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SN : 18.1053
Water Truck 32KL Cap. ISO 9001 : 2015
on VOLVO FMX 440 8x4
SERVICE MANUAL & PARTS CATALOG
Water Truck 32KL Cap. on VOLVO FMX 440 8x4
CUSTOMER:
PT. EKA DHARMA JAYA SAKTI
SN : 18.1053
www.porterrekayasa.com
PT. PORTER REKAYASA UNGGUL WATER TRUCK 30KL on VOLVO FMX 440 8x4 HEAD & WORKSHOP OFFICE : Jl. Gatot Subroto KM. 8 Jatake Tangerang, Banten - Indonesia 15136 Phone : +62-21 - 591 8951 Fax : +62-21 - 591 9037 Website : www.porterrekayasa.com Email : [email protected]
REPRESENTATIVE OFFICE : Jl. MT Haryono No. 90-C Kel. Sepinggan Baru Balikpapan Selatan Kalimantan Timur Phone : +62-542 - 881-0282 +62-542 - 881-0283
CONTACT DETAILS MARKETING Mr. Dony Wijaya
Cell. Phone
: +62 812 5242 3236
Email : [email protected]
PRODUCT SUPPORT Mr. Yayat Syarif H.
Phone
: +62 852 8800 5096
Email : [email protected]
SPARE PART & SERVICES Mr. Iman S. Dirgantara
Phone
: +62 812 97 05 727
Email
: [email protected]
Contact Details
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WATER TRUCK 30KL on VOLVO FMX 440 8x4
DISCLOSURE
Published by PT. PORTER REKAYASA UNGGUL Under Contract to PT. EKA DHARMA JAYA SAKTI
This manual contains proprietary information. Reproduction in whole or in part without the written permission of PT. PORTER REKAYASA UNGGUL is expressly forbidden.
Any person and or the responsible legal body who copies or causes to have copies made will be prosecuted to fullest extent of the law.
Copies this manual are controlled distribution to the offices listed below. Holders of the manual are responsible for its safekeeping and in corporations of amendment as they are issued.
This book is designed for WATER TRUCK 32KL on VOLVO FMX 440 8x4 completed with the system attached which has following serial number :
Serial Number :
18.1053
Disclosure
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WATER TRUCK 30KL on VOLVO FMX 440 8x4
INTRODUCTION
The purpose of this manual is to familiarize you with the controls of your vehicle and to provide sufficient information to enable you to perform minor routine services necessary for continued efficient operation. To protect your equipment, study this manual before you start to operate the vehicle.
Every effort has been made to assure that your new vehicle has been engineered and manufactured to provide continued trouble-free service. Materials selected to manufacture the many parts which make up the vehicle exhaustive test and research to make certain that acceptable, safe service life is realized.
In additional, this manual is purposed to give you good and unequivocal information for the use and maintenance of your vehicle. We strongly advise to store this manual in a save place in the vehicles cabin for later consultation.
Introduction
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WATER TRUCK 30KL on VOLVO FMX 440 8x4
TABLE OF CONTENT CONTACT DETAILS ��������������������������������������������������������������������������������������������������������������������������� i DISCLOSURE ������������������������������������������������������������������������������������������������������������������������������������ ii INTRODUCTION ����������������������������������������������������������������������������������������������������������������������������� iii TABLE OF CONTENT ����������������������������������������������������������������������������������������������������������������������� iv 1. SPESIFICATION & GENERAL ARRANGEMENT DRAWING ���������������������������������������������������������� 1 1.1. Specification of Water Truck 30.000 Liters of Capacity ���������������������������������������������������������������� 2 1.2. General Arrangement Drawing ������������������������������������������������������������������������������������������������������ 4
2. OPERATING INSTRUCTIONS ������������������������������������������������������������������������������������������������������ 5 2.1. Introductions ���������������������������������������������������������������������������������������������������������������������������������� 6 2.2. General �������������������������������������������������������������������������������������������������������������������������������������������� 6 2.3. Operating Procedures �������������������������������������������������������������������������������������������������������������������� 7 2.3.1. At the Beginning of Each Shift �������������������������������������������������������������������������������������������� 7 2.3.2. Road Watering Operation Procedures ������������������������������������������������������������������������������ 7 2.3.3. Water Cannon / Monitor Operation Procedure���������������������������������������������������������������� 9 2.3.4. Filling the Tank from a Reservoir Using the Onboard Pump Set��������������������������������������� 9
3. MAINTENANCE SCHEDULE ������������������������������������������������������������������������������������������������������ 11 3.1. General ����������������������������������������������������������������������������������������������������������������������������������������� 12 3.2. Water Tanker System Maintenance Attention ��������������������������������������������������������������������������� 12 3.3. Maintenance Schedule Chart ����������������������������������������������������������������������������������������������������� 13
4. SCHEMATIC DIAGRAM ������������������������������������������������������������������������������������������������������������ 15 4.1. Schematic of Hydraulic System ��������������������������������������������������������������������������������������������������� 16 4.2. Schematic of Pneumatic System ������������������������������������������������������������������������������������������������� 18 4.3. Schematic of Electric System ����������������������������������������������������������������������������������������������������� 19
5. PART LIST COMPONENTS �������������������������������������������������������������������������������������������������������� 21 5.1. Hydraulic System Part List ����������������������������������������������������������������������������������������������������������� 22 5.2. Water System Part List ����������������������������������������������������������������������������������������������������������������� 24 5.3. Electric-Pneumatic Control Part List ����������������������������������������������������������������������������������������� 26 5.4. Other Part List ����������������������������������������������������������������������������������������������������������������������������� 27
Table of Content
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WATER TRUCK 30KL on VOLVO FMX 440 8x4
6. SUPPORTING PARTS MANUAL ������������������������������������������������������������������������������������������������ 28 6.1. HYVA Gear Pump ������������������������������������������������������������������������������������������������������������������������ . 29 6.2. VICKERS Vane Motor�������������������������������������������������������������������������������������������������������������������� . 36 6.3. SOUTHERN CROSS 100x65-250 Series Centrifugal Pump���������������������������������������������������������� . 40 6.4. MAGNUM MM40 Monitor Water Cannon �������������������������������������������������������������������������������� . 49
Table of Content
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WATER TRUCK 32KL on VOLVO FMX 440 8x4
1 SPECIFICATION & GENERAL ARRANGEMENT DRAWING
Specification and General Arrangement Drawing
1
WATER TRUCK 32KL on VOLVO FMX 440 8x4
1.1. Specification of Water Tank 32.000 L of Capacity DIMENSION Length
: Approximately 6.952 mm
Width
:
Approximately 2.730 mm
Height of Side
:
Approximately 1.775 mm
Capacity
:
32.000 Liters of Capacities
CONSTRUCTION Tank Body
: Non pressurized single (1) compartment tank of a “Double D” design to be fabricated from 6 mm mild steel plate SS400 for side and top wall, and 8 mm mild steel plate SS400 for floor. The tank is completed with baffles to reduce the effect of product surge.
