DA 4131 TM 5 4210 222 14 And P 3
User Manual: DA 4131
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TM 5-4210-222-14&P-3
TECHNICAL MANUAL HEADQUARTERS
No. 5-4210-222-14&P-3 DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 14 April 1986
Operator’s, Organizational, Direct Support,
and General Support Maintenance Manual
(Including Repair Parts and Special Tools List)
for
TRUCK, FIREFIGHTING, DRY CHEMICAL AFFF
NSN 4210-00-484-5729
This manual consists of 3 volumes.
Each volume has its own table of contents. The index found in Volume I pertains only to Volume I.
VOLUME I is the Illustrated Parts Breakdown for the entire truck.
VOLUME II contains the Operation, Maintenance, and Repair Manual for:
ENGINE, TRANSMISSION, CHASSIS, CAB and RELATED ITEMS
VOLUME III contains the Operation, Maintenance and Repair Manual for:
TWIN AGENT UNIT, INVERTER, HYDRAULIC RESCUE TOOL (Jaws of Life),
POWER UNIT, RESCUE SAW 10 TON HYDRAULIC RESCUE KIT,
ELECTRONIC SIREN
NOTE: Throughout these manuals, information has been deleted which is not pertinent.
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this manual. If you find any mistake or if you know of a way to improve the procedures, please let us
know. Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms), or DA Form 2028-2
located in the back of this manual directly to: Commander, U.S. Army Troop Support Command, ATTN: AMSTR-MCTS,
4300 Goodfellow Boulevard, St. Louis, MO 63120-1798. A reply will be furnished directly to you.
REPORTING EQUIPMENT IMPROVEMENT RECOMIENDATIONS (EIR)
If your fire truck needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what
you don’t like about your equipment. Let us know why you don’t like the design. Put it on an SF 368 (Quality Deficiency
Report). Mail it to us at Commander, U.S. Army Troop Support Command, ATTN: AMSTR-QX, 4300 Goodfellow
Boulevard, St. Louis, MO 63120-1798. A reply will be furnished to you.
OPERATION, MAINTENANCE AND REPAIR MANUAL
VOLUME III
TABLE OF CONTENTS
SECTION PAGE
ROCKWOOD INSTRUCTION AND SERVICE MANUAL
TWIN AGENT 1500/250 DRY CHEMICAL/AFFF—UNIT .......................................................................... 4001
SECTION I TWIN AGENT UNIT (DRY CHEMICAL
AND AFFF) ............................................................................................................................... 4002
Stand-By Mode...................................................................................................................... 4003
Operation Instructions, Hose Reel......................................................................................... 4005
Operation Instructions, Turret................................................................................................ 4005
System Purging Operation, Dry Chemical............................................................................. 4006
System Purging Operation, AFFF ......................................................................................... 4006
Bleeding Operation, Dry Chemical ........................................................................................ 4008
Bleeding Operation, AFFF..................................................................................................... 4008
Filling Instructions, Dry Chemical .......................................................................................... 4009
Filling Instructions, AFFF....................................................................................................... 4009
Parts List and Schematic....................................................................................................... 4010
Dry Chemical Unit.......................................................................................................... 4011
Scope..................................................................................................................... 4011
Introduction ............................................................................................................ 4011
Principle of Operation ............................................................................................ 4011
System Components.............................................................................................. 4012
Maintenance .......................................................................................................... 4015
Troubleshooting ..................................................................................................... 4015
Spare Parts............................................................................................................ 4016
AFFF Unit ...................................................................................................................... 4017
Scope..................................................................................................................... 4017
Introduction ............................................................................................................ 4017
Principle of Operation ........................................................................................... 4017
System Components.............................................................................................. 4017
Maintenance .......................................................................................................... 4020
Troubleshooting ..................................................................................................... 4020
Spare Parts............................................................................................................ 4021
SECTION II DATA SHEETS FOR COMPONENTS SUPPLIED................................................... 4023
1+ Inch M Series Ball Valve with Air Actuator ....................................................................... 4023
Hannay Hose Reel................................................................................................................. 4029
SECTION III DISCHARGE DEVICES ........................................................................................... 4034
Twin Agent Handline Index.................................................................................................... 4036
Scope............................................................................................................................. 4037
Nozzle Data ................................................................................................................... 4037
Description..................................................................................................................... 4037
Operating Instructions ................................................................................................... 4038
Maintenance ................................................................................................................. 4038
Spare Parts.................................................................................................................... 4038
1
OPERATION, MAINTENANCE AND REPAIR MANUAL
VOLUME III
TABLE OF CONTENTS
SECTION PAGE
Remote Manual Twin Agent Turret Foam/
Dry Powder Index.......................................................................................................................... 4043
Scope ............................................................................................................................... 4044
Introduction............................................................................................................................ 4044
Figures ............................................................................................................................... 4044
Operating Instructions ........................................................................................................... 4045
Maintenance.......................................................................................................................... 4045
Spare Parts............................................................................................................................ 4046
DYNAMOTE "A-30" INVERTER OPERATING, INSTALLATION
AND SERVICE MANUAL........................................................................................................................... 4062
SECTION I DYNAMOTE LIMITED WARRANTY .......................................................................... 4063
SECTION II GENERAL INFORMATION....................................................................................... 4065
Introduction and Principle of Operation ................................................................................. 4065
Specifications ........................................................................................................................ 4066
Product Configuration............................................................................................................ 4066
SECTION III INSTALLATION INSTRUCTIONS............................................................................ 4068
Instructions ............................................................................................................................ 4068
Route Harness to Alternator.................................................................................................. 4069
Install Automatic Throttle....................................................................................................... 4071
Attach Harness to Alternator ................................................................................................. 4071
Checkout of Harness Installation........................................................................................... 4074
Checkout Inverter Operation ................................................................................................. 4082
SECTION IV SERVICE AND TROUBLESHOOTING
INSTRUCTIONS ........................................................................................................................... 4084
General Information............................................................................................................... 4084
Inverter Removal from Vehicle for Servicing ......................................................................... 4084
Troubleshooting Guide .......................................................................................................... 4085
Inverter Parts List .................................................................................................................. 4097
2
OPERATION, MAINTENANCE AND REPAIR MANUAL
VOLUME III
TABLE OF CONTENTS
SECTION PAGE
4 CYCLE HURST POWER UNIT INSTRUCTION MANUAL ........................................................ 4113
Parts List ............................................................................................................................... 4115
Assembling Instructions......................................................................................................... 4116
Operating Instructions ........................................................................................................... 4120
Troubleshooting Instructions ................................................................................................. 4126
HURST JAWS OF LIFE MODEL 32b INSTRUCTION MANUAL.................................................. 4130
Parts List ............................................................................................................................... 4132
Assembling Instructions......................................................................................................... 4133
Troubleshooting Instructions ................................................................................................. 4137
Maintenance.......................................................................................................................... 4137
Operating Instructions ........................................................................................................... 4139
Cutting Instructions................................................................................................................ 4143
PARTNER K-1200 RESCUE SAW SERVICE MANUAL............................................................................ 4148
Safety Precautions................................................................................................................. 4149
Fitting Cutter Arm .................................................................................................................. 4151
Turning Cutter Arm................................................................................................................ 4152
Replacing Belt........................................................................................................................ 4153
Fuel Mixture........................................................................................................................... 4153
Fuel Tank............................................................................................................................... 4153
Controls ............................................................................................................................... 4153
Starter Unit ............................................................................................................................ 4154
Air Filter ............................................................................................................................... 4154
Carburetor ............................................................................................................................. 4154
Maintenance.......................................................................................................................... 4155
Technical Data....................................................................................................................... 4156
PARTNER K-1200 RESCUE SAW OPERATOR’S MANUAL.................................................................... 4157
Table of Contents .................................................................................................................. 4158
Forward ............................................................................................................................... 4159
Parts Description ................................................................................................................... 4161
Pre-Checkout......................................................................................................................... 4163
Cutter Wheels........................................................................................................................ 4166
Diamond Blades .................................................................................................................... 4167
Carbide-Tipped Blades ......................................................................................................... 4169
Operation............................................................................................................................... 4170
Safety Regulations................................................................................................................. 4176
10 TON HYDRAULIC PORTO-POWER RESCUE KIT
OPERATING INSTRUCTIONS ..................................................................................................... 4178
Troubleshooting Chart Solution............................................................................................. 4180
Troubleshooting Chart........................................................................................................... 4180
3
OPERATION, MAINTENANCE AND REPAIR MANUAL
VOLUME III
TABLE OF CONTENTS
SECTION PAGE
10 TON HYDRAULIC PORTO-POWER RESCUE KIT
OPERATING INSTRUCTIONS - Continued
Function ............................................................................................................................... 4181
Operating Instructions ......................................................................... .................................. 4181
Maintenance.......................................................................................................................... 4182
Inspection ............................................................................................................................. 4182
SIGNAL MODEL PA300* ELECTRONIC SIREN
INSTALLATION AND SERVICE INSTRUCTIONS ....................................................................... 4186
Section I General Description........................................................................................ 4187
Section II Specifications ................................................................................................. 4188
Section III Installation ...................................................................................................... 4189
Section IV Operation........................................................................................................ 4193
Section V Circuit Description .......................................................................................... 4195
Section VI Service and Maintenance............................................................................... 4198
4
OPERATION, MAINTENANCE AND REPAIR MANUAL
VOLUME III
LIST OF ILLUSTRATIONS
TITLE IDENTIFICATION/ PAGE(S)
ILLUSTRATION
ROCKWOOD INSTRUCTION AND SERVICE MANUAL
TWIN AGENT 1500/250 DRY CHEMICAL/
AFFF UNIT
Rockwood Twin Agent RTA 1500/250
System Schematic.............................................. 510-2120-1 4010
1" M Series Ball Valve with
Air Actuator......................................................... C-509-0663 4023
Hannay Hose Reel ............................................. ISO-72 4029
Installation Instructions....................................... 6185-1 4032
Wiring Diagram (Hose Reel) .............................. 6185-1 4033
Dual Agent Handline Foam/Dry Powder............. Figure I 4039
Turret Remote Manual Twin Agent .................... Figure I 4047
Turret Remote Manual Twin Agent
Assembly ........................................................... Figure 1A 4049
Remote Manual Turret ....................................... Figure II 4051
Shaper - AFFF.................................................... Figure III 4054
Dry Chemical Nozzle.......................................... Figure IV 4056
Twin Agent 1500/250 Dual Agent
System................................................................ 510-2120 4058 to 4061
INVERTER, DYNAMOTE A-30
Inverter Off ......................................................... 2.0.2A 4065
Inverter On ......................................................... 2.0.2B 4065
A30 Dimensions ................................................. 2.2.5B 4067
Mounting Configuration ...................................... 2.2.6A 4067
Belt Alignment .................................................... 3.3.2A and 3.3.2B 4070
High Amperage By-Pass Installation.................. 3.5.1A 4071
Diagram of Leece-Neville 4000AA
Series Alternator................................................. 3.5.4C 4073
SCR Checkout Procedure.................................. ----- 4091
Diode Checkout Procedure and
Readings ............................................................ 4.3.10A 4095
A30-70D Unit Wire Diagrams............................. 2075 4101
A30-70D Unit Schematic.................................... 2075-1 4102
HURST 4 CYCLE POWER UNIT
4 Cycle Schematic.............................................. ----- 4114
HURST JAWS OF LIFE
Rescue Tool Schematic ..................................... ----- 4131
Accessories........................................................ ----- 4132
5
OPERATION, MAINTENANCE AND REPAIR MANUAL
VOLUME III
LIST OF ILLUSTRATIONS
TITLE IDENTIFICATION/ PAGE(S)
ILLUSTRATION
PARTNER K-1200 RESCUE SAW
Rescue Saw Schematic ..................................... ----- 4150, 4160
Fitting the Cutter Arm ......................................... ----- 4151
Turning the Cutter Arm....................................... ----- 4152
Tools .................................................................. ----- 4155
Safety Regulations ............................................. ----- 4176
10 TON HYDRAULIC PORTO-POWER RESCUE KIT
Spongy Effect .................................................... Figure 1 4180
Ram Won’t Retract ............................................ Figure 2 4180
Clamps ............................................................... Figure 3 4182
SIGNAL MODEL PA300* ELECTRONIC SIREN
Model PA300 Electronic Siren ........................... Figure 1-1 4187
Rear View of PA300........................................... Figure 3-2 4190
Control Cable Wiring Diagram .......................... Figure 3-3 4190
Horn Ring Connections ..................................... Figure 3-4 4190
Press and Hold Modification .............................. Figure 3-5 4192
Relative PA Loudness Adjustment..................... Figure 3-6 4192
Model PA300 Front View ................................... Figure 4-1 4193
Functional Block Diagram ................................. Figure 5-1 4195
Chassis Removed ............................................. Figure 6-1 4199
Internal View ...................................................... Figure 6-2 4199
Component Location Diagram............................ Figure 6-3 4200
Schematic Diagram ........................................... Figure 6-4 4201
6
OPERATION, MAINTENANCE AND REPAIR MANUAL
VOLUME III
LIST OF TABLES
TITLE IDENTIFICATION/ PAGE(S)
ILLUSTRATION
ROCKWOOD TWIN AGENT 1500/250 DRY
CHEMICAL/AFFF UNIT
Pressure vs Temperature Chart......................... Table 1 4022
DYNAMOTE INVERTER
Harness and Alternator ..................................... 3.6.2A 4081
7
ROCKWOOD TWIN AGENT
1500/250 DRY CHEMICAL/AFFF UNIT
ROCKWOOD INSTRUCTIONS
LOG NO. RIM 1554
KOVATCH CORPORATION
500-600 WEST CATAWISSA ST.
NESQUEHONING, PA 18240
SALES ORDER C100360
MARCH, 1985
REVISED:
JULY, 1985
4001
ROCKWOOD SYSTEMS CORPORATION
640 East Main Street
Lancaster, Texas 75146
SECTION I
TWIN AGENT UNIT
4002
OPERATIONAL PROCEDURES
(SEE SCHEMATIC ON PAGE 4010 FOR ITEM NUMBERS)
STAND-BY MODE:
DRY CHEMICAL
1. The Dry Chemical Tank shall be full and
Fill Cap securely installed. Nitrogen
cylinders shall be full.
2
.
Turret Control Switch; OFF
3. Charging Switches; OFF
4. Nozzle Discharge Valve - 2B; CLOSED
5. Hose Reel Valve - 9B; CLOSED
6. Nitrogen By - Pass Valve - 13C; CLOSED
7. Nitrogen Bleed Valve - 13B; CLOSED
8. Master Nitrogen Valve - 12B; OPEN
9. Master Discharge Valve - 6B; CLOSED
10. M. D. V. Actuator Bleed Valve - 21B; CLOSED
11. Turret Discharge Valve - 109; CLOSED
12. Quick Opening Valves - 81A; SET
AFFF FOAM SYSTEM
1. The AFFF Tank shall be full and
Fill Cap securely installed. Nitrogen
cylinders shall be full.
2. Turret Control Switch; OFF
3. Charging Switches; OFF
4. Nozzle Discharge Valve - 2A; CLOSED
5. Hose Reel Valve - 9A; CLOSED
6. Nitrogen By-Pass Valve - 13A; CLOSED
7. Master Nitrogen Valve - 12A; OPEN
8. Master Discharge Valve - 6A; CLOSED
9. M. D. V. Actuator Bleed Valve - 21A; CLOSED
4003
-1-
Operational Procedures, Cont.
(SEE SCHEMATIC ON PAGE 4010 FOR ITEM NUMBERS)
10. Drain Valve - 7B; CLOSED
11. Turret Discharge Valve - 108; CLOSED
12. Quick Opening Valves - 81A; SET
13. Temperature Relief Valve - 71; CLOSED
4004
(SEE SCHEMATIC ON PAGE 4010 FOR ITEM NUMBERS)
OPERATING INSTRUCTIONS
HOSE REEL
The discharge of large amounts of dry chemical may create hazards to personnel such as reduced visibility and temporary
breathing difficulty.
1. Activate system by placing desired agent(s) "CHARGING SWITCH" in "ON" position. (Press dashboard
actuator if activating from the cab.)
2. Place desired agent(s) hose reel valve 9A/9B in "OPEN" position.
3. Unlock brake on hose reel.
4. Remove nozzle.
5. Unwind hose to desired length.
6. Place desired agent(s) nozzle discharge valve 2A/2B in "OPEN" position; operate as required.
NOTE: The Dry Chemical System and AFFF Foam System-can be used simultaneously or independently.
TURRET
The discharge of large amounts of dry chemical may create hazards to personnel such as reduced visibility and temporary
breathing difficulty.
1. Activate system by placing desired agent(s) "CHARGING SWITCH" in "ON" position. (Press dashboard
actuator if activating from cab.)
2. Release turret handle locking devices
3. Select desired spray pattern.
4. Activate turret by placing selected agent switch in "ON" position. Discharge may be stopped at any time by
placing switch in "OFF" position. To resume discharge, place switch in "ON" position.
NOTE: The Dry Chemical System and AFFF Foam System can be used simultaneously or independently.
4005
(SEE SCHEMATIC ON PAGE 4010 FOR ITEM NUMBERS)
SYSTEM PURGING OPERATION
DRY CHEMICAL
The discharge of large amounts of dry chemical may create hazards to personnel such as reduced visibility and temporary
breathing difficulty.
1. Place "CHARGING SWITCH" in "OFF" position.
2. Shut master nitrogen valve 12B.
3. Slowly open valve 218 and vent tank pressure until relief valve 88A is reseated and valve 6B can be shut; then
shut valve 21B.
4. Shut master discharge valve 6B.
5. Shut bleed valve 13B.
6. Place "CHARGING SWITCH" in "ON" position.
7. Slowly open nitrogen by-pass valve 13C.
8. Cycle nozzle discharge valve 2B. Open and close. Shut nozzle discharge valve when purging is complete.
9. Place "CHARGING SWITCH" in "OFF" position and reset the quick opening valves 81A.
10. Shut nitrogen by-pass valve 13C.
11. Open master nitrogen valve 12B.
AFFF FOAM SYSTEM
1. Place "CHARGING SWITCH" in "OFF" position.
2. Shut master nitrogen valve 12A.
3. Slowly open valve 21A and vent tank pressure until relief valve 88B is reseated and valve 6A can be shut;
then shut valve 21A.
4. Shut master discharge valve 6A.
5. Shut bleed valve 13A.
6. Place "CHARGING SWITCH" in "ON" position.
7. Slowly open nitrogen by-pass valve 13A.
8. Cycle nozzle discharge valve 2A. Open and close. Shut nozzle discharge valve when purging is complete.
4006
System Purglng, Cont.
(SEE SCHEMATIC ON PAGE 4010 FOR ITEM NUMBERS)
9. Place "CHARGING SWITCH" in "OFF" position and re-set the Quick Opening Valves - 81A.
10. Shut Nitrogen By-Pass Valve - 13A.
11. Open Master Nitrogen Valve - 12A.
-5-
BLEEDING OPERATION
(SEE SCHEMATIC ON PAGE 4010 FOR ITEM NUMBERS)
DPY CHEMICAL
1. Place "CHARGING SWITCH" in "OFF" position. Open Valve - 81C to vent actuation line, then re-set the
Quick Release Valve for Dry Chemical Nitrogen Cylinders.
2. Slowly open Valve - 21B and vent tank pressure until Relief Valve - 88A is re-seated and Valve - 6B can be
shut; then shut Valve - 21B.
3. Shut Dry Chemical Master Discharge Valve - 6B.
4. Shut Nitrogen Purge Valve - 13C.
5. Open Hose Reel Auxiliary Discharge Valve - 9B.
6. Slowly open Bleed Valve - 13B.
7. Open Nozzle Discharge Valve - 2B and vent off excess nitrogen pressure. Then shut discharge valve.
8. Shut Bleed Valve - 13B.
AFFF FOAM SYSTEM
1. Place "CHARGING SWITCH" in "OFF" position. Open Valve - 81C to vent actuation line, then re-set the
Quick Release Valve for foam nitrogen cylinders.
2. Slowly open Valve - 21A and vent tank pressure until Relief Valve - 88B is re-seated and Valve - 6A can be
shut; then close Valve - 21A.
3. Shut AFFF Master Discharge Valve - 6A.
4. Open Hose Reel (Auxiliary Discharge) Valve - 9A.
5. Slowly open Bleed Valve - 13A.
6. Open Nozzle Discharge Valve - 2A and vent off excess nitrogen pressure. Then shut discharge valve.
7. Shut Bleed Valve - 13A.
4008
-6-
FILLING INSTRUCTIONS
DRY CHEMICAL
1. Vent the system per enclosed "Bleeding Operation" instructions.
2. Shut master nitrogen valve 12B.
3. Slowly remove fill plug from the top of the tank.
Be sure all pressure is expelled from the dry chemical tank 1B before removing plug. If pressure venting
sound is audible when cap is turned, "STOP" immediately and repeat steps 1, 2, and 3.
Avoid breathing dry chemical dust while filling tank.
4. Fill dry chemical tank 1B to the top with Purple-K-Powder. Do not rod or tamp dry chemical into the tank.
5. Replace fill plug on tank and tighten firmly.
6. Open master nitrogen valve 12B.
7. Check nitrogen pressure. If pressure is below 1800 psi at 70° F., replace cylinder.
AFFF FOAM SYSTEM
1. Vent the system per enclosed "Bleeding Operation" instructions.
2. Shut master nitrogen valve 12A.
3. Slowly remove fill plug from the top of the tank.
Be sure all pressure is expelled from the AFFF tank 1A before removing plug. If pressure venting sound is
audible when cap is turned, "STOP" immediately and repeat steps 1, 2, and 3.
4. Fill AFFF tank 1A to the top with water and AFFF as specified on the refill table located at the rear of the skid
unit.
5. Replace fill plug on tank and tighten firmly.
6. Open master nitrogen valve 12A.
7. Check nitrogen pressure. If pressure is below 1800 psi at 70° F., replace cylinder.
4009
DRY CHEMICAL UNIT
1.0 SCOPE
This manual defines the following for Rockwood’s Self Contained
Dry Chemical Unit : PAGE
a) Principle of operation................... 4011
b) System description ...................... 4012
c) Operating Instructions ................. 4005
d) Maintenance procedures............. 4015
e) Trouble shooting.......................... 4015
f) Recommended spare parts ......... 4016
2.0 INTRODUCTION
2.1 PURPOSE:
Dry Chemical Fire Extinguishing Systems are used throughout the fire protection industry on class B and C
fires for rapid extinguishment and knock down capabilities.
Typical uses for Dry Chemical Extinguishing Systems consist of:
A) Offshore platforms
B) Tankers
C) Bulk fuel handling terminals
D) Heavy industrial marine, petroleum, chemical and petrochemical operations
E) Pipe lines
F) Crash truck and quick response vehicles
G) Wherever fuel and chemical spills create a potential hazard.
2.2 PRINCIPLE OF OPERATION:
The Dry Chemical Unit utilizes dry nitrogen in a pressurized cylinder as the propellant for the extinguishing
agent and therefore requires no other power source.
Nitrogen is released from the cylinder via the bottle stop or quick releasing device. The pressure is then
reduced by going through a special high capacity regulator prior to entering the dry chemical tank where the
dry chemical is fluidized, aggitated and pressurized. Dry chemical is then propelled through a handline or
fixed discharge devices depending upon the application. Flow rates are controlled by the various types of
discharge devices.
4011
3.0 SYSTEM COMPONENTS
The item numbers below refer to the system schematic of Figure 510-2120-1 Page 4010
1B. A.S.M.E. DRY CHEMICAL TANK
The Rockwood Dry Chemical Tank is designed, constructed and inspected in accordance with Section VIII, Rules
For Construction of Pressure Vessels, Division 1 of the ASME Code. All tanks are designed for a working
pressure of 250 PSI.
The Dry Chemical Tank is a spherical steel tank equipped with openings for nitrogen gas input, a combination
nitrogen bleed purge and safety relief, dry chemical discharge, dry chemical fill and dry chemical clean out.
The Dry Chemical Tank has a four inch diameter fill opening and a threaded self venting pressure plug. The plug
is designed so that there are at least four threads engaged when the plug vent is exposed. This protects the
operator from injury should any residual pressure remain in the tank prior to recharging.
The Tanks have a welded on external skirt support to facilitate mounting.
The Dry Chemical Tank must contain a sufficient quantity of dry chemical for the required discharge time of the
system, depending upon the application of the system.
2A, 2B DISCHARGE DEVICE
Rockwood’s Dry Chemical Systems can be used on either portable or stationary systems with either fixed or
manual discharge devices.
Some examples of Rockwood’s Dry Chemical Discharge Devices consist of: Fixed nozzles, hose reels with twin
agent handlines, or Dry Chemical handlines, twin agent turrets and dry chemical turrets. Any one or combination
of these devices are compatable with Rockwood’s Dry Chemical System.
3B. CHECK VALVE
A Check valve is installed downstream of the nitrogen regulator to prevent backflow of dry chemical from the tank
to the regulator. A high back pressure could occur if a discharge outlet were shut off quickly.
4012
4B. NITROGEN REGULATOR
Rockwood’s Dry Chemical System utilizes a special high flow capacity regulator to achieve the constant discharge rate
required. The Regulator reduces the high nitrogen cylinder pressure to 230 psig. The Regulator incorporates a built in
safety valve set to limit the secondary pressure to 400 psig. High and low pressure gage connections are also provided.
6B. MASTER DISCHARGE VALVE
A Discharge Valve is located in the discharge line of the Dry Chemical Tank. This valve is normally open but shall be shut
when the discharge lines are purged with nitrogen or when bleeding off the residual nitrogen pressure in the Dry Chemical
Tank after full or partial discharge. It is recommended that the discharge valve be safety wired in the open position after
the lines have been cleared and the unit is placed in standby condition.
10B. PRESSURE RELIEF VALVE
The Pressure Relief Valve provides the tank with protection against over pressure conditions in the event of a sudden
shutdown of one or more of the discharge devices or failure of the nitrogen regulator. The Relief Valve is set at 275 psi.
11C, D NITROGEN CYL INDER(S)
&E
The Nitrogen Cylinder(s) provide the system with the required supply of high pressure nitrogen to completely discharge all
the chemical agents and clean out all lines after discharge. The cylinders contain dry nitrogen at approximately 2, 400’psig
at 21.10C (700F). Bottle quantity and capacity are based upon required system duration and flow rate. Each bottle has a
hand wheel operated bottle stop (or a quick release device if desired item 16B) and a safety v3lve set at approximately 3,
000 psi.
4013
12B. MASTER NITROGEN SUPPLY VALVE
The Master Nitrogen Supply Valve isolates the dry chemical tank from the nitrogen supply when filling or cleaning out the
tank. This valve is also closed to isolate the tank when purging the system after discharge to clean out the piping and
hose lines.
13C. NITROGEN BY-PASS VALVE
A By-Pass (purging) Valve is located in the lines of the nitrogen manifold system to enable the operator to by-pass the dry
chemical tank with pressurized nitrogen when clearing (purging) the discharge line after use or checking the discharge
lines during maintenance.
13 B BLEED VALVE
A Bleed Valve is located in the lines of the nitrogen manifold system to enable the operator to depressurize the tank and
facilitate purging the discharge line after use.
14B. HIGH PRESSURE GAGE
A High Pressure Gage is located on the inlet side of the nitrogen regulator to indicate cylinder supply pressure. The gage
has a range of 0 3000 psi.
15B. LOW PRESSURE GAGE
A Low Pressure Gage is located on the outlet side of the nitrogen regulator to indicate system pressure. The gage has a
range of 0 - 400 psi with normal operating pressure equal to 230 psi at 700F.
4014
4.0 MAINTENANCE
A periodic check of the following should be made every thirty days.
1. Perform stand-by mode check, page 4003, to ensure valves are in proper position.
2. Check nitrogen cylinder pressure per filling instructions, steps 2 and 6, page 4009. Replace cylinder if
pressure is below 1800 psi at 70° F., as read on gauge 14B (refer to table I). Nitrogen to be per FED-SPEC-
BB-N-411, type I, Class I.
3. Ensure that discharge device works freely. Discharge device (2A, 2B, etc.) control valve should be left shut
when check is complete.
4. Make certain that tank is full.
5. Check gauges for cracked or broken glass.
6. The dry chemical system is virtually maintenance free. Use touchup paint and rust preventatives as required.
If the unit has been worked on, check valve position for proper ready standby configuration per stand-by
mode, page 4003.
5.0 TROUBLESHOOTING
The information listed below provides some direction for troubleshooting difficulties that may be encountered with
dry chemical systems.
TROUBLE PROBABLE CAUSE REMEDY
Dry Chemical System
High pressure gauge Low temperature Check high pressure
shows loss of gauge reading against
pressure data in table 1.
Check for leaks at
cylinder valve.
Cylinder low/empty Replace cylinder.
Low pressure gauge Defective regulator Replace regulator.
reads other than
230 psi Improper setting Consult factory.
4015
TROUBLE PROBABLE CAUSE REMEDY
Decreased flow of Plugged pick-up Clean out line as per in-
dry chemical tube or packed hose struction in dry chemical
resulting from system purging operations,
incomplete clean-out page 4006.
Defective regulator Replace regulator
Discharge valves(s) Turn valve to wide
partially closed open position.
Master nitrogen Turn valve to wide
valve partially open position
closed
Nitrogen by-pass Turn valve to full
(purge) valve closed position
partially open
Nitrogen bleed Turn valve to full
valve partially closed position
open
CAUTION:
BEFORE PRESSURIZING, DEPRESSURIZING OR SERVICING DRY’CHEMICAL UNIT, READ OPERATIONS MANUAL
TO ASSURE STRICT ACCORDANCE WITH INSTRUCTIONS.
