JBT Manual

TABLE OF CONTENTS
CHAPTER 5. MANUFACTURERS APPENDICES
Section 1. Introduction
GENERAL
DESCRIPTION
Section 2. Power Module
CUMMINS INC.
CUMMINS ENGINE QSB 4.5 T3 - OPERATION AND MAINTENANCE MANUAL WITH
PARTS CATALOG
PARTS CATALOG
Section 3: Transmission
GEAR PRODUCTS, INCORPORATE
GEAR BOX PARTS LIST
Section 4. Axle
WESTPORT COMPANY
STEERABLE AXLES FRONT AXLE (625-9152) FRONT AXLE SERVICE MANUAL
MERITOR HEAVY VEHICLE SYSTEMS, LLC
Q-PLUS LX500 MX500 CAM BRAKES, MAINTENANCE MANUAL
ALLIED SIGNAL CORPORATION - BENDIX HEAVY VEHICLE SYSTEM GROUP
BRAKES SERVICE DATA
MANUFACTURERS APPENDICES 5-Contents

Page 1
February 2014
LINCOLN
AUTOLUBE MANUAL
Section 5. Hydraulics
GRESEN MANUFACTURER DANA CORPORATION
MGG2 HYDRAULIC MOTORS SERVICE MANUAL
MGG2 HYDRAULIC MOTORS PARTS CATALOG
GULF CONTROLS CORPORATION
MONARCH 24VDC ELECTRIC PUMP M326-0214 (EMERGENCY PUMP) MANUAL
PARKER-HANNIFIN CORPORATION
PARKER-HANNIFIN HYDRAULIC VALVE PUMP MANUAL
D1VW SERIES DIRECTIONAL VALVES MANUAL
D3W SERIES DIRECTIONAL VALVES MANUAL
SUN HYDRAULICS CORPORATION - (SOLENOID CARTRIDGE VALVES)
CARTRIDGE SERVICE BULLETIN
EATON CORPORATION
420 MOBILE PISTON PUMP MODEL CODES (E-PUPI-TH001-E)
420 PUMP SERIES INSTALLATION INFORMATION (E-PUPI-TI006-E)
420 MOBILE PISTON PUMP CATALOG MANUAL (E-PUPI-TM002-E)
420 MOBILE PISTON PUMP SERVICE PARTS MANUAL (E-PUPI-TP002-E)
TRW, ROSS GEAR DIVISION
HYDRAULIC MOTOR MG, MF, MB, ME SERIES SERVICE PROCEDURE
SAUER SUNDSTRAND
PISTON PUMP SERVICE MANUAL
HYDRAULIC MOTOR SERVICE MANUAL
Section 6. Fluid
TASKFORCE TIPS INCORPORATE
5-Contents MANUFACTURERS APPENDICES

Page 2 .
February 2014
ANTI-ICING NOZZLES TECHNICAL MANUAL
HARDI INCORPORATE
COLD AND HOT FLUID PUMPS DISASSEMBLY INSTRUCTIONS AND LUBRICANT
F.E. MYERS COMPANY
TWO STAGE CENTRIFUGAL PUMP INSTALLATION, SERVICING AND PARTS MANUAL
MISCO VIP INLINE
PROCESS REFRACTOMETER, INSTRUCTIONAL MANUAL
RECTORSEAL - SOOTOMAGIC
HEATER SOOT REMOVAL INSTRUCTIONS
Section 7: Miscellaneous
DAVID CLARK COMPANY INCORPORATE
SERIES 3800 INTERCOM SYSTEM INSTALLATION/OPERATION INSTRUCTIONS
MODELS H3332, H3392 PARTS LIST
ANSUL FIRE PROTECT
INSTALLATION, RECHARGE, INSPECTION AND MAINTENANCE
TROUBLESHOOTING, AND PROGRAMMING
SAGE FLOW MONITOR
INSTALLATION, OPERATION, AND BATTERY REPLACEMENT PROCEDURES
SIGNET FLOW TRANSMITTER
TRANSMITTER INSTRUCTIONS, AND ELECTRICAL INSTRUCTIONS
MILLER
LANYARD AND SHOCK ABSORBER INSTRUCTIONS
GENERAL REQUIREMENTS
JBT AEROTECH
DEICING MONITOR
GENERAL OPERATING INSTRUCTIONS AND PARTS SALES
MANUFACTURERS APPENDICES 5-Contents

Page 3
February 2014
ACCESIBLE TECHNOLOGIES, INC.
AIR FIRST SUPERCHARGER, OPERATION AND MAINTENANCE
AIRTRONIC/ESPAR HEATER SYSTEMS
TECHNICAL DESCRIPTION, INSTALLATION, OPERATING AND MAINTENANCE
INSTRUCTIONS, TROUBLESHOOTING AND REPAIR, HEATER PARTS
CLARSON
TECHNICAL DOCUMENTATION AND OPERATING INSTRUCTIONS
5-Contents MANUFACTURERS APPENDICES

Page 4 .
February 2014
CHAPTER 5. MANUFACTURERS APPENDICES
Section 1. Introduction
WARNING
BEFORE ATTEMPTING TO OPERATE OR MAINTAIN THE VEHICLE, COMPLETELY READ AND
UNDERSTAND THE OPERATION AND MAINTENANCE MANUAL, INCLUDING ALL DANGER,
WARNING, AND CAUTION STATEMENTS. VEHICLE MAINTENANCE MUST BE PERFORMED
EXCLUSIVELY BY TRAINED AND QUALIFIED TECHNICIANS AND ACCORDING TO
MAINTENANCE SCHEDULES AND MANUFACTURERS RECOMMENDATIONS. FAILURE TO
COMPLY WITH THIS WARNING MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR
PROPERTY DAMAGE, INCLUDING DAMAGE TO THE VEHICLE! IF YOU HAVE ANY
QUESTIONS REGARDING THE SAFE OPERATION OR PROPER MAINTENANCE, PLEASE
CONTACT YOUR LOCAL JBT AEROTECH SERVICE CENTER BEFORE PROCEEDING.
This chapter contains instruction bulletins, parts lists, service manuals, etc., issued by major
manufacturers appendices of the Tempest Aircraft Deicer.
Information is included only for components that are considered repairable.
A list of manufacturers and their CAGE codes is included for those major components in Chapter 4,
Section 2.
INTRODUCTION 5-1
Page 1
February 2014
THIS PAGE INTENTIONALLY LEFT BLANK
Section 2: Power Module
CUMMINS INC.
PARTS CATALOG
PARTS CATALOG
MANUFACTURERS APPENDICES 5-2

Page 1
February 2014
Section 3. Transmission
GEAR PRODUCTS, INCORPORATE
GEAR BOX PARTS LIST
5-3
MANUFACTURERS APPENDICES
Page 1
February 2014
Section 4. Axle
WESTPORT COMPANY
STEERABLE AXLES FRONT AXLE (625-9152) FRONT AXLE SERVICE MANUAL
MERITOR HEAVY VEHICLE SYSTEMS, LLC
Q-PLUS LX500 MX500 CAM BRAKES, MAINTENANCE MANUAL
ALLIED SIGNAL CORPORATION - BENDIX HEAVY VEHICLE SYSTEM GROUP
BRAKES SERVICE DATA
LINCOLN
AUTOLUBE MANUAL

Page 1
February 2014
I-BEAM & TUBULAR
STEERABLE AXLES
FRONT AXLE PUSHER & TAG
SERVICE MANUAL
ISO 9001
INDEX
THIS MANUAL COVERS THE FULL LINE OF WESTPORT AXLES.

Section Description Page No.
Section I General Information ..................................................... 3

Section II Model and Part Identification ..................................... 4-6
Section III Troubleshooting Guide ............................................ 7-12
Rev. 1/2/00
-2-
SECTION I
GENERAL INFORMATION
SEAL
BUSHING
WHEEL STOP
SPINDLE
TAPERED PIN
(DRAWKEY)
THRUST
WASHER
SEALED THRUST
BEARING
TIE ROD
END
DESCRIPTION
All Westport axles whether I-Beam or Tubular are of an inclined King Pin configuration as shown
in the illustration above. With the exception of the tubular beam, the I-Beam, knuckles, tie rod and
steer arms are forged, heat treated, high strength carbon or alloy steel.
Inclined king pins of straight (non-tapering) form connect the knuckle to the axle and act as
pivots. The upper and lower ends of the king pins fit into replaceable, steel-backed bronze bushings
which are pressed and burnished into the knuckle yokes. Supplementing the king pin bushings
are steel tapered roller thrust bearings which carry the weight of the axle center and, subsequently
the entire weight of the front of the vehicle.
Steering and tie rod arms are designed to attach to the steering knuckle through a tapered
hole using a Woodruff key for positioning. This allows the axle to be custom built with regards to
specific steering and tie rod arm choices.
All Westport axles that are fully dressed with brakes and wheel equipment at the factory use
the oil bath (wet) system exclusively. Greased wheel ends available, upon request.
Rev. 1/2/00
-3-
SECTION II
MODEL and PART IDENTIFICATION
MODEL IDENTIFICATION
BARE
MODEL RATING DESCRIPTION DROP AXLE
WEIGHT
F4W-0800 8K I-BEAM, STEERABLE AXLE Double 4.0"/1" 240
*F5W-0900 9K I-BEAM, STEERABLE AXLE 5.0" 310
F5W-1200 10.5K, 12K I-BEAM, STEERABLE AXLE 5.0" 315
F3W-1300 13.2K I-BEAM STEERABLE AXLE 3.5" 363
F6W-1400W 14.6K I-BEAM STEERABLE AXLE (Widetrack) 5.62" 373
F3W-1600 17K I-BEAM STEERABLE AXLE 3.5" 396
F6W-1600 17K I-BEAM STEERABLE AXLE 5.62" 415
F3W-2000D 21.5 K I-BEAM STEERABLE AXLE Double 3.5"/2.5" 458
FOW-1300 13.2K TUBULAR STEERABLE AXLE 0 337
FOW-1400 14.6K TUBULAR STEERABLE AXLE 0 337
FOW-1600 16K TUBULAR STEERABLE AXLE 0 370
FOW-1800 18K, 20K TUBULAR STEERABLE AXLE 0 389
FlW-1300 13.2K TUBULAR STEERABLE AXLE 1.5" 380
FlW-1400 14.6K TUBULAR STEERABLE AXLE 1.5" 380
FlW-1600 16K TUBULAR STEERABLE AXLE 1.5" 413
ALL AXLE WEIGHTS ARE LESS STEERING ARM
* Discontinued. Call Westport for parts availability.
Rev. 1/2/00
-4-
PART IDENTIFICATION
SEALED SCREW-IN STYLE KING PIN CAP

1. Axle Beam
2. Tapered Pin (Draw Key)
3. Tapered Pin Nut
4. Thrust Bearing 9
5. Shim Pack
LOWER
6. Seals 6
2 7
7. King Pin Bushing
5
8. Kin Pin 8
1 3
9. Screw-in Cap 22
-5-
10. Knuckle 21 20
11. Thrust Washer

12. Wheel Bearing Nut
15
13. Cotter Pin 18 14
3
4
14. Stop Bolt 17
6
15. Tie Rod Arm 16
2 18 11
16. Woodruff Key UPPER
17
17. Castle Nut (Tie Rod Arm) 10
16 19
18. Cotter Pin (Tie Rod Arm) 7 12

19. Tie Rod Assembly
13
20. Castle Nut (Tie Rod Assembly) 9
21. Cotter Pin (Tie Rod Assembly)

22. Steering Arm
Rev. 1/2/00
SECTION II
Refer to pages 22, 23 and 24 for repair kits.

PART IDENTIFICATION
CONVENTIONAL BOLT-ON STYLE KING PIN CAP
1. Axle Beam
2. Tapered Pin (Draw Key)
3. Tapered Pin Nut 11
4. Thrust Bearing
5. Shim Pack 10
LOWER
6. Seals 6
2
9
7. King Pin Bushing
5
8. Kin Pin
7
9. Gasket 1
10. King Pin Cap 8
11. Bolt (King Pin Cap) 25
3
-6-
12. Knuckle
13. Thrust Washer
3 23
14. Wheel Bearing Nut 4
15. Cotter Pin 6 24
2 16
16. Stop Bolt 21
UPPER
17. Grease (Zerk) Fitting 20 18
19
18. Tie Rod Arm 21
19. Woodruff Key 17
20. Castle Nut (Tie Rod Arm)
12 13
21. Cotter Pin (Tie Rod Arm) 22
20 19
22. Tie Rod Assembly 7
14
23. Castle Nut (Tie Rod Assembly)
9
24. Cotter Pin (Tie Rod Assembly) 15
25. Steering Arm
10
SECTION II
Rev. 1/2/00
Refer to pages 22, 23 and 24 for repair kits.
SECTION III
TROUBLE SHOOTING
CONDITION CAUSE CORRECTION
Steering Wheel Kick 1. Looseness in steering system 1. Inspect/replace or repair all

from steering wheel to tires. loose components.
2. Worn king pin bushings. 2. Replace with king pin kit.
3. Worn tie rod ends. 3. Replace tie rod end.
4. Loose/worn wheel bearings. 4. Adjust or replace wheel

bearings.
Darting/Oversteer 1. King pin bind. 1. Replace with king pin kit.

