Sss

Thank you for selecting Ground Force Manufacturing, L.L.C. as your
supplier of mining and construction support equipment.

Our business is based on providing quality equipment and the service to
support it. Our Parts Department in Post Falls is stocked with the commonly
used parts on your machinery and will be glad to assist you in any way to
provide replacement parts when they are needed, as quickly as you need
them. In addition, trained field mechanics are available to assist your in-house
service personnel should the need arise.

If you have any questions or if we can be of assistance at any time,
please don’t hesitate to call us at (208) 664-9291.

We look forward to a long and mutually rewarding association.

Sincerely,

Ground Force Manufacturing
Documentation Department

Please refer to the following information when calling about service or parts:

UNIT SERIAL NUMBERS: 145-04-001 / 145-04-002

Delivery Date: January 2005

Original Customer: Borusan Makina Kazakhstan

Operation,
Service & Parts
Manual
FUEL / LUBE TRUCKS
Borusan Makina Kazakhstan - Serial # 145-04-001 / 145-04-002

© Copyright 2005, by Ground Force Mfg., L.L.C. All rights reserved. No
part of this manual may be reproduced in any form or by any means
(including electronic storage and retrieval or translation into a foreign
language) without prior agreement and written consent from Ground Force
Mfg. as governed by United States and International copyright laws.

Ground Force Mfg., L.L.C.
E. 5650 Seltice Way
Post Falls, Idaho 83854
(208) 664-9291

Printing History: First Edition - July, 2001
Second Edition - November, 2002
Third Edition – February, 2005

Contents
Part One: GENERAL

Part Two: OPERATION

Part Three: MAINTENANCE / TROUBLE SHOOTING

Part Four: HYDRAULICS / PNEUMATICS / ELECTRICAL

Part Five: PARTS

G3 General defects arising from the selection of materials or the
INTRODUCTION processes of manufacture is limited to the repair of
Your lube truck was built to provide many years of such defects or to the repair or replacement (with a
operation. Durability, ease of operation and high similar item free from the defect in question) of any
speed product delivery have been the goals in the accessory, equipment, or part which is defective in
design of the unit. any such respects.
D. The extent of Ground Force Mfg.’s liability
This booklet will give you the basic operating under this warranty as to defects inherent in
instructions in the use of your new truck. As with design is limited to the correction at its expense
any piece of equipment, each unit will have its own of all such defects becoming apparent in the
individual operating characteristics which will become machine, accessory, equipment or part
familiar to an operator with time. purchased here within six months or 1,000
hours of use, whichever shall first expire.
Should any questions arise while you become familiar E. The warranty of Ground Force Mfg. does not
with your unit please don't hesitate to call us at cover, and Ground Force Mfg. makes no
Ground Force Mfg. Our goal is satisfied customers warranty with respect to:
and we will do all we can to assure we meet that goal. 1. Defects not reported and defective items
not returned to Ground Force Mfg.
within the warranty period;
LW General 2. Failure and damages due to
misapplication, lack of proper
LIMITED WARRANTY maintenance, abuse, improper
A. Ground Force Mfg. warrants that the specialty installation, or abnormal conditions of
equipment it manufactures, including temperature, moisture, dirt or corrosive
accessory equipment and parts manufactured matter;
by Ground Force Mfg., shall be free from: 3. Failure due to operations, intentional or
1. Defects in material and workmanship otherwise, in any improper manner;
furnished by Ground Force Mfg. and 4. Damage caused by components, or
used in the fabrication thereof; parts, or accessories built by others or
2. Defects arising from the selection of which were not manufactured or
materials or processes of manufacture; installed by Ground Force Mfg.
3. Defects in the design thereof in view of 5. Any item which has in any way been
the state of the art on the date hereof. altered by anyone other than an
The foregoing warranty shall apply also to authorized representative of Ground Force
accessories, equipment and parts manufactured to Mfg.
Ground Force Mfg.’s detailed design and 6. Any item damaged in shipment or
specifications and supplied to Ground Force Mfg. by otherwise without the fault of Ground
other manufacturers. Force Mfg.
B. Ground Force Mfg. makes no warranty with Ground Force Mfg. shall in no way be liable for any
regard to component parts not manufactured or expenses incurred by the purchaser in any attempt to
fabricated by it, but agrees to assign to the repair, replace or rework any originally defective item
purchaser all of its rights under any original of sale. Ground Force Mfg. shall in no way be liable
manufacturer's warranty covering such for any losses, costs, forfeiture or damages (including
component parts, and agrees to assist the loss of profits, liabilities of the purchaser,
purchaser in making such contacts with the or its customers, or third persons, and all other
manufacturer of such component parts as may consequential damages), whether direct or indirect,
be necessary to protect its right under the and whether or not resulting from or contributed to by
warranty covering them. the default or negligence of Ground Force Mfg., its
C. In case of defects in materials or workmanship agents, employees and subcontractors, which might
or defects arising from the selection of material be claimed as a result of the defect, use or failure of
or processes of manufacture, such defects the item delivered.
must become apparent in the machine, Except as stated, there is no warranty, express or
accessory, equipment or part within six months implied, in connection with the design, manufacture,
or 1,000 hours of operations, whichever shall sale or use of the machinery, accessories, equipment
first expire after delivery of the machine to the and parts sold by Ground Force Mfg. Ground Force
original purchaser. Mfg.’s liability on its warranty shall in no event
The extent of Ground Force Mfg.’s liability under this exceed the cost of the item of sale.
warranty as to defects in material or workmanship and

PON1a Operation such as hydraulic oil tanks, gear boxes,
IMPORTANT!!! compressor crankcase oil or “Lubricoolant”
tanks, etc. If the unit involves oil-pumping
PRE-OPERATION NOTE equipment (such as lubrication trucks or skids),
Because of strict regulations which govern the
a minimal amount of product oil must be loaded
overseas shipment of equipment, any fluids or oils,
into each particular tank to immerse the suction
which are not pertinent to or necessary for movement
stand pipe. This will guarantee that when the
of this unit, have most likely been removed or drained.
oil product pumps are initially started, there will
This process may have been performed either at
be enough oil to prevent running the pump
Ground Force Mfg.'s facility or prior to loading for
dry.
shipment.
♦ Remove stretch-wrap or shrink film from
Any and all gate valves or ball valves pertaining to
equipment or assemblies. Many times if a
the hydraulic oil tank have been closed to help
particular component needs protection during
eliminate any interior contamination to the tank.
shipment against rough handling, abrasions, or
overall abusive contact, it will be protected by
Any and all valves MUST BE OPENED prior to
means of a wrapping compound or film. This
operation of this unit or severe damage to hydraulic
film, either by itself or accompanied by “bubble
oil pump and hydraulic oil filters WILL occur. Gate
wrap,” cardboard or wood should be removed
valves must be turned fully CCW to open and ball
prior to operation, but not before the final
valves are clearly marked on the handles as to which
stage of commissioning of the equipment.
position is open or closed.