6.0 SPARE PARTS
The following items are the recommended list of spare parts:
ITEM PART NUMBER DESCRIPTION QTY
1 509-0327 Repair Kit: %" M802 B.V. 1
2 509-0329 Repair Kit: 1" M802 B.V. 1
3 509-0331 Repair Kit: 1s" M802 B.V. 1
4 6129-2 Nitrogen Regulator 1
5 6156-15 High Pressure Gage 1
6 6156-12 Low Pressure Gage 1
7 110-3736-1 Gasket 1
4016
AFFF UNIT
1.0 SCOPE
This manual defines the following for Rockwood’s Self Contained AFFF Units:
PAGE
a) Principle of Operation................................ 4017
b) System Description.................................... 4017
c) Operating Instructions ............................... 4017
d) Maintenance Procedures........................... 4020
e) Trouble Shooting ....................................... 4020
f) Recommended Spare Parts ...................... 4021
2.0 INTRODUCTION
2.1 PURPOSE:
AFFF Fire Extinguishing Systems are used throughout the fire protection industry on class B fires and spills.
By securing the hazard with an expanded AFFF solution, the flammable vapors are suppressed, reducing the
possibility of ignition. AFFF systems are designed for quick knock down of the fire, vapor suppression and
blowback resistance.
Typical uses for AFFF Extinguishing Systems consist of:
A) Offshore platforms
B) Tankers
C) Bulk Fuel Handling Terminals
D) Heavy Industrial Marine, Petroleum, Chemical and Petrochemical Operations.
E) Pipe Lines
F) Crash Truck and Quick Response Vehicles
G) Wherever Fuel and Chemical Spills Create a Potential Hazard.
2.2 PRINCIPLE OF OPERATION:
The AFFF Unit utilizes dry nitrogen in a pressurized’ cylinder as the propellant for the extinguishing agent and
therefore requires no other power source.
Nitrogen is released from the cylinder via the bottle stop or quick releasing device. The pressure is then
reduced by going through a special high capacity regulator prior to entering the AFFF tank where the AFFF
premix solution is pressurized. AFFF is then propelled through a handline or fixed discharge devices
depending upon the application. Flow rates are controlled by the various types of discharge.
3.0 SYSTEM COMPONENTS
The item numbers below refer to the system schematic of Fig. 510-2120-1 Page 4010.
1A. A.S.M.E. AFFF TANK
The Rockwood AFFF Tank is designed, constructed and inspected in accordance with Section III, Rules for
Construction of Pressure vessels, Division 1 of the ASME Code. All tanks are designed for a working pressure of
250 PSI.
The AFFF Tank is equipped with openings for nitrogen gas input, a combination, nitrogen bleed purge and safety
relief, AFFF discharge, AFFF fill and AFFF drain.
4017
The Tanks have a welded on external skirt support to facilitate mounting.
The AFFF Tank must contain a sufficient quantity of Foam Solution for the required discharge time of the system.
2A, 2B etc. DISCHARGE DEVICE(S)
Rockwood’s AFFF Systems can be used on either portable or stationary systems with either fixed or manual discharge
devices.
Some examples of Rockwood’s AFFF Discharge Devices consist of: Fixed nozzles, hose reels with twin agent handlines,
or AFFF handlines, twin agent turrets and foam turrets. Any one or combination of these devices are compatable with
Rockwood’s AFFF System.
3A. CHECK VALVE
A Check valve is installed downstream of the nitrogen regulator to prevent backflow of AFFF solution from the tank to the
regulator. A high back pressure could occur if a discharge outlet were shut off quickly.
4A. NITROGEN REGULATOR
Rockwood’s AFFF System utilizes a special high flow capacity regulator to achieve the constant discharge rate required.
The Regulator reduces the high nitrogen cylinder pressure to 230 psig. The Regulator incorporates a built in safety valve
set to limit the secondary pressure to 400 psig. High and low pressure wage connections are also provided.
6A. MASTER DISCHARGE SALVE
A Discharge Valve is located in the discharge line of the AFFF Tank. This valve is normally open but shall be shut when
the discharge lines are purged with nitrogen or when bleeding off the residual nitrogen pressure in the AFFF Tank after full
or partial discharge. It is recommended that the discharge valve be safety wired in the open position after the lines have
been cleared and the unit is placed in standby condition.
7B. FOAM SOLUTION DRAIN VALVE
The Foam Solution Drain Valve is required for maintenance of the tank.
8. FILL CUP
The Fill Cup is used for gravity filling of tile foam solution AFFF Tank.
4018
9A, 9B AUXILIARY DISCIARGE VALVE(S)
Auxiliary Discharge Valve(s) are provided to allow isolation of one or more systems while maintaining the remaining
discharge devices in an operable condition. They can also be used to minimize nitrogen loss when purging the system
after using only one discharge device. These valves are only provided if there are two or more separate discharge
devices/zones.
10A. PRESSURE RELIEF VALVE
The Pressure Relief Valve provides the tank with protection against over pressure conditions in the event of a sudden
shutdown of one or more of the discharge devices or failure of the nitrogen regulator. The Relief Valve is set at 275 psi.
11A. NITROGEN CYLINDER(S)
The Nitrogen Cylinder(s) provide the system with the required supply of high pressure nitrogen to completely discharge all
the chemical agents and clean out all lines after discharge. The cylinders contain dry nitrogen at approximately 2, 400 psig
at 21.1oC (700F). Bottle quantity and capacity are based upon required system duration and flow rate. Each bottle has a
hand wheel operated bottle stop (or a quick release device if desired item 16A) and a safety valve set at approximately 3,
000 psi.
12A. MASTER NITROGEN SUPPLY VALVE
The Master Nitrogen Supply Valve isolates the AFFF tank from the nitrogen supply when filling or draining the tank. This
valve is also closed to isolate the tank when purging the system after discharge to clean out the piping and hose lines.
13A. NITROGEN BY-PASS VALVE
A By-Pass (purging) valve is located in the lines of the nitrogen manifold system to enable the operator to by-pass the
AFFF tank with nitrogen when clearing (purging) the discharge line after use or checking the discharge lines during
maintenance.
14A. HIGH PRESSURE GAGE
A High Pressure Cage is located on the inlet side of the nitrogen regulator to indicate cylinder supply pressure. The gage
has a range of 0 - 3000 psi.
15A. LOW PRESSURE GAGE
A Low Pressure Gage is located on the outlet side of the nitrogen regulator to indicate system pressure. The gage has a
range of 0 400 psi with normal operating pressure equal to 230 psi at 700F.
4019
4.0 MAINTENANCE
A periodic check of the following should be made every thirty days.
1. Perform stand-by mode check, page 4003, to ensure valves are in proper position.
2. Check nitrogen cylinder pressure per filling instructions, steps 2 and 6, page 4009. Replace cylinder if
pressure is below 1800 psi at 700 F., as read on gauge 14A (refer to table I.) Nitrogen to be per FED-SPEC-
BB-N-411, type I, Class I.
3. Ensure that discharge device works freely. Discharge device (2A, 2B, etc.) control valve should be left shut
when check is complete.
4. Make certain that tank is full.
5. Check gauges for cracked or broken glass.
6. The AFFF system is virtually maintenance free. Use touch-up paint and rust preventatives as required. If the
unit has been worked on, check valve position for proper ready stand-by configuration per stand-by mode,
page 4003.
7. Shut master discharge valve 6A. Remove, clean and reinstall strainer basket 5. Open 6A to place system
back into normal stand-by condition.
5.0 TROUBLESHOOTING
The information listed below provides some direction for troubleshooting difficulties that may be encountered with self
contained AFFF systems.
TROUBLE PROBABLE CAUSE REMEDY
AFFF System
High pressure gauge Low temperature Check high pressure
shows loss of gauge reading against
pressure data in table I.
Check for leaks at
cylinder valve.
Cylinder low/empty Replace cylinder.
Low pressure gauge Defective regulator Replace regulator.
reads other than 230
psi Improper setting Consult factory.
4020
TROUBLE PROBABLE CAUSE REMEDY’
Decreased flow of AFFF Plugged or packed Clean out line as per in-
solution. hose resulting from struction in dry chemical
incomplete clean-out system purging operations,
page 4006.
Defective regulator Replace regulator
Discharge valve(s) Turn valve to wide
partially closed open position.
Nitrogen by-pass Turn valve to full
(purge) valve closed position.
partially open
Nitrogen bleed valve Turn valve to full
partially open. closed position
Fill and/or drain Turn valve to full
valve partially open closed position.
CAUTION:
BEFORE PRESSURIZING, DEPRESSURIZING OR SERVICING AFFF UNIT, READ OPERATIONS MANUAL TO
ASSURE STRICT ACCORDANCE WITH INSTRUCTIONS.
6.0 SPARE PARTS
The following items are the recommended list of spare parts:
ITEM PART NUMBER DESCRIPTION QTY
1 509-0327 Repair Kit: ½" M802 B.V. 1
2 509-0329 Repair Kit: 1" M802 B.V. 1
3 509-0332 Repair Kit: 2" M802 B.V. 1
4 6129-2 Nitrogen Regulator 1
5 6156-15 High Pressure Gage 1
6 6156-12 Low Pressure Gage 1
4021
PRESSURE VS. TEMPERATURE CHART
TEMPERATURE PRESSURE CORRECTIONS FOR GAGE READING
°C °F (Base Point 220 psig at 21.1°C (70°F)
* 43.0 (110) Subtract 221 psig from gage reading
38.0 (100) Subtract 166 psig from gage reading
32.2 ( 90) Subtract 111 psig from gage reading
26.7 ( 80) Subtract 55 psig from gage reading
21.2 ( 70) 0
15.6 ( 60) Add 56 psig to gage reading
10.0 ( 50) Add 112 psig to gage reading
4.4 ( 40) Add 168 psig to gage reading
*** 1.1 ( 30) Add 224 psig to gage reading.
-6.7 ( 20) Add 280 psig to gage reading
-12.2 ( 10) Add 336 psig to gage reading
-17.8 ( 0) Add 392 psig to gage reading
-23.0 (-10) Add 448 psig to gage reading
-29.0 (-20) Add 504 psig to gage reading
**
NOTES:
* For temperatures above 43.0°C (110F) subtract 56 psig more from gage reading for every 12.2°C (10°F)
** For temperatures below -29.0°C (-20°F) add 56 psig more to gage reading for every 12.2°C (100F)
*** EXAMPLE:Pressure gage reads 1, 700 psig and outside temperature is 1.1°C (30°F). Actual nitrogen
pressure is 1, 924psig, which is found by adding 224 psig to gage reading.
TABLE 1.
4022
4010
SECTION II. 4023
4024
Page 4026 DELETED
-1-
ADJUST OPEN AND CLOSE VALVE POSITIONS (CON’T)
1. Loosen locknuts on the position adjustment screws (screws are located at the end on each cylinder or end cap.
2. To adjust for correct positioning, rotate position adjustment screws clockwise (into cylinder) for over traveling
condition or counterclockwise (out of cylinder) for under traveling condition. This procedure is applicable for adjusting both
open and close positions.
3. Tighten locknuts on position adjustment screws and operate unit to check corrected positions. If further
corrections are needed, repeat steps 1, 2, and 3.
To Manually Operate
Manual operation of actuator and valve is provided in case of pressure loss or power failure. Standard wrenches fit either
end of actuator output shaft or hexagon Actuator-Valve drive adapter.
MAINTENANCE
Clear, dry air or gas is essential for long service life and satisfactory operation. If instrument air of this quality is not
available, it is recommended that an inline filter be provided to prevent foreign particles from entering the cylinders of the
actuator. Under most normal circumstances the actuator does not require additional lubrication, it should be remembered
that most control valves and solenoids (with the exception of positioners) perform better on lubricated air. For this reason,
an airline lubricator may be installed. Care should be taken to use only lubricants compatible with the seal in the actuator
and control valves.
HYDRAULIC SERVICE
All models of the Actuator can be furnished for using hydraulic fluid as an operating medium. When using water of other
corrosive fluids as the operating medium, plating and coatings compatible with the respective operating medium, must be
used.
STORAGE
Indoor storage, if available is recommended for all actuators. Care should be taken to plug the cylinder ports, control
valves ports and the body ports. Also, actuators should not be stored in an atmosphere harmful to resilient seals.
The piston(s) and other seals used in the Actuator are Buna -N material. Such synthetic materials have a shelf life of
approximately 12 months at which point they go “dead”. In normal use the life of these seals is indefinite, depending upon
the amount of lubrication, etc. However, if the actuator sits for extended periods of non-use, the packing will have a
tendency toward going dead. In such cases, when the actuator is called on to operate, leakage by the piston(s) will be
experienced. The actuator in most cases will stroke the valve but then the gas will leak from the exhause of the control
valve. To prevent this from occuring we recommend that the actuator be cycled several times on at least 90 day intervals.
This will keep the seals and pistion(s) “alive” and flexible.
4025
Page 4026 DELETED
-2-
CYLINDER DISASSEMBLY
Safety First
The maintenance and operation of mechanical equipment SAFETY is the basic factor which must be observed at all times.
Through the use of the proper clothes, tool and methods of handling serious contents cause injury, to you or your fellow
worker can be prevented.
Throughout this manual are listed a number of safety precautions. Study them and follow them, also insist upon those
working for you to do the same. Remember an accident is usually caused by someone’s carelessness neglect or
oversight.
Type AA
Double Acting (Air To Air) Units:
Screw Attachment Models
At the base of the cylinder(s) are four (4) socket head cap screws. Alternately loosen, a little at a time, two screws across
from each other. Similarly, loosen the remaining screws and remove by hand. Care should be taken when removing the
last two screws as the cylinder could become free to drop or fall.
CYLINDER RE-ASSEMBLY
Screw Attachment Models
Replace cylinder "0" ring and air passage seals (it required) and carefully slide cylinder over piston and up to
body. Install the :;socket head cap screws and tighten snugly by hand. Use a wrench and alternately tighten,
a little at a time, two screws across from each other Similarly, tighten the remaining screws.
4027
Page 4026 DELETED
-4-
ACTUATOR WEIGHTS IN POUNDS (APPROX.)
pe AA
PA-25 2.50 Lb.
ACTUATOR FREE AIR CONSUMPTION - ONE 95° STROKE
The following formula may be used to determine the free air consumption for each actuator.
V = Free Air Consumption Per Minute (SCFM)P + 14.7 60
D = Actuator Displacement (Cubic Feet) V = D x P + 14.7x 60
P = Guage Pressure (PSIG) 14.7 x T
T = Actuator Operating Time (Seconds)
Cubic Feet = CUBIC INCHES
1728
TROUBLESHOOTING
Problem: Actuator operates alone but will not operate valve.
Instructions: Check actuator nameplate to insure correct model and spring rating, if so supplied, is
in use.
Check line pressure at actuator.
Check to insure correct solenoid is being used.
Check to insure that air lines are properly connected to solenoid and from solenoid
to actuator.
Check to insure that electric power is properly connected to solenoid.
Check to see if actuator has been stored for any length of time without periodic
cycling (see storage).
LOCATING AND ORDERING PARTS
For ease and accuracy in identifying and ordering spare or
replacement parts, use parts drawings and part lists on the
preceding pages.
Data required from parts drawings and list are:
1. Part number
2. Name of part
To obtain replacement parts submit the following
information from unit nameplate:
1. Serial number
2. Model number
3. Operating pressure
4028
-5-
4029
1 of 5
Bulletin 5821A
FF028 SEAL REPLACEMENT KIT For FS59000-1616-01 Swivel Joints
Kit FF028 Contents
Description Quantity Part Number
DUST SEAL 1 06-099-00
O-RING 1 22550-216
TEFLON BACK-
UP RING
1 FF9552-216
SERVICE INSTRUCTIONS:
1. Remove the sleeve assembly by backing off the set
screw with a 1/e" hex head wrench. Then unscrew
the nut completelywith a screwdriver or spanner
wrench.
2. Pull out the nut and sleeve assembly. One bearing
and race may remain in the housing, however, these
should also be removed. If the shoulder retainer
comes off of the sleeve assembly, it should be
reinstalled. It must cover the shoulder since the rear
of this part acts as a bearing race.
3. Remove and discard the O-ring and back-up ring
from the sleeve or housing. Remove the dust seal
from under the nut, clean area and replace.
4. Wipe the housing and sleeve seal area clean. Apply
an assembly lubricant, such as silicone grease to
these surfaces. Lubricate the O-ring and place in
the housing. Place the white teflon back-up ring on
the O-ring. Again, make sure the skive cut is lined
up as shown.
5. If the rear bearing and race were removed from the
sleeve, they must be reinstalled. The .031" thick
race is placed in the housing first with the bearing on
top.
6. Insert the sleeve assembly into the housing. It is not
necessary to force the sleeve. Allow the nut to
slowly guide the sleeve into the casing with its
threading action. Occasional pressure on the sleeve
should make it possible to seat the nut almost
entirely by hand.
7. Snug the nut with a spanner wrench (or screwdriver).
Then, loosen the nut 1/4 to 1/2 turn (maximum) to
avoid overtightening. Lock the nut with the set
screw.
8. Use a grease gun to grease the swivel at the
lubrication fitting until grease comes out of the relief
hole. Check for smooth rotation to insure proper
assembly.
NOTE: If, during disassembly, a problem is noted
with the bearings or races such as cracks, kit
number FF976 is recommended. The FF975
kit includes seals and bearings to completely
refurbish the swivel assembly.
Aeroqulp Corporation 1981
4030
2 of 5
1. DESCRIPTION OF CIRCUIT BREAKER
The CDLM Circuit Breaker is normally used with Hannay Reels for protection of the rewind motor. This type of breaker
must be manually reset by pressing firmly on the red pushbutton, if it is tripped for any reason. This insures that the
problem will be corrected before the breaker is reset.
2. WIRING PROCEDURES
The circuit breaker is installed into the wiring system by cutting either wire leading to the hose reel motor and connecting
the two resulting ends to the two terminals of the circuit breaker.
3. MOUNTING
The circuit breaker should be firmly mounted using the two mounting holes provided. The mounting position should be
well removed from any abnormal sources of heat such as exhaust manifold and radiator, etc. To use the manual reset
type satisfactorily a small mounting bracket, available from us as Part No. CB-1, should be used so that the reset button
will be easily accessible when needed.
4. AMPERAGE RATINGS
The application will determine shat amperage breaker is required. Under actual operating conditions the breaker should
be of such a rating that when the hose reel motor is held in a stalled condition the breaker will open the circuit in no more
than 30 seconds. To allow the circuit to remain closed for a longer period of time would begin to endanger the other
components in the system. As a guideline, the following ratings would apply to motors used on Hannay Reels:
Reels (except Inverted Type) with 12 volt explosion-proof rewind motor: 50 amp. Circuit breaker.
CAUTION
THIS CIRCUIT BREAKER IS NOT SUITABLE FOR USE WITH AC MOTORS. 3 OF 5
10M HP 7/84
4031 Form H-6913
3 of 5
IMPORTANT WIRING INSTRUCTIONS
FOR CIRCUIT BREAKERS
USED WITH
HANNAY REEL MOTORS
INSTALLATION Electric Rewind Reels
INSTRUCTIONS for 12 Volt DC Operation
NOTE: FAILURE TO FOLLOW THESE INSTRUCTIONS MAY VOID THE WARRANTY.
Unpacking
1. Unpack the reel and inspect for shipping
damage.
2. Check wiring accessories against parts list on
back of page under photo 1 or 2 depending on
your model.
Mounting the reel
1. Fasten reel frame securely to a level surface.
2. Turn reel discs by hand. Spool should turn freely.
If it binds, just adjust self-aligning bearings.
Connecting inlet
1. Threaded-type swivel joint inlets must be
connected to the fluid supply by a flexible
connector or the Hannay Warranty will be void.
2. Victaulic-type swivel joint inlet connections must
be carefully aligned. Two victualic connections,
correctly installed, will normally allow adequate
flexibility for smooth rotation.
3. Install a union fitting as near as possible to the
swivel joint inlet so the joint can be easily
removed for servicing.
Connecting hose
1. Do not attach hose until reel has been installed
and wired. Charge hose BEFORE winding on
the reel to prevent excessive pressure on the
drum when the hose is charged.
2. If the reel is equipped with the flanged outlet
riser remove the entire riser from hub. Be
careful not to damage the gasket. Apply thread
compound to all threads and bushings. Attach
the hose to the outlet riser and tighten securely.
Make sure the gasket is seated properly.
3. Threaded or welded outlet risers cannot be
removed to attach hose.
4. Press the electric rewind operating switch or turn
the hand crank to wind hose on the reel.
4032
4 of 5
Additional wiring materials required
The following are required but not supplied with the reel.
• insulated cable. minimum size No. 2 for 12 volt,
• #16 Twin insulated wire.
• Vapor-proof conduit. (Optional)
• Circuit breaker (see sticker on reel motor for
amperage rating).
• Ground strap for reel.
• Wiring
1. The wiring diagram shows necessary connections
between components. Placement will vary
depending on the installation. IT IS IMPORTANT
THAT ALL GROUND CONNECTIONS ARE GOOD
FOR PROPER OPERATION. Solder all connections
using rosin-core solder.
2. The solenoid should be mounted in the engine
compartment as close as possible to the battery
and/or starter. It should be mounted vertically and
securely grounded
3. Optional vapor-proof conduit may be used for wiring
betweerr the solenoid and motor/switch. A circuit
breaker (not supplied) must be wired into the circuit
between the solenoid and battery.
4. A ground strap must be securely fastened between
the reel frame and a grounded part of the vehicle
body.
5. Check all connections to be sure they are tight.
6. Tape all connections.
7. Seal the open end of the conduit, if used, with a
sealing compound and wrap with plastic tape.
8. Hose reel motor rotation can be reversed by
interchanging the two motor leads at the motor.
Explosion-proof Switch and acessories
supplied with EPJ 12V Reel
A. 1 - explosion proof push button switch
B. 1. - cast aluminum junction box
C. 1. - terminal block for junction box
D. 2 - 5/16” internal lockwashers
E. 1 - 5/16” x 1” round head screw with two brass hex nuts.
F. 1 - 1/12” pipe plug
G. 1” to 3/4” reducing bushing
H. 6’ - 16/2 Type SO cable
I. 1 - solenoid control
J. 2 - 1/2” strain relief connectors
K. 1 - #4 terminal for 5/16” stud
L. 2 - #8 crimp terminals for 5/16” stud
M. 4 - #16 crimp terminals for #10-32 studs
N. 1 - #16-14 crimp terminal for 5/16” stud
4033
SECTION III
DISCHARGE DEVICES
4034
Proven under pressure around the world
R O C K W O O D S Y S T E M S
C O R P O R A T I O N
TWIN AGENT HANDLINE
ROCKWOOD INSTRUCTION MANUAL
RIM 1434
P/N 510-1678
JUNE, 1982
FIRE PROTECTION AND VALVE PRODUCT DIVISION
80 Second Street. South Portland, Maine 04106 Telephone (207) 799-3341 / TWX 710-221-1668
4035
TABLE OF CONTENTS
PAGE
1.0 SCOPE............................................................................................................................................... 4037
2.0 NOZZLE DATA................................................................................................................................... 4037
3.0 GENERAL DESCRIPTION................................................................................................................. 4037
4.0 OPERATING INSTRUCTIONS .......................................................................................................... 4038
5.0 MAINTENANCE ................................................................................................................................. 4038
6.0 SPA.RE PARTS ................................................................................................................................. 4038
FIG. 1 DUAL AGENT HANDLINE
PARTS LIST
4036
RIM 1431
1.0 SCOPE
This manual contains operating instructions maintenance , :procedure and parts list for the Rockwood Twin Agent
Handline Nozzle.
2.0 NOZZLE DATA
Hose Connections: Foam Inlet - Red swivel coupling,
1" - S NI Female National Fire hose
Dry Powder Inlet - Black swivel coupling
1" - 8 Nil female National fire hose thread
Liquid Discharge Rate: 60 GPM @ 100 PSI Foam
Dry Powder Discharge Rate: S-8 I ’s/Sec. @ 250 PSI
-4 DRY POWDER DISCHARGE: 5-8 :3S/Sec. @ 100 PSI
Discharge Pattern Data:
AFFF Barrel: Solid Stream - 60 feet effective range, fully dispersed stream - 15 feet wide at 26 feet range.
Dry Powder Barrel: 25 to 40 feet effective range.
AFFF Quality: Expansion: 8 (Minimum)
One quarter drainage time: 3 minutes (minimum),
Per NFPA 412
3.0 GENERAL DESCRIPTION
The nozzle consists of a dual passageway (one for foam, the other for dry powder), valve shutoffs, discharge
tubes and in the foam line there is a stream forming discharge tip and deflectors. Hose connections are made to
the swivel couplings at the base of the frame assembly.
The discharge valves are operated by the levers in the center portion of the handline. The black handle operates
the dry powder discharge and the red handle operates the foam solution. In the forward position (parallel with the
discharge nozzles) the valve is closed and upright (perpendicular to the discharge nozzles) the valve is open.
The foam stream deflectors are operated by the lever mounted on the foam tube. The two position deflectors are
operated by placing the lever fully forward for the dispersed pattern and all the way back for straight stream.
The foam passageway, operating handle and swivel coupling are color coated red. The dry powder nozzle, handle
and swivel coupling are color coated black.
4037
-1-
4.0 OPERATING INSTRUCTIONS
4.1 GENERAL:
WARNING
The discharge of large amounts of dry chemical may create hazards to personnel such as reduced
visibility and temporary breathing difficulty.
The nozzle may be used right handed or left handed. It is held by placing one arm under
the arm support - between the two swivel couplings and gripping the cross bar handle.
The other arm is used to operate the discharge nozzles and deflectors. The nozzle is
operated by selecting the desired agent and pulling on the valve handle.
The dry chemical discharge valve should always be in the fully open or fully closed
position. Never throttle the discharge rate with this valve.
4.2 AGENT SELECTION
Foam Discharge - Red handle discharge valve.
Deflectors - Open or closed by adjusting lever
on foam discharge barrel.
Dry Powder Discharge - Black handle discharge valve.
5.0 MAINTENANCE
Inspect and manipulate all controls periodically to insure that they are in working order. Apply light silicone based
oil to allow moving connections, sliding parts and friction points. There are no special tools required for
maintenance or disassembly and assembly of this nozzle.
6.0 SPARE PARTS
The following list of items are the recommended list of spare parts.
PART NUMBER DESCRIPTION QUANTITY
6110-6 1¼" Ball Vavle 1
6118-1 Toggle Clamp 1
6119-4 Swivel 1
110-3702-1 Adjustment Adapter 1
10-06665 Hose End Gasket 2
4038
RIM 1434
FIGURE I.
ROCKWOOD SYSTEMS CORP.
4039
Rockwood Systems Corporation
80 Second. Street
South Portland, Maine 04106
RIM-1434
DUAL AGENT HANDLINE - FOAM/DRY POWDER FIG I
TITLE PART NO 510-1678
ITEM QTY PART NO. PART NAME
1 1 510-1749-1 HANDLE
2 2 6110-6 1¼" BALL VALVE
3 1 4803-156H 1¼" NIPPLE
4 1 4426-12 1¼" x 3/4" REDUCING COUPLING
5 1 4803-97H 3/4" CLOSE NIPPLE
6 1 110-0942-3 DRY POWDER NOZZLE
7 1 4803-145 1¼" CLOSE NIPPLE
8 1 110-3691-1 BREECH
9 1 10-08441-2 FOAM TIP
10 1 510-1763-1 SHAPER WELD ASSY
11 4 251-10003 MACHINE SCREW
12 1 6118-1 TOGGLE CLAMP
13 4 152-10006 CAPSCREW
14 4 167-12007 LOCKWASHER
15 1 110-3704-2 DEFLECTOR, ACTIVE
16 2 152-08101 CAPSCREW
17 A/R 4259-7 LOCKTITE
18 1 110-3703-1 ROD
19 1 152-54001 CAPSCREW
20 1 162-040Q1 MACHINE NUT
21 1 6119-4 SWIVEL, STRAIGHT
22 1 110-3702-1 ADAPTER, ADJUSTMENT
23 1 161-05007 HEX NUT
24 2 510-1762-1 VALVE HANDLE
25 2 110-3687-1 SWIVEL COUPLING
26 2 284-15000 RETAINING RING
27 2 780-01125 "o" RING
28 2 10-06665 GASKET
29 1 10-04421 NAMEPLATE
30 4 254-02002 DRIVE SCREW
DATE REV PREPARED BY APPROVED BY
Page 4041 DELETED PAGE 2 OF 2
4040
Proven under pressure around the world
ROCKWOOD SYSTEMS
CORPORATION
REMOTE MANUAL TWIN AGENT TURRET
FOAM/DRY POWDER
PART No, 510-1679
LOG, No, RIM-1433
MAY, 1982
REVISED: AUG., 1982
FIRE PROTECTION AND VALVE PRODUCT DIVISION
80 Second Street. South Portland. Maine 04106 Telephone (207) 799-3341 / TWX 710-221-1668
Page 4041 DELETED
4042
TABLE OF CONTENTS
PAGE
1.0 SCOPE.................................................................................................................................. 4044
2.0 INTRODUCTION................................................................................................................... 4044
3.0 FIGURES LIST...................................................................................................................... 4044
4.0 OPERATING INSTRUCTIONS............................................................................................. 4045
5.0 MAINTENANCE.................................................................................................................... 4045
6.0 SPARE PARTS..................................................................................................................... 4046
FIGURE I REMOTE MANUAL TWIN AGENT TURRET............................................ 4047
PARTS LIST.............................................................................................. 4048
FIGURE II REMOTE MANUAL TURRET, SUB ASSY................................................ 4049
PARTS LIST.............................................................................................. 4050
FIGURE III SHAPER - AFFF........................................................................................ 4054
PARTS LIST.............................................................................................. 4055
FIGURE IV DRY CHEMICAL NOZZLE........................................................................ 4056
PARTS LIST.............................................................................................. 4057
4043
RIM 1433
1.0 SCOPE
This manual defines the following for the Rockwood Remote Manual Twin Agent Turret P/N 510-1679.
a) Introduction
b) Operating Instructions
c) Maintenance
d) Recommended Spare Parts
2.0 INTRODUCTION
Twin Agent Turrets are used throughout the fire protection industry on Class B and C fires for rapid extinguishment, knock
down capabilities and securing the hazardous area.