2. Tie rod end bind. 2. Replace tie rod end.
NOTE: The steering wheel kick cause can be affected by problems

from shock absorbers, pump, or air in system.
The darting/oversteer cause can be affected by problems

from U-joints, steering gear, miter box, or fifth wheel.
NOTES:
Rev. 1/2/00
-7-
SECTION III
TROUBLE SHOOTING
Hard to steer 1. King pin bind 1. Grease king pin

- or -
2. Tie rod end bind
Replace with king pin kit
3. Rusted thrust bearing
2. Grease tie rod ends
4. Incorrect front end alignment - or -
Replace ends
5. Axle overload
3. Replace with king pin kit
4. Align front end
5. Check front end weight

Adjust if necessary
Non-steering Wheel 1. Same as Hard to Steer 1. Same as Hard to Steer

Recovery
2. Same as Hard to Steer 2. Same as Hard to Steer
3. Same as Hard to Steer 3. Same as "Hard to Steer

4. Same as Hard to Steer 4. Same as Hard to Steer
NOTE: The Hard Steering cause can also include problems from
the power steering system, gear, pump, steering linkage, fifth
wheel or tires. These items must be considered when trying
to solve this problem.
NOTES:
Rev. 1/2/00
-8-
SECTION III
TROUBLE SHOOTING
Directional Pull 1. King pin bind 1. Replace with king pin kit
2. Tie rod end bind 2. Replace tie rod end

3. Incorrect front end alignment 3. Align front end
4. Improper wheel bearing 4. Adjust/replace wheel
adjustment bearings
5. Tires 5. Check tire pressure, correct

if necessary
Check for tire damage,
replace tire if necessary
Check for uneven wear,
6. Axle overload 6. Check front end weight
Adjust if necessary
Road Wander 1. Worn king pin bushings 1. Replace with king pin kit
2. Worn tie rod ends 2. Replace tie rod ends
3. Loose or worn wheel bearings 3. Adjust/replace wheel
bearings
4. Looseness in steering system
from steering wheel to tires 4. Inspect/replace or repair all
loose components
5. Tires
5. Check tire pressure, correct
if necessary
Check for tire damage,
Check for extreme wear,

6. Front end alignment 6. Align front axle
7. Vehicle alignment 7. Align all vehicle axles
Rev. 1/2/00
-9-
SECTION III
TROUBLE SHOOTING
Shimmy 1. Worn king pin bushings 1. Replace with king pin kit
2. Worn tie rod ends 2. Replace tie rod ends
3. Loose or worn wheel 3. Adjust/replace wheel
bearings bearings
4. Looseness in steering system 4. Inspect/replace or repair all

from steering wheel to tires loose components
5. Front end alignment 5. Align front axle
6. Vehicle alignment 6. Align all vehicle axles
7. Tires and/or wheels out of 7. Balance or replace wheels

balance and/or tires
8. Worn shocks 8. Replace shocks
Front Suspension - 1. Worn king pin bushings 1. Replace with king pin kit
Noise Groans
or Creaks 2. Worn tie rod ends 2. Replace tie rod ends
3. Loose or worn wheel 3. Adjust/replace wheel

bearings bearings
4. Looseness in steering system 4. Inspect/replace or repair all

from steering wheel to tires loose components
NOTES:
Rev. 1/2/00
- 10 -
SECTION III
TROUBLE SHOOTING
Uneven, Aggressive, 1. Incorrect tire pressure 1. Correct air pressure in tires

Irregular Tire Wear
2. Mismatched tires 2. Make sure front tires are
same size and type
3. Tires out of balance 3. Balance tires and wheels
4. Front axle out of alignment 4. Align front axle
5. Lug nuts not torqued properly 5. Inspect/torque to required

values
6. Front suspension weak or 6. Repair/replace worn
with loose attachments components. Torque
fasteners to specified values
7. Align rear axle
7. Rear axle out of alignment
8. Replace with king pin kit
8. Worn king pin bushings
9. Replace tie rod ends
9. Worn tie rod ends
10. Replace arms to reduce
10. Incorrect tie rod arms ackerman error
11. Re-spec axle. Redistribute
11. Designed axle rating not load weight
matched to actual loads
Worn Tie Rod Ends 1. No lubrication 1. Grease or replace

2. Boot damaged 2. Replace boot or end
3. Excessive preload in tie 3. Replace tie rod end
rod ends
NOTES:
Rev. 1/2/00
- 11 -
SECTION III
TROUBLE SHOOTING
Worn King Pin 1. No lubrication 1. Grease or replace with King

and King Pin Bushings Pin Kit
2. Incorrect lube procedure 2. Refer to lube chart

section VI
3. Incorrect lube 3. Refer to lube chart
section VI
4. Lube frequency not 4. Refer to lube chart
matched to vocation section VI
5. Alemite missing 5. Repair/replace

6. King pin gaskets 6. Replace with king pin kit
worn/missing
Bent or Broken 1. Damage caused by accident 1. Inspect/replace damaged

Front Axle components
Components - or-
Replace axle assembly
2. Front axle over loaded 2. Adjust front axle loads or

replace with different axle
3. Power steering system 3. Adjust power steering

exceeds designed axle system
requirements
4. Abuse 4. Train in proper techniques

and driving habits
5. Incorrect welding on tube
axles 5. Refer to section IV or
contact Westport Eng.
NOTES:
Rev. 1/2/00
- 12 -
Corporate Office: BP Tower
200 Public Square
Suite 2520
Cleveland, Ohio 44114
T: 216.875.7515
F: 216.623.0620
sales@westportaxle.com
www.westportaxle.com
I-BEAM & TUBULAR
STEERABLE AXLES
SERVICE MANUAL
ISO 9001
INDEX

Section IV General Repair/Replacement ................................ 13-22

1. General Precautions/Inspections ..................... 13-15
2. King Pin & Knuckle ........................................... 16-18
3. Tie Rod End .......................................................... 19
4. Wheel Bearing.................................................. 20-21
5. Tube Axle Repair ................................................... 21
Section V Repair Kits............................................................. 22-24

1. All Kingpin Kits - Conventional or Sealed ......... 22-24
2. Knuckle Kits ............................................................ 24
3. Tie Rod Ends.......................................................... 24
Rev. 1/2/00
-2-
SECTION IV
GENERAL REPAIR / REPLACEMENT
a. Cleanliness is very important FIG. 1- BUSHING REMOVING AND

when making repairs. Provide a INSTALLING TOOL
clean place to work.
F4W-0800
b. When assembling, apply an ample
quantity of lubricant to bearing
surfaces and king pins.
c. For safety purposes, use
stationary jacks under axle when
removing wheels. Do not allow
weight to rest on a hydraulic jack
for any length of time. F5W-0900
F5W-1000
d. Use only suitable solvent, such F5W-1200
as kerosene, to wash parts.
Thoroughly dry all parts
immediately after cleaning.
e. The tool, illustrated in Figure 1,

should always be used when
installing new knuckle bushings to
prevent collapse or distortion of
bushings. F3W-1300 F6W-1300
F3W-1400 F6W-1400
F3W-1600 F6W-1600
F3W-2000
F3W-2000D
MAKE LOCALLY FROM BAR STOCK
Rev. 1/2/00
- 13 -
SECTION IV
BASIC INSPECTION
1. Inspect all front axle fasteners for looseness. If loose, retorque to proper value. If worn,
replace.
2. Inspect axle parts for wear or damage, bent or cracked. If detected - replace.
3. Make certain parts move freely through axle turn.
4. Inspect for tire wear patterns.
VERTICAL END - PLAY OF STEER KNUCKLE

1. Raise vehicle off the ground. Support with jack stands.
2. With a dial indicator place magnetic base on I-beam. Place pointer end of indicator on
upper king pin grease cap.
3. Pry the knuckle DOWN.
4. Set dial indicator to ZERO.
5. Pry the knuckle UP.
6. Reading must be between .002 - .010 inch
7. If ZERO, remove shims. If reading exceeds .025, Inspect thrust bearing. Replace, if
necessary, readjust using shims.
KING PIN BUSHING INSPECTION

1. Raise vehicle off the ground. Support with jack stands.
2. With a dial indicator place magnetic base on I-beam. Place pointer end of indicator against
upper steer arm lobe of knuckle. Zero indicator.
3. Move tire/wheel in and out with a push pull motion.
4. If dial indicator reads .010 inch or more, king pin bushings need replacement.
5. Repeat process for lower bushing.
6. If either bushing indicates wear, replace both.
Rev. 1/2/00
- 14 -
SECTION IV
TIE ROD END INSPECTION
1. Grab crosstube to move in any direction. If any movement or looseness is detected,

replace tie rod ends.
WHEEL BEARING INSPECTION
1. Remove bearings.
2. Clean bearings and spindle with a suitable solvent.
3. Inspect rollers cups, and cones for wear, pitting or chipped condition.
4. If detected - replace bearings.
5. Inspect spindle for worn, damaged, or discolored/burnt condition on bearing surfaces.
6. If detected - replace knuckle.
7. If water or other contaminates are found in the wheel cavity replace oil seal.
8. If oil is detected on brake shoes or brake drum area replace oil seal.
TUBE AXLE INSPECTION
1. Inspect welds on tube axles with regards to add on brackets, axle seats, etc., for weld
cracks or broken welds.
2. If the crack or break extends into the tube axle, do not repair. Replace axle tube.
3. If the crack or break is only in the weld, refer to the weld repair section.
Rev. 1/2/00
- 15 -
SECTION IV
KING PIN & KNUCKLE REPLACEMENT
STEERING KNUCKLE REMOVAL
NOTE: This service and repair procedure is with axle I-beam left in place on vehicle.
Disassembly operations should be performed in the following order:

1. Hub caps - remove. Use a container to catch oil.
2. Raise front end until wheels (tires) just clear floor. Place stationary jacks under
axle I-beam.
3. Cotter Pin, Nut and Washer - remove from knuckle spindle.
4. Outer Bearing Cone - shake wheel to remove; then slide wheel off.
NOTE: A wheel dolly should be used to facilitate the removal and installation of wheels.
5. Inner Bearing Cone - remove.

6. Bearings - lift off and set aside for cleaning and inspection.
7. Bearings Cups - if necessary remove from wheel hub.
8. Oil Seal - remove from spindle.
9. Drag Link- disconnect at steering knuckle upper arm.
10. Tie Rod - disconnect at knuckle lower arm.
11. Brake Line - disconnect at brake chamber.
12. Foundation Brake Assembly - remove from knuckle as a complete assembly by first
removing nuts and bolts.
13. Grease Caps and Gaskets - remove from top and bottom of knuckle yoke.
14. Tapered Pin (Draw Key) - remove nut and drive out using bronze drift on threaded end.
15. King Pin - drive out.
16. Knuckle Shims and Thrust Bearing - remove.
17. Fittings - remove (If installed in knuckle).
18. Knuckle Bushing Seal - remove.
19. Knuckle Bushings - if worn, remove, using tool as shown in Figure 1.
NOTE: These operations are for left side. Repeat on opposite side with exception of
Step No. 9.
Rev. 1/2/00
- 16 -
SECTION IV
STEERING KNUCKLE INSTALLATION

1. Knuckle Bushings - conventional bolt on cap - align lube holes on bushings with holes in
knuckle. Press bushings in. Holes in knuckle and bushing must be in-line. Use installation
tool shown in Figure 1, page 13 for this operation.
1a. Knuckle Bushings - sealed screw-in cap - press bushings to dimensions shown. Use
installation tool shown in Figure 1, page 13 for this operation.
2. Ream Bushings to dimensions shown in Figure 2, page 18. Clean bore of shavings.
3. Install king pin seals. See Figure 2, page 18.
4. Install lube fittings. (If steer knuckle has provision).
5. Position and support knuckle on axle.
6. Install thrust bearing - between lower face of I-beam and lower leg of steer knuckle. The
seam created by the top and bottom half of the thrust bearing should point toward the
ground.
7. Align holes of knuckle, I-beam and thrust bearing.
8. Place jack under steer knuckle. Raise to obtain CRUSH on thrust bearing. With feeler
gauge, check clearance between top face of I-beam and upper leg of steer knuckle.
Clearance must not be less than .002, or more than .010. Install proper shims.
9. Align flat on king pin with lock pin holes in I-beam. Install king pin. Remove jack.
10. Install tapered lock pin/pins. Flat on pin to flat on king pin. Secure with locknut.
11. Install grease caps and gaskets.
12. Install foundation brake with bolts and locknuts.
13. Reconnect brake line.
14. Install tie rod assembly to tie rod arms. Secure with nuts and new cotter pins.
15. Reconnect drag link to steer arm. Secure with nuts and new cotter pins.
16. Install bearing cups, if removed from hub.
17. Install oil seal on spindle. Use installation tool.
18. Install inner wheel bearing on spindle. Dip in oil first.
19. Wheel/Hub. Place on spindle. Do not damage oil seal. Dip outer bearing in oil and install
on spindle in hub cavity.
20. Install thrust washer and nut. Hand tighten to draw hub and bearings together. Refer to
wheel bearing adjustment for final assembly. Secure with cotter pin.
21. Install hub caps. Add lubricant to fill line on hub cap or maximum to 1/8" over fill line.
22. Lube all fittings.
23. Adjust brakes, if disturbed.
24. Remove jacks and lower vehicle.
25. Check toe-in and adjust if necessary.
Rev. 1/2/00
- 17 -
SECTION IV
TOP
* POSITION SEAL
LIPS TOWARD BEAM
"A"
GREASE SEALS*
UPPER SEAL
INSTALL FLUSH
WITH KNUCKLE
SURFACE
"A"
LOWER SEAL
BOTTOM
"B" REAM BUSHINGS

(IN-LINE)
KNUCKLE BUSHING AND KING PIN SEAL INSTALLATION

FIG. 2
AXLE MODEL "A" BUSHING GAP "B" REAMED BUSHING DIMENSION
F4W-0800
.172 1.3020
.160 1.3010
F5W-0900
F5W-1000 .165 1.609
F5W-1200 .135 1.608
(All)
F3W-1300, F6W-1300
F3W-1400, F6W-1400
F3W-1600, F6W-1600 Flush with Top & Bottom 1.8125
(Conventional Knuckle Surface 1.8115
Grease Cap)
F3W-2000, F3W-2000D
(Conventional Flush with Top & Bottom 2.0029
Grease Cap) Knuckle Surface 2.0021
F3W-1300, F6W-1300
F3W-1400, F6W-1400
F3W-1600, F6W-1600 .25 1.8125
(Sealed .19 1.8115
Grease Cap)
Rev. 1/2/00
- 18 -
SECTION IV
TIE ROD END
TIE ROD END - REPLACEMENT
1. Remove tie rod assembly from tie rod arms.
2. Loosen clamp nut and unscrew tie rod ends.
3. Install tie rod ends so that the threaded end is past the slot in the tube.
4. Attach tie rod assembly to tie rod arm using nut and new cotter pin.
5. Adjust toe-in. Tighten clamp nuts.
6. On tie rod assemblies with rotating clamp, position clamp away from I-beam.
NOTES:
Rev. 1/2/00
- 19 -
SECTION IV
WHEEL BEARING ADJUSTMENT
WHEEL BEARING ADJUSTMENT

1. Screw wheel bearing adjusting nut against the thrust washer while wheel is rotated. Be
sure there is sufficient clearance between brake shoe and drum so that there will be no
brake drag.
2. Tighten nut to 200 Ft. Lbs. of torque while rotating wheel in both directions.
3. Back off nut one full turn.
4. Tighten nut to 50 Ft. Lbs. of torque while rotating wheel in both directions.
5. Back off nut 1/6 to 1/4 turn (see special instructions).
6. Check adjustment making sure wheel rotates freely. With a dial indicator place magnetic
base on wheel and pointer on end of spindle. Grasp wheel of hub and drum, and with a
push/pull action record amount of axial movement.
7. If movement between .001 - .005 inch, secure with new cotter pin.
8. If movement greater than .005, repeat adjustment procedure. If no movement recorded,
repeat adjustment.
SPECIAL INSTRUCTIONS:
Follow instructions below for proper wheel bearing adjustment on all axle models having 18
pitch thread on wheel ends.
5a. After 50 Ft. Lbs. torque, look for cotter pin hole alignment with nut slot, which can be in
vertical or horizontal position. Note this slot.
5b. Rotate this slot counter-clockwise to next cotter pin hole.
5c. This now equals 1/4 turn see Figure 3 on next page.
5d. Proceed with inspection.
SPECIAL INSTRUCTIONS
Follow instructions below for proper wheel bearing adjustment on all axle models having 12 or
14 pitch thread on wheel ends.
5a. After 50 Ft. Lbs. torque, look for cotter pin hole alignment with nut slot, which can be in
vertical or horizontal position. Note this slot.
5b. Select next clockwise adjacent nut slot.
5c. Rotate this slot counter-clockwise to align with original viewed cotter pin hole.
5d. This now equals 1/6 turn see Figure 3 on next page.
5e. Proceed with inspection.
Rev. 1/2/00
- 20 -
SECTION IV
WHEEL BEARING ADJUSTMENT - (cont'd.)
1/4 TURN 1/6 TURN
... SELECT NEXT (CLOCKWISE)