All other fluids and oils must be checked for proper NUB35 Operation
levels prior to operation.
IMPORTANT!!!
New Unit Break-In
PSP1 Operation 1. Check hydraulic pump drive shaft set screws to
IMPORTANT!!! be sure shipping vibration has not loosened
them.
POST-SHIPMENT PREPARATION
This unit has been specially prepared to eliminate the
2. Check pump and air compressor drive shaft
detrimental effects, which occur to equipment in the
coupling set screws daily until they set and no
environment of ocean transport. There are a few
longer loosen with operation.
procedures that may need to be addressed prior to
operation of this unit.
3. Tighten any hydraulic fittings, which may
loosen. Fittings will commonly loosen and drip
♦ Remove any shipping film that has been
the first few weeks of operation.
applied to surfaces. This film is typically
applied by means of a paint spray gun. This is
4. Check oil level on compressor daily.
meant to provide protection directly on non-
painted, machined surfaces such as control
valves, shafts, couplings, cylinder piston rods, POC15 Operation
etc. The film may be removed by simply wiping
down the surface with a rag soaked with PRE-OPERATION CHECK LIST
lacquer thinner or strong grade rubbing 1. Check hydraulic oil level.
alcohol.
2. Check hydraulic oil tank outlet to be sure it is
Because this film is very tacky and is not open.
soluble with water or most oils, all surfaces
must be cleaned thoroughly to prevent the 3. Check product oil tank outlets to be sure they
malfunction of moving parts such as valve are open.
spools.
4. Check general condition of truck.
♦ Check all fluids pertaining to the operation of
not only the truck chassis (if applicable), but 5. Check motor drive couplings.
also the on-board system tanks or reservoirs

6. Check charge on fire extinguishers. Both methods of mounting incorporate an operating
speed of 1400-1800 rpm engine speed. Consult the
7. Be sure all operating controls are "OFF" "Operating Instructions" in section 2 of this manual
before starting truck. for your particular application.
ESO1c Operation
8. Check compressor crankcase oil level. EMERGENCY SHUT -OFF
POC15 Operation
(Continued) PRODUCT PUMPS
9. Check product levels in tanks - make certain This unit is equipped with an emergency shut-off
that there is enough oil or product in tank to valve which enables the operator to disengage the
immerse the pump suction if tank is not in use. low volume product oil product pumps (by pushing
one valve knob) but ONLY in the case of an
DO NOT RUN PRODUCT PUMPS DRY!!! emergency. Such emergencies would include a low
volume oil product delivery hose failing, or if
equipment tank being filled was not monitored and
HPU1a Operation allowed to overflow. In many cases, the emergency
ENGAGING THE HYDRAULIC shut-off is easier and quicker to push than trying to
figure out in a split second which product control to
PUMP shut off. Keep in mind that the purpose of this valve
This unit is equipped with a variable volume hydraulic IS NOT for daily operation and MUST not be used as
pump. There are two distinct methods which Ground (what some operators have, in the past, been
Force Mfg. uses to mount and couple these pumps to considering) a main On/Off control.
the chassis or drive system. These two methods also
determine the procedure to engage the pump.
WARNING!!!
Direct Front Mount
The first mounting method is pump installation ahead This Emergency Valve has been installed ONLY for
of radiator (front mount) between the chassis frame the above mentioned reason in an EMERGENCY
rails. The pump is then connected to the engine situation. This valve does not turn Off all systems
crankshaft dampener via a flexible u-joint driveline. on the unit. If used as a main shut-off during daily
This driveline also includes a slip-spline for any operations, the potential for damage to other
extreme movement of engine due to torque. Since the pumping systems is extremely high. This damage
direct drive line connection means that the pump is will NOT be covered under warranty.
turning continuously with the engine or power unit, a
ball valve has been installed within the pump
discharge line to disengage the pump. By closing this This emergency shut-off system is operated with a
ball valve and stopping the flow of oil from the pump, single valve and needs simply to be pushed in to the
the pump will remain in a "neutral state". When "off" position IF NECESSARY. The valve is installed
hydraulic pressure is needed to run systems, simply in the hose reel compartment and is clearly marked.
turn on the ball valve. Operators must familiarize themselves with not only
this but all controls.
IMPORTANT!!!
Note: At no time should this vehicle be operated at IMPORTANT!!!
higher than 1500 rpm with hydraulic pump engaged. Note: This valve does not effect the diesel delivery
The pump is designed to run with no load system or any high volume oil product delivery
(disengaged) at speeds up to 2400 rpm without system. Each of these systems have their own
damage. The ball valve must be turned off while unit separate on-off controls.
is being operated at these higher speeds.

OPW1 Operation
PTO or Direct-Couple PTO
The second mounting method consists of a P.T.O. WARNING!!!
using either a drive line or a direct coupled Oil Product Pump
configuration to drive the pump. Typically the pump The oil product pumps on this unit utilize a self
is mounted separate from the P.T.O. on a heavy contained hydraulic control system. This system will
mount which is suspended from truck frame or main automatically control the hydraulic circuit that turns
structure of carriage. the pump/motor on and off. The system relies on a
series of sensing lines and check valves to send
To engage this system is simply to flip the P.T.O. proper signals which determine the demand of any
switch to "Engage" position. one product delivery system.

The most danger to these systems occurs when the 10. If so equipped, using appropriate reel control
supply tanks are run low on product. Once the valve, pull out knob to "UNWIND" position
product pump looses its prime, the product line is not and pull hose from appropriate reel. (See also
OPW1 Operation "Ground Force Hose Reel Operating
(Continued) Instructions".)
allowed to build pressure and will not properly signal
the hydraulic control system. Without signal, the 11. Dispense required amount of product.
pump will continue to run dry and will eventually be
damaged. 12. Return hoses to reel by pushing in on the knob
of the appropriate rewind control valve.
At NO time should these pumps be allowed to run
dry. Damage due to dry-running is typically self- 13. When dispensing of product is complete, turn
evident and is not covered by warranty. Operators the appropriate pump control off.
must be aware of product levels in tanks to prevent
this type of damage. 14. When delivery processes are completed allow
truck engine to idle. Disengage hydraulic
In the case of a product tank being inadvertently run pump.
dry during oiling procedures, the “Emergency Pump
Shut-Off” may be utilized to turn off the dry pump.
Oil Delivery System
Tank must be immediately refilled before engaging the
The oil pumping systems on your new lube truck
“Emergency Pump Shut-Off” again and running the
utilize a self-contained hydraulic control system. This
product pump.
system automatically turns the pump hydraulics on
and off as the truck operator opens the oil discharge
OI237 Operation
nozzle. The truck operator is not required to manually
turn the oil pump systems on. Once the discharge
OPERATING INSTRUCTIONS nozzle is attached to the receiving equipment, the
Fuel/Lube Truck
operator simply needs to turn on the control valve at
1. Do pre-operation checklist.
the end of the delivery hose.
2. Be sure all operating controls are in
The oil pump delivery rates depend on whether the oil
"OFF" position before starting truck.
system is equipped for low volume, fixed delivery, or
for high volume delivery. The high volume system
3. Start truck engine and allow to idle. Make
has a variable output rate with which the truck
certain that parking brakes are set.
operator can adjust from minimum flow to maximum
flow (approx. 20-30 gpm). The delivery speed control
4. Engage the hydraulic pump. Engine must run
is affected by moving the pump speed control lever
at approximately 1500 RPM.
CW to decrease flow, CCW to increase flow. The
output rate of the low volume system is a fixed rate
5. If compressed air is needed, locate
(not adjustable). Pump delivery can be throttled back
compressor control, turn on compressor
however, by partially opening the hose-end delivery
and allow it to charge tank(s) fully.
control valve.
6. Product delivery functions may be
operated from rear compartment. Grease Pumps
Pull out the appropriate control valve for grease reel
7. Reset product totalizer or meter. to engage either the high or low volume grease
pumps. Grease hoses will be charged until the control
8. Engage selected product by pulling valves are turned off (pushed in).
appropriate selector valve handle out to
"ON" position. Waste Oil Pump
Pull out the appropriate control valve to engage the
Note: Low volume oil product pumps have no waste oil pump. If so equipped, a selector valve is
selector valve (see “Emergency Shut-Off Product included in the waste oil plumbing system to allow
Pumps” instructions). both on-loading and offloading. The selector valve is
clearly marked for flow position.
9. All product delivery rates on this truck have
been preset to the maximum allowable, so no
adjusting of pump speeds will be necessary.

