DRY-PRIME DIESEL TRASH PUMP MTP4000DZV • MTP4000DZD MTP6000DZV • MTP6000DZD 01183 OPERATING MANUAL Parts manuals available online at www.generacmobile.
WARNING CALIFORNIA PROPOSITION 65 WARNING: Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm. WARNING CALIFORNIA PROPOSITION 65 WARNING: This product contains or emits chemicals known to the state of California to cause cancer, birth defects, and other reproductive harm.
Introduction This manual provides information and procedures to safely operate and maintain the Generac Mobile Products, LLC unit. For your own safety and protection from physical injury, carefully read, understand, and observe the safety instructions described in this manual. Keep a copy of this manual with the unit at all times. Additional copies are available from Generac Mobile Products, LLC, or can be found at www.generacmobile.com.
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Table of Contents Section 1 - Safety Safety Notes ....................................................................................................................................... 1 Operating Safety................................................................................................................................. 1 Engine Safety ..................................................................................................................................... 2 Pump Safety ..............
Display CAN Add..................................................................................................................................28 Alarm Filter ...........................................................................................................................................28 SPN Version.........................................................................................................................................28 Speed Source..............................................
Towing the Unit................................................................................................................................. 47 Trailer Wheel Bearings ..................................................................................................................... 47 Lifting the Unit................................................................................................................................... 48 Section 4 - Maintenance Daily Walk Around Inspection................
Pump Troubleshooting ..................................................................................................................... 71 Engine Fault Shutdown Troubleshooting.......................................................................................... 72 Control System Troubleshooting ...................................................................................................... 73 Diagnostic Trouble Codes (DTS)........................................................................
Section 1 - Safety SAFETY NOTES This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. This manual contains DANGERS, WARNINGS, CAUTIONS, NOTICES and NOTES which must be followed to prevent the possibility of improper service, damage to the equipment, personal injury or death.
Safety ENGINE SAFETY Internal combustion engines present special hazards during operation and fueling. Failure to follow the safety guidelines described below could result in severe injury or death. Read and follow all safety warnings described in the engine operator's manual. A copy of this manual was supplied with the unit when it was shipped from the factory. • DO NOT run engine indoors or in an area with poor ventilation.
Safety • NEVER wash the engine block or fuel tank with a power washer or steam cleaner. Water may collect in the pump control panel or other electrical parts, causing damage. • If equipment is stored more than 12 months, some of the components or lubricants may have exceeded their maximum shelf life. These must be inspected and replaced as necessary prior to pump operation to ensure proper pump performance.
Safety • Check that lug nuts holding wheels are tight and that none are missing. • Maximum recommended speed for highway towing is 45 mph (72 km/h). Recommended off-road towing speed is not to exceed 10 mph (16 km/h) or less, depending on terrain. Before towing the trailer, check that the weight of the trailer is equal across all tires.
Safety SAFETY SYMBOL SUMMARY This equipment has been supplied with numerous safety and operating decals. These decals provide important operating instructions and warn of dangers and hazards. Replace any missing or hard-to-read decals and use care when washing or cleaning the unit. Decal placement and part numbers can be found in the online parts manual at www.generacmobile.com. Below is a summary of the intended meanings for the symbols used on the decals.
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Section 2 - General Information SPECIFICATIONS GENERAC MODEL MTP4000DZV/DZD MTP6000DZV/DZD Engine Make/Brand.............................................................................Deutz .......................................Deutz Model ......................................................................................D2.9.........................................TD2.9 EPA Tier ..................................................................................4f ....................................
General Information UNIT DIMENSIONS B C A B C A 01184 Figure 1 - Unit Dimensions A B C MTP4000DZV - Skid Mounted 36 in. (.91 m) 65.38 in. (1.66 m) 83 in. (2.11 m) MTP4000DZV - Trailer Mounted 57 in. (1.45 m) 83 in. (2.11 m) 148.5 in. (3.77 m) MTP6000DZV - Skid Mounted 36 in. (0.91 m) 65.38 in. (1.66 m) 88 in. (2.24 m) MTP6000DZV - Trailer Mounted 57 in. (1.45 m) 83 in. (2.11 m) 153 in. (3.89 m) Specifications are subject to change without notice.