Typical uses for Twin Agent Turrets consist of:
a) Municipal Airports
b) Government - Military Installations
c) Crash trucks and fast response vehicles
The Rockwood Twin Agent Turret is a remote manual, panel mounted, foam/ dry powder turret nozzle; with 180° rotation
(minimum), 80° elevation and 20° depression capabilities.
Discharge ranges can be sized to meet hazard requirements with the following ranges.
Foam/Water 100-400 GPM Dry Chemical 10-25 Lbs/Sec.
All functions of the turret can be controlled from inside the cab including;
a) Elevation c) Rotation
b) Depression d) Foam/Water Pattern
Rockwood's Dual Agent Turret is designed to discharge foam and dry chemical either separately or simultaneously.
3.0 FIGURES PAGE
I. Remote Manual Twin Agent Turret, PN 510-1679...................................... 4047
Turret Top Assembly
IA. Remote Manual Twin Agent Turret w/Foam Nozzle ................................... 4049
PN 510-1679-6
II Remote Manual Turret, Foam Solution Waterway ..................................... 4051
PN 10-09170-9, Turret Sub Assembly
4044
-1-
3.0 FIGURES (Cont.) PAGE
III. Shaper Assembly, PN 510-1591................................................................. 4054
Foam/Water Discharge Nozzle
IV. Dry Chemical Nozzle, PN 510-0288............................................................ 4056
Dry Chemical Discharge Device
4.0 OPERATING INSTRUCTIONS
After the turret has been properly mounted on the vehicle and the foam/water (2" 111/2 NPT) and dry powder (11/2" 111/2
NPT) inlets have been hooked up, tested and the handle latch (Item 50, Figure II, page 4051) has been properly aligned
and mounted on the foam/water inlet, the turret may be operated as follows:
Refer to Figures I, Page 4047 and II, Page 4051
Simultaneous or individual discharges may be accomplished by activating the corresponding control valve. Elevation and
rotation are accomplished by raising, lowering and rotating the manual control arm (Item 44, Figure II, page 4051).
The foam pattern may be varied from straight stream (push) to fully dispersed (pull) by adjusting the pattern control cable
(Item 12, figure 1, page 4047).
To prevent damage to the turret, it should always be locked in the travel position when it is not in use. This is
accomplished by locking the manual control arm on to the handle latch.
Refer to the maintenance section after discharging turret.
5.0 MAINTENANCE
After each use of the turret with foam, the turret and supply lines should be thoroughly flushed with clear
water to remove all foam residue.
The discharge of large amounts of dry chemical may create hazards to personnel such as reduced visibility and temporary
breathing difficulty.
After each use of the turret with dry powder, the turret and supply lines should be thoroughly purged with
gas to remove all dry powder residue.
The turret is virtually maintenance free. Use touch-up paint, rust preventative and lubrication as required.
4045
RIM 1433
6.0 SPARE PARTS
The following list is the suggested spare parts for P/N 510-1679; Remote Manual Twin Agent Turret.
PART NUMBER DESCRIPTION QUANTITY
10-06917 Clamp 1
4793-80 Clamp 1
510-0353-4 Hose Assembly 1
4748-341 Quad. Ring 1
10-02975 Gasket 1
780-01228 "0" Ring 1
780-01326 "0" Ring 1
780-01224 "0" Ring 1
10-07732 Head Seal 2
780-01237 "0" Ring 2
780-01234 "0" Ring 2
10-07122 Wearing Ring 2
185-03140 Retaining Ring 4
10-02864-1 Auto Drain Valve 1
334-10001 Tube Connector 1
780-11014 U Packing 2
10-06051 Nyliner 2
4046
-3-
1 of 2
Figure I.
4047
Rockwood Systems Corporation
80 Second Street
South Portland, Maine 04106
RIM-1433
REMOTE MANUAL TWIN AGENT TURRET FIG. 1
TITLE PART NO. 510-1679
ITEM QTY PART NO. PART NAME
1 1 10-09170-9,-10 REMOTE MANUAL TURRET
2 1 510-1591 SHAPER ASSY
3 1 510-0288 NOZZLE DRY CHEMICAL
4 1 510-0353-4 HOSE ASSY, DRY POWDER
5 1 110-0716 SPRING BRACKET
6 1 110-0587 C’BALANCE SPRING
7 1 10-08469 ANCHOR BRACKET
8 2 152-04004 CAPSCREW
9 2 167-1200+ LOCKWASHER
10 1 4354-1 EYEBOLT
11 1 161-04012 HEX, NUT, ESNA
12 1 4593-3 CABLE PUSH PULL
13 2 510-1748-1 SHAPER SPACER ASSY
14 2 4793-80 CLAMP WORM DRIVE
15 2 10-06917 CLAMP
16 1 6108-17 HYDRAULIC SWIVEL
17 2 4816-3 FLANGE, SCREWED
18 2 4465-3 RING GASKET
19 1 4467-12 ELBOW, 90°
20 4 152-08030 HEX BOLT
21 4 161-08001 HEX NUT
22 1 10-08466 NAMEPLATE
23 4 152-05026 CAPSCREW, HEX HEAD
24 4 167-12010 LOCKWASHER
25 1 161-04005 HEX, NUT JAM
DATE REV PREPARED BY APPROVED BY PAGE 2 OF 2
4048
FIGURE 1A
1of 2
4049
Rockwood Systems Corporation
80 Second Street
South Portland, Maine 04106
RIM 1433
REMOTE MANUAL TWIN AGENT TURRET
TITLE PART NO. 510-1679-6 TURRET W/FOAM NOZZLE FIG. 1A
ITEM QTY PART NO. PART NAME
1
2
3
4 1 510-0353-4 HOSE ASSY, DRY POWDER
5 l 110-0716 SPRING BRACKET
6 1 110-0587 C’BALANCE SPRING
7 1 10-08469 ANCHOR BRACKET
8 2 152-04004 CAPSCREW
9 2 167-12009 VLOCKWASHER
10 1 4354-1 EYEBOLT
11 1 161-04012 HEX NUT
22 1 10-08466 NAMEPLATE
23 4 152-05026 CAPSCREW
24 4 167-12010 IOCKWASHER
25 1 161-04013 HEX NUT, JAM
29 1 510-0288-2 DRY CHEMICAL NOZZLE
32A 1 10-04421 GENERAL NAMEPLATE
32B 4 154-02003 SELF TAP SCREW
41 1 510-2148-1 AFFF NOZZLE
42 3.33 FT. 245-10102 PIPE
43 1 110-0332-8 CABLE BRACKET
44 1 6192-6 ADAPTER
45 1 4593-7 PUSH PULL CABLE W/VERNIER CONTROL
46 1 4523-12 COUPLING
47 1 6454-1 ADAPTER
48
49 1 510-2186-1 ACTUATOR ROD CON OR
50 2 252-60002 SCREW
51 1 10-09170-11 REMOIE MANUAL TURRET
DATE REV. PREPARED BY APPROVED BY PAGE 2 OF 2
4050
FIGURE II.
1 of 2
4051
Rockwood Systems Corporation
80 Second Street
South Portland, Maine 04106
RIM-1433
REMOTE MANUAL TURRET FIG. II
TITLE PART NO. 10-09170-9
ITEM QTY PART NO. PART NAME
1 1 10-04526 YOKE (BODY): BRONZE
2
3
4 1 10-02969 BODY RET.RING ASSY
5 2 10-02580 BEARING: STEEL
6 2 185-39330 RETAINING RING
7 1 4748-341 QUARD RING
8 1 10-04556 BASE ASSY
9 1 10-09106-2 MOUNTING PLATE
10OA 4 11-02973 SPACER COLLAR
10 8 167-11013 LOCKWASHER
11 2 161-10008 HEX NUT
12 1 10-02975 GASKET
13 6 165-40004 WASHER
14 6 161-10009 HEX NUT
15 1 780-01228 "O" RING
16 1 10-04531 DRIVE SHAFT BUSHING
17A 2 10-07119 BODY BEARING
17 1 780-01326 "0" RING
18 1 10-04536 DRIVE SHAFT BEARING
19 6 151-08008 MACHINE SCREW
20A 2 161-10012 HEX NUT
20 1 780-01224 "O" RING
21 1 10-04532 DRIVE SHAFT
22 P 152-04009 CAPSCREW
23 8 167-12009 LOCKWASHER
24 1. 110-0129-2 HEAD
25 2 10-07732 HEAD SEAL
26 2 780-01237 "O" RING
27 2 780-01234 "O" RING
28 2 10-07122 WEARING RING
29 1 10-07222 BODY SHAFT
30
31 2 161-10012 HEX NUT ESNA
DATE REV. PREPARED BY APPROVED BY PAGE 2 of 3
4052
Rockwood Systems Corporation
80 Second Street
South Portland, Maine 04106
RIM-1433
REMOTE MANUAL TURRET
TITLE PART NO. 10-09170-9 FIG II
ITEM QTY PART NO. PART NAME
32 2 10-06051 NYLINER
33 2 780-11014 U PACKING
34 1 10-07776 CLEVIS PLATE
35 1 10-04529 ELEV. ROD CLEVIS
36 1 10-04546 ELEV. ROD CLEVIS PIN
37 4 185-03140 RETAINING RING
38 1 10-04544 ELEVATION ROD
39 1 10-04543 ELEVATION ROD CONN.
40 2 167-12013 LOCKWASHER
41 2 161-08014 HEX NUT
42 1 10-04545 CONNECTOR PIN
43 1 10-04555-2 CLEVIS HANGER
44 1 10-04542 MANUAL HANDLE
45 2 10-05105 BUSHING,ELEV. LINK
46 2 10-05182 CLEVIS WASHER
47 1 152-05041 CAPSCREW
48 1 161-05005 HEX NUT
49 1 10-07406 ELEV. ROD BOOT
50 1 10-04547 HANDLE LATCH
51 1 510-0370-2 AUTO. DRAIN VALVE
52 2 152-05018 CAPSCREW
53 2 167-12010 LOCKWASHER
54 1 PAPER TAG
55 1 334-10001 TUBE CONNECTOR
56
57
58
59 1 10-04421 NAMEPLATE
60 4 154-02003 SELF TAP SCREW
65 A/R 4438 DRY FILM LUBRICANT
66 A/R 4474 WATER REPELLANT GREASE
67 1 510-1875-1 MANUAL HANDLE ASSY
DATE
9/2/82 REV.
APREPARED BY APPROVED BY PAGE 3 of 3
4053
No. Fig, III
RIM-1433
ENGINEERING DATA SHEET ROCKWOOD FIRE PROTECTION SYSTEMS
JET - X * WaterFOG * FogFOAM * FOAM
SHAPER - AFFF
PART No. 510-1591
FIGURE III.
DRAWN: GPL
4054
Rockwood Systems Corporation
80 Second Street
South Portland, Maine 04106
RIM- 1433
MONITOR SHAPER ASSY - AFFF
TITLE PART NO. 510-1591 FIG. III
ITEM QTY PART NO. PART NAME
1 1 510-1633-1 SHAPER SUB-ASSY - ALUMINUM
2 1 10-08507 DEFLECTOR ACTIVE - ALUMINUM
3 1 10-08508 DEFLECTOR SLAVE - ALUMINUM
4 4 274-10001 SPIROL PIN - ST. STEEL
5 1 6040-1 SPRING - ST. STEEL
6
7
8 1 251-10052 MACHINE SCREW, ROUND HEAD - STEEL
9 1 161-03004 HEX NUT - STEEL
10 1 10-05836 ROD END, FEMALE
11 1 152-04035 CAPSCREW, HEX HEAD - STEEL
12 1 161-04010 HEX NUT, PALNUT - STEEL
13
14 1 110-0332-2 CABLE BRACKET - ALUMINUM
15
16 1 110-3576-2 BREECH - ALUMINUM
17
18 8 152-05005 CAPSCREW, SOC. HEAD - STEEL
19 8 165-20001 WASHER, PLAIN - STEEL
20 8 267-16008 LOCIKWASHER - ST. STEEL
21 1 510-1663 DISPERSION ORIFICE
22
23
24 1 161-04005 HEX NUT JAM - STEEL
25 1 10-07364 NAMEPLATE
DATE REV. PREPARED BY APPROVED BY PAGE 2 of 2
4055
No. Fig, IV
RIM-1433
ENGINEERING DATA SHEET ROCKWOOD FIRE PROTECTION SYSTEMS
JET - X * WaterFOG * FogFOAM * FOAM
DRY CHEMICAL NOZZLE
PART NO. 510-0288
FIGURE IV.
4056
Rockwood Systems Corporation
80 Second Street
South Portland, Maine 04106
TITLE REPLACEMENT PARTS LIST FOR FIG. NO. IV RIM- 1433
ITEM QTY PART NO. PART NAME
1 1 110-0546 NOZZLE BODY
2 1 110-0545 SHAPER NOZZLE
3 4 151-10002 MACHINE SCREW ¼" LG.
4 1 10-04790 GASKET
DATE
6/16/81 REV. PREPARED BY APPROVED BY PAGE 2 of 2
4057
4058
4059
4060
4061
4062
F2265D
12/82
SECTION I. DYAMOTE LIMITED WARRANTY
1.0 LIMITED WARRANTY
1.1 DYNAMOTE CORPORATION (Manufacturer) warrants, to the original user, that each DYNAMOTE Product is free
from defects in materials and factor workmanship if, and only if, the following requirements are complied with:
A. The produce is installed and checked out properly, according to all guidelines, instructions, and checkout
procedures set forth in the product Installation/Operation/Service Manual, and
B. The installer records all checkout data required and completes, signs, and returns the warranty initiation card to
the DYNAMOTE office within ten (10) days after installation.
1.2 Manufacturer’s obligation under this warranty is limited to correcting without charge any part or parts of such
products which shall be returned to its factory or one of its authorized service facilities, transportation charges
prepaid, within one (1) year from first installation or within eighteen (18) months from date of manufacture,
whichever comes first, provided examination discloses to Manufacturer’s satisfaction that such parts ere originally
defective. Correction of such defects by repair to, or supplying of replacements for defective parts, shall constitute
fulfillment of all obligations to original user.
1.3 This warranty shall not apply to any of Manufacturer’s products which must be replaced because of normal wear,
which have been subject to misuse, negligence, or accident, or which shall have been repaired or altered outside
of Manufacturer’s factory, unless authorized by Manufacturer.
1.4 MANUFACTURER SHALL NOT BE LIABLE FOR ANY CLAIMS, LOSS, DAMAGE, OR EXPENSE
WHATSOEVER RESULTING DIRECTLY OR INDIRECTLY FROM THE USE OF ITS PRODUCT OR FORM ANY
OTHER CAUSE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR
CONSEQUENTIAL DAMAGES, SO THESE LIMITATIONS MAY NOT APPLY TO YOU.
1.5 ANY AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, ARISING BY LAW, COURSE OF DEALING,
COURSE OF PERFORMANCE, USAGE OF TRADE OR OTHERWISE, INCLUDING BUT NOT LIMITED TO,
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE
LIMITED IN DURATION TO A PERIOD OF ONE (1) YEAR AFTER FIRST INSTALLATION OR EIGHTEEN (18)
MONTHS FROM DATE OF MANUFACTURE, WHICHEVER COMES FIRST. SOME STATES DO NOT ALLOW
LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATIONS MAY NOT
APPLY TO YOU. NO PERSON, AGENT, OR DEALER IS AUTHORIZED TO GIVE ANY WARRANTIES ON
BEHALF OF MANUFACTURER OR TO ASSUME FOR MANUFACTURER ANY OTHER LIABILITY IN
CONNECTION WITH ANY OF ITS PRODUCTS UNLESS MADE IN WRITING AND SIGNED BY AN OFFICER
OF MANUFACTURER.
SPECIAL NOTICE TO PURCHASER
REGARDING WARRANTY PROCEDURE
It is absolutely necessary that the requirements of Paragraph 1.1 above be complied with
for warranty to be in effect. MAKE SURE THE INSTALLER HAS COMPLETED AND
SIGNED YOUR PORTION OF THE WARRANTY INITIATION CARD, CERTIFYING
THAT THOSE REQUIREMENTS HAVE BEEN COMPLIED WITH.
If any trouble occurs with this product during installation or before the warranty has
expired, follow these instruction:
With model number and serial number available for reference, as well as all available
installation test readings, dial the DYNAMOTE toll-free WATS line, 1-800-426-2838, and
advise the receptionist that the call is regarding WARRANTY SERVICE ASSISTANCE.
cCopyright 1982, -DYNAMOTE CORPORATION
DYNAMOTE CORPORATION - 1200 W. Nickerson, Seattle, WA. 98119 - 206-282-1000
4063
F2100C 11/82 Sec. 2.0
SECTION II. GENERAL INFORMATION
DYNAMIC INVERTERS
2.0 INTRODUCTION AND PRINCIPLE OF OPERATION:
2.0.1 Your new DYNAMOTE Series A Inverter is designed to provide 120 volt, 60 Hz AC power from the DC (rectified
AC) output of a standard 12 volt electrical system (12 volt alternator in a vehicle or boat). The inverter is compact,
lightweight, and operates silently. It can be placed in any convenient location in the vehicle or boat. Inverters,
when installed in a 12 volt electrical system according to these instructions, can safely operate all electric tools,
lights, appliances, electronic and heavy motor loads up to their rated capacity. Models are available to provide
continuous 120 volt power up to 60 amps.
2.0.2 The relationship of a Dynamic Inverter to the vehicle electrical system is illustrated by the two diagram below:
Figure 2.0.2A Inverter OFT Figure 2.0.2B Inverter ON
(Nominal alternator output voltage,
Inverter ON, Series A - 60 volts)
As shown in Figure 2.0.2A, when the inverter is OFF, the alternator and battery function as in normal 12 volt
operation. The only differences are 1) that Dynamote Regulator C33 controls the output of the alternator, and 2)
that alternator output travels through the Dynamote harness on its way to the battery.
As shown in Figure 2.0.2B, when the inverter is ON, the system operates as follows:
a. All output of the alternator is switched away from the battery and into the inverter;
b. The alternator field is regulated by Dynamote Voltage Regulator CB1 inside the inverter.(See Note 1 below.)
c. The Dynamote regulator controls alternator output at 45 volts (A40) or 60 volts (A30/60) rather than the
standard 14.2 volts;
d. The high voltage output enters the inverter transformer, the inverter produces 120 volt, 60 Hz power, and at
the same time charges the vehicle battery and services the vehicle DC system at 14.2 volts. (See Note 2
below.)
NOTES: 1.When the inverter is energized, the Dynamic Voltage Regulator CB1 senses voltage at the secondary output
of the inverter and regulates the alternator field with battery power to maintain 14.2 volts DC (rectified AC) at
the BLACK wire of the inverter harness, which charges the battery.
2.The inverter transformer is wound so that at an average AC output of 120 volts, the vehicle battery is charged
at 14.2
DYNAMOTE CORPORATION - 1200 W. Nickerson, Seattle, WA 98119 - 206-282-1000
4065
Sec. 2.0 11/82
2.0 INTRODUCTION AND PRINCIPLE OF OPERATION (continued)
volts DC. Both AC and DC voltages are regulated simultaneously by the Dynamote Voltage Regulator. If AC
output voltage below or above 120 volts, battery charging voltage will be reduced or increased proportionately. For
determining proper voltage settings after the inverter is installed, see Section 3.8, "Checkout Inverter Operation.”
2.1 SPECIFICATIONS
1. DC (rectified AC) Input: 60 volts (A30 ).
2. Input Source: 12 volt alternator.
3. Input Electrical System: From 12 volt negative ground alternator systems only.
4. Input Voltage Regulation: Solid-state voltage regulator inside inverter.
5. Output: Simultaneous output of:
a. 120 volt AC ± 5%, 60 Hz ± .1 and
b. 14.2 volt DC for vehicle system battery charging
6. Output Voltage Regulation: Solid-state voltage regulator inside inverter.
7. Output Frequency Regulation: Solid-state, crystal controlled oscillator inside inverter.
8. Output wave Form: Modified square x with no limitations on operation of electronic or electromechanical
loads. Filters are available for wave form modification to sine wave, if required.
9. Ambient Air Requirements: Full load capability at 120°F. ambient if properly vented. Output may be derated
above 120 F.
10. Cooling Air Requirements: Exhaust air must be vented away from the ambient. Intake air must be true
ambient, and must be the amounts shown in Figure 2.1.1A below for each model.
11. Miscellaneous: See following page.
2.1.1 INVERTER SPECIFICATIONS
Watts, Amps, Surge Max. Ship- Required
120VAC 120VAC Cap. DC ping Intake
Model Out- Out- AC Char- Dimensions Wt. Cooling
Number put put Amps ging H x W x D Lbs. Air, CFM
A30-70B 3600 30 60 70 9 ¾"x14 ¼x15" 70. 120
Figure 2.1.1A Inverter Specifications
2.2 PRODUCT CONFIGURATION
2.2.1 Chassis - Dynamic Inverters are housed in a durable aluminum chassis, with four shock absorbing rubber feet.
Cooling air is drawn in through louvers in each side wall and exhausted out through the back panel. Tie down
brackets are provided with t hardware kit; they attach to the four heavy bolts at the bottom of the front and rear
panels of the chassis.
4066
2.2.2 Instrument Panel - Momentary START and STOP buttons, AC voltage indicator, and remote control receptacle are
provided. Two 15 amp convenience receptacles are provided on the front panel. Each receptacle is separately
fused. A control circuit fuse, commutation (input) fuses, and an "on-off" indicator light are also located on the front
panel.
2.2.4 Hookup Harness - Once properly installed to the vehicle electrical system, harness MUST be checked and the
results MUST be recorded on warranty initiation card. The 4-2600 Dynamic Installation Test Module plugs into the
test receptacle on the front of the inverter and provides the readings necessary to checkout the installation and to
record the information on the warranty card.
2.2.5 Chassis Configuration - Shown on figure 2.2.5B.
Figure 2.2.5B
A30 and MPA30 dimensions are:
H - 9 3/4"; W - 14h; D - 15"
2.2.6 Mounting Configuration - Diagram 2.2.6A shows the mounting dimensions for the A30 Series.
Figure 2.2.6A
4067
2.2.7 Miscellaneous - Installation hardware, spare fuses, warranty statement and registration card, and instruction
manual accompanies each new inverter. The manual should be kept with the inverter at all times.
SECTION III. INSTALLATION INSTRUCTIONS
DYNAMOTE SERIES "A" DYNAMIC INVERTERS
FOR INSTALLATION ON VEHICLES AND BOATS WITH 12 VOLT NEGATIVE GROUND ELECTRICAL SYSTEMS
ONLY.
3.0 READ THE INSTRUCTIONS FIRST.
The Dynamote Dynamic Series "A" AC Power Inverter is a precision engineered and manufactured instrument capable of
providing reliable AC electric power for thousands of hours. However, in order for the inverter to perform its job reliably, it
is very important that each component of the system be installed carefully, and that each step be performed correctly.
Therefore, before proceeding with the installation, it is suggested that you take a few minutes to familiarize yourself with
the components of the system and how they are to operate when properly installed.
3.0.1 IMPORTANT NOTE:
There are seven distinct steps which must be followed in sequence to assure proper installation and operation of
the entire system. These steps are summarized below, and described in detail beginning on the next page.
(1)Route harness to alternator.
(2)Install automatic throttle, if used.
(3)Attach harness to alternator.
(4)Checkout alternator connections.
(5)Checkout inverter.
(6)Wire AC output.
(7)Complete, sign, and mail warranty registration card.
3.0.2 RECOMMENDED TOOLS AND EQUIPMENT FOR INVERTER INSTALLATION.
(1)Socket wrench set (*" or 3/8" drive) with ½", 3/8", 7/16", ½", and ¾" socket, ratchet; and 6" extension.
(2)7" mechanic's screwdriver.
(3)½" and 7/16" open end wrenches.
(4)V 0 M (volt-ohm-milliamp meter), #4 Fluke 8020A, Simpson 463, or equivalent; Dynamote 4-2600.
(5)Wire crimpers and lineman's pliers.
(6)Wire stripper.
(7)Electrical tape and electrical putty.
(8)Dynamote 4-2600, Installation Tester.
Figure 3.0.3A on the following pate lists all the hardware items included with the various "A" Series inverters.
Check and identify the various items as you unpack the shipping carton.
4068
Figure 3.0.3A HARDWARE KIT
Part No. Qty. Description Included With: A30
2283-00014 1 Harness - Input - Power x
4283-00010 1 Harness - Control x
1 Field Grounding #16
White Wire (1’) x
4200-06400 2 Fuses, ABU 40 x
4200-02150 3 Fuses, AGC 15 x
4282-00006 2 Holders, Spare Fuse x
3056-11451 4 Brackets, Tie Down x
4442-60920 2 Lugs, RB-257 x
4442-15200 2 Lugs, B-71 x
4442-14200 4 Lugs, B-87 x
4323-00417 1 Rubber Cap x
4722-37008 1 i-20 x 3/8" Bolt x
4520-27000 1 i-20 Kept Nut x
4722-40008 4 #14 x 1" Screws x
4442-16600 3 Lugs F-72 x
4-7211 1 Relay, High Amp. Bypass Optional
4760-14000 5 Ty Raps x
Figure 3.0.3A HARDWARE KIT CONTENTS
3.0.4 Start your installation with the first step and follow each step through in sequence to successful final testing. As it
is completed, check off each step in the space provided adjacent to the step number of the test/warranty
registration card.
DO NOT PROCEED TO ANOTHER STEP UNTIL ALL PREVIOUS STEPS HAVE BEEN SUCCESSFULLY
COMPLETED.
3.2.0 ROUTE HARNESS TO ALTERNATOR
BURNING OR CHAFING THROUGH HARNESS INSULATION WILL DAMAGE THE INVERTER AND THE VEHICLE
ELECTRICAL SYSTEMS. YOU SHOULD BE AWARE THAT THIS IS A COMMON INSTALLATION PROBLEM.
4069
3.2.0 ROUTE HARNESS TO ALTERNATOR - Continued
Route the wiring harness to the alternator, using existing holes where possible. Use tie wraps and tape liberally to secure
the harness wires so they cannot come in contact with the hot engine exhaust or other heat producing components.
Grommets should be used to protect the wiring harness where it comes in contact with hard or sharp edges.
NOTE: Do not attach any wires to the inverter at this time.
3.3.2 The alternator must be installed correctly on the engine, according to the following general guidelines:
(1) Alternator Pulley Alignment: The requirements of the alternator mechanical installation are several: (1) solid,
vibration-free attachment of the mounting bracket to the engine, and of the alternator to the mounting
bracket; (2) correct belt alignment; and (3) protection from road spray or marine water spray, and from engine
exhaust heat. Hardened steel flat washers should be substituted for spring lock washers on bracket and
alternator as mounting hardware. Flat washers tend to provide and retain greater surface tension.
Correct belt alignment is essential for maximum alternator and belt service life. The center line of all pulleys
related to the alternator drive must be within 1/32" of true center; See Figure 3.3.2A.
Dual belts are recommended for heavy duty alternators. Best results are obtained if the belts wrap the
alternator pully 1000 or more. Lesser wrap induces belt slippage, belt and alternator bearing wear; See
Figure 3.3.2B.
Figure 3.3.2A Figure 3.3.2B
4070
3.4.0 INSTALL AUTOMATIC THROTTLE
An automatic throttle provides automatic increase in engine speed to a present RPM when the inverter is energized. It is
designed for stationary use only, and should not be used while underway. IT MUST ALWAYS BE WIRED THROUGH
THE NEUTRAL SAFETY SWITCH OF THE VEHICLE TRANSMISSION.
If the automatic throttle is used, refer now to automatic throttle instruction manual. NOTE: Brown wire from Dynamic
Inverter Harness is to be attached to black wire from Autothrottle Harness.
3.5.0 ATTACH HARNESS TO ALTERNATOR
Installation of all Dynamic Inverters is exactly the same, electrically.
(a) The harness for the larger capacity inverters includes three BLACK AWG #4 wires. Two of these are marked
at the ends with RED and GREEN tape. If these wires are shortened, be sure to color-code the ends
properly.
(b) Instructions for the installation of the inverter harness begin with Section 3.5.1.
3.5.1 BASIC INSTALLATION STEPS
1. Switch battery disconnect located on console inside cab to "OFF".
2. Disconnect all wiring from the positive output (B+) terminal of the alternator.
Figure 3.5.1A
4071
3.5.1 BASIC INSTALLATION STEPS - Continued
3. High Amperage Bypass Installation
(a) Securely mount relay K3 as close to the alternator as is practical with large (5/16") studs down.