Coolant Pump gravity) until control valve is moved to another
Pull out the appropriate control valve to engage the function position.
coolant pump. The coolant pump will run as long as
the control valve is in the “ON” position. This 2. Lock: this function is accomplished by
coolant system will deliver new coolant. “bumping” the control valve handle slightly
from the unwind position to the “center”
position. In this position, the valve will close
OI237 Operation off the flow of hydraulic fluid to the reel drive
(Continued) motor and create a “lock” in the hydraulic
Diesel Fuel Pump circuit, which will allow virtually no reel
Pull out the appropriate control valve to engage the movement.
diesel pump. The pump will run as long as the control
valve is in the “ON” position. DO NOT let this pump This position may also be used after rewinding by
run continually!! Run the pump only as long as simply allowing control valve handle/spool to return
delivery is required. Damage to pump may occur if to the center (lock) position.
allowed to run indefinitely.
3. Rewind: this function is accomplished by using
the control valve handle to the fully “in”
CAUTION!!! position. This is a spring loaded valve
position which when released will return to the
Any time the pump control valves are pulled out, “lock” position. In the “rewind” position, the
the product hoses will be pressurized. DO NOT hydraulic valve controls the powered rewind
open the discharge nozzle or valve unless you are function of the reel. The hydraulic fluid which
ready to have product pumped out!!! drives the reel motor is regulated both in
pressure and flow. Even though this function
is regulated, during this function the operator
must maintain a moderate tension on the
product hose (by physically holding the hose)
OI164 Operation
to eliminate the “freewheeling” effect that will
OPERATING INSTRUCTIONS occur if hose is left unattended.
Ground Force Hose Reels “Freewheeling” can cause serious personal
This unit is equipped with Ground Force hydraulically injury and/or equipment damage if not
controlled product hose reels. Each hydraulic control monitored. Damage encountered because of
for these reels consist of one single spool directional this freewheeling is considered misuse and is
control valve and one hydraulic drive motor which not covered by warranty.
also acts as the live center for the drum (sheave) of
the reel. When the rewinding procedure is completed, simply
release the valve handle, allowing valve to return to
The control valve has three positions being: 1) the “lock” position.
unwind, 2) lock, and 3) rewind. Each of these three
positions will determine the function of the reel. Hose Reels
Each of the Ground Force hydraulic rewind reels
Note: The hydraulic systems on Ground Force includes the use of a specific size and type of hose,
equipment are typically of the load sensing type and which has been installed to accommodate the type
in order for proper operation of the reel controls, one and flow requirements of that particular product
or more product delivery functions may need to be delivery system. Many different fluid flow rates and
engaged. The easiest system to accomplish this is working pressures may be present, so mixing of hoses
the diesel delivery. By engaging this system the main from one reel to another may have detrimental affects.
hydraulic system will maintain its maximum pressure If servicing of reels or replacement of reel hoses is
and provide more control for hose reel circuits. required, make certain that the hoses installed on reels
are of original size and type.
1. Unwind: this function is accomplished by
pulling out on the control valve handle. When
engaged in this position the reel will be allowed Hose Stops
to “float” or coast so that the operator may pull Each Ground Force reel is equipped with a hose stop
any desired amount of hose from the reel. to alleviate the problem of pulling the product hose
Although having a slight tension, this function through the reel fair lead during rewinding
does not allow hose to be held in position by procedures. This hose stop should be occasionally
itself. Hose will continue to feed off of reel (by checked for tightness and positioning, and should be
replaced immediately if any damage shows evident. If

the hose stop is missing or damaged, extreme caution To Operate
should be exercised during reel use, until hose stop After initial warm-up procedures have been followed,
can be replaced. the hydraulic pump must be engaged (see also
“Engaging the Hydraulic Pump” section) and the
Pressure and Flow Regulation “compressor” switch must be turned On.
The hydraulic circuits which control the functions of
the Ground Force hose reels have incorporated relief Note: Compressor switch is sometimes accompanied
OI164 Operation by an On indicator light. If compressor indicator light
(Continued) does not illuminate when switch is turned on, do not
valves and flow controls which have been factory set assume that the compressor is not functioning, check
to accommodate the needs of this particular unit. for faulty bulb.
These controls must not be tampered with.
Allow the compressor to run long enough to fully
charge the receiver tanks (until system shuts down to
CAUTION!!! “standby” mode). Air system is now ready for use.

Severe damage to equipment and/or personal injury Drain tank condensation with each use (see below).
could result if relief valves and flow controls are
readjusted by anyone other than a qualified IMPORTANT!!!
Ground Force technician. This damage will not be
covered as a part of the warranty.
SAFETY NOTE!!!
OI87d Operation Do not assume that the compressor is turned off
OPERATING INSTRUCTIONS simply because it is not running. This system will
intermittently start and stop without warning.
Air Compressor Keep hands and loose clothing clear of all moving
This truck is equipped with an on-board hydraulic- parts and make certain that all guards and shields
drive air compressor. This compressor develops an are properly in place at all times.
air supply which may be used to fill tires, drive air
tools and remote pumps or motors, etc. Included with
this air compressor is one or more receiver tanks, an After use of compressor is complete, turn off
“F.R.L.” package (explained later), and a supply of ½” “compressor” switch (located either in truck cab or at
or ¾” I.D. hose which is loaded on a hose reel. control console). This system should never be left
“on” while not in use. During any “Down-Time” of
The loading of this compressed air supply is an “on- this truck (whether it be for a short period, shift
demand” system. Once the “compressor” switch change, or for prolonged service or maintenance) the
(located either in truck cab or rear control panel) is air compressor as well as all system controls should
turned on, the hydraulic system will drive the be in the “Off” position. Any functions left in “On”
compressor which will run until a pre-set air pressure position could cause potential dangers when
is reached, and then the system will shut down hydraulic system or air system is re-engaged.
leaving the compressor in a “standby” mode. The
compressor will then stay idle until additional air is Air Tank Drain
needed to replenish the supply, or until the
Most air receiver tanks for these air systems are
“compressor” switch is turned off.
equipped with a drain valve for bleeding residual
condensation. This valve should be opened daily
F.R.L. (Optional) and should be considered part of the normal
Installed within the airline system is a “filter-regulator- maintenance for this unit.
lubricator” assembly. This assembly is used to filter
and trap airline contaminants, regulate the airline
pressure, and automatically lubricate the discharge
line air.

The filter must be cleaned and drained on a regular
basis and the lubricator kept relatively full with a high
quality, moisture repelling air system lubricant. Do
not allow lubricator to run dry.

3. MAINTENANCE /
TROUBLE
SHOOTING

M16 Maintenance

INTRODUCTION
Your lube truck was constructed with care and with
quality materials. Simple routine maintenance will
assure that it will continue to operate with minimal
problems. This section of this manual will help you
establish a routine maintenance schedule and will
detail components which may need service at some
time.

Note: This section of the manual has the suggested
schedule of maintenance operations for your new
truck body. Some or all of the schedules will apply to
your individual truck. These schedules are intended
as a guideline only. As long as attention is paid to
lubrication and maintenance a minimum of times as
recommended, your own mine maintenance schedule
can supersede the recommended schedule.

SP1 Maintenance

SAFETY PROCEDURES
1. THINK!!

2. Use EXTREME CAUTION when working on or
servicing any machinery.

3. Before doing any work on equipment, follow
three easy steps:

A. Lock It Out

B. Tag It Out

C. Put The Keys In Your Pocket

4. Before starting equipment after servicing,
check to see that all personnel are clear. When
you are positive all are clear, check again!