General Information UNIT SERIAL NUMBER LOCATIONS Refer to the illustration to locate the unit ID tag and Vehicle Identification Number (VIN) tag on the unit. Important information, such as the unit serial number, model number, VIN and tire loading information are found on these tags. Record the information from these tags so it is available if the tags are lost or damaged. When ordering parts or requesting assistance, you may be asked to provide this information.
General Information 3. Remove the shipping brace and slide it into the trailer tube opening. Secure the brace to the trailer with the bolt located on the underside of the trailer and a new nylon locking nut. Refer to #2 in Figure 3. 4. Flip the trailer tongue down and reinstall the bolts and washers removed in step 2 using two new nylon locking nuts. DO NOT reuse nylon locking nuts. Tighten the bolts to 80-109 ft-lbs (108-148 Nm).
General Information COMPONENT LOCATIONS 2 1 3 4 5 13 6 7 9 8 10 11 12 01238 Figure 5 - Left Side (4 Inch Venturi-Prime Pump Shown) 1. 2. 3. 4. 5. 6. 7. 31609 A Air cleaner Central lift point Priming chamber Pump outlet (discharge) port Rear leveling jacks Battery Fuel pre-filter 8. 9. 10. 11. 12. 13.
General Information 3 4 2 1 13 5 6 7 12 8 9 01239 11 10 Figure 6 - Right Side (4 Inch Venturi-Prime Pump Shown) 1. 2. 3. 4. 5. 6. 7. 12 Mechanical seal oil reservoir Compressor DOC Radiator sight gauge Fuel fill port Fork lift pockets Control panel 8. 9. 10. 11. 12. 13.
General Information 2 1 3 4 5 6 7 8 9 17 16 15 14 10 13 12 11 01479 Figure 7 - Left Side (4 Inch Diaphragm Vacuum Pump Shown) 1. 2. 3. 4. 5. 6. 7. 8. 9. 31609 A Air cleaner Coolant sight gauge Central lift point DOC Exhaust hose Diaphragm vacuum pump Suction hose Priming chamber Pump inlet (suction) port 10. 11. 12. 13. 14. 15. 16. 17.
General Information 6 4 7 8 3 2 1 5 9 21 20 19 18 17 16 15 14 13 12 11 10 01538 Figure 8 - Venturi-Prime Pump Components - Left Side (4 Inch Shown) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 14 Belt and guard Compressor Compressor output fitting Compressor hose Mechanical seal oil reservoir Relief valve Venturi fitting Separator hose Priming chamber Suction spool Discharge hose 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
General Information 2 1 4 13 3 12 11 10 8 9 6 7 5 01539 Figure 9 - Diaphragm Vacuum Pump Components - Left Side (4 Inch Shown) 1. 2. 3. 4. 5. 6. 7. 31609 A Diaphragm vacuum pump Priming chamber hose Mechanical seal oil reservoir Priming chamber Suction spool Volute Run dry gland 8. 9. 10. 11. 12. 13.
General Information CONTROL PANEL The CANplus® 750 (CP750™) control panel is a universal platform to monitor, control and automatically start/stop both electronically and mechanically governed diesel engines. The microprocessor-based, solid-state design uses high power semiconductors instead of electromechanical relays to ensure reliable high current switching. Graphical gauge pages or a single large analog gauge are displayed on the 4.25 in. (10.79 cm) diagonal Liquid Crystal Display (LCD).
General Information switch inputs and a transducer input support a number of control scenarios. Single switch mode allows reliable operation with a single switch. Dual switch operation allows greater hysteresis when needed. The transducer input supports simple start/stop operation by level or pressure and maintenance modes with speed modification. • Programmable high and low set points control start/stop operation.
General Information CONTROL PANEL OPERATION Turning the key switch to the RUN position energizes the ECU, all LEDs illuminate once and a startup screen is displayed while a self test is performed. If the display beeps for longer than one second, it indicates a self test fault. Users can attempt to rectify the fault by restoring factory defaults. Refer to the Configuration menu for details. Refer to the Troubleshooting section on page 7 for fault troubleshooting information.