NUT/SLOT HERE...
IF YOU SEE
... ROTATE BACK (COUNTER-
COTTER PIN HOLE NUT/SLOT
CLOCKWISE) TO THIS POSITION.
(ALL OR PART) HERE... (TYP)
COTTER PIN
HOLES COTTER
PIN
HOLES
IF YOU SEE COTTER
PIN HOLE
... ROTATE (ALL OR PART)
NUT/SLOT BACK HERE...
COUNTER-
CLOCKWISE
TO HERE.
FIGURE 3
TUBE AXLE REPAIR

TUBE AXLE - REPAIR WELDING AND ADD-ON BRACKETS
1. If the crack or break is in the weld area only, grind or back gouge weld to base metal.
2. Reweld area
A. Preferably use welding rod that will produce a minimum 70,000 psi weld.
B. Prior to welding, clean weld joint of grease, dirt, paint, slag, rust, etc.
C. Make sure axle is grounded. However, not through the axle hub or wheel.
D. Bring tube to be welded to 50/60 degrees F. prior to welding.
E. Preheat area to be welded to 450 degrees, minimum, to prevent the formation of
martensite. (Brittle metal)
F. Weld in a flat or horizontal position.
G. A multi-pass weld is preferred.
H. The arc should not be broken at the end of each pass. Back up the electrode to fill in the
fillet crater, at the end of each pass.
I. Do not weld on top or bottom of the tube.
J. Do not test weld on the axle tube.
K. When complete, wrap the weld joint for controlled cool down. This procedure is highly
recommended.
NOTE: This process should also be used when affixing brackets to the tube, at the initial
installation.
Rev. 1/2/00
- 21 -
SECTION V
REPAIR PARTS KITS
Several kits are offered for king pin and knuckle bushing replacement. Provided in the king pin kit
are parts for a complete rebuild. There are separate kits for conventional or sealed style axles.
KING PIN REPAIR KITS

Refer to pages 5 and 6 for part identification and item number.
F4W-0800 SEALED
Kit Number Item Description Quantity
143698-0040 2 Pin Tapered - Upper 2
2 Pin Tapered - Lower 2
6 Seal King Pin 4
5 Shim .005 6
8 King Pin 2
9 Cap King Pin Screw In 4
4 Bearing, Thrust, T1370 2
7 Bushing, King Pin 4
F5W-0900, F5W-1000, F5W-1200 CONVENTIONAL

6 Seal - King Pin 4
10 Cap - King Pin 4
9 Gasket - Cap (not needed in sealed version) 4
11 Bolt Flanged HD 5/16-18 12
5 Shim - .015 2
5 Shim - .005 4
8 King Pin 2
4 Bearing - Thrust T163 2
7 Bushing - King Pin 4
Rev. 1/2/00
- 22 -
SECTION V
REPAIR PARTS KITS
F5W-0900, F5W-1000, F5W-1200 SEALED
6 Seal - King Pin 4
9 Cap - King Pin Screw In 4
5 Shim - .015 2
5 Shim - .005 4
8 King Pin 2
F3W-1300, F3W-1400, F3W-1600, F6W-1300, F6W-1400, F6W-1600

CONVENTIONAL
143698-0002 8 King Ping 2
2 Pin - Tapered - Lower 2
6 Seal - King Pin 2
9 Gasket - Cap 4
5 Shim - .016" 2
5 Shim - .005" 2
5 Shim - .010" 2
F3W-1300, F3W-1400, F3W-1600, F6W-1300, F6W-1400, F6W-1600 SEALED

143698-0052 8 King Ping 2
4 Bearing - Thrust T1822S 2
6 Seal - King Pin 4
9 Cap - King Pin 12/16K Screw In 4
5 Shim - .015" 2
5 Shim - .005" 2
5 Shim - .010" 2
Rev. 1/2/00
-23 -
SECTION V
REPAIR PARTS KITS
F3W-2000 CONVENTIONAL

143698-0018 8 King Pin 2
2 Pin - Tapered - Upper 2
6 Seal - King Pin 4
9 Gasket - Cap 4
5 Shim - .005" 2
5 Shim - .015" 2
5 Shim - .030" 2
10 Cap 4
11 5/16 Bolt 12
KNUCKLE KITS
Contact Westport for kit identification
NOTE: Westport requires axle serial number, (See Section IX for location), or Bill of
Material Number. (Example - 120600-0033)
TIE ROD ENDS

Contact Westport for part numbers.
NOTE: Westport requires axle rating (9K, 12K, etc.)
Rev. 1/2/00
- 24 -
200 Public Square
Suite 2520
T: 216.875.7515
F: 216.623.0620
I-BEAM & TUBULAR
STEERABLE AXLES
SERVICE MANUAL
ISO 9001
INDEX

Section VI Torque Specifications/Lubrication Chart ................ 25-28
Section VII Camber, Caster, Toe-in ......................................... 29-34

1. Overview ................................................................ 29
2. Front Axle Caster .............................................. 30-31
3. Front Axle Camber ................................................. 32
4. Front Axle Toe-In .................................................... 33
5. Other Factors Affecting Tire Wear .......................... 34
Section VIII General Warranty .................................................. 35-39

Recall Policy ............................................................... 39
Section IX Serial Number Location.............................................. 40
Rev. 1/2/00
-2-
SECTION VI
TORQUE SPECIFICATIONS
RECOMMENDED TORQUE VALUES
8K Axle 9K Axle 12/20K Axle

Item Description Torque Value Torque Value Torque Value
7/16" = 20-25 Ft. Lb. 7/16" = 20-25 Ft. Lb.

1 Brake Chamber Unit N/A
5/8" = 33-50 Ft. Lb. 58" = 33-50 Ft. Lb.
2 Brake Assembly/Torque Plate 1/2" = 75-90 Ft. Lb. 5/8" = 150-175 Ft. Lb. 5/8" = 150-175 Ft. Lb.
3 Brake Assembly/Torque Plate N/A 3/4" = 200-225 Ft. Lb.
4 Hub Cap 8K 9K 12/20
4a Zytel (Plastic) 12-16 Ft. Lb. 12-16 Ft. Lb. 12-16 Ft. Lb.
4b Cast Aluminum 12-16 Ft. Lb. 12-16 Ft. Lb. 12-16 Ft. Lb.
4c Stamped Steel 10-14 Ft. Lb. 10-14 Ft. Lb. 10-14 Ft. Lb.
5 Kin Pin Cap Screws N/A 6-10 Ft. Lb. 6-10 Ft. Lb.
6 Tie Rod Assembly Clamp Bolt 50 Ft. Lb. Min. 50 Ft. Lb. Min. 50 Ft. Lb. Min.
7 Tie Rod Arm 300 Ft. Lb. Min. 1-14 300 Ft. Lb. Min. 1-14 680 Ft. Lb. Min. 1 3/8-12
8 Steering Arm 300 Ft. Lb. Min. 1-14 300 Ft. Lb. Min. 1-14 680 Ft. Lb. Min. 1 3/8-12
9 Tie Rod Assembly to Arm 125 Ft. Lb. Min. 125 Ft. Lb. Min. 125 Ft. Lb. Min.
10 Tapered Locking Pin Nut 55-60 Ft. Lb. 55-60 Ft. Lb. 55-60 Ft. Lb.
11 Caliper Retainer Bolt N/A 12-20 Ft. Lb. 5/16-18 12-20 Ft. Lb. 5/16-18
(Rail Slide Hydraulic Brake)
17 Screw-in Grease Cap 75 Ft. Lb. 75 Ft. Lb. 75 Ft. Lb.
13 Bleeder Screw 5-15 Ft. Lb. 5-15 Ft. Lb. 5-15 Ft. Lb.
14 ABS Sensor Bolt 12-16 Ft. Lb.5/16-18 N/A 12-16 Ft. Lb. 5/16-18
(Pin Slide Hydraulic Brake)
Tie Bar Bolt
15 N/A N/A M10=40-50 Ft. Lb.
16 Caliper Retainer Bolt M12=70-80 Ft. Lb. N/A M12=70-80 Ft. Lb.
Caliper Retainer Nut
17 N/A N/A 3/4-16=60-80 Ft. Lb.
(ADB 1560 Air Disk Brake)
18 Caliper Retainer Bolt N/A N/A M20=400-500 Ft. Lb.

(DX195 Air Disk Brake)
Rev. 1/2/00
- 25 -
SECTION VI
LUBRICATION CHARTS
KING PIN GREASING

Procedure: Install grease through alemite until new grease can be seen purging from thrust bearing
and upper shim pack area. The purging may not occur with rubber sealed bearing
T-1920. If excessive pressure is used it may damage grease cap gasket. This situation
is for the lateral alemite design only. Use multipurpose NLGI 2 or any good equivalent
chassis lubrication.
Alemite Axle Operation Lubrication

Position Application Type Interval
Lateral side of the Front steer Normal 6 Mo. / 5000 miles

knuckle
Lengthy off road 3 Mo. / 2500 miles
Muddy, dusty
Tag & Pusher All 3 Mo. / 2500 miles
Top and Front steer Normal 6 Mo. / 5000 miles

bottom
screw-in Lengthy off road 3 Mo. / 2500 miles
design Muddy, dusty
Whichever comes first
Rev. 1/2/00
- 26 -
SECTION VI
LUBRICATION CHARTS
TIE ROD ENDS GREASING

Procedure: Install grease through alemites until new grease can be seen purging from
sealing boot. Use multipurpose NLGI 2 or any good chassis lube.
Axle Operation Lubrication

Application Type Interval
Front Normal 6 Mo. / 5000 miles

steer
Lengthy off road 3 Mo. / 2500 miles
Muddy, dusty
Rev. 1/2/00
- 27 -
SECTION VI
LUBRICATION CHARTS
WHEEL BEARING LUBRICATION

Procedure: Remove the filter plug and add lubricant. After the oil has been allowed to flow through
the bearings (which takes a few minutes), double check if the oil reached the oil level
line on hub cap face. Use EP-SAE 90 gear oil or any good equivalent petroleum
base or synthetic lubricant. DO NOT MIX PETROLEUM BASED WITH SYNTHETIC
BASED OILS THIS COULD CAUSE OIL SEAL FAILURE.
Axle Operation Lubrication

Application Type Inspection
Front All 1000 miles

steer
Tag & Pusher All 1000 miles
WHEEL BEARING LUBRICATION GREASE

Procedure: Pressure or hand pack inner and outer bearings with E.P. NLGI, Grade 2 grease
Install inner wheel bearings on the spindle. Pump or hand pack grease Into the hub
cavity's entire circumference. Fill to level equal to the outer bearing cups inner diameter.
Install hub assembly onto spindle . Do not force entirely on to spindle. Install outer
bearing, thrust washer, and nut on the end of the spindle. Hand tighten to seat the
assembly. Coat the inside surface of the hubcap with a thin coat of grease. Do not fill.
Do not block or cover any hubcap vent/breather hole. Refer to wheel bearing adjustment
for final procedure. Install hubcap, gasket and fasteners. Refer to the torque chart for
proper torque values.
Rev. 1/2/00
- 28 -
SECTION VII
CAMBER, CASTER, TOE-IN DESCRIPTION/ADJUSTMENT
OVERVIEW
Excessive tire wear is one of the most frequently asked questions about front axle problems. Over
half of tire wear problems are caused by incorrect tire inflation pressures. However, tire wear is only
a symptom of a problem in the front axle steering system.
INCORRECT CAMBER CAUSES

LESS THAN 1% OF TIRE WEAR
PROBLEMS CASTER PROBLEMS CONTRIBUTE
LESS THAN 2% OF TIRE WEAR
PROBLEMS
APPROXIMATELY 2% OF
PROBLEMS ARE DUE TO
ACKERMAN GEOMETRY
LOOSE OR WORN COMPONENTS

MISALIGNED SINGLE AND AROUND 7% OF TIRE WEAR.
TANDEM AXLES ARE LOOSE COMPONENTS OFTEN
RESPONSIBLE FOR ABOUT 10% CONTRIBUTE TO TOE SETTING
OF TIRE WEAR PROBLEMS.
AFTER TIRE INFLATION,

INCORRECT TOE SETTINGS
ACCOUNT FOR OVER 80%
OF REMAINING TIRE
WEAR COMPLAINTS.
OVER HALF OF TIRE WEAR

PROBLEMS CAUSED BY
INCORRECT TIRE INFLATION
PRESSURES
Rev. 1/2/00
- 29 -
SECTION VII
FRONT AXLE CASTER
1. Front axle caster is the amount of fore and aft tilt at the top
CASTER
of the king pin, and is measured in degrees.
POSITIVE
2. "Positive" caster is when the top of the pin is tilted toward
the rear
3. "Negative" caster is when the top of the pin is tilted toward
the front.
4. I-Beam axles
Caster is adjusted normally with spacers at the I-Beam
spring pads and is set by the OEM.
Tubular axles SIDE VIEW
Caster setting gauge p/n 1989, can be obtained from FIGURE 6
Westport. This will aid in setting the caster angle on
tubular axles.
5. Caster improves directional stability.
6. Caster should be inspected with a loaded vehicle.
7. Uneven tightening of suspension fasteners can affect caster.
8. Caster does not normally affect tire wear. However, a maximum of 1/2 degree difference
from left side vs. right side must be maintained. Greater than 1/2 degree differential will
cause the vehicle to pull to the side with less caster.
9. Caster cannot and should not be adjusted by bending the I-Beam, cold or with heat. Any
attempts to do so will cause a dangerous condition. Warranty will not cover axles that are
adjusted this way.
CASTER AFFECTS:
Too Little Caster = Unstable steering Too Much Caster = Hard steering
Constant corrections Shimmy
Over steering Road shock
Road walk
Failure to return to straight ahead from a turn
NOTES:
(Continued on next page)
Rev. 1/2/00
- 30 -
SECTION VII
FRONT AXLE CASTER
CASTER SETTING:
As stated before the final caster setting is the responsibility of the OEM. However, the following is
a good starting point
Steerable Axles: 2 Degrees Positive = Best Tread Wear