HS11 Maintenance

HYDRAULIC SYSTEM
Inspection
Inspect your truck daily for worn hoses or loose
fittings. When hoses appear worn (especially if wire
wrappings are showing through), replace the hose
before a failure occurs. Tighten any loose fittings.

Note: When equipment is new, leaks will frequently
occur. This is normal and will cease after the unit has
been in operation for a while when fittings are
tightened and seated.

Hint: When re-sealing pipe thread fittings, use $30 filter is an inexpensive preventative maintenance
anaerobic hydraulic thread sealant (Felpro #51452). for a $6,000.00 hydraulic system.
Do not use Teflon tape (its use voids some
component manufacturers warranties). Suction Filter
This filter is included to capture any large particles
General Fitting Sizes: which may get into the oil reservoir. This filter is the
o 1/4" hose - JIC #4 (37o) screw-on canister filter which is plumbed to the
hydraulic oil tank in the suction oil line.
o 3/8" hose - JIC #8 (37o)

o 1/2" hose - JIC #10 (37o) CAUTION!!!
o 3/4" hose - JIC #12 (37o) Your hydraulic reservoir is equipped with a
pressure holding vent cap. This pressurizes the
o 1" hose - JIC #16 (37o) reservoir to approximately 3 psi to assure adequate
oil feed to the hydraulic pump. DO NOT replace
Hydraulic Oil this cap with a non-pressurized model!!!
Your new truck has been shipped without hydraulic
oil. Utilize preferably a premium grade AW46
hydraulic oil.

Return Oil Filter
These filters are the screw-on canister filters which
are plumbed to the hydraulic oil tank in the return oil
line. Ground Force replacement filters MUST be used
to maintain the factory warranty.

We recommend changing the hydraulic system return
oil filters monthly if your truck is used frequently. A
MS60 Maintenance

MAINTENANCE SCHEDULE
DESCRIPTION DAILY WEEKLY MONTHLY ANNUALLY

Lubricate reel fair lead rollers X

Lubricate hydraulic valves and actuators X

Change hydraulic oil X

Change hydraulic oil filter X

Clean in-tank suction strainer (with oil change) X

Check hydraulic oil level X

Check chassis motor oil X

Check hydraulic control valves X

Check hydraulic hoses and fittings X

Check drive couplings and inserts X

Check body mounting bolts X

Check hydraulic pump driveshaft bolts/coupling X
set screws

Check hydraulic pump mount bolts X

Check compressor crankcase oil level X

Check compressor drive couplings X

Change compressor crankcase oil See Compressor “Maintenance Schedule”

Clean compressor air filter element See Compressor “Maintenance Schedule”

FRL package - drain condensation from
filter/separator - add lubricant oil to lubricator as
needed X

Clean coolant suction strainer (if applicable) X

Replace diesel fuel filters (if applicable) X

Drain condensation from air receiver tanks X

TSG10 Trouble Shooting system, simple tests will narrow down potential
INTRODUCTION problems.
Periodically some problem may occur with your lube Test instruments which are needed to diagnose your
truck. Most problems are minor and can be easily truck are:
solved. This section of this manual is provided to
help you in diagnosing and solving problems you o High pressure and flow test meter.
may encounter.
o Digital electronic multi-meter (Must be digital
Note: Before replacing any major components, isolate with 0-10 amp DC current range).
the problem! As with any hydraulic or electrical

TS11a Trouble Shooting

TROUBLE SHOOTING GUIDE
PROBLEM PROBABLE CAUSE ITEMS TO CHECK

Hydraulic system PTO not engaged or main Cable Shift PTO's: Check cable.
will not operate. pump ball valve not turned
on. Air Shift PTO's: Adequate air pressure to shift?

Air Tank Emergency Valve: Valve functioning?

Control valve working properly?

Shift cylinder on PTO operating?

Check position of ball valve on pump (direct mount
only).

Hydraulic pump not Check PTO-pump driveshaft.
running.
Check keyways in pump, PTO driveshaft.

Check pump shaft.

Check if pump is free or "frozen up."

Hydraulic pump turning, no Check oil level in hydraulic tank.
apparent oil output.
Check pump driveshaft.

Hydraulic pump turning, oil Check pressure build when a circuit is used.
output apparently O.K. a. No/low Pressure: Check circuit or main
relief valve.

b. High Pressure Relieving: Check to be
sure the operating system is not "frozen
up."

(Pressure Compensated Check pressure compensator, reset to 1800 psi.
Pumps Only) Pump output
pressure too low. Check relief valves.

TS11a Trouble Shooting

(Continued)


Product pump will Motor flow control closed. Check inlet flow control to motor; closed, reset for
not run. desired output.

No hydraulic oil at drive Check main hydraulic pump ball valve to be sure it
motor or low oil pressure. is fully opened.

High pressure in system, Pump binding: Check oil flow to be sure pump
pump will not turn. turns with hydraulic motor uncoupled.

Motor turns, pump will not. Check drive coupling.

Hydraulic motor bad. Check motor.

Hose reel will not PTO not engaged. Check PTO.
function.

No hydraulic oil or low Check hydraulic pump.
pressure to control valve.

Relief valve on valve block Check system pressure, if OK and hose reel does
set too low. not develop pressure when running, reset reel
control valve relief.

Hydraulic motor getting oil, Replace motor.
but not functioning.

TS44 Trouble Shooting

HYDRAULIC LOAD SENSING SYSTEM


Hydraulic system will not Plugged load sense bleed valve Remove cartridge, check for debris
return to a standby cartridge. creating obstruction of orifice. Clean
pressure of 300-500 psi and reinstall.
after all circuits have been
disengaged.

Faulty pump compensator. Replace compensator block.

Hydraulic circuit(s) not totally Perform single circuit diagnostics to
disengaged - load sense circuit still determine which circuit remains
receiving signal pressure. open.
Repair circuit components.

Hydraulic system will not Plugged signal port on pump Remove load sense signal line from
develop high pressure (will compensator control block. compensator block. Engage one
not raise above typical 300- circuit (such as “product delivery,”
500 psi standby pressure). compressor, or down riggers).
Signal hose should discharge a
steady stream of oil. Remove
compensator block and thoroughly
clean (see pump service
instructions).

Wrong sized orifice in load sense Check for proper load sense bleed
bleed valve cartridge. Pressure is valve cartridge. If questionable,
not being allowed to build in load replace with 0.1 g.p.m. cartridge.
sense signal circuit.

Leak in load sense signal line Check for leaks, repair as needed.
circuit.

Circuit control valve not being Check for mechanical failure such
engaged properly. as pneumatic pilot not actuating a
hydraulic valve.

Faulty load sense check valve or Systematically run each separate
possible plug. circuit. Determine which circuit
does not bring pump up to pressure.
Replace or repair load sense check
valve on that circuit.

Faulty pump compensator. Replace compensator block.

Hydraulic system pressure Too high of volume of load sense Check for leaks, repair as needed.
will not increase even with circuit signal pressure lost by bleed
all system and circuit relief to tank or by line leaks. Check for proper load sense bleed
valves set. valve cartridge. If questionable,
replace with 0.1 g.p.m. cartridge.

4. HYDRAULICS /
PNUEMATICS /
ELECTRICAL

VVH5 Hydraulics out with the compensator/pump set at high pressure,
VARIABLE VOLUME or system damage could occur if the compensator
setting is too high.
HYDRAULIC PUMP
ADJUSTMENT For further information, see the adjustment
For Part #3286PM3XX, 3286PM4XX, procedures in the appropriate “Overhaul Manual.”