General Information AUTOMATIC START/STOP OPERATION The pump can be configured to start automatically by adding dry-contact closure float level switches. Ensure that the dry-contact closure float switch harness is connected to the port on the back of the control box. Contact the Generac Mobile Products, LLC Technical Service Department at 1-800-926-9768 for more information.
General Information Fill Uses the selected mode to increase the level or pressure. Maintain Out Uses the transducer to maintain the level or pressure at or below the target. Maintain In Uses the transducer to maintain the level or pressure at or above the target.
General Information of each button. The button bar disappears after five seconds if no further buttons are pressed. Note: Different software versions may have slightly different displays. ANALOG GAUGE PAGES Analog Gauge Pages provide four independent pages of analog gauges. To enable Analog Gauge Pages, press any of the first four buttons to show the top level button bar and then press button 1 . Alternate pages are selected by repeated pressing of button 1. The four standard gauge pages are shown below.
General Information below. Page 1 Page 2 Page 3 Page 4 Hours Hours Hours Hours 00346 Note: The 16 gauges are the same for Analog and Digital Gauge Pages. Adjustments in either Analog Gauge Pages or Digital Gauge Pages affect the same gauge in the other mode. SINGLE ANALOG GAUGE Single Analog Gauge uses the entire display for a single large analog gauge. This mode is enabled by pressing any of the first four buttons to show the top level button bar and then press button 3.
General Information acknowledgment, the exit button becomes active. Note: Standard J1939 abbreviations are used for alarms. MS = Most Severe, MOD= Moderately Severe, LS = Least Severe. Refer to “Diagnostic Trouble Codes (DTS)” on page 73 for more information on SPN/FMI codes. ALARM LIST The Alarm List is accessed by pressing any button while an alarm pop-up is displayed or by pressing any of the first four buttons to show the button bar and then button 4 .
General Information menu even when power is removed. Service Timers The top level Configuration menu and its six choices. 00351 Note: Most configuration changes take affect immediately. Some, such as Idle RPM, take effect on the next power up. DISPLAY MENU The Display menu allows the user to configure items affecting how information is displayed. 00352 Units Menu This menu allows the user to set the units used for speed, distance, pressure, volume and temperature independently.
General Information Language Menu This menu allows the user to choose between English, Swedish, French, German, Spanish, Italian, Dutch and Portuguese. The currently selected value is indicated by the check mark . Button 4 selects the highlighted value. Button Beep The soft buttons emit an audible beep when this item is On. Button beep is disabled by setting this item to Off. The audible beep still sounds when an alarm occurs. Button 4 cycles between On and Off.
General Information interval. The service timer descriptions can be changed using the CANplus Configurator. Note: It is not possible to set the service timers if engine hours are not being received by the display. 50 Hour Service 250 Hour Service 500 Hour Service 2000 Hour Service Off Off Off Off 00356 SYSTEM MENU The System menu allows the user to configure items affecting how the system functions. Button 4 cycles through the available values for the selected item.
General Information Setting US Metric Distance Units Miles km Pressure Units PSI kPa Volume Units Gal l Temperature Units ºF ºC Com Viewer Displays CANbus data received and engine configuration transmitted by the ECU. 00359 J1939 Viewer This screen provides a hexadecimal dump of the messages received on the CANbus. This viewer displays the raw data. To see the decoded data, use the Db Viewer. 00360 Button 1 screen.
General Information J1939 Settings This screen allows adjustments specific to the J1939 data link. Engine Source Selects which source the display listens to for gauge data. Every device on a J1939 network has a unique address (in the range 0-254) to which the display can choose to listen. The display listens to a single data source; usually the ECU at address 0. Display CAN Add Note: Incorrectly configuring the Engine Source address will result in no data available for display.
General Information The digits of the PIN are entered by using the buttons corresponding to the digits of the PIN. Button 1 adjusts the first digit of the PIN. Button 2 adjusts the second digit, button 3 the third digit and button 4 the fourth digit. The PIN is entered using button 5 . 00365 PIN Change This allows changing the PIN. The user is prompted for the current PIN. The user is prompted for the new PIN. If the new PINs match, a confirmation screen is displayed.