(Mounting of this relay with the studs up or horizontal would result in improper operation of the relay.) Use
the large # ¼ x3/4 self-tap screws in the hardware kit for this purpose.
(b) Connect the wires removed from the alternator positive output terminal in step 2, above, along with the
BLACK wire from the Dynamote harness to one of the large (5/16") studs of Relay K3. This connection
provides charging current to the vehicle battery system.
(c) Connect a length of #4 AWG wire from the other large (5/16") stud to the positive output terminal of the
alternator.
(d) Connect a #16 or #18 AWG wire from the chassis of Relay K3 to ground.
(e) Connect the BROWN wire from the Dynamote harness to the small #10 stud of Relay K3.
4. Connect the RED wire from the Dynamote harness to the positive output (B+) terminal of the alternator. The
ONLY other wire that can be attached to this terminal is the #4 AWG wire to the K3 Relay if that is installed.
5. Connect the GREEN wire from the Dynamote harness to the negative ground (B-) terminal of the alternator.
Leave any previously attached wires connected to this ground terminal.
NOTE: The B- terminal of the alternator and the negative (-) battery terminal must be securely grounded to the
engine block.
6. Crimp the appropriate terminal in the hardware kit to the BLUE #16 Dynamote harness wire and attach to the
Field (+) Terminal of the alternator. There should be no wire attached to the FIELD (+) terminal except the
BLUE harness wire.
7. Check to see that the negative (-) Field Terminal on the alternator has been grounded to the negative (B-)
terminal of the alternator. If not, use a piece of #16 AWG wire and the ring terminals provided in the
hardware kit accomplish this.
8. Attach the ORANGE wire from the Dynamote harness to the #10 stud on the reverse polarity block which is
connected to the ACC terminal on the ignition switch. Use ring terminals provided in the hardware kit.
9. Switch battery disconnect located on console inside cab to "BOTH".
4072
F8124 12/81
Figure 3.5.4C DIAGRAMS OF LEECE NEVILLE 4000AA SERIES ALTERNATORS
4073
3.6 CHECKOUT OF HARNESS INSTALLATION AND ALTERNATOR OUTPUT.
THE RESULTS OF THIS CHECKOUT PROCEDURE MUST BE RECORDED ON THE WARRANTY INITIATION CARD
AND RETURNED TO THE DYNAMOTE OFFICE. FAILURE TO DO SO WILL PREVENT THE INVERTER WARRANTY
FROM BECOMING EFFECTIVE.
There are two ways to perform the Harness and Alternator Checkout Procedure:
(1) Using the 4-2600 Dynamic Inverter Test Module. See Section 3.6.1.
(2) Using a standard V 0 M (Volt Ohm Meter) with scales of 15VDC, 50VDC, and 100 VDC. (Fluke 8020A or
Simpson 463 or equivalent.) See Section 3.6.2.
3.6.1 CHECKOUT OF HARNESS INSTALLATION WITH DYNAMOTE 4-2600, DYNAMIC INVERTER TEST
MODULE.
If the Dynamote 4-2600 Dynamic Inverter Test Module is available, perform the following steps for checkout of
harness installation. If the 4-2600 is not available, see Section 3.6.2.
1. Follow the instructions in Section 3 to install the inverter harness.
2. Put the test module sequence switch in the OFF position before connecting the module to the Dynamic
Inverter. The vehicle ignition should also be in the OFF position.
3. Plug the six-pin test module into the Test Module Receptacle on the inverter front panel.
NOTE 1: DO NOT plug the test module into the control head receptacle on the inverter.
DO NOT plug the inverter Remote Control head plug into the Test Module Receptacle.
NOTE 2: If the BLACK (B+) lead is connected to a battery selector switch, the switch should be in the ON
(that is, the B1, B2, or BOTH) position.
4. Follow the steps on the chart on the following pages, Figure 3.6.1A.
4074
Figure 3.6.1A INSTALLATION AND INVERTER CHECKOUT USING 4-2600 DYNAMIC INVERTER TEST MODULE)
Switch Terminal Inverter Vehicle Proper Remarks
Position or Wire Start Ignition Meter
Being Button ON Reading
Read Depressed
1 A+ No No 11-13 If voltage reading is outside proper limits,
(Red) VDC recheck installation of inverter harness, RED and BLACK wires.
Also check at K1 relay, Section 4.3.3 and K3 relay, Sec. 4.3.5.
2 Ignition No No 0 If meter reads battery voltage, then the ORANGE wire is
VDC connected to a post which has battery voltage with the ignition
(Orange) ON or OFF. This will allow the battery to drain through the voltage
regulator.
3 B+ Yes No 11-13 If the reading with the Auxiliary Start Button depressed is 0, then
(Black) VDC the harness leads to the K3 relay should be switched.
No No 1l-13VDC
4 A+ Yes No 0 If meter reads any voltage, check out K3
(Red) VDC relay, Section 4.3.5.
5 F Out Yes No 10-12 If voltage reading is outside proper limits; follow-Voltage
(Blue) VDC Regulator Checkout Procedure, Section 4.3.7.
6 Ignition No Yes C0-12 Of meter reading is outside proper limits;, recheck wiring of
(Orange) VDC ORANGE wire to be sure it is wired to a source of battery voltage
with the ignition ON.
For Switch Positions 7 - 10, start the engine and run at approximately 1500-1800 RPM. Also turn ON vehicle headlights to put some load on the vehicle charging
system.
7 B+ No Yes 14.0- If meter reading is outside proper limits,
(Black) 14.2 follow procedure to check out and adjust
VDC Voltage Regulator CB3, Section 4.3.12.
8 A+ No Yes 14.0- If meter reading is outside proper limits,
(Red) 14.2 repeat test on Position 7.
VDC
4075
F8120B 3/83
3.6.1A INSTALLATION AND INVERTER CHECKOUT USING 4-2600 DYNAMIC INVERTER TEST MODULE (continued)
Switch Terminal Inverter Vehicle Proper Remarks
Position or Wire Start Ignition Meter
Being Button ON Reading
Read Depressed
9 B+ Yes Yes 14.0- If meter reading is outside proper limits, per form alternator check
(Black) 14.2 given for Switch Pos. 11(below), reading IMPORTANT NOTE:
VDC first.. Follow checkout procedure and adjust inverter Voltage
Regulator CBI. NOTE: Be sure engine is running at or above the
speed at which the voltage reading is at its maximum. This could
be higher or lower than 1500 RPM, but will be the point at which
increasing the RPM will no longer increase the voltage reading.
10 A+ Yes Yes 11-12 This reading shows alternator output with inverter ON, divided by
(Red) VDC 5 that is, the actual voltage is 5 times the reading. If alternator
(A30, voltage fails to come up to this level, perform alternator check
A60) in the next step.
8-9
VDC
(A40)
IMPORTANT NOTE: The test at Switch Position 11 is to check for a faulty alternator. Before moving the switch to Position 11, return the engine to an idle, turn the
inverter OFF, and remove the commutation fuses on the inverter front panel. When the switch is in Position 11, the voltage regulator is taken out of the circuit and
battery voltage is applied directly to the field of the alternator. This causes the voltage output of the alternator to increase directly with engine RPM. Rotate switch
to Position 11, and slowly increase engine RPM until the voltmeter reads 2OVDC. At this point the actual alternator voltage is 1OOVDC (5 times the meter
reading). If the alternator will not come up to this voltage, then either the alternator or the installation is faulty. The alternator should be removed and sent to an
alternator repair shop.
11 A+ No Yes In- Read IMPORTANT NOTE above.
(Red) crease DO NOT MOVE SWITCH TO OR FROM POSITION 11
to 20 WHEN ENGINE IS ABOVE IDLE.
VDC
Figure 3.6.1A
INSTALLATION AND INVERTER CHECKOUT USING 4-2600 DYNAMIC INVERTER TEST MODULE
4077
3.6.1 CHECKOUT OF HARNESS INSTALLATION WITH DYNAMOTE 4-2600, DYNAMIC INVERTER TEST MODULE
(continued)
— 5. If procedures on Switch Position 1 - 10 check out, you may replace the covers on the inverter. Your
electrical system is ready for operation.
Any problems found during this test procedure can be discussed with the DYNAMOTE Service Department by
calling our toll-free number, 1-800-426-2838.
3.6.2 CHECKOUT OF HARNESS INSTALLATION AND ALTERNATOR OPERATION WITHOUT 4-2600 DYNAMIC
INVERTER TEST MODULE
NOTE: FOR THIS TEST, DO NOT PUSH OR RELEASE START SWITCH WHEN ENGINE IS RUNNING
ABOVE IDLE.
Perform the checkout with a V O M capable of reading 15VDC, 50VDC, and 100VDC (Simpson 463, Fluke 802A
or equivalent).
Access to the terminal posts can be obtained either through the use of a Dynamic Test Strip plugged into the Test
Receptacle on the inverter front panel, or by removing the inverter panels carefully and exposing the terminals
inside the back of the inverter.
TO CHECKOUT THE HARNESS, FOLLOW THIS PROCEDURE: (Colors refer to wires attached to the indicated
terminal posts.)
— 1.Disconnect the RED wire of throttle control module from the #10 stud of relay K3.
— 2.Remove warranty initiation card from Section 1 of the Instruction Manual. Record in pencil the readings from
all the following steps.
— 3.Turn ignition OFF. Connect harness to inverter at this time.
— 4.Connect battery negative ground cable.
— 5.A. With ignition OFF and Dynamote Start Button ON, readings should be as follows:
Ground (GREEN) post to Battery + (BLACK) post = 12-12.8V
Ground (GREEN) post to Alternator B+ (RED) post = 0V
Ground (GREEN) post to F Out (BLUE) post = 12-12.8V
Ground (GREEN) post to Ignition (ORANGE) post = 0V
Ground (GREEN) post to Accessory (BROWN) post = 12-12.8V
B. With ignition ON, engine OFF, and inverter Start
Button NOT depressed, readings should be as follows:
Ground (GREEN) post to F Out (BLUE) post = 10-12.8V
Ground (GREEN) post to Ignition (ORANGE) post = 10-12.8V
cCopyright 1981, DYNAMOTE CORP.
4078
F2111E 11/82
3.6.2 HARNESS & ALTERNATOR CHECKOUT WITHOUT 4-2600 (continued)
Trouble Shooting Steps for Step 5.
1) If GREEN to BLACK is less than 12 volts DC, there could be a faulty ground
condition (GREEN wire or battery ground strap). If properly grounded, the battery may be
dead or defective. Return battery to a charged state before continuing. If battery is
acceptable, the BLACK wire could have faulty connections.
2) If GREEN to RED is greater than zero without K3 Relay, the alternator is still
connected directly to the battery. Check to be sure the Dynamote RED harness wire is
the only one attached to the output terminal of the alternator.
3) If GREEN to RED is greater than zero with K3 Relay, the K3 Relay is incorrectly
installed or not energizing. Refer to Section 3.5.1, Step 3.
4) If GREEN to ORANGE is larger than zero, ORANGE wire is incorrectly connected
to the ignition switch.
— 6. Start engine and increase engine speed to about 1000 RPM (equivalent to engine speed at about 20 MPH.
Voltages should read as follows:
Ground (GREEN) post to Battery + (BLACK) post = 13.5-14.2V
Ground (GREEN-) post to Alternator B+ (RED) post- =13.5-14.2V
Ground (GREEN) post to F Out (BLUE) post - variable up to 14.2V
Ground (GREEN) post to Ignition (ORANGE) post = 12.0-14.2V
Ground (GREEN) post to Accessory (BROWN) post = 0V
Trouble Shooting Tips for Step 6.
1) If BLACK and RED are greater than 14.2VDC or less than 13.5VDC, adjust the
vehicle voltage regulator CB3. If adjusting the CB3 doe* not correct the DC voltage at
BLACK, proceed to
the applicable step following:
a) If BLACK and RED are less than 13.5VDC and BLUE is greater than
13.5VDC, check if BLACK voltage varies with the engine speed. If it does, either
the pulley ratio is too low or the alternator is overloaded. Verify that BLUE is the
only wire on the alternator positive FIELD terminal, and that the alternator negative
FIELD terminal is grounded. If all wiring conditions are correct, then the alternator
is faulty or the belts are slipping.
b) If BLACK and RED are greater than 14.2VDC and BLUE is greater than
12VDC, verify that BLUE is the only wire connected to FIELD positive terminal.
c) If BLACK and RED are less than 13.5VDC and BLUE is less than 100VDC,
CB3 is defective and should be replaced.
DYNAMOTE CORPORATION, 1200 W. Nickerson, Seattle, WA. 98119 - 206-282-1000
4079
3.6.2 HARNESS & ALTERNATOR CHECKOUT WITHOUT 4-2600 Continued)
— 7.With engine still running at about 1000 RPM, remove commutation fuses on inverter, and push Dynamote
Start Button. Voltage readings should be as follows:
Ground (GREEN) post to Battery + (BLACK) post = 12-12.8VDC
Ground (GREEN) post to Alternator B+ (RED) post = 15.0VDC or greater
Ground (GREEN) post to F Out (BLUE) post = 12-12.8VDC
Ground (GREEN) post to Ignition (ORANGE) post = 12-12.8VDC
Ground (GREEN) post to Accessory (BROWN) post =12-12.8VDC
Trouble Shooting Tips for Step 7.
1) If BLACK post voltage is above 12.8VDC, harness is wired improperly or K3 Relay
is not functioning properly. Correct this defect before proceeding. This step assures
proper disconnect of alternator output from vehicle battery when inverter is energized.
2) If RED post voltage reads below 15.0VDC, harness wiring is incorrect or alternator
may be defective. Correct wiring defect, if any, at this time. Alternator defect, if any, will
be determined in Step 8 below.
— 8.DO NOT PUSH OR RELEASE START SWITCH WHEN ENGINE IS ABOVE IDLE FOR THIS TEST
With commutation fuses removed and inverter Start Button depressed as in Step 7 above, slowly increase
engine speed. Voltage from GREEN post to RED post should increase to about 100VDC at or below 2500 engine
RPM. Do not increase engine speed in excess of 100VDC reading, and maintain this condition only long enough
to check voltage output. This step assures that alternator diodes are satisfactory and that the alternator can
provide the voltage necessary for proper operation of the inverter. Readings should be as follows:
Ground (GREEN). post to Battery + (BLACK) post = 12-12.8VDC
Ground (GREEN) post to Alternator B+ (RED) post = Up to 100VDC
Ground (GREEN) post to F Out (BLUE) post = 12- 12.8VDC
Ground (GREEN) post to Ignition (ORANGE) post = 12-12.8VDC
Ground (GREEN) post to Accessory (BROWN) post = 12-12.8VDC
NOTE: Failure to obtain the specified reading is an indication of improper wiring or a defective alternator. If
voltage is above 15VDC at idle but does not increase to 100VDC at higher engine speeds, the alternator
is defective, usually caused by open or shorted diodes. The remedy is to replace the faulty alternator
diode(s). Most alternators have six diodes, three with forward polarity and three with reverse polarity. It
is best to replace a complete set of three diodes when replac-any. Use 200 PIV diodes available from
an auto electr or electronic parts supply house.
Refer to alternator manufacturer's service manual for details of checking and re- pairing alternator
diodes.
4080
F8119 12/81
3.6.2 HARNESS & ALTERNATOR CHECKOUT WITHOUT 4-2600 (continued)
-9. Now compare your readings with the following summary, given in Figure 3.6.2A
Figure 3.6.2A SUMMARY OF TEST VOLTAGE READINGS
-10. Reinstall commutation fuse.
If all steps check out correctly, CONGRATULATIONS. The harness is properly attached to the alternator system
and the alternator is capable of operating the inverter properly. BE SURE ALL CHECKOUT DATA IS RECORDED
ON THE WARRANTY INITIATION CARD BEFORE PROCEEDING.
DYNAMOTE CORPORATION, 1200 W. Nickerson, Seattle, WA 98119 - 206-282-1000
4081
3.7.0 CHECKOUT INVERTER OPERATION
(Put Auto Manual Switch in Manual position. See 2.2.2.1)
3.7.1 Disengage Automatic Throttle by disconnecting the RED wire of throttle control module from the #10 stud of relay
K3.
3.7.2 Check battery charging voltage with inverter OFF. Turn inverter OFF, and increase engine speed to about 1,000
RPM (medium fast idle). Check battery voltage. It should read 13.5 to 14.2 volts DC. If it does not, adjust CB3.
3.7.3 Start Inverter. Start engine, and manually increase engine speed to approximately 1,500 RPM (equivalent to
engine speed at about 30 MPH). Depress the start button. The inverter should START, that is, you should hear the inverter
"hum", the indicator light should turn ON, the cooling fan should be exhausting air through the fan shroud in the rear
chassis panel, and the voltmeter should register AC voltage up to 130 volts. If the inverter does not START, refer to
Troubleshooting Section 4.
3.7.4 Check for proper charging voltage with Inverter ON. With vehicle engine still running at approximately 1,500 RPM,
and with inverter ON, allow 3-5 minutes of inverter operation for charging voltage to stabilize. With inverter still ON, using
an accurate DC voltmeter, check voltage on vehicle system battery. It should read 14.0-14.2 volts DC. If it does not, adjust
CB1. If this does not correct the problem, refer to the Troubleshooting Section 4.
3.7.5 Check AC voltage stability under load. With inverter still operating at 120 volts output, apply the normal AC load
you intend to operate on the inverter. If actual load is not available, simulate the actual load with an equivalent wattage and
type of load (resistive or inductive).
If AC load does not operate properly, or if inverter output voltage drops more than 10 volts, or if inverter shuts off
when AC load is applied, remove AC load, turn inverter OFF and refer to Troubleshooting Section 4.
3.7.6 Adjust Automatic Throtle. Reconnect the RED wire of the throttle control module to the #10 stud of relay K3. Now,
START the inverter. The autothrottle should energize when the inverter starts. Adjust turnbuckle on the autothrottle
linkage to minimum engine speed that will maintain usable AC voltage when inverter is operating under normally expected
AC load.
4082
F8118 8/84
3.8.2 Models A30-70D
A. In these units, AC output is a standard two-wire output, with a hot and neutral lead. ’Only the "hot" lead (AC 1)
cannot be grounded.
B. The AC receptacles can be used up to their fused capacity of 15 amps per receptacle for all models.
C. If permanent connection of inverter is desired, follow these directions:
Connect AC leads to external AC junction box, using circuit breaker or fuses for each separate circuit. Only
the "hot" (BLACK) wire should not be grounded.
3.9 COMPLETE, SIGN AND MAIL WARRANTY INITIATION CARD
The final step is to initiate the inverter warranty. Proper installation is not complete until warranty is properly initiated, as
follows:
A. Fill in the final customer’s name and address and vehicle data.
B. Enter all checkout data from the harness and alternator checkout procedures in Section 6.
C. Sign your name and the company name and address, certifying that the installation was properly completed,
and enter the date of installation.
D. Fill in and sign the Owner’s Certificate of Warranty Initiation card from the first section of the manual.
E. Mail the stamped, self-addressed warranty initiation card to DYNAMOTE CORPORATION.
DYNAMOTE CORPORATION, 1200 W. Nickerson, Seattle, WA 98119 - 206-282-1000
4083
SECTION IV SERVICE AND TROUBLESHOOTING
INSTRUCTIONS FOR DYNAMOTE SERIES "A" DYNAMIC INVERTERS
4.1.0 General Information. PLEASE READ CAREFULLY.
The only reason to be at this point in the manual is that the inverter and/or vehicle charging system are not working
properly.
If this is a new installation and has not yet been in service, be sure to go through the checkout procedures in Section 3.6
before proceeding further. If you have completed the checkout procedure in Sand the inverter still does not work, continue
with this section.
If the inverter has been in service and working properly prior to this failure, and if the installation has not been tampered
with, such as for servicing the vehicle in some way, then the likely cause of failure is in the inverter and can be found
through the troubleshooting procedure.
It is easiest to troubleshoot the inverter while it is installed in the vehicle or boat, as the electrical system provides a power
source to check out all inverter functions. Another alternative is a test bench which includes alternator and battery, and
simulates a vehicle or boat electrical system.
If neither of these is available, many of the troubleshooting tests can be performed by connecting the inverter harness to a
12 volt battery as follows:
GREEN to battery Negative (-)
Black to Battery Positive (+)
ORANGE to Battery Positive (+)
Other wires not connected
The Troubleshooting guide is to be found in section 4.3.0.
4.2.0 INVERTER REMOVAL FROM VEHICLE SYSTEM FOR SERVICING.
NOTE: DO NOT REMOVE INVERTER UNTIL AFTER THE TROUBLESHOOTING PROCEDURE HAS
BEEN COMPLETED AND IT IS DETERMINED THAT THE INVERTER MUST BE REMOVED FOR
SERVICE.
1. Remove inverter mounting screws.
2. Turn inverter to gain access to rear panel. Carefully remove rear panel and disconnect harness wires from
studs in the inverter. (Mark wires and studs for easy reinstallation.) Loosen harness clamps-on top of inverter
and remove harness wires.
3. Remove inverter from vehicle.
4. Tape each ring terminal individually and secure so that terminals do not touch body.
4084
4.2.0 INVERTER REMOVAL FOR VEHICLE SYSTEM FOR SERVICING - Continued
Batteries will not charge while inverter is disconnected. Operation of vehicle while inverter is disconnected
will result in draining of batteries.
4.3.0 TROUBLESHOOTING GUIDE FOR DYNAMOTE SERIES "A" DYNAMIC INVERTERS
Introduction: This troubleshooting section takes the most common symptoms of inverter failure and suggests
probable causes and solutions. The objective is to provide relatively simple solutions for 90% of the problems that
will be encountered. Only the simplest of tools and instruments are required: a Volt-Ohm Meter which reads to
100 VDC, socket wrenches, and a screw driver. A 10" extension on the socket wrench will be helpful if the cathode
leads to the SCRs must be removed.
The remaining 10% of the possible problems are often intermittent or less obvious and require more sophisticated
instruments and technical expertise to solve. This kind of capability can be found at the DYNAMOTE factory and
major warranty and repair centers about the country. If the problem cannot be solved using this troubleshooting
guide with approximately 1 hour, then help should be sought from one of these facilities.
The inverter electrical schematics, included in Section 4.4.0 will be essential in understanding-the checkout
procedures, and the inverter wiring diagrams in Section 4.5.0 will be-useful in locating parts and terminal points.
The parts list is also located in Section 4.5.0 and gives Dynamote part numbers for all referenced components for
use in ordering replacement parts.
4.3.1 USE OF THE TROUBLESHOOTING GUIDE
If the symptom of failure is known, proceed directly to that symptom in the troubleshooting chart, Section 4.3.2. If
the symptom is not known, begin the troubleshooting process by going to symptom #1 in the troubleshooting chart,
pushing the START button and progressing through the chart steps until the applicable symptom is found.
4.3.2 TROUBLESHOOTING CHART
The alternator should be turning approximately 4000 RPM, or about 1500 engine RPM for performing tests to
determine the applicable symptom.
If the inverter is connected only to a battery and not to an alternator, the test at symptom #3 can be performed as
well as the checkout procedures for the voltage regulators, ocillator board, diodes, SCRs, and relays K1, K2 and
K3.
4085
Section 4.3.2 TROUBLESHOOTING CHART
No. SYMPTOM PROBABLE CAUSE SOLUTION
1 Start button pushed, Blown control fuse Check control fuse F5 on inverter front
no response panel. If there is no control fuse on the
inverter, go on to the next probable cause.
Inoperative K2 Relay. Follow procedure to check out K2 Relay,
see Section 4.3.4.
2 Start button pushed, Inverter harness improperly Install RED and BLACK wires properly
relays will not remain installed with RED wire at- according to instillation instructions.
energized but chatter tached to battery and BLACK
on and off wire attached to alternator
output.
3 Start button pushed, Blown commutation fuses Follow procedure to check commutation
relays energize with an fuses, Section 4.3.6.
audible click, but in- Inoperative K3 Relay Follow procedure to check K3 Relay,
verter will not start Section 4.3.5.
(Fan does not turn.)
Inverter voltage regulator in- Follow procedure to checkout voltage
(ENGINE MUST BE RUNN- operative or fuse is blown regulator, Section 4.3.7.
ING APPROXIMATELY 1500
RPM FOR THIS AND Shorted SCR. Follow procedure to checkout SCRs,
REMAINING TROUBLE- Section 4.3.9.
SHOOTING STEPS) Oscillator circuit board in- Follow procedure to checkout oscillator
operative. board, Section 4.3.8.
Diode D5.or D6 open. Follow procedure to checkout Diodes D5
and D6, Section 4.3.10.
Diode D3 and/or D4 shorted. Follow procedure to checkout Diodes D3
and D4, Section 4.3.10.
4 Start button pushed, Diode D2 is open Replace Diode D2.
inverter turns on,
(fan turns), but stops
when start button is
released
4086
F2138C 12/81
No. SYMPTOM PROBABLE CAUSE SOLUTION
5 Low output voltage, Loose alternator belts Tighten belts by adjusting alternator
AC and DC bracket.
Alternator RPM too slow Run engine at faster speed and see if
output voltage goes up.
K3 Relay inoperative Follow procedure to checkout K3 Relay,
Section 4.3.5.
Inverter voltage regulator Adjust voltage regulator.
out of adjustment.
Shorted or open diodes in Follow alternator diode test procedure,
the alternator Section 4.3.11.
6 Inverter will not Inverter voltage regulator Replace inverter voltage regulator, PCB1.
turn off, high out- inoperative or shorted.
put voltage, AC
and DC.
7 Inverter will not Inverter voltage regulator Follow procedure for voltage regulator
turn off, output vol- inoperative checkout, Section 4.3.7.
tage normal K2 Relay points 3 and 9 Follow procedure for K2 Relay checkout,
not disengaging Section 4.3.4.
8 Inverter turns on, but Blocking Diode D5 and/or D6 Follow procedure for Diode D5 and D6
will not carry AC load shorted checkout, Section 4.3.10.
9 High AC output vol- Diodes D3 and/or D4 open Check Diodes D3 and D4, according to
tage, low or normal checkout procedure, Section 4.3.10.
DC output voltage.
10 High DC output vol- Faulty K3 Relay Follow procedure to checkout K3 Relay,
tage, low AC out- Section 4.3.5.
put voltage
11 Improper or no char- Faulty Vehicle Voltage Reg- Checkout Vehicle Voltage Regulator
ging with inverter ulator, PCB3 according to procedure in Section 4.3.12
off, proper opera- Faulty K2 Relay Follow procedure to checkout K2 Relay,
tion with inverter Section 4.3.4.
on
4087
4.3.2 TROUBLE SHOOTING CHART (continued)
MOST LIKELY FAILURES
Based on our experience at DYNAMOTE, the following, in order of descending frequency, are the most likely
causes of inverter malfunction. In each case, there is a procedure to check it out.
1. K3 Relay
2. Blown Commutation Fuses
3. Shorted SCRs.
4. Inverter Voltage Regulator Board - no output.
5. Inverter Oscillator Board.
4.3.3 K1 RELAY CHECKOUT PROCEDURE
Tools Required: Ohm Meter and Voltmeter with 0-15VDC scale, 7/16" socket or open end wrench, screwdriver.
1) Open the inverter by removing the front, top and back panel fasteners. Carefully lay the front and back
panels down and remove the top panel.
2) The engine and ignition should be OFF for the procedure.
3) Locate the K1 Relay, the larger cylindrical silver solenoid contactor on the right side of the inverter near the
rear.
4) Depress the START button and there should be an audible click if the relay is operating.
5) With the Ohm Meter, check the resistance across the two large terminals at the top of the relay. WITHOUT
depressing the START button the meter should read 100K Ohms to infinity, (∝).
WITH the START button depressed, the meter should read less than 5 Ohms. If the K1 Relay does not pass all of
these tests, it should be replaced.
4.3.4 K2 CONTROL RELAY CHECKOUT PROCEDURE
Tools Required: Voltmeter with 0-15VDC scale, 7/16" socket or open end wrench, screwdriver.
1) If there is a control fuse on the inverter front panel, check it first.
2) Open the inverter by removing the front, top, and back panel fasteners. Carefully lay the front and back
panels down and remove the top panel.
3) The engine and ignition should be OFF for this test.
DYNAMOTE CORPORATION, 1200 W. Nickerson, Seattle, WA 98119 - 206-282-1000
4088
F2139C 12/81
4.3.4 K2 RELAY CKECKOUT PROCEDURE (continued)
4) Locate the K2 Relay. It is approximately 1"xl"x3", encased in clear plastic and located on the bottom left side
of the inverter.
5) Depress and release the start button and visually confirm that the relay contacts are moving. If the contacts
do not move, the relay should be replaced.
6) With the START button depressed, check the voltage from the ACC terminal at the rear of the inverter to
GROUND. It should read 10 VDC or higher. If not, the relay should be replaced.
7) With the START Button depressed, check the voltage from the F Out terminal at the rear of the inverter to
GROUND. It should read 10VDC or higher. If there is no voltage at the F Out terminal, and if the Voltage
Regulator has checked good, then replace the K2 Relay.
4.3.5 K3 RELAY CHECKOUT PROCEDURE
Tools Required: Volt Ohm Meter with 0-15VDC scale, screwdriver, 12" jumper wire.
1) The K3 Relay is the high amperage bypass relay and is a cylindrical silver solenoid contactor. It is installed
either in the 4-2500 Dynamic Installation Kit or independently near the alternator under the hood. It can be found
by following the wiring from the POSITIVE (+) terminal of the alternator.
2) The engine and ignition should be OFF for this test.