3286PM6XX, Series Pumps
This Ground Force hydraulic system is designed to HSP4 Hydraulics
operate at less than 1800 psi hydraulic pressure.
Therefore, it is important that the pressure
HYDRAULIC SYSTEM
compensator (which sets the maximum available Pressure Relief Adjustment
hydraulic pressure of the hydraulic pumps) be set Procedures (With Hydraulic Pump
properly or damage to the hydraulic system could Series 3286 PM 3XX, 4XX, and
potentially occur.
6XX/Without Spool Valve Relief)
The pressure compensator is a cast housing which is
attached to the main body of the hydraulic pump. Reference Drawing No. 96019/B32
This cast housing includes two adjustment screws.
One being the load sense pressure adjustment, and Prior to adjusting any relief valves, please verify
the other being the load pressure limiter adjustment. which particular valves are involved with this
The load pressure limiter should be the only procedure. Follow directions precisely and carefully.
adjustment immediately necessary.
A= Main Hydraulic Pump - Flow and Pressure
Some portions of Ground Force hydraulic systems are Compensated
designed to "overdrive" the hydraulic pressure B= Load Sense Adjustment Screw
needed to operate the system, i.e. on air compressors. C= Pressure Compensator Adjustment
This means that when that function of the truck is Screw
engaged, the hydraulic pump will automatically
deliver its maximum pressure rather than just the D= Main System Relief Valve (only one)
pressure needed to operate the system. This aids in E= Cap, Adjustment Screw Cover
adjusting the compensator. Follow the listed F= Adjustment Screw
procedures to adjust the compensator. G= Cartridge, Relief Adjustment

Note: Do not start engine or engage hydraulic
Bulk Explosive Trucks With Variable
system(s) until called for!!!
Volume Pump
Engage the auger delivery circuit to bring the truck to
Adjustment Preparation
maximum pressure. It will be O.K. to leave the product
1. Locate "A" (Hydraulic Pump) and control
selector (ANFO or Blend) off and run the truck as
block which includes “B” (Load Sense
though it is in a "clean out" mode; this will still bring
Adjustment Screw) and “C” (Pressure
the truck up to full operating pressure. When the
Compensator Adjustment Screw).
system is turned on, adjust the pressure limiter
adjusting screw on the pressure compensator control
2. Using a 1/2" wrench, loosen the jam nuts on
up to the desired 1800 psi, and set the lock nut.
“B” and “C,” making sure that “B” and “C” do
not turn in the process. A 5/32" Allen wrench
Service Trucks (Mechanics, Lube, may be used to hold “B” and “C” in place.
etc.)
The air compressor on all Ground Force service trucks 3. Using a 5/32" Allen wrench, turn “C” (Pressure
is designed to overdrive the hydraulic system. Turn Compensator Adjustment Screw) CCW until
on the compressor controls, and while the air spring pressure is no longer observed. Then
compressor is running adjust pressure to 1800 psi and turn the same “C” screw CW approximately 2
set the lock nut. full turns. This will adjust the pump output to
a fairly low pressure.
On All Units
When replacing the main hydraulic pump or the 4. Locate "D" (Main System Relief Valve) and
compensator; be sure to back off the pressure associated components "E", "F", and "G".
compensator adjustment counter clockwise when first
installing the part. Engage the hydraulics and bring
the pressure up and set at 1800 psi. DO NOT start

HSP4 Hydraulics
(Continued) 7. Turn "F" slowly CW until "squealing" stops.
5. Use a 1" wrench to hold "G" (Relief Valve
Cartridge) in place while using a 15/16" wrench 8. Replace "E" (Cap). Do not over tighten, needs
to loosen and remove "E" (Adjustment Screw only to be slightly more than hand tight. Main
Cap). Make certain that during this procedure System Relief Valve is now set and should
the Relief Valve Cartridge "G" does not loosen need no further adjustments.
from its seated position within the main block
of the relief valve (assembly). Place "E" in a 9. Return to main pump and while monitoring the
safe location (to be reinstalled later). pressure gauge, turn "Pump Compensator
Pressure Adjustment Screw" CCW slowly until
6. Make certain ALL controls are "OFF" or in pressure gauge reads 1800 psi pressure.
"NEUTRAL" position, including the "Product
Delivery" control. 10. While holding the adjustment screw with a
5/32" Allen wrench, tighten the jam nut with a
Adjustment Procedures ½" wrench.
Note: Do not attempt any adjustments without first
following steps 1 through 6 of "Adjustment 11. Recheck pressure at gauge. If pressure has
Preparation." changed, pump compensator must be
readjusted.
1. Start engine, engage hydraulic pump, raise to
approximately 1000 rpm. Note: Please keep in 12. Disengage the main hydraulic circuit which had
mind that even the slightest adjustments made been engaged for pressure adjustments.
must be monitored visually on the "Hydraulic
System Pressure Gauge." 13. Locate “B” (Load Sense Pressure Adjustment).
While monitoring the system pressure gauge,
2. Making sure that ALL other operating controls use a 5/32" Allen wrench and adjust the
are "OFF" or in "NEUTRAL" position, turn “Standby” pressure to 400-500 psi.
"ON" one of the main hydraulic circuits:
CW = Increase Pressure
u Stemming/ANFO Trucks = CCW = Decrease Pressure
Product Delivery
Note: After releasing all of the function circuits to
u Mechanic/Service/Lubrication “Neutral” on this system, the “Standby” pressure
Units = Air Compressor or Fuel Pump should drop to 400-500 psi within 30-45 seconds
maximum. If the system does not react in this manner,
3. Locate "C” (Pressure Compensator see the “Load Sense Trouble Shooting” section in
Adjustment) on main pump control block. this manual.

4. Turn “C” (Adjustment Screw) CW while 14. Once the “Standby” pressure has been
monitoring the pressure gauge. Continue to adjusted and rechecked (by engaging and
turn until pressure reads 2000 psi or until "D" disengaging a hydraulic circuit) tighten the jam
(Main System Relief Valve) starts to make a nut on “B” to secure in place.
whistling or squealing sound, whichever
comes first. 15. Disengage the hydraulic pump.

3. If 2000 psi cannot be obtained without the main 16. Allow engine to idle for "cool down" period
system relief valve making noise (which signifies and then stop engine.
that the oil is relieving), then "F" (Relief Valve
Adjustment Screw) must be turned CW no more
than ½ (one-half) turn at a time, along with
continued CW adjustment of the "Pressure
Compensator Adjustment Screw," until a 2000 psi
pressure is reached.

Once the pressure gauge reads 2000 psi, locate
"D" and turn "F" (Adjustment Screw) CCW
until the valve begins to "squeal."