General Information Note: This screen can not be exited until the checksum calculation is complete. Checksum calculation takes approximately 10 seconds and is complete when the checksum value changes from “Calculating”… to a hexadecimal value such as 0x704E – OK. AUTOSTART MENU This submenu allows the user to configure automatic start/stop operation. Refer to “Automatic Start/Stop Operation” on page 19 for more information. Mode This menu selects the basic automatic start/stop operation mode.
General Information Ramp Up/Down This submenu configures the speed profile for automatic start/stop operation. Warm Up s Selects the number of seconds to operate at idle speed before beginning the ramp to intermediate speed. The warm-up time begins when the starter is disengaged. Ramp Up s Selects the number of seconds to ramp from idle speed to intermediate speed after warm-up. 00370 Intermediate s Selects the number of seconds to operate at intermediate speed before ramping to run speed.
General Information Low Set Point For Empty and Maintain Out modes, sets the level that ends an autostart cycle. For Fill and Maintain In modes, sets the level that begins a cycle. Dead Band Sets the amount of change from the target point required to alter the engine speed. Starter This submenu configures starter control options for autostart. Restart Attempts Selects the number of times to attempt restart. Restart Delay Sec Selects the number of seconds to wait before attempting a restart.
General Information Calibrate RPM Calibrates the tachometer input for mechanically governed engines to allow the CANplus I/O Board to measure the engine speed. This signal may be provided by an alternator frequency tap, proximity switch. An optional amplifier/divider can be added for use with a magnetic pickup. Note: Calibrate RPM is only available on mechanically governed engines. The RPM must be calibrated for automatic start/stop operation to function.
General Information Status Displays telemetry and modem status information retrieved from the telemetry module: MODEM TYPE Identifies the modem type CELL REG Identifies cell modem registration CELL STATE Indicates cell state and signal strength GPS Indicates GPS status RTC Indicates number of days since real time clock cellular update MODBUS SSLT Indicates Modbus slave status HDW STATUS Indicates various hardware status items SOFTWARE VER Indicates the version of software in the Messenger 00
General Information and normal operation resumes once data is detected. Note: Incorrectly configuring the Engine Source address will result in no data available for display. Data Not Available Gauges and the Db Viewer will display when parameter data is received. if the desired data is not available. The display value returns to normal ADJUSTING LIGHTING AND CONTRAST Pressing button 5 (the right-hand button) when there is no menu bar opens the lighting and contrast menu bar.
General Information DATA PARAMETERS MONITORED This table lists the engine and transmission parameters that are monitored via the CANbus. The parameters can be displayed by the user-configurable gauge pages or the single analog gauge. DB is an abbreviation for the internal database which stores all data transmitted from the engine/transmission. The complete database can be accessed on the display via the Db Viewer in the Configuration menu.
General Information Icon Parameter Gauge Pages Single Gauge Database Engine Oil Pressure Transmission Oil Pressure Clutch Pressure Air Start Pressure Injector Control Pressure Engine Coolant Temperature Engine Intercooler Temperature Engine Oil Temperature Transmission Oil Temperature Turbo Oil Temperature Intake Manifold Temperature Air Inlet Temperature Exhaust Temperature Auxiliary Tempera
General Information Icon Parameter Gauge Pages Single Gauge Database Fan Speed Vehicle Speed Total Engine Hours Trip Engine Hours Time (h) Service Hours Torque Converter Lock-Up Engaged Miscellaneous Transducer Current Gear Selected Gear CANTX Disable CANplus I/O WELDING ON EQUIPMENT WITH ELECTRONIC CONTROLS Proper welding procedures are required to avoid damage to electronic controls, sensors and associated components.
Section 3 - Operation PUMP SET UP 1. Disconnect the pump from the tow vehicle by turning the tongue jack clockwise to raise the tongue from the hitch. Disconnect all safety chains, surge brake cables and the trailer wiring harness. Block the wheels to prevent the unit from rolling. 2. Lower the rear leveling jacks from the travel position. Turn the jack handles clockwise until the leveling feet are in firm contact with the ground. Adjust the jacks until the pump is as level as possible. 3.