Main Hole/Hatch :
Tank is equipped with semi permanent bolt hatch on the top of tank for inspection with 500 mm of diameter.
Funnel
: A fabricated loading funnel fitted on the center of the vehicle complete with removable mesh strainer and deflector plate to break the force of incoming water.
Bottom Filling
: 1 (one) set 4 inch male-fimale cam lock for bottom filling.
Lifting Lug
: 4 (four) lifting lugs fabricated in to the tank for removal of the tank from the truck.
Piping/plumbing
: All pipes to be fabricated which is fully galvanized, including flanges.
Others
:
Full length main runners under tank and full length coming to top of tank with non-slip paint suitable walkway. Access ladder will be mounted at rear and side of the tank.
Pump unit and spray head to be mounted on platform at rear of the tank. Platform to be fitted with galvanized anti-slip grating and safety handrails with ergonomic range of height.
HIDRAULIC SYSTEM Hyd. Oil Tank
: Approximately 200 liters fitted at the rear of cabin completed with filler breather, oil level & temperature gauge, internal suction filter and return line filter connect with Hydraulic Fan Cooler.
Safety Device
: An automatic low level switch to be fitted in case of low level water in the tank then automatically shut down the water dispensing system.
Hydraulic Pump
: HYVA Hydraulic Gear Pump 092L-BI-4H-BRITE Series P/N : 14562030 Fixed Displacement Pump to each application is coupled with PTO.
Hydraulic Motor
: VICKERS 26M65A a high performance vane motor is coupled to water pump.
Control Valve
: Suitable solenoid operated directional hydraulic control valve is fitted.
Cooler
: PRU Standard Fabricated cooling system plus 24 VDC fan cooler.
Specification and General Arrangement Drawing
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WATER TRUCK 32KL on VOLVO FMX 440 8x4
WATER DISPENSING SYSTEM Water Pump
: SOUTHERN CROSS ISO-PRO 100x65-250 heavy duty centrifugal pump with high flow rate up to 1200 L/m.
Sprayer Head
: 2 (two) only MAGNUM 10 19D or equivalent spray head are fitted on the rear side. All spray head to incoporate air operation on-off valve operation and fully adjustable to achieve good saturation pattern at side. Water Cannon
:
MAGNUM MM40 water cannon with manually operated butterfly valve.
Buffer System
:
Gravity spray bar construct from 4” pipe with manually operated butterfly valve to cover in order the main system is break down.
CONTROL • Electrical power on/off to control the system. • Air switches for each spray heads with visual indicator for activate it. • Electric switches for strobe light and work light. • Low warning arranged series with buzzer.
PAINTING Type of Paint
: PRU Standard Paint, external tank to be blast cleaned.
Primer
: Epoxy
Coating
: Polyurethane type
Tank/Module Color : White, including logo.
ACCESSORIES • Supply and fit rubber mud flup. • Attached serial number and manufacturer’s identification. • Supply 1 set manual book guide line in English version.
WARRANTY TERMS & POLICY Equipment/structure manufactured by PT. PORTER REKAYASA UNGGUL is guaranteed for one year from date of shipment and will rectify any fault which in the opinion of the company needs rectification by reason of defective materials, workmanship or design. Components such as Axles, Cylinders, Pumps, Motors, Valves and etc. that are manufactured by other vendors will be subject to the warranty terms of those manufacturers. Also excluded from general guarantee are normal wear items, including seals, hoses / fittings, and paint finish. We reserve the right to modify or alter materials, dimensions, design, and construction when necessary to improve the performance of the equipment and/or accessories, or to meet customer requirements. We expressly disclaim any liability for damage or injuries resulting from the use, operation, service, maintenance, or failure of equipment. Specification and General Arrangement Drawing
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WATER TRUCK 32KL on VOLVO FMX 440 8x4
1.2. General Arrangement Drawing
Specification and General Arrangement Drawing
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WATER TRUCK 32KL on VOLVO FMX 440 8x4
2
OPERATING INSTRUCTIONS
Operating Instructions
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WATER TRUCK 32KL on VOLVO FMX 440 8x4
2.1. Introductions Before operating your vehicle it is necessary to get familiar with the use and working of this water tanker system. Therefore you have to read this manual carefully in order to use the vehicle in a safe and proper way. Defects and injuries are often related to inexpertness use and incomplete maintenance of your system.