HP22 Parts

HYDRAULIC SYSTEM PARTS
UNIT SERIAL NUMBERS 145-04-001 & 145-04-002
REFERENCE HYDRAULIC DIAGRAM145-02-001_2/H

ITEM PART # DESCRIPTION QTY

1 3286PM604 MAIN HYDRAULIC PUMP 1

2 1227HY301 MAIN RELIEF VALVE 1

3 9475FI010 SUCTION STRAINER, IN TANK 1

4 9475HY003 FILLER/BREATHER CAP - 3 PSI 1

5 9475FI011 FILTER HOUSING, RETURN OIL 1

6 9777FI004 FILTER ELEMENT DO NOT SUBSTITUTE 2

7 9400HY003 CARTRIDGE, LOAD SENSE BLEED VALVE 1

7A 9400HY004 BODY, FLOW CONTROL 1

8 3400VA008 GATE VALVE, 2-1/2" TANK SUCTION 1

9 3451VA054 CHECK VALVE, 3/4" BRONZE 1

10 1812HY001 SIGHT GLASS 2

11 9400HY031 BODY FLOW CONTROL 5

12 9400HY078 CARTRIDGE, FLOW CONTROL - 2.0 GPM 1

13 9400HY007 PRESSURE REDUCING VALVE 1

14 9414HY257 MOTOR, HYDRAULIC - REELS 8

14A 9414HY253 MOTOR, HYDRAULIC - REEL 2

15 9411HY001 VALVE, SINGLE SPOOL - REELS 10

16 6156GG001 PRESSURE GAUGE - 3000 PSI 1

17 2519HY351 VALVE, SELECTOR - 1/2" 3

18 9400HY070 CARTRIDGE, FLOW CONTROL 2

19 9400HY074 CARTRIDGE, RELIEF VALVE 2

20 9424HY001 CHECK VALVE, LOAD SENSE 3

21 9900HY131 MANIFOLD, COMPRESSOR CONTROL 1

22 9400HY083 SOLENOID CARTRIDGE 1

23 9400HY084 SOLENOID COIL - 12 VDC 1

24 9500HY063 CARTRIDGE, LOAD SENSE CHECK 1

25 9400HY052 CARTRIDGE, FLOW CONTROL - 25 GPM 1

HP22 Parts

HYDRAULIC SYSTEM PARTS
UNIT SERIAL NUMBERS 145-04-001 & 145-04-002
REFERENCE HYDRAULIC DIAGRAM
(Continued)

26 9414HY247 MOTOR, HYDRAULIC 1



29 9414HY272 MOTOR, HYDRAULIC - COMPRESSOR COOLING FAN 1

30 10082PM301 MOTOR, HYDRAULIC - GREASE PUMP 2

31 10082PM303 PUMP TUBE, GREASE - HIGH PRESSURE 1

32 10082PM302 PUMP TUBE, GREASE - HIGH VOLUME 1

33 9900HY130 MANIFOLD, PRODUCT PUMP - SEE ALSO DRAWING NO.
94080/B91 5


35 9424HY004 CHECK VALVE, PRODUCT OIL 5

36 2617PM303 PUMP/MOTOR COMBO - SEE ALSO DRAWING NO.
94080/B91 5

37 2519HY352 SELECTOR VAVLE, 3/4" 1


39 9400HY016 BODY, FLOW CONTROL 1

40 9414HY209 MOTOR, HYDRAULIC - WATER PUMP 1

Parts Parts

WARRANTY PARTS TO PURCHASE PARTS:
When Ground Force manufactures Order ALL parts for the items shown in
machinery, we utilize parts and supplies this book through Ground Force not the
made by many vendors. It is an part manufacturer!!!
unfortunate fact of life that a percentage of
these parts that we purchase to assemble Ground Force is a master distributor all
our machinery will be bad. Component the components used to build your
parts all have their respective equipment and can furnish them cheaper
manufacturer's warranties. Since you've and faster than the component
purchased Ground Force manufactured manufacturer.
machinery, we will do everything in our
power to assure you that your equipment When ordering, use the Ground Force
stays in top operating condition and will Part Number to assure receiving the right
back you in any warranty claims. part quickly!

Should any parts on your new unit prove Ground Force maintains an inventory of
to become defective, we can usually ship the common parts which are part of the
a replacement part from our stock normal maintenance and repair of your
overnight if you so desire. What we need equipment.
to do at Ground Force to receive our
warranty credit for parts proven to be
defective is to have parts returned by you,
the owner of the machine, to us, so that
we may apply to parts suppliers for
warranty credit. To do this, it is
imperative that we receive the faulty part
when you replace it with a new one.

Our warranty procedure at Ground Force
is that when we ship a replacement part
for your unit, either on warranty or
standard replacement, we will send an
invoice with that part. When we receive
the defective part back from you, we will
submit that to our suppliers for a warranty
credit. As soon as warranty credit is
received for that part, we will issue a
credit invoice for the amount charged on
your replacement. (Freight charges are
not covered under warranty).

If you have any questions about Ground
Force's warranty system, please contact
Chad Wilson at (208) 664-9291.

DP4a

DOOR PARTS

CATCH

GAS SPRING LATCH LEVER
SIDE COMPARTMENTS
PART # 13500WH501
(LIFT-UP DOORS)
(INCLUDES CATCH)
PART # 15088HW125
2 EACH PER DOOR
EDGE TRIM
PART # 4200WH015 (PER FOOT)
(SIDE-SWING DOORS)
PART # 15088HW035
1 EACH PER DOOR "D" DOOR SEAL (SELF BONDING)
PART # 10600WH939
(ORDER PER FOOT)

ITEM DIM ARESCO DESCRIPTION QTY
A PART #
1266DC401 COUPLING HALF, 1-1/4 x 5/16 AR

1 4.0
1266DC404
1266DC405
COUPLING HALF, 50 mm x 14 mm
COUPLING HALF, 1 x 1/4
AR
AR
1
1266DC412 COUPLING HALF, 1-1/4 AR
14 TOOTH SPLINED
2 1266DC403 INSERT, HYTREL AR
AR
2
1266DC506 COUPLING HALF, 2-1/2 x 5/8

1 1266DC507 COUPLING HALF, 1-1/2 x 3/8 AR
4.8


1
1266DC511 COUPLING HALF, 55 mm x 16 mm AR
1266DC513 COUPLING HALF, 2-1/4 X 3/8 AR
1266DC501 INSERT, HYTREL AR
2
1266DC502 INSERT, NEOPRENE AR
1266DC301 COUPLING HALF, 1 6 TOOTH
SL E
PI D
N AR
1266DC302 COUPLING HALF, 1-1/4 x 5/16 AR DIM A
1266DC304 COUPLING HALF, 3/4 x 3/16 AR OUTSIDE
DIAMETER
1266DC306 COUPLING HALF, 1 x 1/4 AR
1 3.45
NOTE : PART NUMBERS
1266DC314 COUPLING HALF, 7/8 x 1/4 AR
HIGHLIGHTED ARE
1266DC315 COUPLING HALF, 1-3/8 x 5/16 AR APPLICABLE TO
1266DC316 COUPLING HALF, 9/16 x 1/8 AR YOUR TRUCK.
1266DC317 COUPLING HALF, 7/8
13 TOOTH SPLINED AR
2 1266DC303 INSERT, HYTREL AR
1266DC102 COUPLING HALF, 1 x 1/4 AR
1266DC109 COUPLING HALF, 16.5 mm x 5 mm AR
1 2.6
1266DC113 COUPLING HALF, 1/2 x # 404
WOODRUFF AR G o n
r u d F r e Mg
o c f .
1266DC114 COUPLING HALF, 3/8 BORE AR
DRAWING NUMBER : 9-1 2- 3
2 0-5 B

1266DC116 COUPLING HALF, 5/16 BORE AR
DRIVE COUPLING
2 1266DC104 INSERT, HYTREL AR S RE 1 0 3 0 4 0 & 5 0
E I S 0 , 0 , 0 0 .
O
V

JB1

JUNCTION BOX

ITEM PART# DESCRIPTION

1 7813LT012 JUNCTION BOX/COMPLETE

L1

TRUCK LIGHTS

ITEM PART # DESCRIPTION

1 7813LT012 JUNCTION BOX
2 7813LT007 LAMP, CLEARANCE, AMBER
3 7813LT006 LAMP, CLEARANCE, RED
4 7813LT005 IDENTIFICATION BAR
5 7813LT009 LAMP, STOP, OR TURN