3) The small terminals on the relay are the coil terminals and the large terminals are the contacts.
4) Check the voltage from the positive to the negative coil terminal of the relay. With the inverter START button
depressed, there should be an audible click and the voltage should be 10VDC or higher. Without the START
button depressed, the voltage should be 0.
If these conditions are present, go on to Step 5.
If the voltage is 0 with the START button depressed, carefully check the wiring to the positive relay coil terminal
(the one that is not grounded). This should come from the ACC terminal in the rear of the inverter.
If the wiring is correct, then go through the K2 Relay checkout procedure to be sure that there is voltage at the
ACC terminal when the START button is depressed.
5) Check the voltage from the relay contact that is wired to the alternator POSITIVE (+) terminal to GROUND..
Without the START button depressed, the voltage should be 10VDC or higher.
DYNAMOTE CORPORATION, 1200 W. Nickerson. Seattle, WA 98119 - 206-282-1000
4089
4.3.5 K3 RELAY CHECKOUT PROCEDURE (continued)
With the START button depressed, the voltage should read 0.
Otherwise, replace the K3 Relay.
4.3.6 COMMUTATION FUSE CHECKOUT PROCEDURE
Tools Required: Ohm Meter.
1) Commutation fuses are in the larger fuseholders on the front panel of the inverter. There are two
commutation fuses on A30s, and four commutation fuses on A40s and A60s.
2) Remove the commutation fuses. They must be checked with an Ohm Meter, as they are solid fuses and
visual inspection will not determine if they are good.
3) Check the fuses with the Ohm Meter by placing a probe at each end. If there is no resistance, the fuse is
good. If there is high resistance, the fuse is blown.
4) If the fuses are blown, be sure to replace them with the same value fuses.
5) Recheck commutation fuses after new installation.
4.3.7 DYNAMIC INVERTER VOLTAGE REGULATOR PCB1 CHECKOUT PROCEDURE
Tools Required: Voltmeter with 0-15VDC scale, 7/16" socket or open end wrench, screwdriver.
1) Open inverter by removing the front and top panel fastener. Carefully lay the front panel down on its face and
remove the top panel.
2) Locate the inverter voltage regulator CB1 on the left side of the inverter. It is the forwardmost of the two
circuit boards, and there are five wires attached to the board, or to a connector that is plugged into the board.
3) The engine and ignition are OFF for this test.
4) If the voltage regulator has a fuse mounted on the circuit board, check the fuse first.
5) With the inverter START button depressed, check the voltage from the BLUE wire on the voltage regulator
circuit board to ground. Voltage should read 10 volts or more. If there is no voltage, the voltage regulator has
failed in the open position and should be replaced.
6) If voltage at the BLUE wire is 10 volts or more, depress the inverter START button again and check the
voltage from the F OUT terminal inside the rear of the inverter to GROUND. If the voltage at this terminal is not
the same as the voltage at the BLUE wire on the voltage regulator, then the K2 Relay is faulty and should be
replaced. C Copyright 1981, DYNAMOTE CORP.
4090
F2140C 12/81
4.3.8 OSCILLATOR CIRCUIT BOARD CHECKOUT PROCEDURE
Tools Required: Voltmeter with 0-15VDC scale, 7/16" socket wrench or open end wrench, screwdriver.
1) Open inverter by removing the front and top panel fasteners. Carefully lay the front panel down on its face
and remove the top panel.
2) The engine and ignition should be OFF for this test.
3) Locate the SCR gate leads. These are the small white leads to the SCRs which have a plastic connector in
the lead. Separate this lead by disconnecting the plastic connector.
4) With the START button depressed, read the voltage to GROUND from each gate lead connector on the part
of the gate lead which is connected to the Oscillator Circuit Board. The voltage should be between 2VDC and
7VDC, and should be equal ±.3VDC for the two leads. If it is not, the oscillator board should be replaced.
4.3.9 SCR CHECKOUT PROCEDURE
Tools Required: Ohm Meter or Continuity Tester, 7/16’ socket wrench with extender, 3/4" socket wrench with
extender (A40 and A60 only), screwdriver.
1) Prior to checking out the SCRs, be sure that the commutation fuses are good, by following the commutation
fuse checkout procedure.
2) Open inverter by removing the front and top panel fasteners. Carefully lay the front panel down on its face
and remove the top panel.
3) The engine and inverter are OFF for this test.
4) An SCR (Silicon Controlled Rectifier) is a semiconductor device which will not conduct electricity in either
direction unless the GATE is impulsed to turn on the SCR. When the GATE is impulsed, turn the SCR ON, the
SCR will conduct from ANODE to CATHODE only. The purpose of this test is to determine if the SCR will conduct
(i.e., show low resistance) without the GATE being turned on. If so, the SCR is shorted and should be replaced.
DYNAMOTE CORPORATION, 1200 W. Nickerson, Seattle, WA 98119 - 206-282-1000
4091
4.3.9 SCR CHECKOUT PROCEDURE (continued)
5) Remove SCR cathode (ground) leads from ground. These are RED #8 wires for A40/A60, and GREEN wires
for an A30, which are attached to the bottom of the inverter with a bolt and 7/16" nut. The SCR does not have to
be removed from heat sink for this test. The heat sink and anode are at the same potential.
6) Check resistance across SCR with positive (+) lead. from Ohm Meter on heat sink, and negative (-) lead on
the cathode which was removed from ground stud. (See illustration.) If resistance reading is less than 1000
Ohms, the SCR is shorted and should be replaced. A resistance reading of 100, 000 Ohms to infinity (∝) indicates
that the SCR is not shorted.
NOTE: BE SURE EITHER STUD OR GROUND WIRE OF SCR IS REMOVED BEFORE CHECKING
SCR.
7) To replace the SCR, do the following:
a) If the inverter has one-inch holes in the slotted area behind the heat sink, pop the plastic plugs out of
these holes from the inside with a screwdriver. If the inverter does not have holes in the slotted or louvered
area behind the heat sink, then the heat sink must be removed by removing the four screws at the corners.
b) Disconnect the small connector in the SCR gate lead.
c) Remove the SCR, using the 7/16" socket if it is an A30, or the 3/4" socket for an A40 or A60, leaving as
much of the white thermal compound on the heat sink as possible.
C Copyright 1981, DYNAMOTE CORP.4092
4092
F2143E 12/81
4.3.9 SCR CHECKOUT PROCEDURE (continued)
d) Install the new SCR, making sure that the nut is on very tight.
e) Reconnect the Cathode (GROUND) lead.
f) Reconnect the gate lead.
4.3.10 DIODE CHECKOUT PROCEDURE
Tools Required: Ohm Meter or Continuity Tester, 7/16” socket wrench or open end wrench, screwdriver.
1) Open inverter by. removing the front and top panel fasteners. Carefully lay the front panel down on its face
and remove the top panel.
2) A DIODE (Rectifier) is a semiconductor device which functions as an electrical one-way street.
For stud-mounted diodes with normal or standard polarity, the stud is the CATHODE, and the tab or flag is the
ANODE. See diagram below.
For stud-mounted diodes with reverse polarity, the stud is the ANODE and the flag or tab is the CATHODE. See
diagram below.
DYNAMOTE CORPORATION, 1200 W Nickerson, Seattle, WA 98119 - 206-282-1000
4093
4.3.10 DIODE CHECKOUT PROCEDURE (continued)
A diode which is not stud-mounted, but rather has axial leads, conducts in the direction the
band on the diode indicating the CATHODE end, the end opposite indicating the ANODE.
Following is the polarity of the diodes in the Dynamic Inverters:
Diode Polarity
D1 Standard
D2 Axial Leads
D3, D4 Reverse
DS, D6 Standard
D7, D8 Standard
D9, D10 Axial Leads
3) The diodes can be located using the wiring diagram, Figures 4.5.OA to F. Not all models have all ten diodes.
4) Diodes should be removed from the heat sink or chassis before testing. Figure 4.3.IOA on the following page
gives the proper Ohm Meter readings.
C Copyright 1981, DYNAMOTE CORP.
4094
F8123 12/81
DIODE TEST INSTRUCTIONS
NOTE: 1. BE SURE STUD OF DIODE IS REMOVED U13ORE TESTING DIODE.
2. REVERSE POLARITY DIODES WILL HAVE AN "R" IN TIEIR NUMBER (R3720 OR IN1184R), ALSO ALL
DIODES MOUNTED A DYNAMOTE CHASSIS WILL BE REVER-SE POLARITY DIODE (EXCEPT THE:
PIONEER 205).
Figure 4.3.10A DIODE CHECKOUT PROCEDURE AND READINGS
4095
F2144D 11/82
4.3.11 ALTERNATOR DIODE TEST PROCEDURE
FOR THIS TEST, DO NOT PUSH OR RELEASE START SWITCH WHEN ENGINE IS ABOVE IDLE.
Tools Required: Voltmeter with 0-100 VDC scale.
1) Remove the commutation fuses from the inverter front panel.
2) Start the engine and run at approximately 1500 RPM.
3) Check the voltage from the POSITIVE (+) terminal on the alternator to GROUND.
With the START button depressed, the voltage should read 80 to I10VDC. If not, the alternator diodes are bad
and should be replaced. This should be done by an alternator repair shop.
NOTE : If Step 3 is difficult because of the distance from the alternator to the inverter, the alternator
voltage can be read from the A+ terminal inside the rear of the inverter.
4.3.12 VEHICLE VOLTAGE REGULATOR, PCB3, CHECKOUT PROCEDURE
Tools. Required: Voltmeter with 0-15VDC scale, screwdriver
1) Remove the Vehicle Voltage Regulator (VVR) box from the front panel of the inverter by removing the four
screws at the corners.
2) Remove the VVR Circuit Board from the box by removing the two screws on the outside of the box.
3) Check the fuse on the VVR Circuit Board and replace if blown. If not, proceed to the next step.
4) With the ignition ON, inverter OFF, and the inverter harnesses still connected, check the voltage from the
connector pin #4, GREY wire, to GROUND. The pin next to the edge of the circuit board is pin #5. If the voltage
reads 10 volts or more, proceed to Step 5. If there is no voltage, the voltage regulator has failed in the open
position and should be replaced.
5) To determine if the voltage regulator is regulating properly, start the engine and run at approximately 1500
RPM. Turn on a moderate load, such as the headlights. With the inverter OFF, check the voltage from the
inverter B+ (BLACK) terminal post to GROUND (GREEN). If the voltage is other than 13.8 to 14.2VDC, try to
adjust it by turning the screw on the grey potentiometer on the vehicle voltage regulator circuit board with a very
small screwdriver or knife blade. If the voltage cannot be adjusted to approximately 14.2VDC, the voltage
regulator circuit board should be replaced.
NOTE: The inverter voltage regulator, PCB1, inside the inverter front panel is identical to the vehicle
voltage regulator and can be used to replace the vehicle voltage regulator until another board can be
obtained. It can also be used to confirm the diagnosis of a faulty vehicle voltage regulator circuit board.
C Copyright 1981, DYNAMOTE CORP.
4096
F2136B 2/84
Fig. 4.5.0 G DYNAMIC INVERTER PARTS LIST
Circuit Dynamote Description Used In:
Designation Part BOOSTED
See Pages 4110,
4111 and 4112 A30
C1 4092-40502 Output Capacitor x
C2 4092-40502 Output Capacitor x
C3 4092-40502 XFMR. Input Capac. x
C4 4095-24712 Commutation Capac. x
C5 4093-10147 Contactor Suppression Capacitor x
C6, C7 4093-10147 Circuit Board Filter x
C9 4095-74606 AC Output Capacitor x
C10 4093-10825 Boosted. Field Capacitor x
C11 4093-10825 DC Input Capacitor x
D1 4121-43700 Unit Isolation Diode x
D2 4121-14005 K2 Relay Hold-in Diode x
D3, D4 4121-23720 Battery Charging Diode
D3, D4 4121-11183 Battery Charging Diode x
DS, D6 4121-43700 AC Blocking Diode
D5, D6 4121-11186 AC Blocking Diode x
D8, D9 4121-14005 Spike Suppression Diode x
D10, D12 4121-22030 Reverse Parallel Diode
D13 4121-10751 Isolation Diode x
D14, D15 4121-20410 Rectification Diode x
R1, R2 4681-10025 Stabilizing Resistors x
R3 4681-00247 Current Limit Resistor x
R4 4681-08020 VR Stabilizing Resis. x
R9 4602-20110 Meter Adjustment Potentiometer x
F1, F2 4200-06400 Fuses ABU40 x
Fl, F2, F5, F6 4200-06400 Fuses ABU40
F3, F4 4200-02150 Fuses AGC15 x
F5 4200-02150 Fuses-AGC15 x
F7 4200-02150 Fuses AGC15
F1, F2 4282-00005 Fuse Holders Large HPC x
F1, F2, F5, F6 4282-00005 Fuse Holders Large HPC
F3, F4 4282-00003 Fuse Holders Small HKP x
F5 4282-00003 Fuse Holders Small HKP x
F7 4282-00003 Fuse Holders Small HKP
K1 4685-43051 Power Relay x
K2 4685-01156 Control Relay x
K4 4685-02030 VVR Relay x
K5 4685-42592 LVCO Relay
K3 4685-43051 High Amperage Bypass Relay *
* Optional
4097
4.5.0 DYNAMIC INVERTER PARTS LIST (continued)
Circuit Dynamote Description Used In:
Designation Part BOOSTED
A30
S1, S2 4721-08411 Start/Stop Switch x
S4 4721-00256 Field Selection Switch
B1 4046-12337 Fan Motor x
M1 4481-20123 Voltmeter x
PCB1 2081-00005 Regulator (Unit) x
PCB2 2081-00930 Oscillator x
PCB3 2081-00005 Regulator (Vehicle) x
PCB4 2081-00200 Load Demand *
T1 2764-02007 Transformer/Isolated x
SCR1, SCR2 2720-40125 Main SCRs x
J3 4080-03080 Control Head Receptacle x
J4 4683-25320 Output Receptacle x
J7 4080-30160 Test Module Receptacle x
X1 4080-04014 Quick Disconnect Black x
X2 4080-04013 Quick Disconnect Red x
X3 4080-04015 Quick Disconnect Green x
X1, X2, X3 4442-90000 Quick Disconnect Lugs x
*-LD Units Only
4098
4099
4113
Pages 4100 through 4112 DELETED
3
4115
4
1
Remove the power unit from carton. Visually
inspect power unit and confirm that all bolts and
screws are securely fastened, and the unit has
not been damaged in shipment.
2
Remove nylon caps from 16’ length of twin hose
and attach to power unit. Match color code on
hose and swivel connections.
4116
14
3
Hand tighten both swivel connections on the hose.
4
Tighten connection using 5/8" open end wrench.
5
Attach strain relief cable with clip through hole at
base of power unit.
4117
15
6
Remove hex bushing (fill cap) and fill hydraulic
reservoir with Phosphate Ester based hydraulic
fluid (Hurst RT-23/ Aerosafe 2300). Fill to within
1" from the top. Check with dip stick provided.
Replace fill cap and tighten by hand.
8
Install (optional) caps and plugs in hose
connectors. Coil hose and attach to side of
power pack roll cage with the two straps
provided for this use.
4118
4101
4102
4119
12
Make sure the operating lever on the by pass valve is in the open
position (away from the direction of flow) before trying to start power
unit.
13
START-UP
Begin “start up” sequence. Move the choke lever on the power unit
engine control to the closed position.
14
Check operating lever for the governor control. Secure in the “run”
position. Pull starter cord several times to prime carburetor, until
engine pops.
4120
18
15
Return choke to the "open" position.
16
Hold roll cage with one hand and pull cord with other. Pull
cord sharply and the engine should start. If the new engine
does not run after several pulls, repeat the starting
procedure.
17
Connect the couplings from the tool to the Bruning couplings
on the long hoses from the power unit before operating the
by pass valve to the closed position.
4121
19
18
Move the operating lever to the closed or run position
after power unit is started and tool(s) are connected.
19
Remove hex bushing (fill cap) on power unit and check
liquid level in the reservoir. If the liquid level is down,
fill to within 1" of top of reservoir. It is not necessary to
turn off the power unit to check the fluid level in the
reservoir. Replace fill cap and tighten by hand only.
Pages 4123 through 4125 DELETED
4122
20
PROBLEM CAUSE REMEDY
Engine fails to start or • No fuel in tank • Fill tank with clean, fresh fuel
starts with difficulty
Shut-off valve closed • Open v• Obstructed fuel line • Clean fuel screen and line. If necessary,
remove and clean carburetor
• Tank cap vent obstructed • Open vent in fuel tank cap
• Water in fuel • Drain tank. Clean carburetor and fuel lines
Dry spark plug points. Fill tank with clean,
fresh fuel
• Engine overchoked • Close fuel shut-off and pull starter until
engine starts. Reopen fuel shut-off for
normal fuel flow
• Improper carburetor • Adjust carburetor
adjustment
• Loose or defective magneto • Check magneto wiring for shorts or
wiring grounds; repair if necessary
• Faulty Magneto • Check timing, point gap, and if necessary,
overhaul magneto
• Spark plug fouled • Clean and regap spark plug
• Spark plug porcelain cracked • Replace spark plug
• Poor compression • Overhaul engine
• No spark at plug • Disconnect ignition cut off wire at the
engine. Crank engine. If spark at spark
plug, ignition switch, safety switch or
interlock switch is inoperative. If no spark,
check magneto. Check wires for poor
connections, cuts or breaks
Engine misses under load • Spark plug fouled • Clean and regap spark plug
• Spark plug porcelain cracked • Replace spark plug
• Improper spark plug gap • Regap spark plug
• Pitted magneto breaker points • Replace pitted breaker points
• Magneto breaker arm sluggish • Clean and lubricate breaker point arm
• Faulty condenser (except • Check condenser on a tester, replace if
on Tecumseh Magneto) defective
• Improper carburetor • Adjust carburetor
adjustment
• Improper valve clearance • Adjust valve clearance to .010 cold
• Weak valve spring • Replace valve spring
Engine lacks power • Choke partially closed • Open choke
• Improper carburetor • Adjust carburetor
adjustment
Pages 4123 through 4125 DELETED
4126
• Magneto improperly timed • Time magneto
• Worn rings • Replace rings
• Lack of lubrication • Fill crankcase to the proper level
• Air cleaner fouled • Clean air cleaner
• Valves leaking • Grind valves and set to .010 cold
Engine surges or • Fuel tank cap vent hole • Open vent hole
runs unevenly clogged
• Governor parts sticking or • Clean, and if necessary repair governor
binding parts
• Carburetor throttle linkage • Clean, lubricate, or adjust linkage and
or throttle shaft and or deburr throttle shaft or butterfly
butterfly binding or sticking
• Intermittent spark at • Disconnect ignition cut-off wire at the
spark plug engine. Crank engine. If spark, check
ignition switch, safety switch and interlock
switch. If no spark, check magneto. Check
wires for poor connections, cuts or breaks.
• Improper carburetor • Adjust carburetor
adjustment
• Dirty carburetor • Clean carburetor
Engine overheats • Engine improperly timed • Time engine
• Carburetor improperly • Adjust carburetor
adjusted
• Air flow obstructed • Remove any obstructions from air passages
in shrouds
· Cooling fins clogged • Clean cooling fins
• Excessive load on engine • Check operation of associated equipment
• Reduce excessive load
• Carbon in combustion • Remove cylinder head or cylinder and clean
chamber carbon from head and piston
• Lack of lubrication • Fill crankcase to proper level
Engine uses excessive • Engine speed too fast • Using tachometer adjust engine RPM to
amount of oil spec
• Oil level too high • To check level turn dipstick cap tightly into
receptacle for accurate level reading
• Oil filler cap loose or • Replace ring gasket under cap and tighten
gasket damaged causing cap securely
spillage out of breather
• Breather mechanism damaged • Replace breather assembly
or dirty causing leakage
• Drain hole in breather • Clean hole with wire to allow oil to return
box clogged causing oil to to crankcase
spill out of breather
• Gaskets damaged or gasket • Clean and smooth gasket surfaces. Always
surfaces nicked causing oil to use new gaskets
leak out
• Valve guides worn excessively • Ream valve guide oversize and install
thus passing oil into 1132" oversize valve
combustion chamber
• Cylinder wall worn or glazed, • Bore hole, or deglaze cylinder as necessary
allowing oil to bypass rings into
combustion chamber
• Piston rings and grooves • Reinstall new rings and check land
worn excessively clearance and correct as necessary
• Piston fit undersized • Measure and replace as necessary
• Piston oil control ring • Remove oil control ring and clean return
return holes clogged holes
• Oil passages obstructed • Clean out all oil passages
Oil seal leaks • Crankcase breather • Clean or replace breather
• Old seal hardened and worn • Replace seal
• Crankshaft seal contact • Check crankshaft size and replace if worn
surface is worn undersize excessively
causing seal to leak
• Crankshaft bearing under seal • Check crankshaft bearings for wear and
4127
25
is worn excessively, causing replace if necessary
crankshaft to wobble in oil seal
•·Seal outside seat in cylinder • Visually check seal receptacle for nicks
or side cover is damaged, and damage. Replace P.T.O. cylinder cover,
allowing oil to seep around or small cylinder cover on the magneto
outer edge of seal end if necessary
• New seal installed without • Replace with new seal, using proper tools
correct seal driver and not and methods
seating squarely in cavity
• New seal damaged upon • Use proper seal protector tools and
installation methods for installing another new seal "
• Bent crankshaft causing seal • Check crankshaft for straightness and
to leak replace if necessary
• Oil seal driven too far into • Remove seal and replace with new seal,
cavity using the correct driver tool and procedures
Breather passing oil • Engine speed too fast • Use tachometer to adjust correct RPM
• Loose oil fill cap or gasket • Install new ring gasket under cap and
damaged or missing tighten securely
• Oil level too high • Check oil level - Turn dipstick cap tightly
into receptacle for accurate level reading.
DO NOT fill above full mark
• Breather mechanism damaged • Replace reed plate assy.
• Breather mechanism dirty • Clean thoroughly in solvent. Use new
gaskets when reinstalling unit
• Drain hole in breather box • Clean hole with wire to allow oil to return
clogged to crankcase
• Piston ring end gaps aligned • Rotate end gaps so as to be staggered 90'
apart
• Breather mechanism installed • Small oil drain holes must be down to drain
upside down oil from mechanism
• Breather mechanism loose • Install new gaskets and tighten securely
or gaskets leaking
• Damaged or worn oil seals • Replace seals
on end of crankshaft
• Rings not properly seated • Check for worn, or out of round cylinder.
Replace rings. Break in new rings with
engine working under a varying load. Rings
must be seated under high compression, or
in other words, under varied load
conditions.
• Breather assembly not • See section on Breather Assembly
assembled correctly
• Cylinder cover gasket leaking • Replace cover gasket
4128
26
4129
PRINTED IN USA • 159 R029 00 • 2M1281 • PATENT PENDING
Hurst Safety Products reserves the to make changes at any time, without notice or obligation, in prices, materials,
equipment or specifications, and to change or discount models. Check with distributor for current information.
4130
4131
4132
2
1
Remove Rescue Tool from carton; Inspect unit and
confirm that: all bolts and screws are securely fastened,
and the unit has not been damaged In shipment.
2
Attach all sets of Jaws enclosed to both arms to Insure
both Interchangeability and fit of Jaws to the arms of the
tools. Attach automative Jaws to the tool and Insert Jaw
retainer pins.
4133
5
3
Align alot with pin before you connect
or disconnect couplings
Connect couplings on the short hoses from the tool to the
couplings on the long hoses from the power unit.
4
Operate thumb control several cycles until the
arms operate smoothly through full range of
movement - from open to close. The hydraulic
system is self purging and the cycling eliminates
air from the system.
5
Move the thumb controls to the left to open or
spread the arms of the tool. If the controls do
not operate the arms In this manner, the hoses
have been connected Incorrectly on either the
tool or the power unit. Check the color coding
on both and correct. (Turn by-pass valve on the
power unit "OFF" before breaking hose
connections.)
4134
6
6
To attach chain shackles to the tool,
force short jaw retainer pins out of the
arm. (Model 28 only)
7
Slip chain shackle over the jaw and
Insert long faspin, through hole in the
jaw locking shackle to arm. (Model
32B only)
8
Make sure hooks are both facing the
same direction, up or down. Attach
the chains from the same direction
(side) to prevent the arms from
twisting.
4135
7
9
So alignment illustration on
page 6 step 3
After storage and before re-using the Rescue Tool,
disconnect the male and female couplings on the
short and long hoses and attach together to
connect the power unit to the tool. Make
connections BEFORE STARTING THE POWER
UNIT.
10
Important: Your Rescue Tool must be registered
with HURST to remain in warranty. PLEASE
RETURN THE ENCLOSED WARRANTY SLIP TO
US IN THE ENCLOSED SELF-ADDRESSED
ENVELOPE.
Should you have to contact us about your Rescue
Tool, refer to the tool serial number (found on the
tool). This Identification will expedite any service
you may require and will also enable us to keep
current your records.
4136
8
AND GENERAL MAINTENANCE*
LUBRICATION
• Grease control spring and links with
Hurst’s Shifty Doctor Grease.
• Spray jaws, Jaw retainer pins, arms, frame
and cylinder with silicone lubricant.
• Excess grease and lubricant should be
removed.
DAILY MAINTENANCE/INSPECTION
• Inspect carefully for Hydraulic leaks.
• Inspect hoses and couplings for wear or
damage.
• Check control valve operation for easy
operation and free return.
• Check inside frame for dirt & debris.
• Be sure all parts are clean.
• Check jaws for damage.
• Check the unit that all nuts, bolts, retainer rings and
screws are In place and securely fastened.
STORAGE
• Protect unit against or store In location free of moisture.
• Store in space adequate to prevent damage to hoses,
connectors or tool Itself.
AFTER USE MAINTENANCE
• Clean and lubricate.
• Check for wear or damage on all parts.
• Check all nuts, bolts, retainer rings, screws, and pins are
In place and securely fastened.
• Check for wear or damage on all parts.
• Check all nuts, bolts, retainer rings, screws, and pins are
in place and securely fastened.
6 MONTH OR 50 USE HOURS MAINTENANCE
• Pressure check all valve and internal seals. Replace as
required.
• Check AC and Auto Jaws for damage and wear. Replace
as required.
• Check hose and couplings for damage, replace as
required. • Clean and lubricate.
ANNUAL INSPECTION
• Pressure check valves and internal seals. Replace as
required.
• Check operating pressure, unloaded, through full
operating cycle.
• Magnaflux or penetrant dye check Auto and AC jaws.
• Check force output of tool under load in opening and
closing modes, at 18” S 2” open at tip of Jaws.
• Replace operating decals.
• Replace hoses, couplings and fasteners as required.
• Clean and lubricate.
• Call your authorized Hurst Distributor for maintenance and
annual Inspection care.
4137
9
TROUBLE SHOOTING GUIDE 32B/28
PROBLEM CAUSE REMEDY
Tool operates eratically, • Hydraulic Fluid is low. • Check fluid level in reservoir and add fluid
slowly, or falls to operate as required.
• Air In Hydraulic System • Cycle tool full open to fully closed several
times.
• Valve thumb control level • Tighten or replace screw on thumb control
loose. lever, or replace thumb control lever
assembly as required.
Tool has apparent loss • Leak In valve seals • Replace all "O" rings in valve and between
of power valve and D.P.C.V. valve block*
• Internal 'T' Ring seal failure. • Remove internal seals and replace with new
"T, seals*.
• Piston failure • Remove and replace piston.
Tool falls to operate • Coupling failure - fails to • Replace coupling
open Internal check when
connected.
• Pilot operated check valve • Replace dual pilot "O" Rings or springs
falls to open. as required.
• No flow from Power Unit • Check power and repair as required.
Tool operates In reverse • Hoses reversed on power • Reverse hoses from Power Unit.
supply
• Connectors reversed on tool • Reverse connectors on short hose on the
tool.
Jaw Retainer Pin fails to • Detent ball on pin is jammed • Flush dirt or grit from pin till ball moves
stay In arm w/dirt or grit freely; replace If necessary.
• Spring on detent ball broken • Replace jaw retainer pin.
• Call your authorized Hurst Distributor for maintenance
and annual Inspection care.
4138
10
1
To raise the car roof, insert the jaws of the
Rescue Tool between the roof of the automobile
and the top of the door, hinged side, If possible, or
any firm surface. Move the operating thumb
control to the "open" position, and open the Jaws.
The tool will open insuring sufficient opening to
survey the interior of the vehicle.
2
Operate the thumb control to open position,
opening the jaws only wide enough to grab front
edge of door. Close jaws and pinch the door
edge. Rotate the tool and open the hinge side of
the door.
4139
11
3
After opening the leading edge by pinch
pry operation insert the jaws between
the body of the car and the door above
or below the hinge or lock. Move the
operating thumb controls to the "open"
position.
4
After the door is open, it may be completely removed by
breaking the hinges repeating step 3.
5
Assure additional access by pushing
the front seat backward. Insert the
jaws of the Rescue Tool between the
front door frame and the front edge of
the seat and open the Rescue Tool
arms. Seat contact should be slightly
lower than door frame.
4140
12
13
4141
9
The steering wheel can
be displaced several
inches by pushing
against the rocker
panel and column from
the inside
14
4142
1
When cutting an access hold through
metal with the Hurst Power Rescue
Tool, remove the automotive spreading
jaws and attach the cutting jaws.
Attach the wide, smooth jaw on one
arm and the narrow, concave jaw on
the other arm. * The tool will cut in the
direction of the narrow jaw giving
directional cutting.