Operation openings to equal 28 sq. in. (181 sq. cm) or more (6 in. pump). The screen should be rigid enough to prevent collapse when flow is reduced due to clogging. B C A A = Suction Lift: The distance between the centerline of the pump impeller and the surface of the liquid being pumped. B = Vertical Discharge Head: Vertical distance from the centerline of the pump inlet to the centerline of the highest point of discharge.
Operation Table 1: Pipe Submergences FLOW (GPN) 500 1000 1500 6 2.1 3.7 5.3 8 10 1.7 1.6 2.8 3.8 2.3 3.1 2000 4.9 3.8 2500 6.0 4.6 3000 5.4 3500 6.1 4000 6.9 4500 7.6 7. Attach a flexible hose to the outlet (discharge) side of the pump. Make sure the O-ring seal is present in the fitting on the pump before attaching the fitting. Note: Lubricate the O-ring seal with grease to ensure an airtight seal. 8.
Operation Ensure belts and couplings (shaft) are properly adjusted, aligned, and guards are in place. Ensure all thrust blocks and supports are adequate. Ensure all electrical connections and electrical equipment are installed by a qualified and licensed electrical contractor. Never operate electric motors or pump equipment without all protective covers, screens and guards properly in place. Ensure pump drain is closed. Ensure the pump rotates freely by hand.
Operation • The temperature, viscosity, and amount of entrained solids in the liquid being moved. • The length, diameter, and number of bends of the intake and outlet hoses. • The total suction height (lift) of the pump. • The altitude above sea level where the pump is operating. WARNING Never adjust the pump flow by attaching a valve to the intake or outlet side of the pump. Restricting the flow in this way can cause the pump to overheat, creating extreme pressure inside the pump volute.
Operation Speed Feet x .305 = Meters Inches x 25.4 = Millimeters GPM x .227 = Cubic Meters/Hour GPM x 3.785 = Liters/Minute HP x .746 = KW Solids Dia. Impeller Dia. Style 10.09" ENCLOSED VARIOUS Suction 3300 6" Discharge 6" No. vanes 2 MOUNTING CONFIG.: CC, VM, F, VF, EM, VC METERS FEET SINGLE VOLUTE 3.0" NS 180 40 30 20 TOTAL DYNAMIC HEAD 50 160 210 7 FT.(2.1 M.) NPSH REQUIRED PM 10 FT.(3.0 M.) 60 120 70 180 0R 100 75 15 FT.(4.6 M.
Operation Operation Priming time is a function of the volume of air in the suction line and the RPM of the vacuum pump. High lifts and larger suction line diameters will require longer priming times. If the pump will not prime or maintain prime, or if the vacuum pump runs hot or passes water, refer to “Troubleshooting” on page 71. CAUTION Do not operate at higher than recommended speed to shorten priming time or the service life of the vacuum pump will be shortened.
Operation kPa) of mercury or more. If it does not, check for air leaks at the suction piping gaskets. BEARING TEMPERATURE CHECK Bearings normally run at higher than ambient temperatures because of heat generated by friction. Temperatures up to 160ºF (71ºC) are considered normal for bearings, and they can operate safely to at least 180ºF (82ºC). Measure the bearing temperature with a contact-type thermometer. STOPPING THE UNIT 1.
Operation REMOTE/AUTO STARTING OPTION The unit can be configured to start automatically by adding dry-contact closure float level switches. Contact the Generac Mobile Products, LLC Technical Service Department at 1-800-926-9768 for more information on this option. TOWING THE UNIT 1. Use the jack to raise or lower the trailer onto the hitch of the towing vehicle. Lock the hitch coupling and attach the safety chains or cables to the vehicle. Raise the jack foot completely. 2.
Operation LIFTING THE UNIT Remove suction and discharge piping from pump prior to moving. Make sure the equipment being used to lift the unit is in good condition and has sufficient capacity. Central Lift Point Note: Refer to “Specifications” on page 7 for approximate weights. Always remain aware of the position of other people and objects around you as you move the unit. A central lift point is located on the top of the unit. Attach any slings, chains or hooks directly to the lift point.
Section 4 - Maintenance Normal maintenance service and replacement of parts are the responsibility of the owner/operator and, as such, are not considered defects in materials or workmanship within the terms of the warranty. Poorly maintained equipment can become a safety hazard. In order for the equipment to operate safely and properly over a long period of time, periodic maintenance and occasional repairs are necessary. NEVER perform even routine service (oil/filter changes, cleaning, etc.