2.2. General While the main purpose of the Tanker is for road watering, it has been designed to be a multifunctional piece of equipment. Typical uses of the Tanker are as follows: 1. Road Watering with Spray Heads or Gravity Spray Bar. 2. Fire Fighter (Water only) with Monitor or Spray Heads. 3. Washing down heavy equipment with high-pressure jets from the monitor. The tank has a capacity of 30,000 liters and can be filled from an overhead storage tank through the fill funnel located in the top of the tank or from a reservoir such as a lake, pond, river etc. using the onboard pump provided through 4” cam lock. This water dispensing system drive by Engine-PTO’s for more safely and long lasting. Water pumping is carried out by a SOUTHERN CROSS ISO-SOUVEREIGN 100*65-250 heavy duty centrifugal pump which has 1350 liter/minute flow rate. The control and monitoring panel for the system and pump unit is located in the driver’s cabin and includes an automatic shutdown system which is activated and shuts the hydraulic system down in the event of low water level in the tank. The system is fitted with a 10 bar water pressure relief valve which opens when excessive pressure is developed in the system, it can be caused the engine RPM is too high for the water volume being dispensed or the engine is run at high RPM and all dispensing points are closed. This prevents damage to the pump and in particular the pump seals from the water in the pump overheating. There is also a control switch located alongside the driver which controls the water delivery volume and pressure by increasing or decreasing the engine RPM. Additional controls located in this control box include pneumatic switches to control the spray heads, electric switches for all strobe lights and work lights and an audio visual alarm, which alerts the operator when the water level is low. The alarm is activated by a float switch installed in the tank, which also shuts down the system when water falls below the safe working level. Water dispensing is completed with two MAGNUM SPRAY HEADS located at the rear platform of the tanker for road watering. These spray heads can be adjusted for spray angle and type to ensure optimum distribution of water on the road. Moreover as be alternative for road watering, we can also use a GRAVITY SPRAY BAR which manual operated use gravitation for watering. There is a MAGNUM WATER MONITOR located on the top of tank at rear, which can be used to direct a jet of water in the desired direction. To complete the function of water discharging system, there is 1 ½” suction hose at right side of platform which can be used for hand watering, washing down, fire fighter and filling storage tanks by connecting the hose to suction hose. There is a 4” male coupler suction located on the left side of platform, which can used as be filling point when we want to filling water from a reservoir. Operating Instructions
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WATER TRUCK 32KL on VOLVO FMX 440 8x4
2.3. Operating Procedures 2.3.1. At the Beginning of Each Shift 1. Check the hydraulic oil level in the tank. 2. Check the water level in the tank and refill as necessary. 3. Briefly open the tank drain valve (gravity valve) and check that pure water is discharged. Should water not flow freely from the drain or if significant amounts of sediment are discharged, the tank should be emptied by the normal method and then returned to maintenance for cleaning of all sediment. 4. Ensure the main butterfly valve for supply of water from the tank to the pump inlet is in the open position and all other valves are in the correct position for the desired operation. 5. Ensure all items are properly secured for operation.
2.3.2. Road Watering Operation Procedures
In this case the Hydraulic Gear Pump is coupled to PTO Engine, it should to start the Engine first by pushing the ignition start switch to the “Start” position. As soon as the engine has started and the oil pressure rises to normal, release the Tattletale button. a. By Spray Heads : 1. Set all Butterfly Valves to the required position a. Butterfly Valve to Water Pump
Open Position
b. Butterfly Valve Pump to Spray Heads
Open Position
Closed position
d. Butterfly Valve for Water Canon
Closed position
e. Butterfly Valve for Gravity Spray Bar
Closed position
c. Butterfly Valve for Drain Suction
Picture 2.1 On Board Pump Set 2. Drive the Truck to about 100 meters before the desired watering point. Operating Instructions
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WATER TRUCK 32KL on VOLVO FMX 440 8x4
3. Turn on the Main Switch located the cabin dashboard.
Picture 2.1 Main Control Switch on dashboard
4. Put the truck in gear and accelerate to the desired road watering speed. 5. When the truck reaches the point where road watering is to begin, select the required spray head(s) on the cab control panel and turn to the “On” position. 6. Increase the water output and pressure by increase the engine RPM until the desired output is reached. 7. Continue road watering operation until the end of the area of watering is reached or the tank reaches the low water level. 8. If the end of the road watering area is reached before the water in the tank is exhausted, the road watering operation must be stopped by : a. Return the RPM engine to the idle position. b. Turn the spray heads switch off and close butterfly valve for spray head. c. Turn the Main Switch off and close butterfly valve for water pump. d. If watering is to be suspended for more than 1 minute the engine should be switched off to prevent pump seal damage. 9. If water in the tank is exhausted before the end of the area of road watering is reached, the low water level will warn to the operator by indicator light then automatically shut down the water dispensing system. b. By Gravity Spray bar : This tanker is completed with gravity spray bar as buffer system in the case of the water dispensing system is break down. The system can be operated by turn the butterfly valve for gravity spray bar located under the water pump to “open” position. That’s are ready to road watering. After the area of road watering is reached stop watering by close the valve.
