open and close the tailgate. YES NO B. I know to clean the tailgate gasket after each dump in order to prevent damage to the tailgate gasket and prevent leaks. YES NO C. I know how and when to properly use the tailgate pin. YES NO

28 D. I understand the functions of the check valves on the tailgate. YES NO FLOAT BALL: A. I understand the function of the float ball and how it operates. YES NO BLOWER: A. I understand how to properly engage and disengage the blower. YES NO WATER PUMP: A. I understand how to properly engage and disengage the water pump. YES NO B. I understand how to properly utilize the water pressure safety relief valve. YES NO SLIDE GATE: A. I understand how to operate the slide gate valve for underwater operation. YES NO PENDANT CONTROL: A. I understand that the hand held pendant controls all boom functions including the slide gate valve. YES NO

29 DAILY CHECK: I understand how to check and maintain the following items: A. Engine Oil YES NO B. Cooling system YES NO C. Battery YES NO D. Drive belts YES NO E. Air cleaner YES NO F. Lube oil filter YES NO G. Fuel YES NO H. Vacuum pump oil YES NO I. Water pump oil YES NO J. Hydraulic oil YES NO K. Hydraulic return/suction filter YES NO L. All grease fittings YES NO M. Float system YES NO N. Knuckle relief valve YES NO O. Air dry/heater YES NO P. Transfer case oil YES NO Q. Drive line lubrication YES NO R. Shift tower lights YES NO S. S. Hoist control lever raises and lowers the debris body. YES NO T. Tank flush flushes debris from the debris tank. YES NO U. Decant valve removes excess liquid from the body. YES NO

30 Notes on trainee: Trainer s Signature: Trainee s Signature: Company Name: Location: Phone: Contact