2
Pierce the material to be cut by using
the weight of the tool to force the jaws
to penetrate the metal. If more
practical, any other piercing tool may
be used for initial hole.
15
4143
3
Operate the thumb
controls to the “open”
position, spreading the
4
Repeat this cutting procedure,
opening the tool perpendicular to
the first cut.
5
This second cut will provide an "L"
shaped cutout in the material to be
opened. Remove the narrow cutting
jaw and replace with the other wide
cutting jaw.
16
4144
6
Pry “open” resulting flap of metal. This
opening should afford entry or exit.
7
When it is not possible to force the points of
the Rescue Tool through metal, use any
existing opening to start cutting with the
Rescue Tool.
8
Follow cutting procedures numbers 3
through 7.
4145
17
9
NOTE: Since the narrow cutting jaw has a concave
face, the strip removed from the material cut with
the Rescue Tool will be coiled.
4146
18
PRINTED IN USA • 159-R022 00 • 5M681 • PATENT PENDING
Hurst Safety Products reserves the right to make changes at any time without notice or obligation in prices materials, equipment or
specifications and to change or discontinue models. Check with distributor for current information.
4147
PARTNER®
K1200
INSTRUCTION BOOK
Contents:
Safety precautions................................... Correct starting position and
Identification ............................................ starting of the saw...................................
Fitting the cutter arm K1200.................... Starter unit...............................................
Turning the cutter arm K1200 ................. Air filter K1200.........................................
Cutter disc ............................................... Carburetor ..............................................
Guard ...................................................... Spark plug...............................................
Working technique . ................................
Vee-belt K1200........................................ Maintenance scheme .............................
Fuel mixture............................................. Tools . .....................................................
Fuel tank.................................................. Technical data ........................................
Controls ..................................................
4148
Operator Safety Precautions
1 Never operate the machine when you are
fatigued
2 Use safety footwear. snug-fitting clothing.
safety goggles. and hearing- and head-
protection devices and gloves.
3. Always use caution when handling fuel. Move
the cutting machine at least 10 feet from the
fueling point before starting engine.
4. Do not allow other persons to be near the
machine when starting or cutting. Keep
bystanders and animals out of the work area.
5. Never start cutting until you have a clear work
area and secure footing 6 Always hold the unit
firmly with both hands when the engine Is
running. Use a firm grip with thumbs and fingers
encircling the handles.
6. Always hold the unit firmly with both hands when
the engine is running. Use a firm grip with
thumbs and fingers encircling the handles.
7 Keep all parts of your body away from the cutter
disc when the engine is running.
8 Never operate without the disc guard.
9 Do not cock. wedge or jam the disc in the cut
10 Before starting the engine, make sure that the
disc is not contacting anything
11 Always carry the machine with the engine
stopped and the muffler away from your body.
12 Never operate a cutting machine that Is
damaged. Improperly adjusted. or not
completely and securely assembled Be sure that
the disc stops moving when the throttle-control
trigger Is released
13. Always shut off the engine before setting the
machine down.
14 Keep the handles dry, clean, and free of oil or
fuel.
15 Operate the machine only in well-ventilated
areas. Failure to use the power cutter in a well-
ventilated area can lead to serious Injury or
death.
16. The cutter disc should be removed from the
cutting machine when it Is transported or stored.
17. All service other than items listed in the machine
builder’s maintenance instructions should be
performed by competent service personnel.
18 Do not operate a cutting machine unless
specifically trained to do so.
19. For health reasons, never cut material containing
asbestos.
20 When cutting concrete, stone, etc, sprinkle
water to bind the dust
Care of cutter discs
All cutter discs are breakable and, therefore, care shall
be exercised in their handling and storage to prevent
damage. Immediately after unpacking, all discs shall be
closely inspected to make certain that they have not
been damaged from handling, shipping or other causes.
Cutter discs should be laid flat on a flat surface away
from excessive heat or moisture. Discs should not be
stored subject to: exposure to high humidity, water, other
liquids, or freezing temperatures. Discs used on ma-
chines on emergency vehicles should be dismounted
after use and discared or carefully stored as described In
this section.
4149
K1200
Pos. Description
1. Cutter disc
2. Guard
3. Knob for guard
4. Stop control
5. Choke
6. Idling catch
7. Throttle control
8. Starter throttle
control
9. Starting handle
10.Starter unit
11.Lock nut for air filter
12.Air filter
13.Spark plug
14.Cylinder
15.Vee-belt
16.Cutting arm
17.Knob for guard
4150
Fitting the cutter arm K1200
Remove both the drive belt protecting casings (4 screws.
knob and bushing) (1) Remove the attaching bolt (2) for
the cutter arm
Fit the bolt on which the knob was placed in the upper
hole in the arm and tighten the attaching bolt (2) by hand.
Fit the vee-belt and tension it by turning the eccentric (3)
to its bottom position (clock- wise) using socket wrench
505381306. Tighten the attaching bolt (4) (anti)clock-
wise) using socket wrench 505381317.
Fit the drive belt protective casings. the bushing and the
knob (5) Tension the vee-belt after 1-2 tank refills and
thereafter every day See the next page concerning
turning the arm.
4151
Guard
Never operate without the disc guard.
The guard should be adjusted so that its
rear section is close to the workpiece.
Particles, dust or sparks from cutting are
then collected by the guard and directed
away from the operator. By using the
knob the guard can be loosened and
adjusted to the desired position.
Turning of the cutting arm
When the cutting arm is in Its normal
position. the cutter disc Is held in
position b) means of a screw with a
right-hand thread (a) while the cutter
arm attaching screw lb) has a left-hand
thread This facilitates cutting close to
The cutter arm is loosened in the
same way as when changing the drive
belt, see page 16. Loosen also the
knurled knob and the screw retaining
the stay. Turn the protective casing
through 1800. Fit the drive belt on the
engine and then on the cutter arm so
that the screw on the stay fits into the
lower hole in the crankcase.
It h db Fitth
The disc is located between the
flange hub (a) and the flange washer
(b). Turn the flange washer round
so that it fits into the flange hub.
The cutter disc should be tightened
by using the fixed wrench
505381317 that is included in the
tool kit. Support the shaft with/ the
spark plug wrench. The disc is to be
ti ht d l k i b t if th tt
4152
Vee-belt K1200
To stretch the belt, loosen the screw retaining
the cutting arm by turning clockwise using the
socket wrench included in the tool set and rotate
the cutter disc a few turns by hand, When the
screw has loosened slightly, stretch the belt by
using the automatic belt tensioner.
Replacing the vee-belt
K1200,
To replace the belt, remove both the casings on the
cutting arm Loosen the screw (at the arrow) holding the
cutting arm
Turn the eccentric counter-clockwise by using the spark
plug wrench so that the tension on the spring is released
The cutting arm can then be pressed back and the belt
removed
The belt tensioner consists of a powerful spring
tensioned by turning the eccentric clockwise as much as
possible The belt will then be tensioned by the spring
power exactly as much as necessary.
A new belt should be tensioned after 1-2 refillings of the
fuel tank Thereafter check the tension daily.
Fuel mixture
The engine is lubricated by the oil in the fuel mixture.
Petrol (gasollne)
1. Use "regular" petrol (gasoline). Premium grade
is not necessary.
Oil
1. For best performance use Partner-oil. Mixture
ration 1:50 02 %).
2 If no Partner oil is available, other two- stroke oil
of good quality can be used Mixture ratio 1:25 (4
%).
3. Never use multi-grade oil (10W-30) or any oils
formulated for 4-cycles engines. The petrol
(gasoline) and the oil must be thoroughly mixed
before being put into the fuel tank Always shut
the engine off before filling the tank.
Fuel tank
The fuel tank must be protected from Impurities when
filling up with fuel. This decreases the risk of running
Interruptions caused by blockage of the fuel tank filter.
The filter cartridge cannot be cleaned but must be
replaced if it becomes blocked This replacement should
be done once a year.
Controls
A Stop control. When the button is pressed
backwards, the engine stops. The button remains in this
position and must be returned to its initial position before
the engine is started the next time.
B Choke button. A cold engine is to be started with
the choke flap closed (the button pressed backwards). A
warm engine is as a rule to be started without choke.
C Starter throttle catch. Press in the throttle
control and thereafter the starter throttle catch. Release
the throttle control and the throttle is blocked in half
throttle position. The catch is released when the throttle
control is pressed in all the way.
D Throttle control. The throttle control is used to
regulate engine speed and the speed of the cutter disc.
E Idling catch. This catch will prevent the throttle
from opening accidentally when the engine is at Idling
speed. When working with the machine the catch is re-
leased by the hand holding the rear handle.
4153
Starter unit
Replacing the starter cord
Loosen the fan casing. Pull out the starter cord a little
and prevent the cord drum from rotating back. Place the
starter cord in the recess and let the cord drum rotate
back.
Loosen the lock spring and lift up the cord drum. Pull the
new starter cord through the hole In the cord drum and
further through the fan casing to the starter handle,
where the cord is secured by a knot.
Attach the other end to the cord drum. Take up a few
turns of the cord and fit the cord drum. Tension the
starter spring by giving the cord drum one or two turns
clockwise. Pull the starter cord to make sure that the
starter unit functions before screwing the fan casing into
position.
Replacing the starter spring
Follow the same procedure as described above for
replacement of the starter cord Then loosen the screw
holding the spring cassette to the fan casing.
Place the eyelet of the spring into the cord before the
fitting. In order to guarantee dependable functioning of
the starter unit, the cord drum bushing and the starting
hooks should be lubricated with silicon oil or similar
lubricant at least once a month.
Correct starting position and starting of the
machine
Due to the setting of the throttle, ’the disc will start to
rotate as soon as the engine fires so be sure that you
and the machine are firmly positioned when starting. Pull
the starter cord out smartly a few times until the engine
starts
Air filter K1200,
The air filter systems consists of a pre-filter (1). a main
filter (2) and a spill filter (3) The spill filter may only be
replaced by an authorized workshop.
The pre-filter can be changed without using any tools
and is easy to clean. It protects the main filter from
becoming blocked too quickly.
The pre-filter must be pulled off and shaken clean in
connection with every tankning operation. The pre-filter
should be thoroughly washed or replaced after 30 hours
of operation in steel material or after 20 hours of
operation in concrete or similar material which gives rise
to intensive dust.
Remove the main filter by loosening the nuts retaining
the filter housing and lifting off the housing. The main
filter is a paper unit of a special quality grade which must
not be washed or blown clean. The filter may only be
shaken clean. Washing, blowing clean or attempts to
clean the filter by using tools damage It to such an extent
that it is ruined.
When cutting steel, change the filter after about 60 hours
of operation and when cutting concrete after about 40
hours of operation. More frequent changing should be
carried out when working under more severe conditions.
NOTE! Incorrect servicing or neglect to change the
pre-filter end main filter at the specified Intervals can
result In engine break-down.
Removing the spark plug, K1200/K850:
Loosen three screws retaining the cylinder casing. Then
lift off the cylinder casing together with the air filter.
Loosen the spark plug by using the socket wrench in the
tool kit
.
Carburetor
When delivered from the factory the carburetor Is basicly
set. This means about ’/4 turns open on both the high-
speed screw (H) and the low-speed screw (L). The idling
screw (t) is to be screwed in 1/2 turns after contact with
the throttle shaft lever. After the saw has been run warm
the carburetor is ready for fine adjustment. The low-
speed screw (L) is to be set so that the engine does not
stop at idling speed. The high-speed screw (H) is to be
set so that the engine runs well at full
speed. Then open the screw ’14 turns. The carburetor
Is fitted with an excess speed governor to prevent
excessively high engine speed, which would result in the
cutter disc turning too fast. At full speed and with
unloaded disc you can hear clear variations of the engine
speed. This is normal and only a sign of the fact that the
speed governor is working. The idling screw (t) is set so
that the engine runs at Idling speed without the disc
rotating.
.
4154
Maintenance scheme
The following is a summary of various measures mentioned in the book and which Is essential for the correct servicing of
the cutting machine The time intervals mentioned should be applied if the cutting machine is used for at least 4 hours
every day If the machine is used for a shorter time each day. the shortest intervals can be extended without any ill effects.
Unit on cutter Operation Frequency
Guard Check function always
Controls Check function always
Starter unit Clean and lubricate moving parts every month
Air filter
Pre-filter Shake clean at every tanking
operation
Main filter Clean - replace see page 25 and 27
Spill filter Clean - replace by authorized workshop
Carburetor Check, adjust when necessary
Spark plug Check and adjust electrode gap when necessary
Replace every other month
Engine Clean cooling vanes every other week
Vee-belt New belt to be tensioned after 1-2 refillings
thereafter check belt tension daily
Fuel tank Replace filter cartridge at least once a year
Screws, bolts and nuts Check tightening every week
4155
Technical data
Engine
air-cooled, two-stroke
capacity
Ignition system
transistor Ignition system
spark plug
electrode spark gap
Carburetor
speed governor
range of regulations
Fuel
oil mixture ratio
with PARTNER oil
tank capacity
K1200
100 c.c
Electrolux
Champion CJ7Y
0.8 mm (.031”)
Tilloston HS-175 B
9.600 + 400
4% (1:25)
2% (1:50)
1.0I (1.76 Imp. pints -
2.12 US pints)
CUTTING EQUIPMENT
Cutter disc Gear ratio Max. peripheral speed
12" (K1200) 1:17 100m/s 100m/s
4156
4157
Table of contents Page no.
Foreword ....................................................................................................................................................................4159
Part of the Cut-Off Saw
Gasoline ......................................................................................................................................................................4161
Electric 4162
The. Operator
Physical condition .......................................................................................................................................................4163
Personal Safety Equipment.........................................................................................................................................4163
Checking the Cut-Off Saw Before Use
Attachment ..................................................................................................................................................................4164
Drive Shafts & Flanges................................................................................................................................................4164
Cutter Wheel ...............................................................................................................................................................4164
Cutter Wheel Size .......................................................................................................................................................4164
Reducing Bushings......................................................................................................................................................4164
Blotters 4164
Securing the Cutter Wheel ..........................................................................................................................................4164
Guard...........................................................................................................................................................................4164
V-Belt/Belt Covers .......................................................................................................................................................4165
Handles .......................................................................................................................................................................4165
Vibration Isolating Elements........................................................................................................................................4165
Air Flter4165
Controls .......................................................................................................................................................................4165
Cooing Passages ........................................................................................................................................................4165
General4165
Cutter Wheels ............................................................................................................................................................4166
Abrasive.......................................................................................................................................................................4166
Areas of Use
Masonry.......................................................................................................................................................................4166
Metal Wheels...............................................................................................................................................................4166
Special Wheels............................................................................................................................................................4167
Care and storage of.....................................................................................................................................................4167
Inspection ....................................................................................................................................................................4167
Bursting Wheels ..........................................................................................................................................................4167
Diamond blades ..........................................................................................................................................................4167
Design .........................................................................................................................................................................4167
Characteristics.............................................................................................................................................................4168
Cooling of ....................................................................................................................................................................4168
Direction of Rotation....................................................................................................................................................4168
Protecting your Investment..........................................................................................................................................4169
Carbide Tipped Blade..................................................................................................................................................4169
Special Safety Precautions..........................................................................................................................................4169
Putting the Cut-Off Saw Into Use.............................................................................................................................4170
Fueling.........................................................................................................................................................................4170
Starting ........................................................................................................................................................................4170
4158
Guard...........................................................................................................................................................................4171
Cutter Wheel ...............................................................................................................................................................4171
Working Technique .....................................................................................................................................................4172
Wet Cutting..................................................................................................................................................................4172
Sharpening of the Wheel.............................................................................................................................................4172
Vibrating Wheels .........................................................................................................................................................4172
Reactive Forces ..........................................................................................................................................................4172
Kick-back.....................................................................................................................................................................4173
Pull-in...........................................................................................................................................................................4174
Pinching/Rotation ........................................................................................................................................................4174
Muffler and Exhaust Gases.........................................................................................................................................4175
Maintenance 4175
Safety Regulations....................................................................................................................................................4176
Foreword
Cut-off saws have proven themselves to be very useful and versatile for many jobs - from everyday industrial work where
the saw facilitates and makes possible certain jobs, to dramatic rescue work where cut-off saws can save lives. The
following Instructions are intended to provide guidelines and advice with respect to the use and handling of the cut-off saw
with the accent on safety. The instruction book and the workshop manual provide detailed technical information for each
individual model.
Due to their special importance, certain sections of this book have been highlighted. However, that does not mean that the
remaining text is less important and can be ignored. All instructions should be carefully read and understood. Do not
hesitate to call your dealer if you do not fully understand the text or if more information is needed. Since safety regulations
can vary between different countries and states, you must always contact the local authorities and carefully follow their
regulations.
This manual covers both gasoline and electrically powered cut-off saws. When an instruction only applies to one of the
two, that will be indicated by a "G" (gasoline) or "E" (electric). All repair work, over and above routine servicing specified in
the instruction book, may only be carried out by an authorized service workshop. For safety reasons, only genuine parts
should be used for repair purposes.
Under no conditions may a cut-off saw be modified from its original design except with the permission of the
manufacturer in writing. Non-authorized modifications can lead to serious injury or death to yourself or others.
ELECTROLUX MOTOR
3
4159
4160
Parts of the cut-off saw
GASOLINE POWERED CUT-OFF SAW
Definition:
1. Cutter wheels. Are available in three major types: abrasive wheels, diamond blades, and carbide-tipped blades.
2. Guard. Provide protection against sparks and particles thrown off when cutting.
3. Knob for Guard. Together with 17, the knob locks the guard in position. To adjust the guard, knob 3 and 17
have to be loosened.
4. Front handle. Handle bar for the left hand at the front of the saw.
5. Stop Control. Lever for stop control. When lever is pulled backward, the engine stops.
6. Choke control. Lever for choke control. When lever is pulled backward, the engine is choked. (Starting position,
cold engine.)
7. Safety Throttle Lock. Must be depressed before the throttle trigger can be activated. Prevents accidental
acceleration.
8. Rear Handle. The support handle for the right hand. Incorporates throttle trigger and safety throttle lock.
9. Vibration Rubber Elements. Isolate the handles from the vibrations of the engine.
10. Throttle trigger. Controls speed of the engine.
11. Starting Throttle Control. To be activated when starting a cold engine. Is released when the throttle trigger is
pressed.
12. Drive Flange. Transmits the torque from the drive shaft to the cutter wheel.
13. Starter Grip. The grip of the pull starter which is the device to start the engine.
14. Air Filter. Cleans the incoming air to the cylinder.
15. Muffler. Attenuates exhaust noises and diverts exhaust gases in the required direction.
16. Belt Covers. Protects the operator from getting caught in the V-belt as well as protecting the belt from dust and
water.
17. V-belt. Transmits the power from the engine to the cutter wheel. (Not Illustrated.)
18. Cutting Arm. Attaches the cutting equipment to the power head.
19. Knob for Guard. Together with 3, the knob locks the guard in its position. To adjust the guard, knob 3 and 17
have to be loosened.
20. Belt Tensioner. Should be loosened to adjust the belt to proper tension.
21. Clutch. Couples engine to drive wheel when engine is accelerated beyond idle speed (not Illustrated).
22. Fuel Filler Cap. For closing the fuel tank.
Note:
Different models may have different parts and controls.
See your specific model Instruction Book for details.
PAGE 4162 DELETED 4161
5
The Operator
Physical Condition
Never use a cut-off saw without having received Instructions for its use. If not handled properly and with care, a cut-off
saw can be a dangerous tool. Operation of a cut-off saw should be restricted to mature, properly Instructed adults.
Don’t work when tired under stress, fatigue or under the influence of medicine, drugs or alcoholic beverages.
Be alert, If you get tired while operating the cut-off saw, take a break. Tiredness may result in loss of control.
Personal Safety Equipment
Clothing must be sturdy and snug-fitting but allow complete freedom of movement. Protect your hands with gloves. Heavy
duty, non-slip gloves improve your grip and protect your hands.
Good footing is most important. Wear sturdy boots with non-slip soles. When working with a carbide tipped blade, steel
toed safety boots shall be used.
Proper eye protection is a must. Use approved goggles or full face shield. Wear approved helmet to protect your head.
Hearing protectors are recommended if the cut-off saw is to be used over an extended period of time (more than 30
minutes per day).
A breathing mask should be used if you are cutting material which gives rise to a large amount of dust.
Leg protectors can protect your clothes from bums by sparks generated when cutting steel.
Checking the cut-off saw before use
Checking the cut-off saw before use
Competent persons shall be assigned to the inspection and care of the cutting-off machines. Such persons shall be fully
instructed in the use, care, and protection of the machines as defined in this manual.
Attachment
Never modify a cut-off saw in any way. Only attachments supplied by Electrolux Motor or expressly by approved
by Electrolux Motor for use with a specific cut-off saw are authorized. Although certain unauthorized
attachments may be usable with the powerhead, their use may, in fact, be extremely dangerous.
The following inspections should always be carried out on the saw before it is to be used.
Drive Shafts and Flanges
The drive shaft must be checked to ensure that its threads are not damaged. The contact surfaces on the cutter wheel
and flanges must be flat, run true on the arbor, and be free from foreign objects. Do not use flanges that are of different
size, warped, nicked, sprung or not clean.
Cutter Wheel
Check that the wheel you intend to use has been approved for hand-held portable high speed cut-off saws and that the
maximum operating speed established for the wheel is
PAGE 4162 DELETED
4163
7
not exceeded by the cut-off saw. Immediately before installation, all wheels shall be closely inspected to make sure that
they have not been damaged in transit, storage, or otherwise. Cracked wheels or wheels that show any evidence of
abusive handling or storage shall not be used.
Apart from visual inspection, the following test can be used for abrasive wheels. Support the wheel at the center hole and
knock lightly with a piece of wood on the side of the wheel. If there is no ring to the noise, or if the noise sounds
cracked, then the wheel is damaged in some way and may not be used. Do not use a wheel that has been
dropped. The impact may result In breakage.
A diamond or carbide-tipped blade which has lost one or more of its segments (tips) may not be used. Do not discard
such a blade. In many cases, it can be repaired. Contact your dealer for more information.
Cutter Wheel Size
Never use a cutter wheel that is larger than the size for which the guard is dimensioned. The cutter wheel must rotate
freely under the guard and must not chafe anywhere.
Cutter wheels are normally available in three different sizes of arbor holes (the center hole in the wheel): 20 mm, 7/8" (22.2
mm), and 1" (25.4 mm). The hole and the drive shaft must match each other.
There must be a tolerance of 0.2 mm (.010 inch) between the drive shaft and the cutter wheel’s center hole in order to
avoid the wheel being subjected to any thrust forces in connection with assembly. If the wheel fits too loosely on the arbor,
it can become badly out of true and will noticeably "pound". Do not force a wheel onto the cut-off saw or alter the size
of the arbor hole. Do not use a wheel that fits too tight or too loose. If the wheel doesn’t fit the cut-off saw, get one
that does. It is also possible on cut-off saws to change the size of the arbor or to use a reducing bushing.
Reducing Bushings
If a reducing bushing is used in the cutter wheel’s center hole, it must not be wider than the thickness of the cutter wheel
and must not come into contact with the flanges. Loose reduction bushings, which are not retained in position
mechanically, should not be used together with cutter wheels which are thinner than 3 mm (1/8"). Only an appropriate
reducing bushing may be used to compensate for an oversized hole.
Blotters
Mounting of cutter wheels should incorporate the use of blotters. They should be made of highly compressible material
such as blotting paper, and should not exceed 0.5 mm (.020") in thickness.
Securing the Cutter Wheel
Be sure the flanges are tightened sufficiently to drive the wheel and to prevent slippage, but not too tightly to avoid
springing the flanges and changing the pressure area.
Guard
The guard must be inspected for cracks or other forms of damage. During wet cutting in concrete, the inside of the guard
can become clogged by concrete dust. Similar build-up can take place when cutting asphalt or tar paper. The deposits
must be removed before a new wheel is installed. Check that the guard moves easily and the locking mechanism
functions so that the guard can be moved to different positions and securely locked. Always have the guard property
adjusted to the work you intend to carry out
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V-belt/Belt Covers (G)
Keep the V-belt properly tensioned. Too loose or too high tension will drastically reduce the life length of the belt. Always
protect yourself and the belt by having the belt covers property mounted. Fingers and/or clothing can get caught in an
exposed belt; and as a result, an injury can occur. The covers also protect the belt from exposure to dust, water and other
impurities. The protection will increase the life length of the belt.
Handles
Check that handles are well tightened and not cracked. Keep the handles dry, clean and free from fuel and oil.
Vibration Isolating Elements (G)
The rubber elements may not be seared or noticeably damaged by exposure to fuel and oil. Damaged vibration
elements impair the control of the cut-off saw and may cause you to lose control while working.
Air Filter (G)
A clean air filter gives the engine more power and reduces the fuel consumption. Clean prefilter every time when
refueling.
Controls (G)
The throttle control must move freely. The carburetor must be adjusted so that idling speed is below clutch cut-in speed.
With the wheel off-load and the throttle fully opened, the speed of the cutter wheel must not exceed that in the
recommendation.
When pulled backward the stop switch must stop the saw. The safety throttle lock may not be put out of service by taping
it down or through any other means.
(G.E.) Non-working controls imply a safety hazard. You must not run the saw unless all controls work properly. If
necessary, have the saw adjusted by an authorized workshop.
Cooling Passages
Keep all cooling passages and cylinder vanes (G) free from deposits. Clean passages mean lower engine temperature
and longer life.
General
Check power head and the cutter arm for wear and cracks. Check that all the screws are well tightened. Regular
maintenance must always be carried out in accordance with the instruction book for each individual model.
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Cutter Wheels
Cutter wheels are available in three basic types: abrasive wheels, diamond blades and carbide-tipped blades. Electrolux
Motor branded wheels and blades are specially manufactured for hand-held portable high speed cut-off saws. If another
manufacturer’s wheel is used, you must make sure the wheel meets all regulations and standards relating to this kind of
hand-held portable high speed equipment. Under no circumstances may the maximum operating speed established
for the wheel be exceeded.
Certain wheels for special purposes are available which meet the peripheral speed requirements but may not be
used for HAND-HELD PORTABLE HIGH SPEED CUT-OFF SAWS. Such wheels may only be used in stationary
equipment They may be used together with attachments such as the rail cutting attachment- However, in cams
like this, you should always contact your local authorities to make certain that you follow regulations and
standards which pertain to your area.
ABRASIVE WHEELS
The cutting material in abrasive wheels consists of abrasive grains held together by organic bonds. The term reinforced
as applied to cutting-off wheels defines a class of organic wheels which have webbing fabric or filament that provides
resistance to total breakage at the designated maximum operating speed should the wheel become cracked or damaged.
The term reinforced does not apply to wheels which have webbing fabric or filament around the flange area only.
The wheel’s performance is determined by:
Type of grinding particles
Size of grinding particles
Type of bonding material
Hardness of bonding material
An operating condition which causes a wheel to have shorter life and faster cutting rate is said to make the blade act
softer. A blade with longer life and slower cutting rate is a harder acting blade.
Choice of abrasive wheel should be made according to the best wheel economy. Low priced wheels often have a poor
cutting capacity and a short life expectancy. Due to that, their cost per square inch of cut material is very high. The best
economy is usually achieved when a high-quality wheel is used.
Areas of use
Masonry Wheels
Can be used to cut concrete, asphalt, stone, masonry, cast iron, aluminum, copper, brass, cables, rubber, etc. This type
of wheel is a good all-around wheel with good economy. It can, for example, be used in reinforced concrete with a high
content of steel. Water spraying of the wheel during work to decrease dusting is recommended and will increase the life
length of the wheel.
Metal Wheels
Intended for steel, steel alloys and other hard metals. Without competition in this area. The wheel performs poorly in
concrete or similar masonry material. Water spraying will decrease the cutting capacity and is not recommended.
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Special Wheels
If your work requires a lot of cutting in the same material, it is often economical to get a wheel that has been specially
designed for that kind of material. An example is the rail cutting wheel. This wheel has been specially designed for the
quality of the rail material. It provides good life length and high cutting speed. A standard wheel for metal will also cut the
rail but much slower and with poor economy.
The Care and Storage of Abrasive Wheels
Great attention must be paid to the care and storage of abrasive wheels in order to prevent them from being damaged
during handling. Thin, abrasive wheels with organic bonding agents must be stored on a level, firm surface and must not
be subjected to heat or moisture. If an abrasive wheel is delivered with a fitted cardboard blotter, then a suitable spacer
must be placed between the wheels to keep them flat. Abrasive wheels must not be stored in such a way that will expose
them to high air humidity, moisture, other fluids or temperatures below the freezing point. Avoid storage at such low
temperatures which can result in condensation on abrasive wheels when they are moved from storage to the working site.
After the work has been completed, the wheel should be removed after its use and properly stored. If the wheel remains
on the cut-off saw, there is a great risk for wheel damage during transport.
Inspection
Immediately after a pack has been opened, all the abrasive wheels in the pack should be thoroughly inspected in order to
determine that they have not been damaged during transport, storage or in any other way.
Bursting Wheels
Abrasive wheels for use on hand-held portable high-speed cut-off saws belong to a class of extremely strong wheels which
are difficult to break under normal conditions. If an abrasive wheel has failed (burst), a thorough investigation must
therefor be carried out by the operator to determine the cause of the breakdown so it does not need to happen again. If
more assistance is needed, the abrasive wheel manufacturer or the cut-off saw manufacturer must be contacted. Since
the more common causes of wheel breakage have been traced to use of wrong wheel, improper mounting, Improper
speeds, abusive operation, and/or careless handling of the saw or of the wheel, proper and regular maintenance, service
and inspection procedures obviously are of great importance in preventing wheel breakages. Regular inspection and
maintenance procedures must, of necessity, be the responsibility of the user.