Operating Instructions
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WATER TRUCK 32KL on VOLVO FMX 440 8x4
2.3.3. Water Canon / Monitor Operation Procedure 1. Set all valves to the required position : a. Butterfly Valve to Water Pump
Open Position
b. Butterfly Valve Pump to Spray Heads
Closed Position
c. Butterfly Valve for Drain Suction
Closed position
d. Butterfly Valve for Water Canon
Open position
e. Butterfly Valve for Gravity Spray Bar
Closed position
2. Drive the Truck to about 100 meters before the desired watering point. 3. Turn on the Main Power Switch located the main electrical control panel. 4. Mount the rear operator platform, release the swivel locks and point the Monitor to the desired direction. 5. Fully open Butterfly Valve for water canon and start spraying water by monitor. 6. When spraying with the Monitor is completed, close butterfly valve for water canon to stop spraying operation and dismount the operator platform. 7. If water in the tank is exhausted before Monitor operation is completed, the low water level alarm will sound the warning light will come on then automatically shut down the water dispensing system.
2.3.4. Draining Water from the Tank Using the Onboard Pump Set 1. Set all butterfly valves to the required position a. Butterfly Valve to Water Pump
Closed Position
b. Butterfly Valve Pump to Spray Heads
Closed Position
c. Butterfly Valve for Drain Water
d. Butterfly Valve for Water Canon
Closed position
Closed position
e. Butterfly Valve for Gravity Spray Bar
Open position
2. Remove the cam-lock cap located under the tank and connect the suction hose assembly. 3. Open Butterfly Valve for drain water. 4. When the tank is empty, close the butterfly valve for drain water. 5. Remove the suction hose from the Cam-lock coupling and refit the Cam-lock cap. 6. Dismantle the suction hose assembly and return to the appropriate storage positions.
Operating Instructions
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WATER TRUCK 32KL on VOLVO FMX 440 8x4
Note : If water in the tank in the limit level, the low water level light will warn to the operator then automatically shut off the water dispensing system. In this condition, there is little water spare in the tank. If we want to continue operation as the emergency condition or to exhaust all residual water in the tank, switch “On” the emergency switch which located in the right behind of cabin. And returns the emergency switch to “Off”, when water in the tank is filled.
Picture 2.2 Emergency Button This vehicle also completed with work lamp and strobe lamp to support in being process and fulfill safety requirement.
Picture 2.3 Work/Strobe Lamp Switch Attention: 1. Always shutdown the water dispensing system after the operations have been completed and when all butterfly valves are in the closed position to prevent pump seal damage. 2. Carry out regular inspections of the tanker and report any problems or concerns. 3. The tank should be kept filled with water at all times. 4. Frequently check and confirm the operation of the low level alarm.
Caution:
High pressure jets from the Monitor can cause bodily harm, never point them at any person. Beware, a wet tank can be very slippery, climbing on the tank can be hazardous. Always exercise extreme caution and use only designated hand rails and no skid walkways.
Operating Instructions
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WATER TRUCK 32KL on VOLVO FMX 440 8x4
3
MAINTENANCE SCHEDULE
Maintenance Schedule
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WATER TRUCK 32KL on VOLVO FMX 440 8x4
3.1. General Our products are built to high standards and are engineered to give years of dependable service, but regular attention is recommended for continuous efficient running. Maintenance procedures are carefully set out in this booklet to enable the operator to obtain the most satisfactory performance from the equipment and operators are expected to perform these recommended maintenance procedures as a condition of our warranty. When renewing parts, use only genuine parts, as they are correctly designed and manufactured to exacting standards of quality control to ensure optimum performance. When ordering parts, always quote the component or equipment serial number and type designation. Illustrated parts lists are available on “Part List Components” Section. The following schedule refers to Water Tanker System running under normal conditions. During servicing, replace defective items with genuine parts.
3.2. Water Tanker System Maintenance Attention
An eventual maintenance contract for your system does not release you of your obligation to take care of good maintenance.
Filling the oil tank above the maximum level can result in overflow of the tank.
Grease all turning points prior to long lasting standstill to avoid sticking turning points by rust.
Maintenance near or on rotating parts is dangerous
Clean the outside of the filler opening of the tan prior to refilling to avoid contamination of the hydraulic system.
If there is direct eye contact with hydraulic oil then rinse it out with plenty of water for at least 15 minutes. Then consult a physician.
Maintenance Schedule
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WATER TRUCK 32KL on VOLVO FMX 440 8x4
1.
TASK
30
90
180 365 730
Other
2-Yearly
Annually
14
Six-Monthly
7
Quarterly
1
Monthly
days >>
Bi-Weekly
Weekly
Item
Daily
Initially and after 2 wks
3.3. Maintenance Schedule Chart
Comments
Attachment Structure
Grease the bushing and all turning parts through grease nipples
X
X
Check all structural for wear or cracks
X
X
Check and adjust all bolt/nut torque’s
X
X
2.
Hydraulic & Pneumatic Line Ensure the Hydraulic Oil Level & add to permitted level as necessary
X
Check Hydraulic Lines for Leaks
X
Check Pneumatic Lines for Leaks
X
Ensure the hydraulic & Pneumatic system are working properly
X
Ensure Condition of Hoses & Fittings are fitted properly
X
3.
Use Oil Shell Tellus 68
X
Electric Line
Check Electrical Lines for Fretting
X
Check Strobe Light Operation
X
Check Work Light Operation
X
Check Rear Brake & Turn Lights and clean lenses as necessary
X
Ensure the Control Panel is working properly
X
Control Box Fuses
X
Check the solenoid valve spool/coil for malfunction 4.