4 Degrees Positive = Best Handling
Tag/Pusher Steerable Axles: Set Caster at 3 to 5 Degrees Positive
NOTE: Because of variation in axle types, suspension types, loads and position in the
chassis, we suggest you start with the least amount of caster. Increase the angle by 1/2
degree increments until tag/pusher axle stabilizes.
NOTES:
Rev. 1/2/00
- 31 -
SECTION VII
FRONT AXLE CAMBER
1. Front axle camber is the sideways

inclination of the wheel from a CAMBER
vertical plane.
2. Positive camber is an outward tilt or
inclination of the wheel at the top.
3. Negative camber is an inward tilt of the

wheel at the top.
4. Camber is not adjustable. No attempt
should be made to adjust camber by
bending the I-Beam, cold or with heat.
Any attempts to do so will cause a
dangerous condition. Warranty will not
cover axles that are adjusted this way.
5. Camber should be inspected with a
loaded vehicle.
6. Actual front axle loads different than

design loads will display values in
camber other than what was actually
designed. FIGURE 7
7. Too much camber, positive or negative will affect tire wear. This wear will show up on the
inside or outside edge of the tire.
CAMBER AFFECTS:
Too Much Positive = Excessive wear outside shoulder of tire
Quick steering response
Front end vibration
Too Much Negative = Hard steering

Possible wandering
Excessive wear inside shoulder of tire
Too Much Differential = Vehicle will pull to the side with greatest
Left side vs. right side amount of positive camber
Max. differential = 1/2 degree greatest positive camber
Rev. 1/2/00
- 32 -
SECTION VII
FRONT AXLE TOE-IN
1. Toe-In is the amount which the wheels

point inward at the front, and is B
A-B= TOE - IN
necessary to offset the effect of camber
on tire wear.
2. Maximum allowable camber requires
maximum allowable toe-in.
3. Proper toe-in along with camber will
insure long tire life.
4. Toe-in is measured from the center of
the treads at height of wheel centers.
5. Measurement should be made with the
wheels in a straight ahead position and A
after the vehicle has been moved

forward to take up all play in steering FIGURE 8 - TOE-IN
connections.
6. Toe-in adjustment must be taken with the tires on the ground with full load on axle.
7. Adjustment is made through the front axle tie rod assembly. The crosstube or the tie rod
assembly can be rotated, once the clamp fasteners are loosened, when adjustment is
completed secure fasteners on the clamps with the proper torque.
NOTE: Tie rod assemblies with welded clamps.

Do not cut weld to reposition clamp bolt after adjustment is completed. Clamp
bolt must be positioned over cut slot in the tube. Failure to do this can result in
a weakened attachment.
Tie rod assemblies with rotational clamps. (not welded)
After adjustment these clamps can be positioned 360 degrees around the tube
without sacrificing clamp load.
TOE-IN AFFECTS:
Excessive toe-in (positive) = Rapid tire wear on the outside shoulder of the tires.
Toe-out (negative) = Rapid tire wear on the inside shoulder of the tires.
TOE-IN SETTINGS:
Even though toe-in is the responsibility of the vehicle manufacturer or receiving dealer of the unit,
the following setting gives favorable results.
1/32 1/32 loaded unit
Rev. 1/2/00
- 33 -
SECTION VII
OTHER FACTORS THAT AFFECT TIRE WEAR
1. Fifth wheel placement and location of heavy components, such as batteries, fuel tanks, etc.
have a significant effect on weight distribution, therefore, tire wear.
2. Light front axle loads display irregular wear pattern.
3. Weak or improper sized shock absorbers.
4. Proper tire inflation.
5. Tire and wheel balancing.
6. Adjusted wheel bearings.
7. Loose or worn front axle and suspension components.
8. Bent axle parts.
9. Front axle squareness to the chassis.
10. With tandem rear axles. Squareness to the chassis and parallel to each other.
11. Improper Ackerman (tie rod) arms specified on axles that are installed into vehicles that
make many turns.
12. Trailer axle squareness and parallelism.
NOTE: Front axle alignment alone may not be the ultimate cure to tire wear problems.
Most of the items listed should be corrected or looked at first. Since many of these
items left unchecked could negate any front axle alignment.
Rev. 1/2/00
- 34 -
SECTION VIII
STANDARD WARRANTY POLICIES
Westport Axle warrants its axles to be free from defects in material or workmanship under normal
use and service with its obligations under this warranty being limited to repairing and/or replacing.
Westport reserves the right to examine all parts and records that are subject to warranty claim.
This warranty shall NOT apply to any axle or axle componentry which has been subject to misuse,
negligence or accident or has been altered or repaired outside the directives setup by Westport's
authorized dealers or engineering. This includes componentry (i.e. brake devices or wheel parts)
NOT certified by Westport Axle, yet installed later by the axle buyer or owner whom assumes all
responsibility as to the axle rating and performance.
This warranty is made expressly in lieu of any other warranties or conditions, expressed or implied,
including any implied warranty or condition of merchantability or fitness for a particular purpose and
any other obligations or liability on the part of the manufacturer including without limitations of the
foregoing consequential and incidental damages.
All conditions of warranty are NULL and VOID if any additional components are welded or drilled
after shipment from Westport, to any forged part such as I-beams, tie rods or steer arms, and knuckles
of the axle assembly. This also applies if proper weld process is not followed on Westport tubular
steerable axles. Refer to Section IV.
WESTPORT AXLE CORPORATION

837 East 79th Street Cleveland, OH 44103-1807
Phone: (216) 431-2000 Fax: (216) 431-0077
NOTE: Warranty coverage is bound by proper maintenance which includes scheduled

lubricant intervals. See Section VI for each particular axle requirement.
WARNING
TOE IN
Westport Axle Corporation is not responsible for final toe in, which can only be done on a truck
chassis or finished vehicle. When requested to provide a positive stop length it will be provided, but
must be checked and verified by the customer prior to releasing the assembly to their customer.
GREASE FITTING LUBRICATION
Westport Axle Corporation will grease all fittings on the axle assembly prior to shipment, but the
customer is resonsible to assure final lubrication to release to their customer.
OIL LUBRICATION
Westport Axle Corporation will provide proper wheel end oil fill at time of shipment to our customers
unless requested not to do so, however, due to possible static seepage from the hub cap, the
customer is responsible for proper oil level after the axle leaves our facility.
Rev. 1/2/00
- 35 -
WARRANTY COVERAGE AND LIMITATION * ALLOWANCES
HOURS MONTHS X MILES X KILOMETERS PARTS LABOR +
Construction type vehicle for Off-Highway use. Warranty

covers workmanship on beams, knuckles, steer and N/A 24 50,000 80,450 100% 12 Months Only
ackerman arms. Exclusions listed below - A and B.
Refuse type vehicle with primary use to utilize front or rear

loader compactor container attached. Exclusions listed N/A 24 100,000 160,900 100% 12 Months Only
below - A and B.
Highway tractor type vehicle used primarly to pull a trailer

on a smoothed paved surface. Exclusions listed below - A N/A 24 100,000 160,900 100% 12 Months Only
and B.
Straight truck type vehicle used primarily as a general

freight hauler that travels on a smoothed paved surface. N/A 24 100,000 160,900 100% 12 Months Only
Exclusions listed below - A and B
Fire apparatus or general utility type vehicle. Exclusions

N/A 24 100,000 160,900 100% 12 Months Only
listed below - A and B.
- 36 -
School or transit type vehicle or bus and recreational
N/A 24 100,000 160,900 100% 12 Months Only
vehicles. Exclusions listed below - A and B.
Axles used and retrofited for tag, pusher or lift suspension

utilized for weight distribution. Exclusions listed below - A N/A 12 25,000 40,225 100% 12 Months Only
and B.
Item A)
Warranty does not cover wearing parts such as King Pins, Wheel Bearings, Gaskets, Seals and Bushings. Also not covered are add-on components such as
wheel equipment, brake assemblies, air chambers and slack adjusters, these are covered under the warranties of the individual component manufacturer.
Item B)
No warranty will be allowed on parts that display misuse, general abuse or lack of prescribed maintenance. Westport Axle reserves the right to inspect and
review all vehicle records that pertain to general operational procedures.
X = Which ever occurs first, months or miles are implied. Must start at in service only.
* = Certain warranty coverage and limitations can be implied to a particular OEM company that has a previous agreement with Westport Axle
+ = Labor scales are negotiable due to constant changes in national average labor rates.
Rev. 1/2/00
SECTION VIII
SECTION VIII
WARRANTY NOTIFICATION FORM
A.Information Requested Below MUST BE COMPLETE Claim #: __________________
Date: _____________________
RETURN THIS FORM TO: FROM:

WESTPORT AXLE CORPORATION
ATTN: SALES DEPARTMENT ___________________________________________
(COMPANY)
837 EAST 79TH STREET ___________________________________________
CLEVELAND, OHIO 44103-1807 (ADDRESS)
___________________________________________
(CITY) (STATE) (ZIP)
PHONE: 216/431-2000 ___________________________________________
FAX: 216/391-1610 (PHONE) (FAX)
Part Description Axle Serial Number Purchased From Westport
NO: YES:
I-BEAM (Located on Spring Pad Edge)
TUBULAR (Located on Stub under Lock Pin) OTHER:
Axle Type: (circle one) FRONT STEER PUSHER TAG
Type of Vehicle: ________________________________________________________________________

Westport Axle Contract: __________________________________________________________________
Form Completed by: ____________________________________________________________________
Months in Miles in
Quantity Reason for Warranty Claim Service Service
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
DO NOT WRITE BELOW THIS LINE
PARTS RETURNED VIA (SHIPPER): ___________________________ B/L# (SHIPPER #):____________

REVIEWED BY: _________________________ DEPT:____________________ DATE:________________
ACCEPTED: ___________ REJECTED: ___________
COMMENTS:
ACKNOWLEDGE BY: SALES ___________________
ENGINEERING ____________________
QUALITY CONTROL ____________________
RETURN GOODS AUTHORIZATION
NUMBER (RGA#):_____________________________ PURCHASING ____________________
Rev. 1/2/00
- 37 -
SECTION VIII
INSTRUCTIONS FOR COMPLETION OF

WARRANTY NOTIFICATION FORM
To expedite and allow all pertinent details on your warranty claim to be as explicit and precise, please
note the following instructions:
1). Call the warranty or service department from whom you purchased the Westport axle or
component if further information is needed. Upon receipt Westport Axle will review the claim
and contact originator within three (3) days.
2). Months or Miles in service should have documentation when requested by Westport Axle.
Westport will accept an authorized Bill of Sale or some type of service contract.
3). If the assembly or component can be repaired without being returned, the Westport Axle
Warranty Notification Form must be completed and acknowledged to justify any recovered
expense(s).
4). If the assembly or component(s) must be returned to Westport Axle, an RGA number
(Return Goods Authorization) must be issued direct from Westport Axle Corporation. You
must call Westports Quality Assurance Department for this number.
5). All questions or request for written information on the Warranty Notification Form must be
answered exact and complete. Incomplete forms will be rejected.
6). Westport Axle Corporation reserves the right to inspect, question and verify all information
on the Warranty Notification Form.
7). When the claim information is completed and considered credible, a claim number will be
assigned by Westport Axle.
The phone number for Westport Axle Corporation is (216) 431-2000.

The fax number is (216) 391-1610.
Rev. 1/2/00
- 38 -
RECALL POLICY
For the purpose of understanding Westport's policy with regard to product recall, the following is
Westport's position:
1) Product recall -- Specifically mandated recall based on advice from the National Highway
Safety Board due to incidents of supposed product failure.
A. Westport will identify the specific population of potential problem axles and will notify those
customers of a potential recall.
1) Traceability of product will be done by heat codes and/or serial numbers produced during
a specific period of time.
2) Our customers will be requested to prepare a list of the final customers (end users) that
have received the suspect product.
3) We will advise what is to be replaced, i.e., specific part numbers at Westport's cost and
will identify average labor rates to apply and specific number of hours, or fractions thereof,
which will be allowed.
4) Such information will be made available once the replacement material is in stock and
verification tests have been run confirming potential problems. Testing will be waved
depending on failure mode.
5) All purchased components such as but not limited to brakes, hubs and drums, slack
adjusters, chambers, bearings, seals and hub caps are not Westport's direct responsibility
and will be passed on to the supplier of that component.
Rev. 1/2/00
- 39 -
SECTION IX
STAMPED SERIAL NUMBER LOCATION
SERIAL NUMBER OR
I-BEAM
xxxx
FRONT OF VEHICLE
LOCKPIN
XXXX
SERIAL NUMBER
TUBE
ASSEMBLY
Rev. 1/2/00
- 40 -
200 Public Square
Suite 2520
T: 216.875.7515
F: 216.623.0620
Issued 06-97
$2.50
TM
Q Plus LX500 and
MX500 Cam Brakes
Maintenance Manual No. MM-96173
Service Notes
This maintenance manual describes the correct service and repair procedures for Meritor Q PlusTM LX500
Service Notes
and MX500 cam brakes. The information contained in this manual was current at time of printing and is
subject to change without notice or liability.
You must follow your company procedures when you service or repair equipment or components.
You must understand all procedures and instructions before you begin to work on a unit. Some
procedures require the use of special tools for safe and correct service. Failure to use special tools when
required can cause serious personal injury to service personnel, as well as damage to equipment
and components.
Meritor uses the following notations to warn the user of possible safety problems and to provide
information that will prevent damage to equipment and components.
WARNING NOTE: A NOTE indicates an operation, procedure

A WARNING indicates a procedure that or instruction that is important for proper service.
you must follow exactly to avoid serious A NOTE can also supply information that will
personal injury. help to make service quicker and easier.
CAUTION
A CAUTION indicates a procedure that This symbol indicates that fasteners must
you must follow exactly to avoid damaging be tightened to a specific torque.
equipment or components. Serious personal
injury can also occur.
Visit Our Web Site Videos

Visit the Technical Library section of Meritor Cam Brake Maintenance
www.meritorauto.com for additional product (Video 90233)
and service information on Meritors
Drivetrain PlusTM component lineup. Automatic Slack Adjuster Installation and
Maintenance (Video 90234)
Drivetrain Plus Technical New Generation Automatic Slack Adjuster