DIAMOND BLADES
Used properly, the diamond blades provide both better performance and economy. The diamond blade gives good cutting
economy in all masonry materials. Its high cutting capacity also makes the diamond blade suitable for work in reinforced
concrete where the blade economy with an abrasive wheel is less beneficial. Normally diamond blades shall-not be used
for metal cutting.
Design
In principle, diamond blades have the same composition as an abrasive disc. Industrial diamonds are held together by a
bonding material. Initial cost of a diamond blade is primarily dependent on the diamond content. A popular misconception
is that diamond content and performance are directly proportional. This does not always hold true. In
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practice, there are an optimum number of diamond particles of a specific grit size in a specific metal bond which will
provide optimum performance for a specific application. On many applications, lower cutting costs are obtained by using
lower, rather than higher, diamond concentration which, in some cases, will not cut at all.
Characteristics
Compared to an abrasive wheel, a diamond blade has the following features and benefits.
Features Benefits
Less cost per cut compared to using Reduced material and labor costs for
abrasive wheels the contractor
Faster cutting than abrasive wheels Less time spent cutting
Reduced labor costs
Less operator fatigue
Increased productivity
Substantially reduced number of blade Eliminates wasted labor and time
changes compared to abrasive wheels Increased productivity
Diamond blade maintains constant depth Eliminates waste caused when abrasive
of cut wheels are thrown out before they are
completely worn out
Increased profits
Less dust than high-speed abrasive Improved working conditions
wheels
Cooling
Heat is the number one enemy of a diamond blade. If the heat becomes too high, the joints may melt, and the segment
will be thrown away with great force. This implies a safety hazard which may result in possible injuries.
Cooling the blade through continuous water sprinkling increases the life expectancy of the diamond blade considerably.
This is also true for blades designed for dry cutting. The life length for dry cutting blades can be extended if the work is
executed in short cycles where the blade is given an opportunity to cool off somewhat between the work cycles.
This is especially true when working in hard materials. To cool the blade periodically by sprink-
ling water on the blade must be avoided as rapid changes in temperature will shock the diamonds and lower the life of the
blade.
Direction of Rotation
Most diamond blades must run in a specific direction of rotation. Look for an arrow stamped in the blade. If the blade is
run in the opposite direction, the blade may be ruined.
Protect Your Diamond Blade Investment
Your diamond blade will be a good investment only if you take care of it.
Do not run the blade in the wrong direction.
Do not bump the blade into the workpiece.
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Do not wedge the blade in the cut.
Do not force a blade that has lost its cutting ability. Have it resharpened. See page 16.
Do not cool by periodically springling with water. You will only shock the diamonds.
Do not keep the blade on the saw during transport. It may be damaged.
Do cool the blade by constant water spraying.
CARBIDE-TIPPED BLADES
Abrasive wheels and diamond blades work primarily through an abrasive action. The carbide-tipped blade has carbide tips
brazed to a blade of steel. The cut material is carried away in a cutting action rather than an abrasive action. The blade is
suitable for cuts in aluminum, sheet metal, etc., or when you need to cut many different materials at the same time. It is
primarily used for rescue work when speed is important, and you have to quickly open an airplane body or make an
opening in roofs and doors in fire fighting. It should only be used by specially trained and educated personnel who are
familiar with the operation of carbide-tipped blades.
Due to its design, the blade can throw large particles of the work piece a long distance. if the blade is forced into the
material too fast or if the material suddenly changes hardness; e.g., a heavy nail embedded in a wooden beam, one or
more of the tips can come loose. This can happen during normal operation. Those tips or particles from the work piece
will be thrown away with great force. If such a tip were to hit an unprotected eye or other exposed part of the body, severe
injury could result.
This type of blade is more subject to kick back than other cutter wheels Please refer to Page 16 for more detailed
information about this safety hazard.
Local regulations in certain areas prohibit the use of carbide-tipped blades except when used under special circumstances
such as fire fighting or other rescue operations, and no other means are available. Check with your local authorities to
conform with all regulations.
Special Safety Precautions
When using a carbide-tipped blade, the following safety precautions must be followed in conjunction with those mentioned
elsewhere in this manual.
1. Only personnel who have received special instruction in the use of carbide tipped blades shall operate the cut-off saw.
2. The carbide-tipped blade shall only be used when the situation warrants such use.
3. The operator must use a helmet with a full face shield.
We also strongly recommend approved safety goggles to be used In conjunction with the face shield. Steel toed
safety boots shall be used.
4. All personnel assisting the operator must use the same protective equipment.
5. All bystanders not equipped according to (3) above, must be kept at a safe distance as they can be exposed to
thrown-away particles. The safety distance should not be less than 30 m. (100 feet).
6. Beware of kick back. Hold the saw firmly with both hands, and encircle fingers around grips, wrapping thumbs on the
opposite side from fingers.
7. Special attention should be given to the starting procedure. See Page 14.
8. Do not touch a rotating blade.
9. Carbide tipped blades may only be used on cut-off saws equipped with a slipping clutch.
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Putting the cut-off saw into use
Before the machine is started, the necessary safety checks must be carried out. See Page 7. After ensuring that the saw
and the cutter wheel are in good condition and that the maximum cutter wheel speed is not exceeded at full throttle, off
load, the saw can then be used.
Fueling (G)
Your gasoline driven cut-off saw uses an oil/gasoline mixture for fuel. Please refer to your instruction book.
Gasoline is an extremely flammable fuel. Use extreme caution when handling gasoline or fuel mix. Do not smoke
during fueling or bring any fire or flame near the fuel.
Fuel your cut-off saw in well-ventilated areas, outdoors only. Always shut off the engine and allow it to cool before
refueling. Relieve fuel tank pressure by loosening fuel cap slowly. Select bare ground for fueling and move at least 3 m.
(10 feet) from fueling spot before starting the engine. Wipe off any spilled fuel before starting your saw and check for
leakage.
Check for fuel leakage while fueling and during operation. If fuel leakage is found, do not start or run the engine until leak
is fixed and spilled fuel has been wiped away.
Starting (G)
Your cut-off saw is a one-person saw. Do not allow other persons to be near the saw.
Start and operate your saw without assistance.
Place the saw on firm ground or other solid surface in an open area. Maintain a good balance and secure footing.
Be absolutely sure that the cutter wheel is clear of you, all other obstructions and objects, including the ground. To start a
cold engine, starting throttle (half throttle) must be used. The starting throttle will cause the engine to operate above idle
rpm. The engine speed will be fast enough for the clutch to engage the drive wheel and turn the wheel which can cause
an accident if the wheel catches something. Hold the saw with a firm grip. When a heavy diamond or carbide-tipped
blade is used, the saw can be slightly front heavy. When the saw is placed on its support, it may tilt forward until the blade
touches the ground. Before the saw is started, place it on its support to see if it tilts forward. If the saw is front heavy, it
should not be placed on the ground after it has been used until the blade has come to a complete stop. During starting,
when the saw is placed on the ground, the blade will turn until the starting throttle is released. Do not allow the blade to
touch the ground until it has come to a complete stop. (G, E)
When you pull the starter grip, don’t wrap the starter rope around your hand. Do not allow the grip to snap back but guide
the starter rope fully back to permit the rope to rewind property. Failure to follow this procedure may result in injury to
hands or fingers and may damage the starter mechanism. Pull the starter rope out smartly a few times until the engine
starts. Your instruction book gives detailed information as to how your specific model shall be started.
As soon as the engine starts, the throttle should be squeezed slightly to release the starting throttle. The engine can now
assume idle speed.
Warning (G)
When the throttle control is released, it must move by itself to the idling position. When the engine is idling, the
wheel must stop and remain stationary. If the RPM does not return to idle after the throttle is squeezed and
released (release of the
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starting throttle), the cut-off saw must be adjusted. See the appropriate section of your instruction book.
Do not drop start. This method is very dangerous because you may lose control of the saw.
Never attempt to start the cut-off saw when the wheel is in a cut. This can result in “kick-back” and/or damage to
the wheel and implies a safety hazard.
Guard
The guard must be set so the rear section is close to the work piece. Grinding particles and dust are then trapped by the
guard and directed away from the operator.
Under no conditions may the guard be modified from its original design except with the permission of the manufacturer in
writing. Non-authorized modifications can imply considerable safety risk and cause serious injury.
It is strictly prohibited to run the cut-off saw:
- Without a guard;
- with a guard that is damaged;
- with a guard that has an unauthorized modification;
- with the guard not properly adjusted.
Cutter Wheel
When to cutter wheel is new, you should run it at full throttle without load for 30 seconds before putting it to use. The
guard must be in place. This test will reveal any hidden defects. If the wheel wobbles or "pounds” or shows any signs of
cracks, it must be discarded.
Working Technique
The different types of wheels have specific characteristics. The following working techniques are of a general nature.
Check under the instructions for each type of wheel for their individual characteristics.
Best results are obtained if a combination of high wheel speed and high feed pressure are used. Diamond blades require
less feed pressure than abrasive wheels. Too high pressure will lower the wheel speed too much. Too high or too light
pressure will slow down the cutting speed. The gasoline driven cut-off saw gives best performance around 7000-8500
RPM engine speed. The wheel RPM is always lower due to the belt reduction. Always open the throttle fully before you
apply the wheel to the material and regulate the RPM of the cut-off saw by increasing or decreasing the feed pressure.
The abrasive cutting operation generates a great deal of localized heat which causes rapid expansion of the piece being
cut. Move the wheel slowly backward and forward in the cut to get as small surface area and as high surface pressure as
possible.
A small surface area reduces friction induced-heat in favor of a more rapid cutting action. That will also ensure conduction
of heat away from the wheel. If possible, cool the wheel with water when cutting stone, concrete, etc. The results are less
dusting, excellent wheel economy and longer wheel life.
Be sure the work piece is securely held down -- both sides of the cut if practical. The work piece should ways be
supported so that the cut will open when the cut is executed. Beware of “Pinching”, page 18. Start the cut gently at full
throttle. Do not bump or jam the wheel to start a cut. Feed the wheel through the work as fast as possible without slowing
the wheel in the cut. Don't baby the wheel through the cut. Do not catch, wedge or jam the wheel in the cut. That will
increase the temperature and lower the life expectancy of the wheel. It can also cause an abrasive wheel to break which
can lead to possible injury.
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Wet Cutting
Wet cutting is used primarily for two reasons. If the wheel is sprinkled with water, the water will keep the dust down. This
is important for the operator as well as the neighborhood. Water sprinkling also cools the wheel which results in a longer
life length of the wheel. Wet cutting is thus recommended in masonry materials. Wet cutting is not recommended when
metal wheels are used.
The disadvantages with wet cutting, except the extra work with hoses and water tanks, are mainly:
- the operator will be exposed to water;
- problems when working in freezing temperatures;
- the mixture of concrete and water could be damaging, for example, to floors.
When the work is done and the water sprinkling has stopped, an abrasive wheel should be allowed to run at operating
speed for at least 30 seconds before the wheel is stopped. That will allow all water to be thrown off. If a wheel is wet when
stored, the water will gather at the lowest part, and the wheel will become out of balance. The imbalance may be so
severe that the wheel breaks, you lose control of the saw, or both. In any case, this implies a safety hazard which may
result in possible injuries.
Due to the risk for electrocution, wet cutting may, under no circumstances, be used in conjunction with any
electric cut-off saw.
Sharpening of the Wheel
The wheels become dull very fast and lose their cutting ability if the bonding material is not worn away at a proper speed.
This could happen if a too low feed pressure is used or when cutting in heavily reinforced concrete. The steel will polish
the wheel rather than grinding away the binding material. When using a dry cutting diamond blade, it is extremely
important that the blade is kept sharp as the risk for too high temperatures is greater during dry cutting. If you continue to
force a wheel that has lost its cutting ability, this will result in over heating, and if using a diamond blade, eventually the loss
of one or more segments.
Dress (cut) on soft material such as sandstone, silica brick, haydite brick, or similar. The wheel may require additional
dressing (sharpening) if hard material is still being cut.
Vibrating Wheels
If the wheel is jammed into the material or too high feed pressure is used, the wheel may become out of round. This will
cause the wheel to vibrate. Lower the feed pressure until the vibration has disappeared. When a lower pressure is used,
the wheel has a tendency to round itself. If the vibration does not disappear, the wheel has to be discarded.
DO NOT
DO NOT use a wheel that has been dropped. The impact may result In breakage.
DO NOT, under any circumstances, cut with the side of the abrasive wheel. If the side is used, the reinforcing
web will be cut off. Due to the high peripheral speed, large sections of the wheel can be broken off and thrown
away at high speed. This Is a safety hazard and can cause serious injury to the operator or any bystander.
Reactive forces
Reactive forces that may occur during any cut are kick-back, pull-in and rotation. Reactive forces can be dangerous.
With any cut-off saw, the powerful force used for the cutting operation can be reversed and work against the operator. If
the rotating wheel is suddenly stopped by contact with a workpiece, the reactive forces instantly occur.
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These reactive forces may result in Ioss of control which may, in turn, cause injury. An understanding of the
cause of these reactive forces may help you to avoid loss of control.
Kick-Back
Kick-back may occur when the outer quadrant of the wheel contacts the work piece or is pinched. The reaction of the
cutting action of the wheel causes a rotational force of the cut-off saw in the direction opposite to the wheel movement.
This may fling the saw in an uncontrolled arc mainly in the plane of the wheel.
Under some circumstances, the wheel can move toward the operator and may cause severe injury. The greater the force
of kick-back reaction, the more difficult becomes for the operator to control the saw. Many factors influence the
occurrence and force of the kick-back reaction.
- The speed of contact at which the wheel contacts the object. Kick-back forces increase with rate of impact.
- The contact angle between the wheel and the object. Kick-back is most pronounced in the outer quadrant of the wheel.
- Type of wheel used.
Kick back can occur with any wheel. However, due to its design, carbide tipped blades are more subject to kick back and
they also cause a more severe injury if they touch a person.
To avoid kick back
The best protection from personal injury that may result from kick back is to avoid kick-back situations.
1. Hold the cut-off saw firmly with both hands.
Use a grip with the thumb and fingers encircling the handles as shown.
2. Maintain a good balance and secure footing.
3. Avoid cutting with the outer quadrant of the disc.
4. Don’t overreach.
5. Don’t cut off balance.
6. Begin and continue cutting at full throttle.
7. Use caution when reentering a previous cut.
8. Be alert for shifting of the work piece or other forces that may cause the cut to close and pinch the wheel.
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Pull-in
Pull-in occurs when the lower quadrant of the wheel is suddenly stopped or if the cut slowly closes. The reaction of the
wheel pulls the cut-off saw forward causing the operator to lose control.
To avoid pull-in
Same as for avoiding kick back. The reasons for pull in are mostly too low wheel speed or a closing cut. In the latter
case, the work piece is not properly supported.
See “Pinching" below.
Pinching/Rotation
Be alert for shifting of the work piece or other forces that may cause the cut to close or pinch the wheel. If the closing
forces are strong enough, the wheel cannot work itself away from the work piece as in the case of kick back. When the
wheel stops, the reactive forces will, with great force, pull the cut-off saw downwards, rotating around the center of the
wheel.
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To avoid pinching
The work piece should always be supported so the cut will open (not close) when the cut is executed.
Muffler and Exhaust Gases
The noise from a two-stroke engine may cause impaired hearing, especially over a long period of use. Always wear
hearing protectors while working with a cutoff saw. The muffler should be in good condition. A cracked or broken muffler
increases the noise level which is detrimental both to the operator and the neighborhood. When the engine is running, the
muffler is hot and causes bums if touched.
The exhaust gases contain poisonous elements such as carbon monoxide. Only run the cut-off saw in welI-
ventilated areas. Special attention must be given to the danger of carbon monoxide poisoning if working in deep
excavations and trenches. Such poisoning can be fatal.
Maintenance
Please refer to the instruction book for your model which lists necessary maintenance and service work that can be
performed by the operator.
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Safety Regulations
Any person who is to use and/or be responsible for the maintenance of a cut-off saw must be well acquainted with current
safety regulations, the way in which the machine is to be used, and serviced. Use cutter wheels which have been selected
and tested for these types of cutoff saws from the viewpoints of safety, cutting capacity and life length.
1. Never use a cut-off saw unless you have been trained for this purpose. If not handled properly and with care, a
cut-off saw can be a dangerous tool.
Operation of a cut-off saw should be restricted to mature, properly instructed adults. Contact your local authorities
and carefully follow their regulations.
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2. Don’t work when tired, under stress, fatigue or under the influence of medicine, drugs or alcoholic beverages.
3. Do not work alone. Make sure you can contact people in the event of an accident.
4. The following safety equipment must always be used:
- Helmet
- Hearing protectors
- Protective goggles of approved type
- Snug fitting clothing
- Safety footwear
5. Check out the cut-off saw before it is to be used.
Never use a saw that is damaged, faultily adjusted or not completely and securely assembled.
6. The saw must never be used without the guard.
The guard must be adjusted so that its rear section is close to the work piece.
7. Only use cutter wheels that have been approved for hand-held portable high-speed cut-off saws. The maximum
operating speed established for the wheel may never be exceeded. Inspect all wheels before mounting for
possible damage in transit. Do not use a wheel that has been dropped.
8. Always allow newly mounted abrasive wheels to run at operating speed with guard in place for at east 30 seconds
before you start to use them.
9. (G) Always be very careful when handling fuel. Move the cut-off saw at least 3 m. (10 feet) from the fueling spot
before starting the engine.
10. Do not permit anyone to stand close to the cut-off saw when it is running or in use. Make sure spectators or
animals are kept away from the working site.
11. (G) Before starting and using the machine, make sure that you have a secure foot-hold. When the machine starts,
the cutter wheel begins to rotate. This makes it important to stand firmly and ensure that the wheel can rotate
freely. Do not start cutting until you have a clear work area and secure footing.
12. Always hold the cut-off saw with both hands while the engine is running. Use a firm grip with thumbs and fingers
encircling the handles. Keep all parts of your body away from the cutting-off wheel when the engine is running.
13. When the throttle control or switch is moved to the idling position, the cutter wheel must stop and remain
stationary.
14. Keep the handles dry, clean and free from oil or fuel.
15. Do not cock jam or wedge the wheel in the cut.
16. Do not grind on the side of a cutting-off wheel.
17. Do not cause sparks in the vicinity of anything that is flammable.
18. After wet cutting, an abrasive wheel should be run at operating speed for 30 seconds after water sprinkling has
ceased to allow all water to be thrown off.
19. (G) Exhaust fumes are poisonous. Only use the cut-off saw in well-ventilated places. Failure to use the cut-off
saw in well-ventilated areas can lead to carbon monoxide poisoning.
20. The engine must be switched off when the cut-off saw is carried. Make sure the muffler faces away from your
body.
21. The cutter wheel must be removed from the cut-off saw when it is transported or stored.
22. All service with the exception of maintenance service described in the instruction book must be carried out by an
authorized service workshop. Under no conditions may a cut-off saw be modified from its original deign without
the written permission from Electrolux Motor AB. Non-authorized modifications can lead to serious injury or death
to yourself or other people.
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BLACKHAWK
Porto-Power
Operating Instructions
Body Repair Equipment
Printed in U.S.A. 1/85 IS-306
4178
PORTO-POWER SOLVES 1,001
FORCE RELATED PROBLEMS
• Auto Body/Frame Repair
• Heavy Duty Truck Repair & Maintenance
• Construction - Road Equipment - Building, Etc.
• Farm - Fleet Equipment Maintenance
• Rescue
And the list could go on and on.
Your Porto-Power is the world's finest remote controlled hydraulic jack. Porto-Power, with its wide range
of rams and attachments, provides countless combinations for pushing-pulling-spreading clamping and
pressing. It has universal application in all of the above mentioned fields.
Porto-Power has been designed and engineered with unusual thought and consideration to help you solve
difficult problems and make your job easier. The wide variety of field-tested attachments can be
assembled into many combinations providing you with 1,001 valuable aids to make your work more
efficient.
Porto-Power - BIackhawk
are registered trade marks
4179
TROUBLE-SHOOT CHART SOLUTIONS
1. Spongy effect
Air trapped in the hydraulic system easily com-
presses under pressure and causes
spongyness.
To bleed system: Place pump at a higher
elevation than the hose and ram. The objective
is to "float" the air bubbles up hill and back to the
reservoir where they belong. See figure 1.
Figure 1.
Close valve and extend ram as far as possible. Open
valve fully allowing oil and air to return to reservoir.
Repeat this procedure until ram starts to extend on the
first stroke of the handle. Usually two or three times will
do the trick.
2. Ram won’t extend all the way
Usually just low on hydraulic fluid. FILL MARK
ON DIP-STICK. DON’T OVERFILL. Ram
should be fully retracted to check oil level. This
hydraulic unit needs tile prescribed amount of air
chambered in the reservoir, as it works on a
partial vacuum to avoid venting to the outside.
Figure 2.
3. Ram won’t retract
Usually just too much oil and/or air in the system.
Bleed system and fill to proper level. If that
doesn’t correct the problem, inspect closely for a
bent plunger. If neither of these is the cause, the
quick-coupler is probably damaged. Replace it.
TROUBLE-SHOOT CHART
4180
4. Ram leaks down under pressure Make sure
release valve is fully closed. If it still leaks down,
there is probably dirt in the return check ball
valve. Flush the system with mineral spirts or
kerosene. lf the problem still exists, valve is
damaged and unit should go to a Blackhawk
authorized repair facility.
5. Handle kick-back
Dirt in check valve - flush system.
Damaged check valve · should go to Blackhawk
authorized repair facility.
6. Works properly one time, but not the next Loose
dirt or air bubble In valve system. Flush and refill
system.
CAUTION:
DO NOT USE: BRAKE,
TRANSMISSION OR ANY FLUID
OTHER THAN A GOOD HYDRAULIC
OIL. 67070 BLACKHAWK (LX21) OR
EQUIVALENT. FLUIDS OTHER THAN
HYDRAULIC OIL MAY DAMAGE CUPS
AND PACKINGS, CORRODE METAL
PARTS AND VOID YOUR WARRANTY.
FOR AIR OPERATED HYDRAULIC
PUMPS REFER TO INSTRUCTION
MANUAL FOR THAT SPECIFIC
PRODUCT.
FUNCTION:
Porto-Power equipment Is designed to perform many
functions The pump, ram and attachments may be used
to:
Porto-Power is available with either threaded/lock-on or
SS" slip-on tubing and attachments. Threaded/ lock-on
tubing and attachments can be threaded together or
"lock-on" connectors can be used. "SS" slip-on tubing
and attachments are not threaded and just push together
for fast, easy set up.
Adaptors are available to connect one to the other.
CAUTION: When using threaded extensions and
attachments, always thread all the way In. The se offset
attachments reduces the capacity of this equipment by
one-half.
Extreme care should be taken when using extension
tubing and/or offset attachments to prevent damage to
these Items due to overloading.
WARNING
DO NOT OVERLOAD RAM. OVERLOADING CAN
CAUSE CRACKED CYLINDERS, BLOWN CAPS, BENT
PLUNGERS AND RUPTURED HOSES. DO NOT
OVER- EXTEND THE RAM. THIS MAY PUSH THE
PLUNGER OUT OF THE TOP OF THE RAM WITH
!VIOLENT RESULTS. WHEN USING A CHAIN DO,
NOT STAND IN LINE WITH THE CHAIN AT ANY TIME.
DO NOT CROSS TWIST, KINK, KNOT OR SHORTEN
ANY CHAIN WITH A PIN. DO NOT ALLOW RUNNING
LOADS TO PASS OVER CHAINS. DO NOT USE
CHAINS OVER SHARP CORNERS WITHOUT
PROTECTIVE PADDING. DO NOT FORM A LOOP BY
PUTTING THE POINT OF A HOOK INTO A LINK. DO
NOT USE HEAT NEAR OR ON A CHAIN OR ANY
ATTACHMENT. DO NOT USE A CHAIN WHOSE
LINKS ARE TWISTED OR BENT, HAVE, NICKS OR
GOUGES, SHOWS EXCESSIVE WEAR STRETCH OR
SPREAD IN THE LINKS. ANY SUCH CHAIN SHOULD
BE REPLACED IMMEDIATELY. FAILURE TO HEED
THESE WARNINGS MAY RESULT IN DAMAGE TO
THE EQUIPMENT AND/OR FAILURE RESULTING IN
PERSONAL INJURY AND/OR PROPERTY DAMAGE.
TO USE:
Select the best ram suited for your application. Connect it
to the pump and hose by placing the male end of the
coupler firmly into the ram half. Tighten threaded collar
coupler down completely by hand. (Pliers or vise-grips
will damage the seat)
Thread or push on the desired attachments to the
ram.
To extend the ram close the release valve, located near
the hose end of the pump, by turning clockwise until
fingertight. It Is not necessary to overtighten this valve
as this will cause wear or breakage.
To operate the pump hold in the horizontal or vertical
(hose end down) position and pump the handle.
To release the ram and load turn the release knot
slowly, counter-clock-wise.
4181
TO PROTECT THIS EQUIPMENT:
Guard ram threads with protector ring whenever
possible. Protect ram plunger end or threads by using
serrated saddle or other pushing attachments.
Guard against the entrance of dirt and foreign matter into
the system as this may cause pump failure when coupler
halves are disconnected always screw on the dust caps.
IMPORTANT: When applying off-center loads use
extreme caution, and pump carefully. Off-center loads
produce strain on the ram plunger, attachments, and
extension tubes, which may result in equipment failure.
Loads will be off-center when using such attachments
as: Notched Pull Toe, Edge Clamp-Pusher-Head,
Adjustable Body Spoon and Lift Toe. (See figure 3)
Figure 3.
OFF-CENTER LOAD REDUCES CAPACITY
WARNING
HIGH PRESSURE HYDRAULIC OIL CAN CAUSE
PERSONAL INJURY. DO NOT HOLD HOSE OR
FITTINGS IN YOUR HAND WHILE UNDER
PRESSURE.
DO NOT DROP HEAVY OBJECTS ON HOSE. A sharp
impact can damage wire braid of hose leading to
possible failure or personal injury. Avoid sharp kinks and
bends in hose. Periodically, inspect hoses for kinks, cuts
and bulges. Remove hose from service immediately if
the foregoing are observed. Do not carry the pump by
the hose.
Always position set-up so that the hose and Speed-D-
Coupler have clearance when the ram is extended.
Keep your equipment away from excessive heat and
flame such as welding or cutting torches. Such damage
may weaken or damage the equipment, expecially hoses
and flex heads, and could lead to failure or personal
injury.
Do not adjust spring retaining screw located in the
cylinder wall near the bottom, of the 20 and 50 ton rams.
This screw anchors the plunger return spring and is not
adjustable.
MAINTENANCE:
As with any fine tool, care must be taken to keep
equipment clean. Periodically clean and lubricate all
moving parts. Always store equipment in a clean dry
area to prevent corrosion. Repair or replace damaged,
marred or bent extensions and threads before its next
use. One damaged thread and one good thread equals
two damaged threads.
INSPECTION:
Visual inspection should be made before each use of the
equipment, checking for leaking hydraulic fluid,
damaged, loose, or missing parts. All equipment must
be Inspected by a Blackhawk authorized repair facility
immediately if accidently subjected to an abnormal load
or shock. Any equipment which appears to be damaged
in any way, is found to be badly worn, or operates
abnormally MUST BE REMOVED FROM SERVICE until
necessary repairs are made by a Blackhawk authorized
rep r facility. It is recommended that an inspection of
the equipment be made by a Blackhawk authorized
repair facility once a year, and that any defective parts,
decals or warning labels be replaced with manufacturer’s
specified parts. A list of authorized repair facilities is
available from Blackhawk.
OWNER AND/OR USER RESPONSIBILITY:
Owner and/or user must study and keep these
instructions for future use.
OPERATION: The owner and/or user must have an
understanding of these operating instructions and
warnings before using this equipment. Warning
information is very important and should be fully
understood. If the operator speaks or reads a language
other than English, these instructions and warnings must
be read to and discussed with the operator in the
operator’s native language. The purchaser/owner must
make sure that the operator understands its contents.
4182
BASIC SET-UPS USING PORTO-POWER RAMS AND ATTACHMENTS. THE PUSH, SPREAD, CLAMP, PULL, AND
STRETCH SYMBOLS SHOWN BELOW AND ON THE FOLLOWING PAGES TELL YOU HOW EACH SET CAN WORK
FOR YOU. OFFSET LOADS REDUCE CAPACITY BY ONE HALF.
4183
4184
WARRANTY
COMMERCIAL WARRANTY: This equipment is warranted by Applied Power Inc. to the original commercial user- owner
against defective materials or workmanship for a period of 90 days from the date of delivery. Hand jack models 67225,
67226, 67227, 67228, 67229, 67230, 67237, 87239, 67240, 87242, 67245, 67246 and all Porto- Power- equipment and
accessories are warranted for a period on one (1) year from date of delivery. During the warranty period, equipment found
to be defective will be repaired or replaced (at the warrantor’s option) without charge. The equipment must be returned,
transportation charges prepaid, with proof of delivery date to an Authorized Service Center. The repaired or replaced
equipment will be returned with transportation charges prepaid by the Service Center.
This warranty does not cover defects in the equipment caused by ordinary wear and tear, abuse, misuse, overloading,
accident (including shipping damage), improper maintenance, alteration, use of improper fluids, or any other cause not the
result of defective materials or workmanship.