X
X
X
X
X
Water Dispensing System
Check Spray Head Positioning & Adjust to reach for good saturation
Check Pump - Bearings & Seals for leaks
Check All Nut & Bolt Torque and retighten as necessary
Maintenance Schedule
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WATER TRUCK 32KL on VOLVO FMX 440 8x4
Clear Debris from Pump Inlet Strainer
X
Check Water Lines for Leaks
X
Check the gear coupling for loose, wear or crack
X
Check all butterfly valve for leak
X
Ensure the Monitor /Water canon working properly
X
NOTES:
1. The life expectancies of the various components are estimates only 2. If the product fails any portion of the weekly inspection, it must be internally inspected immediately. 3. Please refer to the appropriate detailed parts and maintenance manual on each product in “Supporting Parts Manual” Section.
Maintenance Schedule
14
WATER TRUCK 32KL on VOLVO FMX 440 8x4
4
SCHEMATIC DIAGRAM
Schematic Diagram
15
WATER TRUCK 32KL on VOLVO FMX 440 8x4
4.1. Schematic of Hydraulic System
Schematic Diagram
16
WATER TRUCK 32KL on VOLVO FMX 440 8x4
Schematic Diagram
17
WATER TRUCK 32KL on VOLVO FMX 440 8x4
4.2. Schematic of Pneumatic System
Schematic Diagram
18
WATER TRUCK 32KL on VOLVO FMX 440 8x4
4.3. Schematic of Electric System
Schematic Diagram
19
WATER TRUCK 32KL on VOLVO FMX 440 8x4
Schematic Diagram
20
WATER TRUCK 32KL on VOLVO FMX 440 8x4
5
PART LIST COMPONENTS
Part List Components
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WATER TRUCK 32KL on VOLVO FMX 440 8x4
5.1. Hydraulic System Part List
No.
Part no.
1
140.16.300
Description/Picture
Qty
1 pc
HYVA 100L/79L Hydraulic Tank
2
147 80 306
1 pc
HYVA Return Line Filter
3
081 02 116
1 pc HYVA Filler Breather
4
14562030
1 pc HYVA Gear Pump 092-BI-4H-Brite Series
5
---
1 pc
HYVA Oil Level & Temperature Gauge
6
BV.HV.1.1-2
1 pc HYVA Brass Ball Valve 1 ½”
Part List Components
22
WATER TRUCK 32KL on VOLVO FMX 440 8x4
7
26M 65A1C20
1 pc
VICKERS 26M65 Hydraulic Vane Motor
8
PC100/1-8
1 pc
NUCLEO Modular Directional Control Valve
9
KC5018
1 pc
KC5018 Chain Coupling
10
LA-G20-31.5BZ-80
1 pc Flow Control with Check Valve 1”
11
AH1012-CD1
1 pc
COOLBIT Hydraulic Fan Cooler
Part List Components
23
WATER TRUCK 32KL on VOLVO FMX 440 8x4
5.2. Water System Part List
No.
Part no.
1
PSGD2A
Description/Picture
Qty
1 pc
SOUTHERN CROSS PSGD2 100X65-250 Centrifugal Pump
2
CDCV-W
1 pc TOZEN Doubledoor Check Valve 4”
3
BFV-W W/P 16 BAR
3 pcs
YONE Butterfly Valve 4”
4
W/P PN10
2 pcs YONE Butterfly Valve 2½”
5
MFW.A
1 pc
HISEC Safety Valve 2”
6
2234
1 pcs
MAGNUM Water Cannon - MM40 Part List Components
24
WATER TRUCK 32KL on VOLVO FMX 440 8x4
7
400DC
1 pc 4“ CAMLOCK Alumunium Cap
8
A400
1 pc 4“ CAMLOCK Alumunium Body
9
200.209.TFJ205
1 pc TOZEN Twin Flex Rubber Joint 2½”
10
200.209.TFJ205
2 pcs TOZEN Twin Flex Rubber Joint 4”
11
2 pcs
7182278 MAGNUM Spray Head Maxi
Part List Components
25
WATER TRUCK 32KL on VOLVO FMX 440 8x4
5.3. Electric-Pneumatic Control Part List No.
Part no.
1
PL4224.AH
Description/Picture
Qty
1 pc PRIMER LIGHT PL4224-AH 12-36VDC Strobe Lamp
2
PL1511
1 pc PRIMER LIGHT Work Lamp
3
300.318.ELEC.20PL1511.24
1 pc PRIMER LIGHT Work Lamp (PL1511) 24 volt
4
KW-210ARW
2 pcs LED Rear Combination Lamp
5
JF32-LS
1 pc
Low Level Switch
6
PA5110
1 pc Buzzer Standard 12-48VDC 80dB
Part List Components
26
WATER TRUCK 32KL on VOLVO FMX 440 8x4
5.4. Other Part List
No.
Part no.