L2

TRUCK LIGHTS

1

2


7813LT009 LAMP, STOP OR TURN/COMPLETE

1 1156 BULB
2 7813LT025 LENS, REPLACEMENT - RED

L4

ICC LIGHTS


1 7813LT005 IDENTIFICATION BAR
2 7813LT001 LENS
3 T-67 BULB

L5b

FLOOD LIGHT ASSEMBLY


7813LT014 FLOOD LIGHT, AMBER/COMPLETE
7813LT008 FLOOD LIGHT, CLEAR/COMPLETE
7813LT013 FLOOD LIGHT, HALOGEN/COMPLETE
1 7813LT017 BULB, HALOGEN
2 7813LT018 BULB, CLEAR FLOOD
3 7813LT022 BULB, AMBER

L7a

CLEARANCE LIGHT ASSEMBLY

ITEM. PART # DESCRIPTION

1 7813LT006 LAMP,CLEARANCE RED/COMPLETE
2 7813LT007 LAMP, CLEARANCE AMBER/COMPLETE
3 7813LT002 LENS, AMBER
4 7813LT003 LENS, RED
5 56 GROMMET
6 T67 BULB

WIRING LOOM AND FITTINGS

90 ELBOW (3/8" - 635-053)
(1/2" - 635-065)
3/8" TUBING - PT24006
1/2" TUBING - PT24008

STRAIGHT FITTING (3/8" - 600-053
(1/2" - 600-063)

WIRING JUNCTION BOX (BOX - #4900EL125)
(PANEL - #4900EL126)

1615AP002

PART # 6500-04-02

1615AP001

PART # 6500-04-02

PART # 6500-04-02
PART # 6500-04-02
PART # 6500-04-04

PART # 6500-04-04

PART # 222P-4-4

PART # 6500-04-04

PART # 6500-04-04

PART # 6500-04-04

3936AP006

PART # 222P-4-4

PART # 6500-04-04

3936AP007
Ground Force Mfg. PLUMBING AIR VALVES
DRAWING NUMBER : 3 9 3 6 A P ( 6 5 P 0 ,1 1 A 0 2 9 6 P 0 / 0 )
1 1 A 0 1 6 5P 0 , 3 A 0 6 0 7
3

ov

G3 G5
2 1 8 7

4 4

5

10
3

6 9

ITEM PART # DESCRIPTION QTY
1 9483HY028 STACKING BOLT, G3 AR
2 9483HY029 CLAMP BOLT, G3 AR
3 9483HY030 CLAMP WELD PLATE, G3 AR
4 9483HY031 CLAMP INSERT, G3 AR
5 9483HY032 CLAMP, 1/4 TUBING, G3 AR
9483HY033 CLAMP, 1/2 TUBING, G3 AR
9483HY039 CLAMP, 1 TUBING, G3 AR
6 9483HY040 CLAMP, RAIL WELD PLATE, G3 AR
7 9483HY048 STACKING BOLT, G5 AR
8 9483HY049 CLAMP BOLT, G5 AR
9 9483HY050 CLAMP WELD PLATE, G5 AR
10 9483HY054 CLAMP 1 PIPE, G5 AR
9483HY056 CLAMP 1-1/4 PIPE, G5 AR

Ground Force Mfg. RIGID HYDR. TUBE MOUNTING
DRAWING NUMBER : 9-1 2- 1
2 0-4 B PARTS

DL25dc

DRIVELINE - COMPLETE

1 2 3 4 5

7 6 6 7
Highlighted Items Apply to This Unit
Note: Quanity "A/R" = As Required

LENGTH USED IN INCHES

ITEM PART # QUANTITY DESCRIPTION
4 2-40-1701DS SPLINE STUB 1 2-2-329 1
FLANGE YOKE

2-40-1711DS SPLINE STUB 2-2-479 1
FLANGE YOKE

5 2-3-5221KX SLIP YOKE 3-2-119 1
FLANGE YOKE

3-3-1501KX SLIP YOKE 2 2-28-1757 TUBE YOKE
1

6 1-0153HD U-JOINT ASSEMBLY 3-28-47 TUBE YOKE
2

2-0053 U-JOINT ASSEMBLY 3 DOM 2 X .120 DRIVELINE TUBING
2

5-280X U-JOINT ASSEMBLY DOM 2-1/2 X .083 DRIVELINE TUBING
2

7 2-4-433 END YOKE, 3/4" X 3/16" KEY A/R

2-4-473 END YOKE, 1" X 1/4" KEY A/R

2-4-1741 END YOKE, SPLINED A/R

2-4-533 END YOKE, 1-1/4" X 5/16" KEY A/R

2-4-1233 END YOKE, 1-1-/2" X 3/8" KEY A/R

2-4-3331 END YOKE, 7/8" SPLINED A/R

8 50-2502 SET SCREW A/R

NOT SHOWN

1-0099 U-BOLT KIT FOR 2-0053 A/R

3-4-24 YOKE, TAPER A/R

6-4-7541X YOKE A/R

6-4-7561X YOKE A/R

Instructions – Parts List
Parts

ALUMINUM AND STAINLESS STEEL

Huskyt 1040 Air-Operated
Diaphragm Pumps 308479AD
Aluminum Model Shown
120 psi (0.8 MPa, 8 bar) Maximum Fluid Working Pressure
120 psi (0.8 MPa, 8 bar) Maximum Air Input Pressure

*Model No. D73____ Aluminum Pumps
*Model No. D83____ Aluminum Pumps, Remote
*Model No. D74____ Stainless Steel Pumps
*Model No. D84____ Stainless Steel Pumps, Remote
*Model No. D7C____ Aluminum BSPT Pumps
*Model No. D8C____ Aluminum BSPT Pumps, Remote
*Model No. D7D____ Stainless Steel BSPT Pumps
*Model No. D8D____ Stainless Steel BSPT Pumps, Remote
*Model No. DR4____ Stainless Steel Plus Pumps
*Model No. DS4____ Stainless Steel Plus Pumps, Remote
*Model No. DRD____ Stainless Steel BSPT Plus Pumps
*Model No. DSD____ Stainless Steel BSPT Plus Pumps, Remote
Model No. 232501 Private–Label Aluminum 1040 Pump (See page 24.)
(not certified )
Model No. 234124 Private–Label Aluminum 1040 Pump (See page 24.)
*NOTE: Refer to the Pump Matrix on page 24 to determine
the Model No. of your pump.

NOTE: Plus models include stainless steel center sections.

US and Foreign Patents Pending

Read warnings and instructions.
See page 2 for table of contents

02632C

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
Copyright 1994, Graco Inc. is registered to I.S. EN ISO 9001

Table of Contents Symbols
Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Warning Symbol
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 WARNING
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 This symbol alerts you to the possibility of serious
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 injury or death if you do not follow the instructions.
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pump Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Caution Symbol
Repair Kit Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 CAUTION
Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . 31
Technical Data and Performance Chart . . . . . . . . . . . 32 This symbol alerts you to the possibility of damage to
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . 34 or destruction of equipment if you do not follow the
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 instructions.

WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
INSTRUCTIONS

D This equipment is for professional use only.

D Read all instruction manuals, tags, and labels before operating the equipment.

D Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor.

D Do not alter or modify this equipment. Use only genuine Graco parts and accessories.

D Check equipment daily. Repair or replace worn or damaged parts immediately.

D Do not exceed the maximum working pressure of the lowest rated component in your system.
This equipment has a 120 psi (0.8 MPa, 8 bar) maximum working pressure at 120 psi
(0.8 MPa, 8 bar) maximum incoming air pressure.

D Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the
Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s
warnings.

D Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents in pressurized aluminum equipment. Such use could result in a
chemical reaction, with the possibility of explosion.

D Do not use hoses to pull equipment.

D Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not ex-
pose Graco hoses to temperatures above 82_C (180_F) or below –40_C (–40_F).

D Do not lift pressurized equipment.

D Comply with all applicable local, state, and national fire, electrical, and safety regulations.

2 308479

WARNING
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the
skin, inhaled, or swallowed.