REPAIR OR REPLACEMENT IS THE EXCLUSIVE REMEDY FOR DEFECTIVE EQUIPMENT UNDER THIS
WARRANTY. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, INCLUDING ANY IMPLIED
WARRANTY OF MERCHANTABILITY OR ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE
ON THIS EQUIPMENT. APPLIED POWER INC. SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL OR
INCIDENTAL DAMAGES FOR BREACH OF ANY EXPRESS OR IMPLIED WARRANTY ON THIS EQUIPMENT.
Service parts, warranty, and regular repair service for products are available through a
nationwide system of Authorized Service Centers which are carefully selected by the
Automotive Division. Your distributor or jobber can provide you with a list of Service
Centers in your area.
For additional PRODUCT AND SERVICE Information Contact:
Applied Power Inc.
Automotive Division
P.O. Box 27207
11 333 W. National Ave.
Milwaukee, WI 53227
1-800-558-4558 (Not valid In Wisconsin)
PRODUCT REPAIR: Products for repair should be forwarded to the nearest Service Center.
PRODUCTS FOR REPAIR SHOULD NOT BE RETURNED TO THE FACTORY.
Applied Power Inc.
Automotive Division
PO 80x 27207 4185
INSTALLATION AND SERVICE INSTRUCTIONS
4186
SECTION I
GENERAL DESCRIPTION
Figure 1-1. Mod PA300 Electronic Siren.
The Federal Model PA300 (figure 1-1) is a
precision built, efficient and economical, full-featured
electronic siren of advanced design. It provides wail,
yelp and hi-lo siren tones, as well as the Tap II feature,
public address (PA), radio rebroadcast and an air horn
sound.
The siren may be installed in positive or negative
ground vehicles with 12-volt electrical systems. It is
protected against failure modes (including reversed
polarity) by a fuse that is replaceable without tools. No
components protrude from the bottom of the siren to
interfere with mounting arrangements.
A noise-cancelling microphone is wired-in to prevent loss
or theft. It provides high quality voice reproduction
without feedback "squeal". The microphone push-to-talk
switch overrides any siren signal for instant PA use. PA
and radio volume are adjustable by means of a front
panel GAIN control. Radio interconnect wires are built
in. No additional cables are required.
The Model PA300’s 100-watt output is designed
to drive a single high power speaker.
The Tap II feature allows the driver to change
the siren sound from wail to yelp (or vice-versa) via the
vehicle’s horn ring. Tap II provides especially effective
traffic clearing capability. In addition to Tap II, additional
alternate sounds can be activated in two other selector
switch positions by depressing and holding the horn ring
for as long as the alternate sound is desired. The charts
in Section IV of this manual illustrate the operation of
these features more fully.
Other special features of the Model PA300
include:
o High degree of reliability is
achieved through the use of
integrated circuits and silicon
output transistors.
o Control panel is illuminated with
non-glare lighting.
o Newly designed printed circuit
board provides improved
performance and durability under
a wide range of environmental
conditions.
4187
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SECTION II
SPECIFICATIONS
Input Voltage........................................................................................11VDC to 16VDC (16V operation limited
to 15 minutes).
Polarity..................................................................................................Negative or positive ground.
Standby Current...................................................................................50mA max. (not incl. panel light).
Operating Temperature Range............................................................-300C to +650C.
Operating Current (14VDC-Wail mode)...............................................10 amperes, max.
Frequency Range.................................................................................500 to 1500Hz.
Cycle Rate............................................................................................Wail-10 cycles/min.
Yelp-180 cycles/min.
Hi-Lo-60 cycles/min.
Voltage Output (approx.)......................................................................64V peak-to-peak.
Dimensions (HWD)..............................................................................2-1/2" (6.35cm) x 6-1/2" (16.51cm) x
8-1/2" (21.59cm).
Net Weight (incl. microphone).............................................................4-1/2 lbs. (2.04kg).
Shipping Weight...................................................................................6-1/2 lbs. (2.94kg).
NOTE
The following parameters were obtained with the radio input potentiometer and GAIN
control set at maximum.
Audio Frequency Range.......................................................................300 to 10,000Hz
Harmonic Audio Distortion (300-3,000Hz)............................................10% max. all power levels from 1/2 to 50 watts
(frequency response ±3dB).
Input Impedance (Radio)......................................................................2000 ohms
Input voltage required to obtain 20VRMS
across speaker load (Radio)................................................................0.55VRMS
4188
-2-
SECTION III
INSTALLATION
3-1. UNPACKING.
After unpacking the Model PA300, examine it for
damage that may have occurred in transit. If the
equipment has been damaged, file a claim immediately
with the carrier stating the extent of the damage.
Carefully check all envelopes, shipping labels and tags
before removing or destroying them.
3-2. MOUNTING BRACKET.
The PA300 comes equipped with a swinging
bracket which enables it to be mounted in a variety of
positions. Positioning the bracket above the unit allows
mounting to the underside of the dash. Positioning the
bracket below the unit will permit mounting on any
horizontal surface or, by the use of Federal’s TU-70
Tunnel Mount on the vehicle’s transmission hump.
The unit should be mounted in a position that is
both comfortable and convenient to the operator. Keep
visibility and accessibility of controls in mind. To install
the unit under the dash, determine the mounting location
and proceed as follows (see figure 3-1).
CAUTION.
The unit must be installed in an
adequately ventilated area. Never install
near heater ducts.
A. Use one of the mounting brackets as a
template and scribe two drill positioning marks at the
selected mounting location under the dash.
B. Drill two 1-inch diameter holes at the
position marks.
C. Secure the mounting bracket to, the dash
with (2 each) ¼-20 x 3/4 hex head screws, ¼ split
lockwashers and ¼-20 hex nuts as shown in figure 3-1.
D. Secure the PA300 unit to the mounting
bracket with 1-20 x 3/8 hex head screws and I split
lockwashers.
E. Tilt the unit to the desired position. Tighten
the 1-20 x 3/8 hex head screws.
NOTE: When installing the PA300 on the transmission
hump, a Federal Model TU-70 Tunnel Mount is
recommended. The TU-70 Tunnel Mount is drilled and
tapped for the PA300 mounting bracket.
Follow the installation instructions packed with each unit.
3-3. POWER CABLE INSTALLATION.
The power cable included in the carton is
equipped with a twelve-prong plug (P5) that mates with
the connector (J5) on the rear of the electronic siren (see
figure 3-2). The various wires on the connector must be
connected as described below.
4189
-3-
Figure 3-2. Rear View of PA300.
WARNING
Do NOT connect the siren to the vehicle
battery until ALL other electrical
connections have been completed.
A. Speaker.
The unit is designed to operate with one 11-ohm,
high power speaker.
A speaker is not included as part of the
electronic siren. FEDERAL speakers are weatherproof
and may be installed in any convenient location; on the
roof, fender, behind the grille, etc. Any special mounting
instructions applicable to the type of speaker you have
selected will be found in the speaker carton.
Connect the speaker leads (18 gauge wire) to
the blue power cable leads of P5 (pins 1 and 3) as
shown in figure 3-3.
B. Radio.
To allow incoming radio messages to be
rebroadcast over the outside speaker, connect the two
brown zip cord leads (P5, pins 9 and 12) across the two-
way radio’s speaker.
Figure 3-3. Control Cable Wiring Diagram.
C. Horn Ring.
In order to utilize the Tap II and Press-and-Hold
features of the siren, the following procedure must be
performed.
1. Locate the wire that connects the
vehicle horn ring switch to the horn or horn relay. Cut
this wire.
2. See figure 3-4. Splice the white/yellow
control cable wire (P5, pin 7) to the horn ring side of the
wire that was cut in step 1. Insulate the splice with the
wire nuts (supplied).
CAUTION
The horn ring transfer circuit of the siren
is capable of switching a maximum of 2-
amperes. Some vehicles do not have a
horn relay and, consequently, will draw
more than 2-amperes when the vehicle
horn is activated. Consult your vehicle
service manual or a qualified mechanic
to determine the current required to
activate the horn. If it is less than 2-
amperes, perform the procedure in step
3. If it is greater than 2-amperes,
perform steps 4 through 10.
Figure 3-4. Horn Ring Connections.
4190
-4-
3. Splice the white control cable wire (P5,
pin 10) to the horn side of the cut wire. Insulate the
splice with a wire nut.
4. Obtain a SPST relay of sufficient
contact current capacity to activate the vehicle horn.
Refer to figure 3-4 while performing the following steps.
5. Mount the relay in a suit- able location.
6. Connect the horn side of the wire cut in
step 1 to the relay contact terminal.
7. Determine the "sense" of the vehicle’s
horn ring activation circuit, i.e., does the horn circuit
require a switched positive voltage or switched ground
for activation.
8. Connect the relay wiper terminal to the
positive or negative potential determined in step 7.
9. Connect the white control cable wire to
one end of the relay coil.
10. Connect the other end of the relay coil
to the opposite potential of that connected to the wiper in
step 8.
D. Connection to Power Source.
The PA300 can operate from any 12-volt positive
or negative ground vehicle electrical system. Therefore,
before making any electrical connections, determine the
polarity of the vehicle electrical system ground.
Power for the siren can be obtained from the vehicle’s
power distribution center (Federal’s Model PDC70 is
recommended) or directly from the vehicle battery. If
power is going to be obtained directly from the vehicle
battery, drill a hole in the vehicle firewall for the power
lead to enter the engine compartment. Place a grommet
or similar device in the hole to protect the wire against
damage from rough edges.
CAUTION
When drilling holes on ANY part of the
vehicle, ensure that both sides of the
surface are clear of parts that could be
damaged; such as brake lines, fuel
lines, electrical wiring or other vital parts.
If your vehicle has a negative ground electrical
system, perform the procedure in paragraph 1. Perform
the procedure in paragraph 2, if the vehicle has a
positive ground system.
1. Negative Ground.
a. Connect the green (PS, pin 5) and
black (PS, pin 4) control cable leads to the vehicle
chassis as close as practical to the siren. Scrape paint
away from the selected bolt hole to ensure a good
electrical connection to the chassis.
b. Route the red control cable lead
(P5, pin 6), through the previously drilled hole, into the
engine compartment. Route the wire through existing
clamps and holders toward the battery.
c. To protect the wire when
connected to the battery terminal, use an in-line
fuseholder and 15-ampere fuse (not supplied). The
fuseholder should be installed as close as practical to the
battery. If necessary, additional #14 gauge or heavier
wire can be spliced to the red lead.
d. Connect the in-line fuseholder lead
to the positive (+) battery terminal.
2. Positive Ground.
a. Connect the green (PS, pin 5) and
red (PS, pin 6) control cable leads to the vehicle chassis
as close as practical to the siren. Scrape paint away
from the selected bolt hole to ensure a good electrical
connection to the chassis.
b. Route the black control cable lead
(PS, pin 4), through the previously drilled hole, into the
engine compartment. Route the wire through existing
clamps and holders toward the battery.
4191
-5-
c. To protect the wire when
connected to the battery terminal, use an in-line
fuseholder and 15-ampere fuse (not supplied). The
fuseholder should be installed as close as practical to the
battery. If necessary, additional #14 gauge or heavier
wire can be spliced to the red lead.
d. Connect the in-line fuseholder
lead to the negative (hot) side of the battery terminal.
3-4. AIR HORN PRESS AND HOLD
MODIFICATION.
The unit comes from the factory set so that the
peak-and-hold sound will be heard when the Selector
switch is set to MANUAL and the vehicle horn ring is
activated. To change the sound to air horn, merely move
jumpers JU1 and JU2 from the "PEAK" position on the
P.C. board to the "AIR" position (see figure 3-5).
Figure 3-5. Press and Hold Modification.
3-5. RELATIVE PA LOUDNESS ADJUSTMENT.
After the PA300 is completely installed in the
vehicle, set the Selector switch to MANUAL. Depress
the microphone push to-talk switch, speak in a normal
voice, and adjust the GAIN control for the desired sound
level outside the vehicle. Turn on the vehicle’s two-way
radio and adjust the volume to a comfortable listening
level inside the vehicle. Then set the Selector switch to
radio. Stand outside of the vehicle and note the radio
rebroadcast loudness. If the sound volume is too loud or
too soft, adjust R11 through the hole at the bottom of the
siren (see figure 3-6) to the desired sound level.
After the adjustment is completed, the loudness
of the radio rebroadcast and public address may be
varied with the front panel GAIN control.
Figure 3-6. Relative PA Loudness Adjustment
4192
-6-
SECTION IV
OPERATION
Figure 4-1. Model PA300 Front View.
4-1. GENERAL.
All controls utilized during normal operation of
the Model PA300 are located on the front panel (see
figure 4-1).
The wired-in noise cancelling micro- phone
provides high quality voice reproduction in the public
address mode. The microphone push-to-talk switch will
overide all siren functions, except radio rebroadcast, for
instant PA use.
4-2. GAIN CONTROL.
The GAIN control is used to turn the siren on
and off. Also, it is used to control the volume when the
siren is used for public address or radio amplification.
Clockwise rotation of the knob increases voice volume in
the public address or radio amplification mode. The
GAIN control does not control the volume of the siren
signals.
The maximum clockwise setting of the control
will be determined, in most cases, by the point at which
feedback or "squeal" occurs. This will depend upon the
microphone gain, open windows, speaker placement,
proximity of reflecting surfaces (building or other
vehicles), etc. Adjust the GAIN control to a position just
below the point at which feedback occurs or as desired.
4-3. SELECTOR SWITCH.
The Selector switch is a five-position rotary
switch used to select the mode of operation. The
following are positions on the Selector switch.
A. RADIO.
In this position, incoming radio messages are
amplified by the siren and rebroadcast over the outside
speaker.
B. MANUAL.
In this position, it is possible to operate the siren
by activating the HORN/SIREN switch. The siren can
also be activated by means of an auxiliary switch, such
as the horn ring button (refer to paragraph 4-6).
C. WAIL.
In this position, the siren produces a continuous
"wailing" sound, up and down in frequency.
D. YELP.
In this position, a continuous rapid "warbled"
tone is generated.
E. HI-LO.
In this position, a two-tone sound will be heard. This
distinctive tone may be reserved for any special
indication or situation.
4-4. HORN/SIREN SWITCH.
The HORN/SIREN switch, located on the left
side of the front panel, activates the electronic air horn
sound (up) or peak-and-hold sound (down) in any siren
mode except radio.
4-5. TAP II FUNCTIONS.
Tap II allows the driver to change the audible siren sound
via the vehicle’s
4193
-7-
horn ring. This feature is especially effective for clearing
traffic. The chart below demonstrates how the horn ring
can be used to change the siren sound:
TAP II FUNCTIONS
Selector First Horn Second Horn
Switch Ring Tap Ring Tap
Position Produces Produces
Wail Yelp Wail
Yelp Wail Yelp
4-6. PRESS AND HOLD FUNCTIONS.
Additional alternate sounds can be activated in
two other Selector switch positions, by depressing and
holding the horn ring for as long as the alternate sound is
desired. The chart below shows these additional "Press
and Hold" functions:
PRESS AND HOLD FUNCTIONS
Selector Press on Release of
Switch Horn Ring Horn Ring
Position Produces Produces
Hi-Lo Air Horn Hi-Lo
Manual Peak and Coast down
Hold or and silence
Air Horn or silence
4194
-8-
SECTION V
CIRCUIT DESCRIPTION
5-1. GENERAL.
The Model PA300 circuitry can be divided into
seven functional blocks. Refer to figure 5-1 and 6-4 while
reading the following paragraphs.
5-2. RATE OSCILLATORS AND VOLTAGE
CONTROLLED OSCILLATOR.
The heart of the Model PA300 circuitry is the rate
oscillator and VCO sections. The rate oscillator not only
determines the cycling rate of each siren tone, but also
generates the control voltage that operates the voltage
controlled oscillator (VCO). The VCO generates a
square-wave output whose frequency is directly
proportional to the control voltage. The output of the
VCO is coupled to the siren’s power output amplifier.
The siren rate oscillator consists of an LM556
dual timer configured as two astable oscillators. The first
astable oscillator (IC12A) employs analog switches
(IC10A, IC10B) to select the resistance for the RC timing
network which determines the astable oscillator’s cycling
rate. IC10C, another analog switch, connects the
discharge pin of IC12A to the RC timing network. When
the peak function is called for, the control pin (IC10-6)
goes low putting the switch in a high impedance state
(OFF), and allows the RC rate capacitor (C11) to charge
as the siren tone peaks.
IC12B, another astable oscillator, generates the
control voltage required to generate the air-horn sound.
Normally, IC 12B is held in the reset state (IC12-10 low)
until the air horn control line is pulled high.
Figure 5-1. Function Block Diagram.
4195
-9-
IC8C, a one-of-two analog switch, selects the
siren or air horn control voltage from IC12A or IC12B.
IC8B selects either the RC control voltage (manual, wail
and yelp modes) or the square wave control voltage (hi-
lo) derived from the output of IC12A. The voltage divider
network of R27, R28, R29 and CR8 provides the DC
level shifting of the IC 12A output necessary to obtain the
desired hi-lo tone frequencies.
IC13, a phase-locked loop, contains the voltage
controlled oscillator. C21, R46, R47, R57, and the
control voltage on pin 9 determine the output frequency.
As the siren coasts down in the manual mode,
the output of the VCO must be disabled to prevent
frequencies lower than 350Hz from damaging the
amplifier’s output transistors. IC4D, a voltage
comparator, compares the VCO control voltage to the
low frequency reference voltage set by R40 and R41.
When the VCO control voltage drops below the
reference, IC4-8 goes high and forces the inhibit pin of
the VCO high through OR gate IC9D. The VCO is also
inhibited when the radio or microphone push-to-talk input
is selected. These logic inputs are gated through IC7B,
IC9C and IC9D to the VCO inhibit pin.
5-3. SIREN MODE CONTROL.
The siren mode is controlled by the logic levels
applied to J2-3, 5, 6, 7, 8 and J3-1, 2 and 7 (via Selector
switch SW2), HORN/SIREN switch SW3, and the
microphone push-to-talk switch. IC2 buffers the control
inputs. IC3 and IC9 provide most of the decoding
necessary to control the rate oscillator and analog
switching of the audio and VCO control voltages.
5-4. TAP II CONTROL.
As long as power is applied to the siren circuitry,
the vehicle’s horn ring switch will be connected through
P3-5 and K1A to the inputs of a window comparator
consisting of IC4A and IC4B. A positive or negative horn
ring contact will result in a logic "1" pulse of equal
duration at the junction of CR1 and CR2.
When the siren is in the wail or yelp mode, the
horn ring pulse passes to the input of IC6A, is
"debounced", and then applied to toggle flip-flop IC6B.
Every time the horn ring is operated, the output of IC6B
(pin 5) changes state and inverts the state of the yelp
control line. (The exclusive OR gate contained in IC13
functions as a controlled inverter where a logic "1"
present on pin 3 forces the output (pin 2) to Y or "yelp
not".)
If the Selector switch mode is changed during a
Tap II operation, the circuitry consisting of IC7A, ICSB
and IC7C resets the toggle flip-flop (IC6B) and allows the
true state of the yelp control line to pass to the rate
oscillator section. This is necessary to insure that the
Selector switch position corresponds to the audible siren
tone produced.
NOTE
The reset circuitry relies on the fact that
the Selector switch is of the non-
shorting type.
When the siren is in the manual mode, and JU1
and JU2 are left connected to "PEAK" (factory setting),
the window comparator output will be passed through
AND gate IC5C to activate the peak siren function, as
long as the horn ring switch is depressed.
If manual or hi-lo is the selected mode and JU1
and JU2 are set to "AIR", the window comparator output
will be passed through AND gate IC5D to activate the air
horn override circuitry (refer to paragraph 5-2).
5-5. AUDIO SELECTOR AND POWER AMPLIFIER.
The siren has two audio inputs: radio
rebroadcast and microphone public address.
The radio input is derived from direct connection
to the radio speaker. A fraction of the audio voltage
developed across the radio balance potentiometer (R11)
is applied to the input of a differential amplifier (IC4C).
The differential
4196
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amplifier eliminates any ground reference problem that
may exist between the PA-300 and various makes of
radios. The microphone has a built-in transistor amplifier
and therefore requires no external pre-amplifier.
Resistor R14 serves as the collector bias resistor for the
microphone’s amplifier. The micro- phone output,
derived from J2-1, and the radio audio from IC4C are
selected via 1 of 2 analog switch IC8A. Normally, the
microphone audio is gated through the multiplexer
unless the Selector switch is set to the RADIO position.
The selected audio is applied to IC11-2.
IC11 is an audio power amplifier integrated
circuit which provides the necessary power gain to drive
the push-pull amplifier stages beyond driver .transformer
T1. A biasing network consisting of TH1, CR15, Q4,
R52, R53 and R54 is activated whenever the radio or the
microphone push-to-talk switch is activated. This
eliminates all "crossover" distortion associated with the
push-pull output amplifier.
5-6. 8-VOLT REGULATOR, POWER CONTROL
AND HORN RING TRANSFER.
When the GAIN control (on/off switch) is rotated
clockwise, B+ is applied to the circuit board via J3-4 and
J4-4. The networks consisting of CR4, C6 and CR10,
R36, C17 provide filtering of the B+ voltage for the 8-volt
regulator (IC1) and the audio amplifier (IC11). The large
capacitances employed insure that all control logic
remains stable and prevents "popping" noises heard
through the loudspeaker when power is turned off.
Q1, Q2, Q3 and associated components form
the power-on control circuitry. This network delays the
activation of K 1 approximately one-second after B+ is
applied. During the interim, all siren control logic
stabilizes allowing C 15 to charge, bypassing the primary
of driver transformer T1. This circuitry suppresses loud
turn-on "thumps" from the loudspeaker and allows the
vehicle horn ring switch to operate the siren’s Tap II
feature.
4197
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SECTION VI
SERVICE AND MAINTENANCE
6-1. GENERAL.
Most of the component electronic parts used in
the Model PA300 are standard items that can be
obtained from any radio or electronics supply shop. In
order to reduce equipment down-time, Federal
recommends that the entire printed circuit board (Part
No. 200C860) be replaced. The printed circuit boards
are relatively inexpensive allowing you to keep an
adequate supply in your repair shop.
The diagrams in this section should be an aid to
a repairman in isolating a malfunction and locating
components.
The factory can and will service your equipment
or assist you with technical problems, should any arise,
that cannot be handled satisfactorily and promptly locally.
Communications and shipments should be
addressed to:
Service Department
Federal Signal Corporation
2645 Federal Signal Drive
University Park, IL 60466
If any unit is returned for adjustment or repair, it
can be accepted only if we are notified by letter or phone
in advance of its arrival. Such notice should clearly
indicate the service requested and give all pertinent
information regarding the nature of malfunction and, if
possible, its cause.
6-2. SIREN.
A. General.
Any competent radio repairman or electronic
technician should have little difficulty in tracing and
correcting a malfunction, should any occur. For
emergency replacement of any of the small components,
care must be used when soldering. Heat easily impairs
transistors capacitors and circuit boards. It is therefore
advisable to use longnose pliers or a similar heat sink on
the lead being soldered.
If IC13 or C21 are replaced, it may be necessary
to adjust R57. With the Selector Switch set to MANUAL,
hold the paddle switch in the SIREN position and adjust
R57 for 1400Hz at the siren output.
B. Removal for Servicing.
When removing the chassis for servicing, loosen
the two hexagon head screws on the underside of the
unit, near the front edge. Slide the entire chassis out of
the case as shown in figure 6-1.
C. Removal of Circuit Board.
The PC board is secured to the chassis by four
Phillips head screws. Unplug the four wafer connectors
and microphone before removing the screws.
D. Replacement of Output Transistors
Failure of one or both of the out- put transistors
(Q7, Q8) is usually the result of a defective speaker
(short circuited voice coil). Rebroadcast of unsquelched
radio or music for long periods will also have a
detrimental effect on the output transistors, and is
therefore not recommended.
Federal recommends that both output transistors
be replaced should only one device prove to be
defective. This practice will ensure long periods of
service between failures.
When installing new output transistors, ensure
that the Sil-Pad insulators are installed between the heat-
sink and transistors.
CAUTION
Make certain that the speaker is not
defective prior to installing the repaired
PA300.
4198
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Figure 6-1. Chassis Removal.
Figure 6-2. Internal View
4199
-13-
Figure 6-3. Component Location Diagram.
4200
-14-
Figure 6-4. Schematic Diagram.
4201
-15-
PARTS LIST
Schematic Schematic
Symbol Description Part No. Symbol Description Part No.
*RESISTORS INTEGRATED CIRCUITS
R1,4,14,15 4700 Ohm,5% 100A298 IC1 UA78MO8CKC 128A097
R2,5,6,42,45 100K Ohm,5% 100A262 IC2 CD4050BE 128A092A-01
R3 27K Ohm,5% 100A244 IC3,IC9 MC14071BCP 128B 082
R7,17,18, 19, 10K Ohm 100A207 IC4 LM324N 128A098
22, 33, 44 IC5 MC14081BCP 128A077
R8 68K Ohm 100A235 IC6 MC14027BCP 128A044
R9,12 36K Ohm,5% 100A709 IC7 MC14069UBCP 128A100
R 10,13,20 15K Ohm,5% 100A239 IC8 MC14053BCP 128A099
R11 2K Ohm, Potentiometer 106A203A-01 IC10 MC14066BCP 128A047
R16,30 18K Ohm,5% 100A258 IC1i LM380N 128A046
R21,55 5600 Ohm 100A253 IC12 NAT LM556 128A038-01
R23,31,32, 1000 Ohm 100A233 IC13 MC14046BCP 128B079
34,38
R24 16K Ohm,2% 100A723 TRANSISTORS
R25,29 68K Ohm,2% 100A775
R26 270K Ohm,2% 100A720 Q1 TIS93,PNP 125B133
R27,41 33K Ohm,5% 100A 771 Q2,3,4 TIS92,NPN 125B132
R28 47K Ohm,5% 100A701 Q5,6 2N6109,PNP 125B431
R35 27 Ohm 100A250 Q7,8 2N5885,NPN,Power 125B432
R36,49,50 10 Ohm 100A251
R37 10K Ohm, Potentiometer 106A116 MISCELLANEOUS
GAIN
R39 10K Ohm, 5% 100A257 J1,2,3,4 Connector, Wafer 140A170
R40 56K Ohm, 5% 100A704 J5 Connector, 12-pin 139A152
R43,47 1.5 Megohm, 5% 100A726 H 1,2,3,4 Terminal, Male 233A106
R46 82K Ohm, 2% 100A750 P5 Plug,12-pin 140A154
R48,51 150 Ohm 100A238 K1 Relay,180 Ohm,12V, 131A130A-01
R52 27 Ohm 100A250 DPDT
R53 8.2 Ohm, 5% 100A724 Z1 Resistor Network, 100A801
R54 270 Ohm, 2 watt, 103A128 9 x 10K
Wirewound RT1 Termistor,200 Ohm 104A111
R56 2700 Ohm 100A206 T1 Transformer, Driver 120B 145
R57 100K Ohm,PotentiometeriO6A203A-02 T2 Transformer, Output 120C151A-01
R58 470 Ohm 100A255 F1 Fuse,15A,3AG, 32V 148A107
*Unless otherwise specified, DS1 Lamp,14V,#1893 8107A085
all RESISTORS are carbon SW2 Switch, Rotary 122B215
type, +10%, 1/4 watt. SW3 Switch Paddle 122A214
TB 1 Terminal, Strip 229A127
CAPACITORS Microphone 258B577
Socket, Transistor 138A 125
C1,2,18,22,23 0.001UF,500V,Disc 107A263 (Q7,Q8)
C3,20 10UF,16V,Electrolytic 108A143 Socket, Lamp (DS1) 138A126B
C4,5,13 2.2UF,25V,Electrdytic 108A142 Holder, Fuse (F1) 143A106
C6,17 1000UF, 35V,Elecytic 108A149 Knob, GAIN control 141A102
C7,8,12,16 10UF,10OV,Tantalum 107A634 Knob, Selector 14IAlll
C9 22UF,16V,Electdytic 108A144 Insulator (Q7, Q8) 235A123A-01
C10 0.1UF,35V,Tantalum 107A1103 Circuit Board 130C301B
C11 6.8UF,15V,Tantalum 107A604 (without parts)
C14 0.005UF,1OOV,Disc 107A211 Circuit Board (with 200C860B
C 15 150UF,16V,Elect-rytic 108A147 parts installed)
C19 0.22UF,Radial Tantalum 107A1101 Standoff 230A123
C21 0.15UF,5%,100V,Poly 107A766 Bracket, Lamp 8536A025
C24,25 0.005UF, 100V,Disc 107A211 Bracket, Mounting 8536B 022
C26 500UF, 15V,Electrolytic 108A122 Bracket, Transistor 8537B303
DIODES (Q7, Q8)
CR1,2,3,6, TI55 115B101
7,8,9,11
CR4,5, 10, ED3002S 115B301
13,14,15
CR16 IN4738, 8.2V, Zener 115A232
CR17 Rectifier, 6 amp.50V 115A317
4202
-16-
TM 5-4210-222-14&P-3
By Order of the Secretary of the Army:
JOHN A. WICKHAM, JR.
General, United States Army
Official:
Chief of Staff
R. L. DILWORTH
Brigadier General, United States Army
The Adjutant General
DISTRIBUTION:
To be distributed in accordance with Special List.
U.S. GOVERNMENT PRINTING OFFICE: 1"5 - 38421/01476
PIN: 059727-000
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