1
300.338.FLAP950.700.2
Description/Picture
Qty
2 pcs
Mud Flap 950x700mm 2 ply
2
300.360.BELT.06
2 pcs
Mud Guards
3
BX-1040360394
1 pc
Toolbox
Part List Components
27
WATER TRUCK 32KL on VOLVO FMX 440 8x4
6
SUPPORTING PARTS MANUAL
Supporting Parts Manual
28
WATER TRUCK 32KL on VOLVO FMX 440 8x4
6.1 HYVA SUPPORTING PARTS
HYVA Supporting Parts
29
WATER TRUCK 32KL on VOLVO FMX 440 8x4
6.1.1. Hyva Gear Pump 2030
HYVA GEAR PUMPS EXTERNAL GEAR TYPE - BRITE SERIES Hyva
gear pump type : part number : rotation :
page # 1 / 2
specifications
gear pump 092L - BI - 4H - BRITE 145 62 030 bi-rotational
power and torque
displacement per revolution maximum peak pressure maximum intermittent pressure maximum continuous pressure maximum speed without load max. speed at intermittent press. min. speed at intermittent press. oil temperature range inlet pressure range (suction side) recommended oil viscosity range maximum starting viscosity filtration : - working pressure < 200 bar - working pressure > 200 bar connection : - inlet - straight internal thread - outlet - straight internal thread minimum suction hose bore diameter shaft DIN 5462 mass noise level at 900 min-1 and 100 bar noise level at 1500 min-1 and 100 bar
3
: 91,56 : 265 : 265 : 205 : : 2250 : 400 : -25 80 : 12 3 : 12 100 : 750
cm bar bar bar min-1 min-1 min-1 o C bar (abs) mm2/s (cSt) mm2/s (cSt)
: :
m m
25 10
: 1,25 : 1,25 : 1,75 : 8*32*36 : 17,0 : 64,8 : 68,3
“ B.S.P. “ B.S.P. inch mm kg dB(A) dB(A)
efficiency diagram on request
pressure definition
Pressure (bar)
50
100
150
200
250
265
Torque (Nm)
84
159
230
298
359
375
Power (kW) 500
4
8
12
16
19
20
1000
9
17
24
31
38
39
1500
13
25
36
47
56
59
2000
18
33
48
62
75
78
2500
22
42
60
78
94
98
500
44
43
43
42
42
42
1000
88
86
85
85
84
84
1500
132
130
128
127
127
127
2000
176
173
171
169
169
169
2500
220
216
213
212
211
211
Flow (L/min.)
p (bar) 1)
hydraulic pump symbol
2)
3)
max. 20 s
1) max. peak pressure
max. 8 s
2) max. intermittent pressure
3) max. continuous pressure subject to change without notice
DO-E 14562030 / 07 05 29 / RV AB
HYVA Supporting Parts
30
WATER TRUCK 32KL on VOLVO FMX 440 8x4
HYVA GEAR PUMPS EXTERNAL GEAR TYPE - BRITE SERIES Hyva
gear pump type : part number : rotation :
page # 2 / 2
gear pump 092L - BI - 4H - BRITE 145 62 030 bi-rotational
24
drawing for part number reference only
2 18 15
8
25 6 19
27 30 13 31
21 17
11 22 4
26
16
9 28
10 29
23 1 3 14 5
spare part list gear pump pos. 1 2 3 4 5 6 8 9 10 11 13 14 15 16 17 18 19 21 22 23 24 25 26 27 28 29 30 31
code no. 145 62 030 01 145 62 030 02 022 59 405 145 62 030 04 145 62 030 05 145 62 030 06 145 62 030 07 145 62 030 09 145 62 030 10 145 62 030 11 145 62 030 13 145 62 030 14 145 62 030 15 145 62 030 16 145 62 030 17 145 62 030 18 145 62 030 19 145 62 030 21 145 62 030 22 145 62 030 23 145 62 030 24 145 62 030 25 145 62 030 26 145 62 030 27 145 62 030 28 145 62 030 29 145 62 030 30 145 62 030 31
145 62 030
description body front cover thrust plate Brite drive shaft driven gear roller bearing screw dowel 1/8" washer lock washer O-ring seal shaft seal shaft seal shaft seal circlip circlip back-up ring spacer spacer for cover sleeve bearing threaded locking ring back-up washer steel support shaft ball steel bushes steel plug protection plug
subject to change without notice
qty. 1 1 2 1 1 2 8 2 8 1 1 2 1 1 1 1 1 2 1 1 4 1 1 1 2 4 2 1
seal kit code no. 024 60 005
description seal kit complete
qty. 1
(comprises 13, 14, 15, 16, 17, 21 & 26)
general information and mounting possibilities. The mentioned data on page 1 is for mineral based oil. For other fluids, please contact our engineering dept. The filtration as mentioned is for tippers only. For different applications we advise filtration according ISO 4406 class 17/14. To avoid cavitation, the suction hose must be kept as short and straight as possible, and the minimum oil level in the oil tank must be above the inlet of the pump.