D Know the specific hazards of the fluid you are using.

D Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.

D Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid
and solvent manufacturer.

D Pipe and dispose of the exhaust air safely, away from people, animals, and food handling areas.
If the diaphragm fails, the fluid is exhausted along with the air. See Air Exhaust Ventilation on
page 9.

FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.

D Ground the equipment. Refer to Grounding on page 4.

D If there is any static sparking or you feel an electric shock while using this equipment, stop
pumping immediately. Do not use the equipment until you identify and correct the problem.

D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.

D Pipe and dispose of the exhaust air safely, away from all sources of ignition. If the diaphragm
fails, the fluid is exhausted along with the air. See Air Exhaust Ventilation on page 9.

D Keep the work area free of debris, including solvent, rags, and gasoline.

D Electrically disconnect all equipment in the work area.

D Extinguish all open flames or pilot lights in the work area.

D Do not smoke in the work area.

D Do not turn on or off any light switch in the work area while operating or if fumes are present.

D Do not operate a gasoline engine in the work area.

308479 3

Installation
General Information Grounding

D The Typical Installations shown in Figs. 2–4 are
only guides for selecting and installing system
WARNING
components. Contact your Graco distributor for FIRE AND EXPLOSION HAZARD
assistance in planning a system to suit your needs. This pump must be grounded. Before
operating the pump, ground the system
as explained below. Also, read the sec-
D Always use Genuine Graco Parts and Accessories. tion FIRE AND EXPLOSION HAZARD,
Refer to Product Data Sheet 305588. on page 3.

D Reference numbers and letters in parentheses refer
To reduce the risk of static sparking, ground the pump
to the callouts in the figures and the parts lists on
and all other equipment used or located in the pumping
pages 26–28.
area. Check your local electrical code for detailed
grounding instructions for your area and type of equip-
D Aluminum Husky 1040 Pump Model No. 239823, ment. Ground all of this equipment.
with straight-thread manifolds, is available and can
be ordered separately. D Pump: Connect a ground wire and clamp as shown
in Fig. 1. Loosen the grounding screw (W). Insert
one end of a 12 ga (1.5 mm@) minimum ground wire
(Y) behind the grounding screw and tighten the
screw securely. Connect the clamp end of the
WARNING ground wire to a true earth ground. Order Part
TOXIC FLUID HAZARD No. 222011 Ground Wire and Clamp.
Hazardous fluid or toxic fumes can
cause serious injury or death if splashed
in the eyes or on the skin, inhaled, or
swallowed.
Y
1. Read TOXIC FLUID HAZARD on page 3.

2. Use fluids and solvents which are compatible
with the equipment wetted parts. Refer to the
Technical Data section of all equipment manu-
als. Read the fluid and solvent manufacturer’s
warnings.

W
02646B
Fig. 1
Tightening Screws Before First Use
D Air and fluid hoses: Use only grounded hoses with
After you unpack the pump, and before you use it for a maximum of 500 ft (150 m) combined hose
the first time, check and retorque external fasteners. length to ensure grounding continuity.
Retorque the fluid cover screws first, then the manifold
screws. This keeps the manifolds from interfering with D Air compressor: Follow the manufacturer’s recom-
tightening the fluid covers. See the Service section for mendations.
torque specifications.
D All solvent pails used when flushing: Follow the
local code. Use only metal pails, which are conduc-
After the first day of operation, check and retorque the tive. Do not place the pail on a non-conductive
fasteners again. Although the recommended fre- surface, such as paper or cardboard, which inter-
quency for retorquing fasteners varies with pump rupts the grounding continuity.
usage, a general guideline is to retorque fasteners
every two months. D Fluid supply container: Follow the local code.
4 308479

Installation
Mountings c. The air line filter (F) removes harmful dirt and
moisture from the compressed air supply.

CAUTION
2. Install a grounded, flexible air hose (A) between
The pump exhaust air may contain contaminants. the accessories and the 1/2 npt(f) pump air inlet
Ventilate to a remote area if the contaminants (N). See Fig. 5. Use a minimum 3/8” (9.5 mm) ID
could affect your fluid supply. See Air Exhaust air hose. Screw an air line quick disconnect cou-
Ventilation on page 9. pler (D) onto the end of the air hose (A), and screw
the mating fitting into the pump air inlet snugly. Do
not connect the coupler (D) to the fitting until you
D Be sure the mounting surface can support the
are ready to operate the pump.
weight of the pump, hoses, and accessories, as
well as the stress caused during operation.
Installation of Remote Pilot Air Lines
D For all mountings, be sure the pump is bolted
directly to the mounting surface. 1. Refer to Parts Drawings. Connect air line to pump
as in preceding steps.
D For ease of operation and service, mount the pump
so the air valve cover (2), air inlet, and fluid inlet
and outlet ports are easily accessible. 2. Connect 1/4 in. O.D. tubing to push type connec-
tors (14) on air motor of pump.
D Rubber Foot Mounting Kit 236452 is available to
reduce noise and vibration during operation.
NOTE: by replacing the push type connectors, other
sizes or types of fittings may be used. The new fittings
Air Line
will require 1/8 in. npt threads.
3. Connect remaining ends of tubes to external air
WARNING signal, such as Graco’s Cycleflo (P/N 195264) or
A bleed-type master air valve (B) is required in Cycleflo II (P/N195265) controllers.
your system to relieve air trapped between this
valve and the pump. Trapped air can cause the NOTE: the air pressure at the connectors must be at
pump to cycle unexpectedly, which could result in least 30% of the air pressure to the air motor for the
serious injury, including splashing in the eyes or on pump to operate.
the skin, injury from moving parts, or contamination
from hazardous fluids. See Fig. 3. Fluid Suction Line

1. Use grounded fluid hoses. The pump fluid inlet (R)
1. Install the air line accessories as shown in Figs. is 1” npt(f). See Fig. 5. Screw the fluid fitting into
2–4 on pages 7 and 8. Mount these accessories the pump inlet securely.
on the wall or on a bracket. Be sure the air line
supplying the accessories is grounded.
2. If the fluid inlet pressure to the pump is more than
a. Install an air regulator (C) and gauge to control 25% of the outlet working pressure, the ball check
the fluid pressure. The fluid outlet pressure will valves will not close fast enough, resulting in
be the same as the setting of the air regulator. inefficient pump operation.

b. Locate one bleed-type master air valve (B)
3. At inlet fluid pressures greater than 15 psi (0.1
close to the pump and use it to relieve trapped
MPa, 1 bar), diaphragm life will be shortened.
air. See the WARNING above. Locate the
other master air valve (E) upstream from all air
line accessories and use it to isolate them 4. See the Technical Data on page 32 for maximum
during cleaning and repair. suction lift (wet and dry).

308479 5

Installation
Fluid Outlet Line 1. Use grounded fluid hoses (L). The pump fluid
outlet (S) is 1” npt(f). See Fig. 5. Screw the fluid
fitting into the pump outlet securely.
WARNING
A fluid drain valve (J) is required to relieve pres- 2. Install a fluid drain valve (J) near the fluid outlet.
sure in the hose if it is plugged. The drain valve See the WARNING above, and Figs. 2–4 on
reduces the risk of serious injury, including splash- pages 7 and 8.
ing in the eyes or on the skin, or contamination
from hazardous fluids when relieving pressure. 3. Install a shutoff valve (K) in the fluid outlet line.
Install the valve close to the pump fluid outlet. See
Fig. 3.

6 308479

Sss

Empfohlen

Empfohlen

Weitere ähnliche Inhalte

Ähnlich wie Sss

Ähnlich wie Sss (20)

Kürzlich hochgeladen

Kürzlich hochgeladen (12)

Sss