(Video T-9443V)
Electronic Library (TEL) on CD
The CD includes product and service How to Order
information on Meritors Drivetrain PlusTM
Call Meritors Customer Service Center at
component lineup. $20. Order TP-9853.
800-535-5560.
Table of Contents
Asbestos and Non-Asbestos Fibers Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Exploded Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Section 1: Introduction
Q PlusTM LX500 Cam Brake Package with the Extended Lube Feature . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Q PlusTM MX500 Cam Brake with the Extended Maintenance Package Option
Available for On-Highway Linehaul Applications Only
Identifying Q PlusTM LX500 and MX500 Brakes
Q PlusTM LX500 Cam Brakes
Q PlusTM MX500 Cam Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Comparing 15-Inch Q PlusTM LX500 and MX500 Brakes with the 15-Inch Q Series Brake
Q PlusTM LX500 and MX500 Features
Specifications
Section 2: Disassembly
Remove Wheel Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Remove Brake Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Remove Camshaft and Slack Adjuster
Section 3: Prepare Parts for Assembly
Cleaning Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Dry Parts After Cleaning
Corrosion Protection
Inspect Parts
Slack Adjusters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Drums
Section 4: Assembly
Install Camshaft, Seals and Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
For Brake Assemblies with Cast Spiders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
For Brake Assemblies with Stamped Spiders
Install Brake Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Before Specified Time or Mileage Lubrication Intervals
After Specified Time or Mileage Lubrication Intervals
Q PlusTM LX500 and MX500 Specifications
Installing Meritors Automatic Slack Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Handed and Unhanded Slack Adjusters
Pull Pawls
Installation Procedure
Checking Brake Chamber Push Rod Stroke and Adjusting the Clevis Position . . . . . . . . . . . . . . . . . . .16
Brake Slack Adjuster Position (BSAP) Method
Meritors Automatic Slack Adjuster Template
Adjust the Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Section 5: Reline the Brakes
Reline the Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Table of Contents
Section 6: Lubrication
Lubrication Intervals for Q PlusTM LX500 and MX500 Cam Brakes with
Automatic Slack Adjusters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Do Not Lubricate the LX500 and MX500 Brakes and Automatic Slack Adjusters
Before Specified Time or Mileage Intervals
Lubricating the Q PlusTM LX500 and MX500 Cam Brakes and Automatic Slack
Adjusters After Specified Time or Mileage Intervals
Section 7: Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Section 8: Recommended Periodic Service
Recommended Periodic Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Section 9: Inspection
Brake Inspections Before the Recommended Lubrication Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Brake Inspections After the Recommended Lubrication Interval
Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Federal Roadside Inspection
Brake In-Service Adjustment Inspection
Truck or Tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Section 10: Torque Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Asbestos and Non-Asbestos Fibers
ASBESTOS FIBERS WARNING NON-ASBESTOS FIBERS WARNING
The following procedures for servicing brakes are recommended to reduce The following procedures for servicing brakes are recommended to reduce
exposure to asbestos fiber dust, a cancer and lung disease hazard. Material Safety exposure to non-asbestos fiber dust, a cancer and lung disease hazard. Material
Data Sheets are available from Meritor. Safety Data Sheets are available from Meritor.
Hazard Summary Hazard Summary
Because some brake linings contain asbestos, workers who service brakes must Most recently manufactured brake linings do not contain asbestos fibers. These brake
understand the potential hazards of asbestos and precautions for reducing risks. linings may contain one or more of a variety of ingredients, including glass fibers,
Exposure to airborne asbestos dust can cause serious and possibly fatal diseases, mineral wool, aramid fibers, ceramic fibers and silica that can present health risks if
including asbestosis (a chronic lung disease) and cancer, principally lung cancer and inhaled. Scientists disagree on the extent of the risks from exposure to these
mesothelioma (a cancer of the lining of the chest or abdominal cavities). Some studies substances. Nonetheless, exposure to silica dust can cause silicosis, a non-cancerous
show that the risk of lung cancer among persons who smoke and who are exposed to lung disease. Silicosis gradually reduces lung capacity and efficiency and can result in
asbestos is much greater than the risk for non-smokers. Symptoms of these diseases serious breathing difficulty. Some scientists believe other types of non-asbestos fibers,
may not become apparent for 15, 20 or more years after the first exposure to asbestos. when inhaled, can cause similar diseases of the lung. In addition, silica dust and
ceramic fiber dust are known to the State of California to cause lung cancer. U.S. and
Accordingly, workers must use caution to avoid creating and breathing dust when international agencies have also determined that dust from mineral wool, ceramic fibers
servicing brakes. Specific recommended work practices for reducing exposure to and silica are potential causes of cancer.
asbestos dust follow. Consult your employer for more details.
Accordingly, workers must use caution to avoid creating and breathing dust when
Recommended Work Practices servicing brakes. Specific recommended work practices for reducing exposure to
non-asbestos dust follow. Consult your employer for more details.
1. Separate Work Areas. Whenever feasible, service brakes in a separate area away
from other operations to reduce risks to unprotected persons. OSHA has set a maximum Recommended Work Practices
allowable level of exposure for asbestos of 0.1 f/cc as an 8-hour time-weighted average
and 1.0 f/cc averaged over a 30-minute period. Scientists disagree, however, to what 1. Separate Work Areas. Whenever feasible, service brakes in a separate area away
extent adherence to the maximum allowable exposure levels will eliminate the risk of from other operations to reduce risks to unprotected persons.
disease that can result from inhaling asbestos dust. OSHA requires that the following 2. Respiratory Protection. OSHA has set a maximum allowable level of exposure for
sign be posted at the entrance to areas where exposures exceed either of the maximum silica of 0.1 mg/m3 as an 8-hour time-weighted average. Some manufacturers of non-
allowable levels: asbestos brake linings recommend that exposures to other ingredients found in non-
DANGER: ASBESTOS asbestos brake linings be kept below 1.0 f/cc as an 8-hour time-weighted average.
CANCER AND LUNG DISEASE HAZARD Scientists disagree, however, to what extent adherence to these maximum allowable
exposure levels will eliminate the risk of disease that can result from inhaling non-
AUTHORIZED PERSONNEL ONLY
asbestos dust.
RESPIRATORS AND PROTECTIVE CLOTHING
ARE REQUIRED IN THIS AREA. Therefore, wear respiratory protection at all times during brake servicing, beginning
with the removal of the wheels. Wear a respirator equipped with a high-efficiency
2. Respiratory Protection. Wear a respirator equipped with a high-efficiency (HEPA) (HEPA) filter approved by NIOSH or MSHA, if the exposure levels may exceed OSHA or
filter approved by NIOSH or MSHA for use with asbestos at all times when servicing manufacturers recommended maximum levels. Even when exposures are expected to
brakes, beginning with the removal of the wheels. be within the maximum allowable levels, wearing such a respirator at all times during
3. Procedures for Servicing Brakes. brake servicing will help minimize exposure.
a. Enclose the brake assembly within a negative pressure enclosure. The enclosure 3. Procedures for Servicing Brakes.
should be equipped with a HEPA vacuum and worker arm sleeves. With the a. Enclose the brake assembly within a negative pressure enclosure. The enclosure
enclosure in place, use the HEPA vacuum to loosen and vacuum residue from the should be equipped with a HEPA vacuum and worker arm sleeves. With the enclosure
brake parts. in place, use the HEPA vacuum to loosen and vacuum residue from the brake parts.
b. As an alternative procedure, use a catch basin with water and a biodegradable, b. As an alternative procedure, use a catch basin with water and a biodegradable,
non-phosphate, water-based detergent to wash the brake drum or rotor and other non-phosphate, water-based detergent to wash the brake drum or rotor and other
brake parts. The solution should be applied with low pressure to prevent dust from brake parts. The solution should be applied with low pressure to prevent dust from
becoming airborne. Allow the solution to flow between the brake drum and the becoming airborne. Allow the solution to flow between the brake drum and the
brake support or the brake rotor and caliper. The wheel hub and brake assembly brake support or the brake rotor and caliper. The wheel hub and brake assembly
components should be thoroughly wetted to suppress dust before the brake shoes components should be thoroughly wetted to suppress dust before the brake shoes
or brake pads are removed. Wipe the brake parts clean with a cloth. or brake pads are removed. Wipe the brake parts clean with a cloth.
c. If an enclosed vacuum system or brake washing equipment is not available, c. If an enclosed vacuum system or brake washing equipment is not available,
employers may adopt their own written procedures for servicing brakes, provided carefully clean the brake parts in the open air. Wet the parts with a solution applied
that the exposure levels associated with the employers procedures do not exceed with a pump-spray bottle that creates a fine mist. Use a solution containing water,
the levels associated with the enclosed vacuum system or brake washing and, if available, a biodegradable, non-phosphate, water-based detergent. The
equipment. Consult OSHA regulations for more details. wheel hub and brake assembly components should be thoroughly wetted to
d. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA for use suppress dust before the brake shoes or brake pads are removed. Wipe the brake
with asbestos when grinding or machining brake linings. In addition, do such work in parts clean with a cloth.
an area with a local exhaust ventilation system equipped with a HEPA filter. d. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA when
e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a grinding or machining brake linings. In addition, do such work in an area with a local
HEPA filter when cleaning brake parts or assemblies. NEVER use carcinogenic exhaust ventilation system equipped with a HEPA filter.
solvents, flammable solvents, or solvents that can damage brake components as e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a
wetting agents. HEPA filter when cleaning brake parts or assemblies. NEVER use carcinogenic
solvents, flammable solvents, or solvents that can damage brake components as
4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter or wetting agents.
by wet wiping. NEVER use compressed air or dry sweeping to clean work areas. When
you empty vacuum cleaners and handle used rags, wear a respirator equipped with a 4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter
HEPA filter approved by NIOSH or MSHA for use with asbestos. When you replace a or by wet wiping. NEVER use compressed air or dry sweeping to clean work areas.
HEPA filter, wet the filter with a fine mist of water and dispose of the used filter with care. When you empty vacuum cleaners and handle used rags, wear a respirator equipped
with a HEPA filter approved by NIOSH or MSHA, to minimize exposure. When you
5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or replace a HEPA filter, wet the filter with a fine mist of water and dispose of the used filter
smoke. Shower after work. Do not wear work clothes home. Use a vacuum equipped with care.
with a HEPA filter to vacuum work clothes after they are worn. Launder them separately.
5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or
Do not shake or use compressed air to remove dust from work clothes.
smoke. Shower after work. Do not wear work clothes home. Use a vacuum equipped
6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters with a HEPA filter to vacuum work clothes after they are worn. Launder them separately.
with care, such as in sealed plastic bags. Consult applicable EPA, state and local Do not shake or use compressed air to remove dust from work clothes.
regulations on waste disposal. 6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters
with care, such as in sealed plastic bags. Consult applicable EPA, state and local
Regulatory Guidance regulations on waste disposal.
References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the
United States, are made to provide further guidance to employers and workers Regulatory Guidance
employed within the United States. Employers and workers employed outside of the References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the
United States should consult the regulations that apply to them for further guidance. United States, are made to provide further guidance to employers and workers
employed within the United States. Employers and workers employed outside of the
United States should consult the regulations that apply to them for further guidance.
1
Exploded Views
Exploded Views
23
22
10
25
16 19
1 11
15 27 21
26
2 20
28
14 24
18
3
4
16
17
13
8 11
7 12 9
6
5
10
15-INCH Q PLUSTM LX500 AND MX500 CAST SPIDER BRAKE
Item Description Item Description Item Description

1 Shoe and lining assembly 12 Spring brake shoe 20 Washer spacing
return
2 Spring shoe retaining 21 Snap ring camshaft
13 Cast Spider brake
3 Bushing anchor pin 22 Dust shield
14 Seal chamber bracket
4 Anchor pin brake shoe 23 Capscrew dust shield
15 Bracket camshaft &
5 Camshaft LX500 chamber 24 Seal ASA
6 Washer camhead 16 Capscrew chamber 25 Orange seal ASA
7 Orange seal camshaft bracket 26 Bushing camshaft
17 Plug pipe 1.50" I.D.
8 Bushing camshaft
1.625" I.D. 18 Washer camshaft 27 Seal camshaft
9 Pin return spring (thick) 28 Washer spacing (thin)
10 Roller brake shoe 19 Slack adjuster
automatic
11 Retainer shoe roller
2
Exploded Views
Exploded Views
21
22
10
22
1 11 20
24
2 15
18
28
25 27
19
26 23 29
17
13
3
14
4 15
8
7
25 16
6
5 11
12
9
26
10
1
16.5-INCH Q PLUSTM DRIVE AXLE LX500 AND MX500 STAMPED SPIDER BRAKE
Item Description Item Description Item Description

1 Shoe and lining assembly 12 Spring brake shoe 21 Dust shield
return
2 Spring shoe retaining 22 Capscrew dust shield
13 Stamped spider brake
3 Bushing anchor pin 23 Seal ASA
14 Bracket camshaft &
4 Anchor pin brake shoe chamber 24 Orange seal ASA
5 Camshaft S head 15 Capscrew Grade 8 25 Washer (4) hard
6 Washer camhead 16 Plug pipe 26 Nut (4) Grade 8
7 Orange seal camshaft 17 Washer camshaft 27 Bushing camshaft
(thick) 1.50" I.D.
8 Bushing camshaft
1.625" I.D. 18 Slack adjuster 28 Seal camshaft
9 Pin return spring automatic 29 Washer spacing (thin)
10 Roller brake shoe 19 Washer spacing
11 Retainer shoe roller 20 Snap ring camshaft
3
Section 1
Introduction
Q PlusTM LX500 Cam Brake

Section 1
Introduction
Identifying Q PlusTM LX500 and
Package with the Extended MX500 Brakes
Lube Feature NOTE: Do not remove the identification tag from
the camshaft bracket during the extended
WARNING maintenance period.
To prevent serious eye injury, always wear safe You can identify Q PlusTM LX500 and MX500 cam
eye protection when you perform vehicle brakes by checking the identification tags affixed
maintenance or service. to the brake.
NOTE: You must continue to observe all other 1. A brake shoe tag identifies the brake as
brake preventive maintenance schedules and Q PlusTM.
procedures for Q PlusTM LX500 and MX500 cam
brakes with factory-installed Meritor automatic 2. An additional identification tag imprinted with
slack adjusters. SEE MERITOR MAINTENANCE MANUAL
MM-96173 FOR LUBE INFO, which is affixed
Meritors new Q PlusTM LX500 cam brake package to the brake chamber bracket over the top of
includes: the plugged grease hole, identifies the brake
r Q PlusTM LX500 cam brakes as a Q PlusTM LX500 or MX500 brake.
r Meritor factory-installed automatic slack 3. Q PlusTM LX500 and MX500 brakes and Meritor
adjusters with threaded or welded clevises automatic slack adjusters do not have grease
fittings.
r Extended Lube Feature: For on-highway
linehaul applications, the Q PlusTM LX500
camshaft and slack adjusters do not require Q PlusTM LX500 Cam Brakes
periodic lubrication for three years or
The Q PlusTM LX500 package consists of:
500,000 miles (805,000 km), whichever comes
first. For all other vehicle applications, the r 15-inch u 4-inch or 5-inch cam brakes on
lubrication interval is one year, regardless steer axle
of mileage.
r 16.5-inch u 7-inch or 8-inch cam brakes on
drive axle
Q PlusTM MX500 Cam r 15-inch u 8-5/8-inch cam brakes on drive axle
Brake with the Extended for 19.5-inch wheels. Figure 1.1.
Maintenance Package Option
Figure 1.1
Available for On-Highway Linehaul
Applications Only
Meritors new Q PlusTM MX500 cam brake is
available for on-highway linehaul applications
only and includes:
r Extended Maintenance Package: Proprietary
friction material on 5-inch shoes for steer axles
and 8-inch shoes for drive axles for more
wearable volume than LX500 Q PlusTM brakes.
r Extended Lube Feature: The Q PlusTM MX500
camshaft and slack adjusters do not require 16.5" Q PLUSTM LX500 BRAKE
periodic lubrication for three years or WITH STAMPED SPIDER
500,000 miles (805,000 km), whichever
comes first.
r Meritor factory-installed automatic slack
adjusters with threaded or welded clevises
4
Section 1
Introduction
Q PlusTM MX500 Cam Brakes Q PlusTM LX500 and