Side and/or rear ports can be used as desired. Torque plugs: ¾" 60 Nm 1" 75 Nm 1¼" 115 Nm
DO-E 14562030 / 07 05 29 / RV AB
HYVA Supporting Parts
31
WATER TRUCK 32KL on VOLVO FMX 440 8x4
6.1.2. Gear Pump Kit
GEAR PUMP KIT KIT CB 082 WITH OPTIONS Hyva
kit :
gear pump 082L - BI - 4H - BR
page # 1 / 1
kit number :
CB 082
6 5
3
7
4
2
1
gear pump 082L - BI - 4H - BR : pos. 2 3 4 5 7
code 147 99 000 145 62 025 013 13 848 017 17 933 146 24 850
high pressure adapter : suction adapter :
straight straight
1" hose connection 1¾" hose connection
gear pump 082L - BI - 4H - BR : pos. 2 3 4 5 6 7
code 147 99 000 145 62 025 013 13 848 017 17 933 013 17 982 146 24 850
CB 082 AC
description qty. hose pillar LD28 - 1"BSPOT 1 gear pump 082L - BI - 4H - BR 1 bonded seal 1" 1 straight adapter 1"BSPOT - 1"BSPOT 1 ISO -seal 4H 1
CB 082 BC
description qty. hose pillar LD28 - 1"BSPOT 1 gear pump 082L - BI - 4H - BR 1 bonded seal 1" 1 straight adapter 1"BSPOT - 1"BSPOT 1 adapter 90o 1"BSPIT - 1"BSPOT 1 ISO -seal 4H 1
high pressure adapter : suction adapter :
90o straight
1" hose connection 1¾" hose connection
gear pump 082L - BI - 4H - BR : pos. 1 3 4 5 7
code 147 99 020 145 62 025 013 13 848 017 17 933 146 24 850
high pressure adapter : suction adapter :
straight 90o
1" hose connection 1¾" hose connection
gear pump 082L - BI - 4H - BR : pos. 1 3 4 5 6 7
code 147 99 020 145 62 025 013 13 848 017 17 933 013 17 982 146 24 850
CB 082 AD
description qty. 1 hose pillar 90o LD28 - 1"BSPOT gear pump 082L - BI - 4H - BR 1 bonded seal 1" 1 straight adapter 1"BSPOT - 1"BSPOT 1 ISO -seal 4H 1
CB 082 BD
description qty. 1 hose pillar 90o LD28 - 1"BSPOT gear pump 082L - BI - 4H - BR 1 bonded seal 1" 1 straight adapter 1"BSPOT - 1"BSPOT 1 adapter 90o 1"BSPIT - 1"BSPOT 1 ISO -seal 4H 1
high pressure adapter : suction adapter :
subject to change without notice
90o 90o
1" hose connection 1¾" hose connection
DK-E CB082 / 07 06 01 / RV AB
HYVA Supporting Parts
32
WATER TRUCK 32KL on VOLVO FMX 440 8x4
6.1.3. Oil Tank
HYVA OIL TANK
R
Hyva
Standard tank series
Oil tank model：
Page # 1 / 1
Part NO.
V
TYPE
L
B
H
L1
L2 ΦD
56281 052
52L
066L/052L-CM-MP-RF 500 300 500 90 155 Φ11
56281 060
60L
076L/060L-CM-MP-RF 570 300 500 90 155 Φ11
56281 077
77L
098L/077L-CM-MP-RF 720 300 500 123 290 Φ11
56281 088
88L
112L/088L-CM-MP-RF 820 300 500 123 290 Φ11
56281 108 108L 132L/108L-CM-MP-RF 750 350 550 123 305 Φ13 56281 120 120L 148L/120L-CM-MP-RF 840 350 550 123 305 Φ13 56281 130 130L 153L/130L-CM-MP-RF 700 350 685 123 250 Φ13 56281 140 140L 165L/140L-CM-MP-RF 750 350 685 123 305 Φ13 56281 158 158L 185L/158L-CM-MP-RF 840 350 685 123 305 Φ13
Part list NO. Part NO. 1
Mounting instruction Name
QTY Remark
Tank body
1
Check tank opening and connections if there are residual packing, pollutant or micro granule before mounting.
2
081 02 129
Oil level indicator
1
3
L206A
Heighten flange ASSY
1
KIT
4
081 02 116
Air filter ASSY
1
KIT
5
14780306
Return filter ASSY
1
Description Pay attention to the following points ● Mount the tank according the mounting instructions； ● Fill the tank with the recommended hydraulic oil to the
centre of the spy glass (level indicator)； ● Change the oil once a year； ● Replace the return filter and air breather filter every 6
months；and replace them every 3 months at least in severe environment (for example mining area)； ● Do not use the tank as support or to stand on； ● Do not weld to the oil tank.
Installation of tank support beam
The tank should be mounted closely to cylinder while mounting it on support beam, and be sure that after mounting: a. The side of oil level indicator should be towards outside； b. Do not interfere with other parts of vehicle, installation of HP oil hoses and operation of ball valves under tank. Use the rubber pads together with the bolts, washers and self-locking nuts. Make sure all four bolts are evenly tightened. Do not overtighten the bolts, since this can damage pads and cause deformation of tank, so it will cause leakage. Seal the ball valves and connections correctly with fluid sealant or Teflon tape. Content such as have change without prior notice
EC‐C OIL 5628 1000 20110105 RV AA
HYVA Supporting Parts
33
WATER TRUCK 32KL on VOLVO FMX 440 8x4
6.1.4. Air Breather Filter 6.6.2. Air Breather Filter
HYVA Supporting Parts
34
WATER TRUCK 32KL on VOLVO FMX 440 8x4
6.1.5. Return Line Filter
6.6.3. Return Line Filter
HYVA Supporting Parts
35
WATER TRUCK 32KL on VOLVO FMX 440 8x4
Vickers® Service Data
Vane Motors
Vane Motors 25M & 26M Series -20 Design
6.2 VICKERS 26M65 Vane Motor
Revised 12/01/87
M-2741-S
VICKERS Vane Motor
36
WATER TRUCK 32KL on VOLVO FMX 440 8x4
Model Designation 2*M*A-**20 2*M*B-**20
Cover 312140 317283
11165 Screw (4 req’d) Torque to 100 5 lb. ft.
Model Designation
Cartridge Kit
2*M42*-**20 2*M55*-**20 2*M65*-**20
923160 923161 923162
Back-up Ring
”O” Ring
271699 187000
Screw (2req’d) Torque to 2-4 lbf. ft.