Maintenance Failure to perform a daily inspection may result in serious damage to the prime mover. GENERAL MAINTENANCE Refer to the original equipment manufacturer’s operating manual for a complete list of maintenance requirements. Failure to comply with the procedures as described in the engine operator manual will nullify the warranty, decrease performance and cause equipment damage or premature equipment failure. Maintenance records may be required to complete a warranty request.
Maintenance * Change the engine oil and oil filter after the initial 50 hours of operation, then at the appropriate interval thereafter. Refer to engine manual for engine oil recommendations. ** Add three to six pumps of grease at each grease zerk fitting with a hand grease gun. Refer to Figure 8 on page 14 and Figure 9 on page 15 for grease zerk locations. Checking the Engine Oil Low engine oil and overfilling lead to engine damage.
Maintenance Changing the Oil Filter Note: The filter cartridge should never be pre-filled. There is a danger of dirt contamination. 1. Loosen and unscrew the filter with filter tool. Refer to engine manual for more information. 2. Collect the draining engine oil. 3. Clean the sealing surface of the filter support with a lint-free, clean cloth. 4. Oil the gasket of the new filter cartridge lightly. 5. Screw on the new filter by hand until the gasket is touching and then torque to 11-13 ft-lbs (15-17 Nm). 6.
Maintenance JACK MAINTENANCE The following procedures should be performed at least annually. Side-wind Models • The internal gearing and bushings of the jack must be kept lubricated. Apply a small amount of automotive grease to the internal gearing by removing the jack cover, or if equipped, use a needle nose applicator or standard grease gun on the lubrication point found on the side of the jack near the crank. Rotate the jack handle to distribute the grease evenly.
Maintenance 2. Remove the impeller lockscrew with a breaker bar. Do not use an impact wrench. Make sure to apply steady and even torque to break lockscrew loose. Allen head tooling to remove the lockscrew should be in excellent condition. Discard the lockscrew. Remove the impeller washer. Refer to Figure 21 and Figure 22. 12 6 2 3 4 5 7 8 9 10 11 1 19 18 17 16 2 15 14 13 01275 Figure 21 - 4 Inch Pump Cross-Section 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Maintenance 6. The suction wear ring can be removed by drilling the ring longitudinally in three places to relieve compression and collapsing the three sections together. Use care not to drill into the volute casting. Better control is obtained if small pilot holes are first drilled and then enlarged to “cut” the ring. This same technique can be used to remove the hub wear ring. 12 7 2 3 4 5 8 6 9 10 11 1 14 22 21 20 19 2 18 17 16 13 15 01284 Figure 22 - 6 Inch Pump Cross-Section 1. 2.
Maintenance 3. Use new gaskets. In case of an emergency situation where you need to reuse the old gaskets, make sure the gaskets are moist and flat. 4. Replace the impeller key and impeller. For solids handling pumps, install the impeller shims to maintain .030 inch minimum clearance between the backplate and impeller backvanes. Use the a long capscrew and several washers to press on the impeller. Do not use the impeller lockscrew.
Maintenance CAUTION Care should be taken when removing lockscrew to prevent damaging the screw head. 2. If the breaker bar will not loosen the impeller lockscrew, apply heat to the lockscrew for 2-4 minutes. Do not exceed 400°F (204°C). WARNING Care should be taken when applying heat so as not to receive serious burns. 3. Allow lockscrew to cool and remove with a breaker bar. FRAME DISASSEMBLY AND ASSEMBLY Disassembly 1. Remove the deflectors from the shaft. 2. Remove the drive end shaft key. 3.
Maintenance LUBRICATION INSTRUCTIONS Bearings in all frames are greased at the factory before shipment. Lubrication requirement vary with speed, power, load, ambient temperatures, exposure to contamination and moisture, seasonal or continuous operation and other factors. The brief recommendations which follow are general in nature and must be coupled with good judgment and consideration of the application conditions. For re-greasing periods, refer to the table below.