The Q PlusTM MX500 package consists of: MX500 Features
r 15-inch u 5-inch cam brakes on steer axle with r LX500 and MX500 seals, bushings and grease,
proprietary lining along with precision-machined components,
keep water and contaminants out and
r 16.5-inch u 8-inch cam brakes on rear drive axle lubrication in the assembly.
with proprietary lining
r A larger heat-treated cam head journal diameter
r Plus LX500 components reduces bearing stress to increase cam and
bushing life.
Comparing 15-Inch Q PlusTM r A new Teflon-coated, steel-backed bushing at
LX500 and MX500 Brakes with cam head.
the 15-Inch Q Series Brake r The MX500 package includes wider shoes with
proprietary friction material for more wearable
Q PlusTM LX500 and MX500 15-inch cam brakes lining volume.
offer the following features not available on the
15-inch Q series brake. r New fiber-blended spline-end bushing improves
wear resistance.
r Double web shoe
r Optional: An integrated brake spider is available
r Cast spider on the Easy Steer PlusTM front axle.
r 1.5-inch, 28-spline camshaft
r 1.75-inch offset
r 0.75-inch tapered block lining
Specifications
NOTE: Specific applications require approval from Meritor brake engineering. For complete technical
information, specing assistance or original equipment manufacturer (OEM) replacement parts, contact
Meritors Customer Service Center at 800-535-5560 or your Meritor representative.
Recommended Size Configuration

GAWR* Range Diameter T Width
(lbs) (inch) Shoes Spiders Applications
7-14,000 15 u 4 Fabricated Cast Steer Axle
10-14,600 15 u 5 Steer Axle
15-20,000 15 u 8-5/8 Drive Axle (19.5 Wheels)
17-23,000 16.5 u 7 Stamped Drive Axle
17-23,000 16.5 u 8 Drive Axle
* Gross Axle Weight Rating
5
Section 2
Disassembly
Remove Wheel Components

Section 2
Disassembly
CAUTION
WARNING You must disengage a pull pawl or remove a
conventional pawl before rotating the manual
To prevent serious eye injury, always wear safe adjusting nut, or you will damage the pawl teeth.
eye protection when you perform vehicle A damaged pawl will not allow the slack adjuster
maintenance or service. to automatically adjust brake clearance. Replace
Asbestos and Non-Asbestos damaged pawls before putting the vehicle in
Fibers Warning service.
Some brake linings contain asbestos fibers, a 6. Use a screwdriver or equivalent tool to
cancer and lung disease hazard. Some brake disengage the pawl assembly. Figure 2.1.
linings contain non-asbestos fibers, whose
long-term effects to health are unknown. You
must use caution when you handle both asbestos Figure 2.1
and non-asbestos materials. MANUAL
ADJUSTING NUT
WARNING
Block the wheels to prevent the vehicle from
moving. Support the vehicle with safety stands.
Do not work under a vehicle supported only by
jacks. Jacks can slip and fall over. Serious personal
injury can result.
1. The vehicle must be on a level surface.
2. Put blocks under the wheels not being raised
to keep the vehicle from moving.
3. Raise the vehicle so that the area to be DISENGAGE
serviced is off the ground. Support the vehicle PAWL
with safety stands.
7. Use a wrench to turn the manual adjusting nut
WARNING until the brake shoes are fully retracted.
When you work on a spring chamber, carefully
follow the service instructions of the chamber 8. Remove the screwdriver so the pawl snaps
manufacturer. Sudden release of a compressed back into engagement.
spring can cause serious personal injury. 9. Use standard procedures to remove the
4. If the brake has spring chambers, carefully wheels and drums from the axle.
cage and lock the spring so that the spring
cannot actuate during disassembly.
5. Fully release the slack adjusters so that the
shoes retract and the drums clear the linings.
6
Section 2
Disassembly
Remove Brake Shoes Figure 2.4

1. Push down on the bottom brake shoe and pull
on the roller retaining clip to remove the
bottom cam roller. Figure 2.2.
2. Lift the top brake shoe and pull on the roller
retaining clip to remove the top cam roller.
3. Lift the bottom shoe to release the tension on
the brake return spring. Remove the spring.
Figure 2.3.
4. Rotate the bottom shoe to release the tension
on the two retaining springs. Remove the
springs and brake shoes. Figure 2.4.
Figure 2.2
Remove Camshaft and

Slack Adjuster
NOTE: Meritor recommends checking the
bushings at every reline. If the bushings need
replacement, follow the procedure listed below.
1. Remove the large and small clevis pins.
CAUTION
You must disengage a pull pawl or remove a
adjusting nut, or you will damage the pawl teeth.
A damaged pawl will not allow the slack adjuster
to automatically adjust brake clearance. Replace
damaged pawls before putting the vehicle in
Figure 2.3 service.
2. Disengage the pull pawl. Rotate the slack
adjuster away from the clevis.
NOTE: You cannot remove a welded clevis from
the chamber assembly. If the welded clevis is
damaged or worn, replace the chamber assembly.
To remove a threaded clevis, loosen the jam nut
and unthread the clevis from the brake chamber
rod.
3. Remove the snap ring, washer, spacing
washer and orange Automatic Slack Adjuster
(ASA) seal from the camshaft.
4. Remove the slack adjuster from the camshaft.
5. Pull the camshaft from the spider and bracket.
7
Section 3
Prepare Parts for Assembly
Section 3Parts for Assembly
Prepare
Corrosion Protection
WARNING
NOTE: Parts must be clean and dry before you
To prevent serious eye injury, always wear safe lubricate them.
eye protection when you perform vehicle
maintenance or service. 1. If you assemble parts immediately after you
clean them: Lubricate parts with grease to
Solvent cleaners can be flammable, poisonous prevent corrosion. Parts must be clean and dry
and cause burns. Examples of solvent cleaners are before you lubricate them.
carbon tetrachloride, emulsion-type cleaners and
petroleum-based cleaners. To avoid serious 2. If you store parts after you clean them: Apply
personal injury when you use solvent cleaners, a corrosion-preventive material. Store parts in
you must carefully follow the manufacturers a special paper or other material that prevents
product instructions and these procedures: corrosion.
r Wear safe eye protection.
Inspect Parts
r Wear clothing that protects your skin.
It is important to carefully inspect all parts before
r Work in a well-ventilated area. assembly. Check all parts for wear or damage.
r Do not use gasoline, or solvents that contain Repair or replace them as required.
gasoline. Gasoline can explode. 1. Check the spider for expanded anchor pin
r You must use hot solution tanks or alkaline holes and for cracks. Replace damaged spiders
solutions correctly. Follow the manufacturers and anchor pin bushings.
instructions carefully. 2. Check the camshaft bracket for broken welds,
cracks and correct alignment. Replace
CAUTION damaged brackets.
Do not use hot solution tanks or water and 3. Check anchor pins for corrosion and wear.
alkaline solutions to clean ground or polished Replace damaged anchor pins.
parts. Damage to parts will result.
4. Check brake shoes for rust, expanded rivet
Only use solvent cleaners on metal parts. Damage holes, broken welds and correct alignment.
to parts will result. Replace a shoe with any of the above
conditions.
Cleaning Parts On 16.5-inch brake shoes only: Anchor
pin holes must not exceed 1.009-inches
CAUTION (25.63 mm) in diameter. The distance from the
Do not disassemble the factory-installed center of the anchor pin hole to the center of
automatic slack adjusters on Meritors Q PlusTM the roller hole must not exceed 12.779-inches
LX500 and MX500 cam brakes. Damage (32.46 cm). Replace any shoe with
to components can result. measurements that do not meet specifications.
1. Use soap and water to clean non-metal parts. 5. Check the camshaft for cracks, wear and
corrosion. Check the cam head, bearing
2. Use soft paper or cloth that is free from dirt, journals and splines. Replace damaged
oil or abrasives to dry the parts completely. camshafts.
Dry Parts After Cleaning

Dry the parts immediately after cleaning. Dry parts
with clean paper or rags, or compressed air.
8
Section 3
Prepare Parts for Assembly
Slack Adjusters
CAUTION
CAUTION Do not disassemble the factory-installed
Always replace used clevis pin retainer clips with automatic slack adjusters on Meritors Q PlusTM
new ones when servicing the automatic slack LX500 and MX500 cam brakes. Damage to
adjuster or chamber. Do not reuse clevis pin components can result.
retainer clips after removing them. Discard used r If the torque value exceeds the specifications,
clips. When removed for maintenance or service, the slack adjuster is not working correctly.
clevis pin retainer clips can be bent or gapped Inspect and replace the slack adjuster as
apart and can lose retention. Damage to necessary.
components can result.
You must disengage a pull pawl or remove a Drums
adjusting nut, or you will damage the pawl teeth. NOTE: Meritor recommends that you do not turn
A damaged pawl will not allow the slack adjuster or rebore a brake drum. Turning or reboring
to automatically adjust brake clearance. Replace drums can decrease the strength and heat
damaged pawls before putting the vehicle in capacity of the drum.
service. 1. Check the brake drums for cracks, severe heat
1. Check the clevis pins and the bushing in the checking, heat spotting, scoring, pitting and
arm of the slack adjuster. Replace the pins if distortion. Replace drums as required.
they are worn. Replace the bushing if its 2. Measure the inside diameter of the drum in
diameter exceeds 0.531-inch (13.5 mm). several locations with a drum caliper or
2. Check Meritor automatic slack adjusters by internal micrometer. Figure 3.2. Replace the
rotating the adjusting nut to the LEFT with an drum if the diameter exceeds the
inch-pound torque wrench. Figure 3.1. Turn specifications supplied by the drum
the gear 360 degrees (22 rotations of the manufacturer.
adjusting nut).
r For a new slack adjuster, the torque MUST
WARNING
remain less than 25 lb-in (2.8 Nm) for Do not operate the vehicle with the brake drum
360 degrees. worn or machined beyond the discard dimension
indicated on the drum. The brake system may not
r For an in-service slack adjuster, the torque operate correctly. Damage to components and
MUST remain less than 40 lb-in (4.52 Nm) serious personal injury can result.
for 360 degrees.
3. Check dust shields for rust and distortion.
Repair or replace damaged shields as
Figure 3.1 necessary.
Figure 3.2
ROTATE
GEAR 360
9
Section 4
Assembly
Install Camshaft, Seals and Bushings

Section 4
Assembly
Figure 4.1
WARNING
To prevent serious eye injury, always wear safe
maintenance or service.
Asbestos and Non-Asbestos
Fibers Warning
Some brake linings contain asbestos fibers, a
cancer and lung disease hazard. Some brake
must use caution when you handle both asbestos
and non-asbestos materials.
NOTE: To help avoid shorter lining life, Meritor
recommends replacing springs, rollers, and
anchor pins at each reline.
Figure 4.1
STAMPED SPIDER VERSION
Camshaft seals closed end SPACER WASHER THICK
towards slack adjuster.
RETAINING RING SEAL
SPACER WASHERS
(0.03" [0.762 mm]
MAX END PLAY) STEEL BACKED
BUSHING
SEAL (ORANGE)
SLACK ADJUSTER
SEAL
(ORANGE)
SEAL (BLACK)
Seal lip towards

CAMSHAFT
slack adjuster. BUSHING
(BLACK COMPOSITE)
CAST SPIDER VERSION

Seal lip towards
slack adjuster.
SPECIAL CAMHEAD
SEAL/WASHER FOR USE
WITH STAMPED SPIDER
BRAKES ONLY
10
Section 4
Assembly
1. Check that all the spider mounting bolts are For Brake Assemblies with
tightened to the correct torque specified in
Figure 4.2. Stamped Spiders:
r Install both seals and bushings in the chamber
bracket tube. Figure 4.1.
Figure 4.2
1. Use a seal driver to install new camshaft
bushings and seals in the spider and camshaft
bracket. Figure 4.3.
Figure 4.3
BOLT
SIZE TORQUE
7/16"-20 60-75 LB-FT 81-102 Nm
1/2"-20 85-115 LB-FT 115-156 Nm
9/16"-18 130-165 LB-FT 176-224 Nm
5/8"-18 180-230 LB-FT 244-312 Nm
CAUTION
To disassemble the bracket from the spider,
remove the bolts. Rotate the bracket wing to
loosen the bracket. Do not hit the end of the
chamber bracket tube that protrudes from the
spider. Damage to components can result.
CAUTION
2. If the camshaft bracket was removed, install You must install both seals with the lips facing
the O-ring and bracket on the spider. Tighten TOWARD the automatic slack adjuster, so that
the capscrews to the correct torque specified grease can purge from the slack adjuster end of
in the table in Section 10. the camshaft. If grease purges from the cam end,
damage to components can result.
WARNING
2. Install the seals with the seal lips facing
To prevent serious eye injury, always wear safe TOWARD the automatic slack adjuster.
eye protection when you perform vehicle Figure 4.4.
Prior to installing the camshaft into the brake:
Figure 4.4
3. Clean the journals with an emery cloth.
4. Lubricate the camshaft splines with Meritor
specification O-695, NLGI Grade 2 lubricant.
For Brake Assemblies with

Cast Spiders:
SEAL
r Install one seal and bushing in the spider. SEAL
LIP
LIP
r Install one seal and bushing in the chamber
bracket tube. Figure 4.1.
SPIDER
CAMSHAFT
BRACKET
11
Section 4
Assembly
3. Install the cam head washer onto the camshaft Q PlusTM LX500 and
with the bent flaps toward the spider.
MX500 Specifications
4. Apply Meritor specification O-695 synthetic
grease to the camshaft bushings and journals. The illustrations below show specifications for
15-inch and 16.5-inch Q PlusTM LX500 and MX500
5. Install the camshaft through the spider and cam brake shoes and cams. Figure 4.6.
bracket so that the camshaft turns freely by
hand. Figure 4.5.
Figure 4.6 COMPONENTS
Figure 4.5 FMSI NO. 4707 28 RIVET HOLES