Pressure Plate S/A (Including Bushing and Pins)
276618
312145
Rotor
Vane Kit 10 Vanes 30 Springs
Pin (2 req’d)
Ring
Pressure Plate
312155
923158
158465
313426 313427 313428
312143
These parts are services in Cartridge Kit
Vickers, Incorporated 1997 All Rights Reserved
VICKERS Vane Motor
37
WATER TRUCK 32KL on VOLVO FMX 440 8x4
Model Designation 25M**-**20 26M**-**20
Bearing 1705 232750
120128 Retaining Ring 191400 Lock Ring
Screw Mounting Bracket Model (Incl. Screws) (2 req’d) FB-B-10 199740 2*M**()-**20 (Viewed from Shaft End) 2 = Body Port @ 12 O’clock Position 3 = Body Port @ 3 O’clock Position 6 = Body Port @ 6 O’clock Position 9 = Body Port @ 9 O’clock Position
Back-up Ring (See table) ”O” Ring (See table) 312152 Hub Adapter Seal (See table) ”O” Ring (See table)
Mounting Bracket (See table)
”O” Ring (See table) Back-up Ring (See table) 224476 Wiper 394976 Shaft Seal 190362 Washer
Screw (See table) Model Designation 2*M*A-**20 2*M*B-**20 Model Designation 2*M**-1*20 2*M**-3*20 2*M**-11*20
Back-up Ring
Shaft 312153 431243 312154
Body 312139 317282
Key 9955
Back-up Ring
Model Designation
Cartridge Kit
”O” Ring
2*M42*-**20 2*M55*-**20 2*M65*-**20
923160 923161 923162
187000 271699 154080 271791 312388 278708
”O” Ring
”O” Ring
Seal
These parts are serviced in Cartridge Kit
Service all units with F3 Seal Kit 923157
VICKERS Vane Motor
38
WATER TRUCK 32KL on VOLVO FMX 440 8x4
Model Code
1
Model Series
1
25 - Standard bearing 26 - Heavy duty bearing Vane Motor
2
M 3
Ring Capacity Torque Rating (lbf. in per 100 PSI)
25 30 35 42 55 65 -
25 30 35 42 55 65
2
3
4
AB5
2369-
4
5
6
7
Port Connections 4 bolt flange Str. thread Bracket Mounting (Viewed from shaft end) Body port @ 12 o’clock Body port @ 3 o’clock Body port @ 6 o’clock Body port @ 9 o’clock
8
9
7
A - Cover port opposite body port B - Cover port 90 CCW from body port C - Cover port in line with body port D - Cover port 90 CW from body port 8
Shaft Type
Design Number
20 9
6
Port Locations (Viewed from cover end)
Special Features
1 - Straight keyed 3 - Straight threaded 11 - Splined
When ordering spare cartridge parts, it is recommended they be obtained in cartridge kits. Kits are assembled and tested before shipment.
For satisfactory service life of these components in industrial applications, use full flow filtration to provide fluid which meets ISO cleanliness code 20/18/15 or cleaner. Selections from Vickers OFP, OFR, and OFRS series are recommended. Printed in U.S.A.
VICKERS Vane Motor
39
WATER TRUCK 32KL on VOLVO FMX 440 8x4
6.3. SOUTHERN CROSS 100x65-250 Series Centrifugal Pump
Southern Cross Centrifugal Pump
40
WATER TRUCK 32KL on VOLVO FMX 440 8x4
Southern Cross Centrifugal Pump
41
WATER TRUCK 32KL on VOLVO FMX 440 8x4
Southern Cross Centrifugal Pump
42
WATER TRUCK 32KL on VOLVO FMX 440 8x4
Southern Cross Centrifugal Pump
43
WATER TRUCK 32KL on VOLVO FMX 440 8x4
Southern Cross Centrifugal Pump
44
WATER TRUCK 32KL on VOLVO FMX 440 8x4
Southern Cross Centrifugal Pump
45
WATER TRUCK 32KL on VOLVO FMX 440 8x4
Southern Cross Centrifugal Pump
46
WATER TRUCK 32KL on VOLVO FMX 440 8x4
Southern Cross Centrifugal Pump
47
WATER TRUCK 32KL on VOLVO FMX 440 8x4
Southern Cross Centrifugal Pump
48
WATER TRUCK 32KL on VOLVO FMX 440 8x4
6.4. MAGNUM MM40 Monitor Water Cannon
Magnum MM40 Water Canon
49
MAGNUM AUSTRAL
WATER TRUCK 32KL on VOLVO FMX 440 8x4Australia Melbourne,
Reno, Nevada. USA. www.mywatermark.com
www.magnumaustralia.com
MM40 - Manual Monitor Easy installation Pressure tested to 3000 kpa 40mm (1 ½") BSP M Inlet Connection Engineered balanced and compact design - see dimensions Positive fixed positional swivel brake locking Designed for mobile or fixed mounted applications Patented "non-flog" Magnum Australia swivel bearings Accepts Magnum Mini Valve (MMV/B) for adjustable fan spray Director nozzle supplied as standard - 16mm ( 5 /8 ") orifice - 30 metres water throw at 7 bar All s/s fasteners and locking components 12 month product warranty Spare parts readily available Fully serviceable R
300
520
631
840
water monitor
300
360
299
Inlet 1 1/2 ” BSPM (40mm) Nozzle outlet 5 /8 ” (16mm)
M M 4 0
Anaid Nominees Pty Ltd ABN 86 004 924 994 35 Parkhurst Drive, Knoxfield, Victoria, Australia 3180 Telephone: (61 3) 9801 8433 Facsimile: (61 3) 9800 3240 Email: [email protected] Web: www.magnumaustralia.com Magnum MM40 Water
Canon
50
WATER TRUCK 32KL on VOLVO FMX 440 8x4
Monday, April 28, 2008 17:11:10
Magnum MM40 Water Canon
51