Maintenance Removing the O-ring Seat If the seal is being replaced, remove the backplate (gland is built in) and press out the stationary seat. . 5 4 3 2 1 6 8 9 7 01287 Figure 23 - Mechanical Seal Components 1. 2. 3. 4. 5. Stationary seat O-ring seat Retainer Bellows Spring 6. 7. 8. 9. Driving band Disc Rotating seal face Stationary seal face Installing the O-ring Seat Clean all parts before starting reassembly. Oil the outer surface of the seat and the O-ring with a light oil (not grease).
Maintenance 4. Wipe the lapped sealing faces of the seat and the primary seal perfectly clean. Use extreme care to avoid marking the sealing face or the primary seal. Slide the rotating portion of the seal, including the spring, along the shaft. Once the rotating portion has been placed on the shaft, the rest of the installation must be made at once. Delay may result in the rubber bellows seizing on the shaft in the wrong position. Install the impeller.
Maintenance 3. The valve stem assembly may be removed by a similar action of pin removal. Two cross-drilled holes in the lower end of this part, with slightly separated center lines, accommodate accumulated tolerances in the assembled linkage parts. In most instances the drill from which the clevis pin has been removed will be the one to re-use on reassembly. Linkage Replacement 1. Reverse the previous procedure steps. 2.
Maintenance Valve inspection - If inspection of the valve is required, follow the disassembly instructions. 1 2 3 1 4 5 FLOW 01488 Figure 24 - Discharge Check Valve 1. Cover bolts 2. Disc 3. Cover 4. Gasket 5. Check valve body Disassembly The valve can be disassembled without removing it from the pump. WARNING The line must be drained before removing the cover or pressure may be released, causing bodily harm. To relieve pressure and drain the pump: 1. Remove the cover bolts from the top cover. 2.
Maintenance 4. Cover bolts should be tightened to the following specification during assembly. Table 5 - Bolt Torque Values Bolt Size 3/8 in. 1/2 in. 5/8 in. 3/4 in. Torque 24 ft-lbs (33 Nm) 59 ft-lbs (80 Nm) 117 ft-lbs (159 Nm) 205 ft-lbs (278 Nm) DIAPHRAGM PUMP SYSTEM Disassembly 1. Loosen the clamp and disconnect the air hose from the priming valve. 2. Drain the oil from the seal oil reservoir via the line on the lower reservoir connection. 3.
Maintenance 8. The vacuum pump support table and seal oil reservoir can now be unbolted and removed if desired. 1 40 39 38 37 36 2 3 35 34 33 4 5 6 46 45 44 43 17 41 29 28 27 26 25 24 23 22 21 20 42 19 7 8 9 10 32 31 30 11 12 13 14 15 16 17 18 19 19 43 01461 Figure 25 - Diaphragm Vacuum Pump Cross-section 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
Maintenance Reassembly 1. Reinstall the vacuum pump support table and oil reservoir. 2. Orient the oil reservoir so that the inlet and outlet ports are on the same side of the pump as the inlet and outlet ports of the gland. 3. Reinstall the oil lines between the gland and reservoir. The upper and lower ports of the gland and reservoir should be connected together. 4. Reinstall the pulley on the pump main shaft. Position the toothed drive belt in the adapter support bracket and install the pulley.
Maintenance ACTUATOR NECK SEAL REMOVAL AND REPLACEMENT 1. Remove the actuator assembly as described in “Suction Valve Removal and Replacement” on page 65. 2. Remove the priming chamber hose from the suction nozzle. 3. Remove the four hex nuts holding the lower housing to the pedestal. 4. Remove the vacuum pump lower housing and actuator neck seal. 5. Lubricate the new actuator neck seal and push it into the vacuum pump lower housing. 6. Fit the assembly over the actuator shaft. 7.
Maintenance Replacement: 1. On a new replacement shaft, with a zero lead ground lip seal surface, no speed-sleeve is required. On a reinstalled shaft, when surface condition dictates, or on a new shaft with a turned surface, install a speedsleeve .06-.12 in. (1.52-3.0 mm) past the outside drive end shoulder. Refer to Figure 25 on page 64. 2.