PLUS-SHAPED HOLES (+) IN TABLE
STAMPED IN TABLE
MERITOR
16.5 Q PLUS
TM NO BULGE
ON WEB
TM
MERITOR 16.5 Q PLUS
STAMPED ON WEB
SHOE TAG
16.5" SHOE
FMSI NO. 4702

16 RIVET HOLES
USED WITH SPIDER IN TABLE
MERITOR
TM
15 Q PLUS
Install Brake Shoes MERITOR

15 Q PLUSTM NO BULGE
STAMPED ON WEB ON WEB
Before Specified Time or Mileage
DOUBLE WEB
Lubrication Intervals 15" SHOE
TM
When you install brake shoes on Q Plus LX500 CAM TIP TO TIP = 4.25"
and MX500 cam brakes BEFORE the specified time PART NUMBER
LOCATED HERE
or mileage lubrication intervals, only grease clevis
pins, anchor pins and shoe rollers. Refer to Do
Not Lubricate the LX500 and MX500 Brakes and
Automatic Slack Adjusters Before Specified Time
or Mileage Intervals in Section 6 of this manual.
1.18 DIA.
16.5
After Specified Time or Mileage Q PLUSTM
LOCATED HERE
Lubrication Intervals 16.5" CAM (1.5" DIA.-28 SPLINES)
TM
When you install brake shoes on Q Plus LX500
and MX500 cam brakes after the specified time or CAM TIP TO TIP = 3.38"
PART NUMBER
mileage lubrication intervals, refer to Lubricating LOCATED HERE
the Q PlusTM LX500 and MX500 Cam Brakes and
Automatic Slack Adjusters After Specified Time or
Mileage Intervals in Section 6 of this manual for
service procedures.
0.988 DIA.
15
Q PLUSTM
LOCATED HERE
15" CAM (1.5 DIA.-28 SPLINES)
12
Section 4
Assembly
1. Put the upper brake shoe in position on the 3. Pull each brake shoe away from the cam to
top anchor pin. Hold the lower brake shoe on permit enough space to install the cam rollers
the bottom anchor pin and install two new and retainers. Press the ears of the retainer
brake shoe retaining springs. Figure 4.7. together to permit the retainer to fit between
the brake shoe webs. Figure 4.9.
4. Push the retainer into the brake shoe until
Figure 4.7
its ears lock in the holes in the shoe webs.
Figure 4.10.
Figure 4.9
WEBS
SQUEEZE
2. Rotate the lower brake shoe forward and

install a new brake shoe return spring. Install
the open end of the spring hooks toward the
camshaft. Figure 4.8.
NOTE: Use of a spring tool may be required to
assemble the new brake shoe return spring. Figure 4.10
Figure 4.8
WEB
HOLE
PUSH
13
Section 4
Assembly
Installing Meritors Automatic

Slack Adjuster Figure 4.11
HANDED UNHANDED
Handed and Unhanded
Slack Adjusters
There are two different automatic slack adjuster
designs: HANDED and UNHANDED. For most
applications, install a HANDED automatic slack
adjuster so that the pawl faces INBOARD on the
vehicle.
The pawl can be on either side or on the front of
the slack adjuster housing. Figure 4.11.
Pull Pawls
Pull pawls are spring loaded. Pry the pull pawl at
least 1/32-inch to disengage the teeth. Figure 4.12.
When you remove the pry bar, the pull pawl will Figure 4.12
re-engage automatically.
Installation Procedure
If you are installing a new automatic slack PAWL
adjuster, it must be the same type and size as the
one you will replace. The table below shows slack
adjuster lengths for each brake chamber size.
PRY UP
Chamber and Slack Adjuster Sizes
PULL PAWL
Length of Slack Size of Chamber
Adjuster (Inches) (Square Inches)
5-1/2 16, 20, 24, 30, 36
1. Install the thick large O.D. spacing washer on

the camshaft.
Figure 4.13
2. Install the automatic slack adjuster seal on the
camshaft in the direction shown in Figure 4.13.
3. Install the slack adjuster on the splines of the
camshaft.
4. Install the orange slack adjuster seal in the ORANGE
direction shown in Figure 4.13. SEAL
5. Place the appropriate number of spacing
washers between the slack adjuster and the
snap ring to ensure less than 0.020-inch
(0.51 mm) axial end play of the camshaft.
SEAL
14
Section 4
Assembly
Figure 4.15
CAUTION
You must disengage a pull pawl or remove a LARGE CLEVIS PIN
conventional pawl before rotating the manual CLEVIS
AND
adjusting nut, or you will damage the pawl teeth. RETAINER CLIP
A damaged pawl will not allow the slack adjuster LARGE CLEVIS PIN
to automatically adjust brake clearance. Replace ACTUATOR RETAINER CLIP
damaged pawls before putting the vehicle in ROD P/N 2257-D-1174
service.
6. Disengage the pawl. Turn the manual
adjusting nut to align the holes in the slack
SMALL CLEVIS PIN
adjuster arm and the clevis. Figure 4.14. RETAINER CLIP
P/N 2257-C-1173
SMALL CLEVIS PIN
CAUTION AND RETAINER CLIP
Always replace used clevis pin retainer clips with
new ones when servicing the automatic slack The clevis pin
adjuster or chamber. Do not reuse clevis pin retainer clips
retainer clips after removing them. Discard used must be fully
clips. When removed for maintenance or service, installed and
clevis pin retainer clips can be bent or gapped positioned
apart and can lose retention. Damage to around the side
components can result. of clevis pin.
For a Welded Clevis

7. Apply anti-seize compound to the two clevis
pins. Install the clevis pins through the clevis
and the slack adjuster.
8. Install the cotter pins or clevis pin retainer
clips to hold the clevis pins in place.
Figure 4.15.
For a Threaded Clevis

r Refer to Installing a Threaded Clevis on
page 17.
Figure 4.14
Align
holes.
Disengage
pawl.
15
Section 4
Assembly
Checking Brake Chamber Meritors Automatic Slack

Push Rod Stroke and Adjusting Adjuster Template
the Clevis Position Order the correct automatic slack adjuster template
from Meritors Customer Service Center at 800-535-5560.
NOTE: You cannot adjust the clevis position on a Specify part number TP-4786 for truck or tractor drum
chamber push rod that is equipped with a welded brakes.
clevis.
CAUTION
There are two methods you can use to adjust the
clevis position on a chamber push rod that is Use Meritors dark brown automatic slack
equipped with a threaded clevis: adjuster template for truck or tractor drum
brakes, part number TP-4786, to ensure that
r The Brake Slack Adjuster (BSAP) method. you install the automatic slack adjuster correctly.
This template is not interchangeable with other
r Meritors automatic slack adjuster template
Meritor slack adjuster templates. An incorrect
(for standard stroke chambers only).
installation can cause the automatic slack
adjuster to overadjust or underadjust. Brake drag,
Brake Slack Adjuster Position increased stopping distances and damage to
(BSAP) Method components can occur.
When installing the automatic slack adjuster, Measure the Automatic Slack Adjuster
verify that the BSAP dimension of the chamber
matches the table in Figure 4.16. 1. Use Meritors automatic slack adjuster
template part number TP-4786 to measure the
length of the slack adjuster. Figure 4.17. The
Figure 4.16 marks by the holes in the small end of the
template indicate the length of the slack
3.750" adjuster. Figure 4.18.
BRACKET OFFSET
BSAP +
0.125" Figure 4.17
SLACK
LENGTH
5.50"
Color of Part
Template Number Brake Description
Standard Stroke Long Stroke Dark TP-4786 Truck or tractor drum brake
(inch) (inch) brown
2.75 2.25
NOTE: A welded clevis is long stroke only.
16
Section 4
Assembly
4. Check for these specifications:

Figure 4.18 r Thread engagement between the clevis
and the push rod must be at least 1/2-inch
(12.7 mm). Figure 4.20.
Measure slack r The push rod must not extend through the
adjuster arm length. clevis more than 1/8-inch (3.18 mm). If
necessary, cut the push rod, or install a new
push rod with a new air chamber.
Figure 4.20
MINIMUM 1/2"
CAMSHAFT CENTER
Installing a Threaded Clevis

MAXIMUM 1/8"
1. Install the large clevis pin through the large
holes in the template and the clevis.
2. Select the hole in the template that matches
the length of the slack adjuster. Hold that hole
on the center of the camshaft. THREADED CLEVIS
3. Look through the slot in the template. If

necessary, adjust the position of the clevis
until the small hole in the clevis is completely 5. Tighten the jam nut against the clevis to
visible through the template slot. Figure 4.19. specifications in the table below.
Jam Nut Torque Specifications

Figure 4.19
Threads Torque
THREADED
CLEVIS 1/2-20 20-30 lb-ft (27-41 Nm)
5/8-18 35-50 lb-ft (48-68 Nm)
SLOT
CAMSHAFT END
17
Section 4
Assembly
Adjust the Brake 6. The difference between the measurements in

Step 2 and Step 5 is the adjusted chamber
stroke. The adjusted stroke MUST NOT be
CAUTION greater than the dimensions shown in the
You must disengage a pull pawl or remove a Commercial Vehicle Safety Alliance (CVSA)
conventional pawl before rotating the manual North American Out-of-Service Criteria
adjusting nut, or you will damage the pawl teeth. Reference Charts in Section 9.
A damaged pawl will not allow the slack adjuster
to automatically adjust brake clearance. Replace 7. Release the pawl assembly.
damaged pawls before putting the vehicle in
service. WARNING
1. Disengage the pawl. Turn the adjusting nut When you work on a spring chamber, carefully
until the linings touch the drum. Turn the follow the service instructions of the chamber
adjusting nut 1/2 turn in the opposite direction. manufacturer. Sudden release of a compressed
spring can cause serious personal injury.
2. Measure the distance from the center of the
large clevis pin to the bottom of the air 8. If the brake has spring chambers, carefully
chamber. Figure 4.21. release the spring.
9. Test the vehicle to make sure that the brake
system operates correctly before you put the
Figure 4.21 vehicle into service.
Measure this distance
brakes off brakes on.
THREADED WELDED
CLEVIS CLEVIS
3. Use a pry bar to move the slack adjuster so

that the linings are against the drum. Measure
the same distance again. The difference
between this measurement and the
measurement in Step 2 is the free stroke.
4. Turn the adjusting nut until free stroke is
between 5/83/4-inch (15.919.1 mm).
5. Check the adjustment. Apply the brakes. Hold
the pressure at 85 psi (586 kPa). Measure the
distance from the center of the large clevis pin
to the bottom of the air chamber.
18
Section 5
Reline the Brakes
Reline the Brakes

Section
Reline the
5 Brakes
WARNING
To prevent serious eye injury, always wear safe
Asbestos and Non-Asbestos
Fibers Warning
Some brake linings contain asbestos fibers, a
cancer and lung disease hazard. Some brake
must use caution when you handle both asbestos
and non-asbestos materials.
Vehicle brake systems require the correct lining
material to perform as originally designed. The
type of lining material that is specified is based on
several technical considerations and DOT braking
performance regulations. Always use the lining
material specified by the vehicle manufacturer.
Always reline both wheels of a single axle and all
four wheels of a tandem axle at the same time.
Always install the same linings and drums on both
wheels of a single axle and all four wheels of a
tandem axle. It is not necessary for front and rear
axles to have the same linings and drums.
Figure 5.1
19
Section 6
Lubrication
Lubrication Intervals for

Section 6
Lubrication
Lubricating the Q PlusTM LX500 and
Q PlusTM LX500 and MX500 MX500 Cam Brakes and Automatic
Cam Brakes with Automatic Slack Adjusters After Specified
Time or Mileage Intervals
Slack Adjusters
1. Remove the identification tag from the
WARNING chamber bracket.
To prevent serious eye injury, always wear safe 2. Remove the grease plugs from both the
eye protection when you perform vehicle chamber bracket and the automatic slack
maintenance or service. adjuster.
The Q PlusTM LX500 and MX500 Cam Brake 3. Install the grease fittings. Use Meritor-approved
packages include factory-installed Meritor synthetic grease O-695 NLGI Grade 2 to
automatic slack adjusters. Q PlusTM LX500 and lubricate the brake assembly through the
MX500 cam brakes and slack adjusters do not grease fitting in the bracket until new grease
require lubrication for an extended period of time. flows from the inboard (slack end) seal.
(Refer to the table below.)
4. Use Meritor-approved synthetic grease O-695
The camshaft hardware (seals, bushings and to lubricate the automatic slack adjuster
washers) do not require replacement for the same through the grease fitting until new grease
time period. purges out of the pull pawl.
However, you must continue to observe all other 5. Replace the grease fittings with grease plugs.
brake preventive maintenance schedules and Cover the bracket plug with a new
procedures for both Q PlusTM LX500 and MX500 identification tag.
cam brakes and Meritor automatic slack adjusters.
6. After the first lubrication, follow the
manufacturers chassis lubrication schedule
Lubrication Intervals and your regular preventive maintenance
schedule. You should also continue to perform
Q PlusTM LX500 Cam Brake periodic inspections of the brakes. (Refer to
On-Highway 3 years/500,000 miles Section 9, page 24.)
Linehaul (805,000 km)
All Other 1 year, regardless of mileage
Applications
Q PlusTM MX500 Cam Brake
On-Highway 3 years/500,000 miles
Do Not Lubricate the LX500 and

MX500 Brakes and Automatic Slack
Adjusters Before Specified Time or
Mileage Intervals
r Do not remove the identification tag that covers
the grease plug.
r Do not grease the brake assembly or the
automatic slack adjuster prior to the specified
lubrication interval times or mileages in the
table on this page.
20
Section 6
Lubrication
Q PlusTM LX500 and MX500 Greasing Approved Greases

Service Intervals and Specifications
Lubricant Recommendation
Q PlusTM LX500 Cam Brake O-617-A Multi-Purpose Lithium
On-Highway 3 years/500,000 miles O-617-B Chassis Grease
O-645 Mobilgrease 28 (Military)
All Other 1 year, regardless of mileage
Applications Mobiltemp SHC 32 (Industrial)
Q PlusTM MX500 Cam Brake Aerospace Lubricants Inc.
Tribolube 12-Grade 1
On-Highway 3 years/500,000 miles
Linehaul (805,000 km) O-692 Amoco Super PermalubeTM #2
Citgo Premium Lithium EP-2 #2
Exxon Ronex MP-2 #2
Kendall L-427 Super Blu #2
Mobilith AW-1 #1
Sohio Factran EP-2 #2
O-695 EVO-LUBE TEK-615
Meritor NLGI Outside