Maintenance 11. Fill the bearing housing with 10W-30 oil to where the static oil level is below the center of the sight glass. Do not overfill. ROLLER BEARING REMOVAL AND REPLACEMENT Follow procedures in “Crankshaft Removal and Replacement” on page 66 and “Crankshaft Lip Seal Removal and Replacement” on page 67. CONNECTING ROD/DRIVE ROD ASSEMBLY It is recommended that these items be purchased pre-assembled with bearing finish machined and reamed.
Maintenance 8. Ensure all bare metal areas are coated with a rust preventative. 9. Inspect unit every four weeks and replace drying agents (Silica Gel) as required, or a minimum of every six months. 10. Keep an inspection record showing dates of inspection with any maintenance performed and condition of drying agents (Silica Gel). 11. Before use ensure that all rust protection has been removed. Also, remove any foreign material that may have accumulated during storage. 12.
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Section 5 - Troubleshooting PUMP TROUBLESHOOTING Symptom Possible Cause No discharge 1,2,3,4,5,7,8,9,10,17,18,19,20,37 Reduced capacity 2,3,4,5,7,8,9,10,11,17,19,20,21,38,39,40,47 Reduced pressure 5,7,8,11,13,18,19,38,39,40,47 Loss of prime 2,3,4,7,10,11,20,21,22,23 Power consumption excessive, engine runs hot 6,12,13,17,18,19,24,33,34,35,36,37,38,41,42,43,44 Vibration and noise 2,4,9,10,14,15,17,26,27,28,29,30,31,32,33,34,35,36, 39,40,41,42,43,44,48 Seal: excessive leakage, short life, seal h
Troubleshooting ENGINE FAULT SHUTDOWN TROUBLESHOOTING Symptom Possible Cause Solution Low oil level Check oil level, replace as necessary Faulty oil pressure sender Replace oil pressure sender Incorrect oil grade Change engine oil, refer to engine operating manual Worn oil pump Refer to engine operating manual Oil leak Refer to engine operating manual Low coolant level Check coolant level, replace as necessary Faulty temperature sender Replace temperature sender Coolant leaks Refer to engi
Troubleshooting CONTROL SYSTEM TROUBLESHOOTING Symptom Control system does not perform self test Control system shuts down Display does not display data Engine will not crank Possible Cause Solution Tripped overcurrent protection Correct fault, replace or reset overcurrent protection Faulty connection to battery Correct battery connections Faulty control system Repair or replace control system Engine stop LED illuminated Correct ECU stop condition, use ECU diagnostics Display lost power Turn
Troubleshooting Table 6 - Typical SPN Codes SPN Description 111 Coolant Level FMI Codes FMI codes are defined by SAE J1939-71. Refer to ECU documentation for correct interpretation of FMI codes for a specific SPN.
4A RD/GY 4 3 80AMP 80AMP 87A RD/GY RD/WT 30 18 AWG FUSE LINK RD/WT E-STOP FUSE LINK 18 AWG 30 86 87 RD/WT BK/WT 12 AWG RD 12 AWG RD 12 AWG RD RD/GY RD 12AWG 60 64 59 65 37 62 38 77 66 76 61 18 AWG BK/WT 83 X BK BK BK BK BK J10 8 3 63 58 18 AWG 18 AWG 12 AWG 12 AWG 12 AWG 12 AWG 12 AWG 12 AWG 18 AWG 15 58 30 1 2 KEYSWITCH 50 3 4 J4 1 J7 1 J6 1 J5 J16 1 1 N M L K J H W C P 18 AWG 82 BK/WT 84 THROTTLE 2 BK RD RD RD BK RD/BK
Wiring Diagrams TRAILER LIGHTS WIRING DIAGRAM AMBER MARKER LAMP BLK BLK WHT WHT TO MOUNTING STUD WHT STOP-TURN SIGNAL LAMP (LEFT) WHT GRN YEL BRN TRAILER PLUG AMBER MARKER LAMP TO MOUNTING WHT STUD YEL GRN BRN BRN STOP-TURN SIGNAL LAMP (RIGHT) PLATE LAMP 90228_ORG_05.09.
Service Log OIL GRADE: _____________________________________ BRAND: __________________________________ COOLANT MIXTURE: _____________________________ BRAND: __________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ _______________________________________________
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