Component Specification Grade Grease Type Temperature
Camshaft Splines and O-695 2 Synthetic Polyurea 40F (40C)
Clevis Pins
Anchor Pins O-617-A 1 Lithium 12-Hydroxy Refer to the grease
or Stearate or manufacturers
When the brake is
O-617-B 2 Lithium Complex specifications for the
disassembled, or when
temperature service
necessary, lubricate the
limits.
anchor pins where they
touch the brake shoes. O-645 2 Synthetic Oil, Clay Down to 65F (54C)
Base
O-692 1 and 2 Lithium Base Down to 40F (40C)
Shoe Rollers O-617-A 1 Lithium 12-Hydroxy Refer to the grease
or Stearate or manufacturers
When the brake is
O-617-B 2 Lithium Complex specifications for the
disassembled, or when
temperature service
necessary, lubricate the
limits.
rollers where they touch
the brake shoes. DO NOT
get grease on the part of
the roller that touches the
cam head.
Automatic Slack O-695 2 Synthetic Polyurea 40F (40C)
Adjusters
Figure 6.1
21
Section 7
Diagnostics
Section 7
Diagnostics
WARNING
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
Symptoms Possible Causes Corrective Actions

r Adjusted stroke r Incorrect slack adjuster part number r Check with Warehouse Distributor or
is too long. Original Equipment Manufacturer.
r No adjustment r Clevis installed at wrong angle. r Use correct template or BSAP
setting to install clevis correctly.
r Excessive wear between clevis and collar r Replace with threaded clevis.
(more than 0.060" [1.52 mm])
r Loose jam nut at clevis r Tighten to specification.
r Worn clevis pin bushing in slack arm (ID r Replace bushing.
larger than 0.53" [13.46 mm])
r Weak or broken return spring in air chamber r Replace return spring or air chamber.
(Spring force must be at least 32 lb. [142.4 N]
at first push rod movement.)
r Spring brake does not retract fully. r Repair or replace spring brake.
r Worn or stripped teeth on pawl or actuator r Replace slack adjuster.
High torque is required to rotate worm when r Replace slack adjuster.
slack is removed from vehicle.
r In service slack, maximum worm torque:
45 lb-in (5.09 Nm)
r New or rebuilt slack, maximum worm torque:
25 lb-in (2.83 Nm)
r Excessive looseness between splines of r Replace powershaft, gear or
camshaft and ASA gear automatic slack adjuster as needed.
r Worn components (cam bushing, for r Replace components.
example) in foundation brake
r Adjusted stroke r Non-Original Equipment Manufacturer r Use Meritor approved linings.
is too short. replacement linings with excessive swell
and/or growth
r Linings drag.
r Incorrect slack adjuster part number r Check with Warehouse Distributor or
Original Equipment Manufacturer.
r Clevis installed at wrong angle. r Use correct template to install
clevis correctly.
r Loose jam nut at clevis r Tighten to specification.
r Spring brake does not retract fully. r Repair or replace spring brake.
r Wrong manual adjustment r Adjust brake
r Poor contact between linings and drum, or r Repair or replace drums or linings.
drum is out-of-round.
r Brake temperature imbalance r Correct brake balance.
Figure 7.1
22
Section 8
Recommended Periodic Service
Recommended Periodic Service

Section
Recommended
8 Periodic Service During a major overhaul, the following parts must
be carefully checked and replaced with genuine
Meritor Replacement Parts if required:
WARNING
To prevent serious eye injury, always wear safe 1. Spiders for distortion and loose bolts.
eye protection when you perform vehicle 2. Anchor pins for wear and correct alignment.
3. Brake shoes for wear at anchor pin holes or
roller slots.
CAUTION
Do not let brake lining wear to the point that the 4. Camshaft and camshaft bushings for wear.
rivets or bolts touch the drum. Damage to the 5. Shoe return springs must be replaced.
drum will occur.
6. Brake linings for grease on the lining, wear
and loose rivets or bolts.
Adjustment
7. Drums for cracks, deep scratches or other
r Adjust the brakes when the air chamber stroke damage.
exceeds the limits shown in the CVSA charts on
page 26. To help ensure maximum lining life, Meritor
recommends that springs, rollers, and anchor pins
Lubrication be replaced at each reline.
Figure 8.1
r Lubricate the brake and automatic slack
adjuster according to the schedules on page 20.
Reline
r Reline the brake when lining thickness is
0.25-inch (6.3 mm) at the thinnest point.
r Replace shoe springs, check the drum and
perform a major inspection.
Inspection
r Refer to Section 9 of this manual.
Complete Overhaul
r At every second reline, or as required.
A schedule for the periodic adjustment, cleaning,
inspection and lubrication of the brake equipment
must be made according to experience and the
type of operation.
Brakes must be adjusted as frequently as required
for correct operation and safety. The adjustments
must give correct clearance between the lining
and drum, correct pushrod travel and correct
balance between the brakes.
NOTE: Correctly adjust wheel bearings before
adjusting the brake.
Brakes must be cleaned, inspected and adjusted
every time the wheel hubs are removed.
23
Section 9
Inspection
Brake Inspections Before

Section 9
Inspection r If radial free play movement is less than
0.020-inch (0.51 mm): Do not replace the
the Recommended bushings and seals.
Lubrication Interval r If radial free play movement exceeds
0.020-inch (0.51 mm): Replace the bushings
WARNING and seals.
To prevent serious eye injury, always wear safe r If axial end play exceeds 0.030-inch (0.76 mm):
eye protection when you perform vehicle Remove the snap ring. Add the appropriate
maintenance or service. number of spacing washers between the
NOTE: You do not have to replace Q PlusTM LX500 automatic slack adjuster and the snap ring to
and MX500 brake camshaft bushings and seals achieve between 0.005-inch and 0.030-inch
when you reline the brake prior to the (0.127-0.762 mm) axial free play movement.
recommended service interval.
1. Periodically inspect brake shoe linings. If the
lining thickness is 0.25-inch (6.35 mm) at the
thinnest point, reline the brakes. Refer to
Install Brake Shoes in Section 4 of this
manual.
2. Periodically inspect the brakes for correct
clearance between the lining and drum. If you
must manually adjust the brakes because of
excessive air chamber stroke, correct the
problem. Refer to Adjust the Brake in
Section 4 of this manual.
Brake Inspections After

the Recommended
Lubrication Interval
At the first reline, inspect the cam-to-bushing
radial free play and axial end play. Radial free
play movement must be less than 0.020-inch
(0.51 mm). Figure 9.1.
Figure 9.1
24
Section 9
Inspection
Visual Inspection 7. The return springs must retract the shoes

completely when the brakes are released.
For safe operating conditions and longer Replace the return springs each time the
component life, make these visual inspections brakes are relined. The spring brakes must
before the vehicle is put into service: retract completely when they are released.
1. Check the complete air system for worn hoses 8. Check the air chamber size and the slack
and connectors. With air pressure at 100 psi adjuster length of all wheel ends. All drive axle
(689 kPa), brakes released and engine off, loss wheel ends should have the same size air
of tractor air pressure must not exceed two psi chamber and slack adjuster length. Both steer
a minute. Total tractor and trailer loss must not axle wheel ends should have the same size air
exceed three psi per minute. chamber and slack adjuster length.
2. Check air compressor performance. Air system
pressure must rise to approximately 100 psi Federal Roadside Inspection
(689 kPa) in two minutes.
3. The governor must be checked and set to the Brake In-Service
specifications supplied by the vehicle Adjustment Inspection
manufacturer.
NOTE: Check brake adjustment with 80-90 psi
4. The tractor or truck air system must match (551-620 kPa) air pressure in the brake chambers
the specifications supplied by the vehicle when the brakes are fully applied. 100 psi
manufacturer. (689 kPa) in the air tanks with the engine OFF
5. Both wheel ends of each axle must have the will supply 80-90 psi (551-620 kPa) in the
same linings and drums. All four wheel ends chambers when the brakes are fully applied.
of tandem axles also must have the same r If necessary run the engine to INCREASE the
linings and drums. It is not necessary for the pressure to 100 psi (689 kPa).
front axle brakes to be the same as the rear
driving axle brakes. Figure 9.2. r Turn the engine OFF. Apply and release the
brakes to DECREASE the pressure to 100 psi
(689 kPa).
Figure 9.2
TANDEM AXLES FRONT AXLE
Both wheel ends of each axle must

have identical drums and lining.
6. Always follow the specifications supplied by

the vehicle manufacturer for the correct lining
to be used. Vehicle brake systems must have
the correct friction material and these
requirements can vary from vehicle to vehicle.
25
Section 9
Inspection
Truck or Tractor Commercial Vehicle Safety Alliance

(CVSA) North American Out-of-Service
Use the following procedures to check the Criteria Reference Charts
in-service adjustment (adjusted chamber stroke) of
truck or tractor air brakes with slack adjusters. NOTE: A brake found at the adjustment limit is
not a violation.
1. Check the gauges in the cab to make sure
that the air pressure in the tanks is 100 psi
(689 kPa) with the engine off and the spring Standard Stroke Clamp Type Brake
chambers released. Chamber Data
2. With the brakes not applied, measure the
distance from the bottom of the air chamber to Outside Diameter Brake Adjustment
the center of the large clevis pin on all the Type (inches) Limit (inches)
brakes. Figure 9.3A. Record each dimension. 16 6-3/8 1-3/4
3. Have another person apply and hold one full 20 6-25/32 1-3/4
brake application. Figure 9.3B.
24 7-7/32 1-3/4
4. Repeat Step 2 and measure with the service
brakes applied. Figure 9.3C. Record each 30 8-3/32 2
dimension.
36 9 2-1/4
5. Release the brakes.
6. Calculate the adjusted chamber stroke of each Long Stroke Clamp Type Brake
brake:
Chamber Data
a. Subtract the dimension that was measured
in Step 2 from the dimension measured in Outside Diameter Brake Adjustment
Step 4. Type (inches) Limit (inches)
b. The difference between the two dimensions 16 6-3/8 2.0
is the adjusted chamber stroke. The adjusted
chamber stroke must not be greater than the 20 6-25/32 2.0
stroke length shown in the CVSA reference 24 7-7/32 2.0
charts for that size and type of air chamber.
24* 7-7/32 2.5
c. If the adjusted chamber stroke you
measured is greater than the maximum 30 8-3/32 2.5
stroke shown in the CVSA reference charts,
* For 3" maximum stroke type 24 chambers
inspect and replace the slack adjuster if
necessary.
Figure 9.3A Figure 9.3B Figure 9.3C
Measure Measure
Spring brakes Spring brakes

released released
Service brakes Service brakes
not applied 100 psi (689 kPa) in air applied
tank engine OFF
26
Section 10
Torque Table
Fastener Torque Table for Q PlusTM LX500 and MX500

Section 10
Brakes
CAM BRACKET MOUNTING (4)

.500"-13 Thread (Cast Spider)
DUST SHIELD MOUNTING (4) or (6) Grade 8 = 90-120 lb-ft (122-163 Nm)
Grade 5 = 65-100 lb-ft (88-136 Nm) T
CAST SPIDER
Tighten dust shield .562"-12 Thread (Stamped Spider) PUSH ROD LOCK NUT (1)
mounting screws Grade 8 = 180-190 lb-ft (243-257 Nm) T .625"-18 Thread
0.375-16, Grade 5 to
25-50 lb-ft (34-68 Nm) T
25-35 lb-ft
(34-48 Nm) T
.500"-20 Thread
STAMPED SPIDER 20-30 lb-ft (27-41 Nm) T
Tighten dust shield
mounting screws
0.312-18, Grade 5 to
15-20 lb-ft
(20-27 Nm) T
Add camshaft spacing

BRAKE MOUNTING BOLTS washers to provide
Grade 8 bolts with lock nuts and two between 0.005-0.030"
hardened washers on each bolt. (0.13-0.76 mm)
AIR CHAMBER MOUNTING (2) maximum end play.
CAST SPIDER STAMPED SPIDER
Tighten chamber Tighten chamber
Bolt bracket mounting bracket Grade 8
Size Torque T bolts mounting nuts to
1/2"-20 85-115 lb-ft (115-156 Nm) Grade 5: 65-85 lb-ft 180-19 lb-ft
9/16"-18 130-165 lb-ft (176-223 Nm) (88-116 Nm) T (244-257 Nm) T
5/8"-18 180-230 lb-ft (243-311 Nm) Grade 8: 90-120 lb-ft
(122-163 Nm) T
Grade 8 Nuts and Hard Flat Washers
Chamber Size 16 20 24 30 36 Spring Chamber
Bendix 30-45 lb-ft 45-65 lb-ft 65-85 lb-ft

(41-61 Nm) (61-88 Nm) (88-115 Nm)
Midland 35-50 lb-ft 70-100 lb-ft

(48-68 Nm) (95-136 Nm)
MGM 35-40 lb-ft 100-115 lb-ft

(48-54 Nm) (136-156 Nm)
Anchorlok 110-115 lb-ft with hex nut and washer

(149-203 Nm)
85-95 lb-ft with lock nut and washer

(115-129 Nm)
27
Meritor Heavy Vehicle Systems, LLC Information contained in this publication was in effect at the time the publication was approved for printing and is
2135 West Maple Road subject to change without notice or liability. Meritor Heavy Vehicle Systems, LLC, reserves the right to revise the
Troy, MI 48084 U.S.A. information presented or discontinue the production of parts described at any time.
800-535-5560
www.meritorauto.com f Copyright 1997 Maintenance Manual No. MM-96173
Meritor Automotive, Inc. Issued 6-97
All Rights Reserved Printed in the USA 16579/24240
Section 5. Hydraulics
GRESEN MANUFACTURER DANA CORPORATION
MGG2 HYDRAULIC MOTORS SERVICE MANUAL
MGG2 HYDRAULIC MOTORS PARTS CATALOG
GULF CONTROLS CORPORATION
MONARCH 24VDC ELECTRIC PUMP M326-0214 (EMERGENCY PUMP) MANUAL
PARKER-HANNIFIN CORPORATION
PARKER-HANNIFIN HYDRAULIC VALVE PUMP MANUAL
D1VW SERIES DIRECTIONAL VALVES MANUAL
D3W SERIES DIRECTIONAL VALVES MANUAL
SUN HYDRAULICS CORPORATION - (SOLENOID CARTRIDGE VALVES)
CARTRIDGE SERVICE BULLETIN
EATON CORPORATION
420 MOBILE PISTON PUMP MODEL CODES (E-PUPI-TH001-E)
420 PUMP SERIES INSTALLATION INFORMATION (E-PUPI-TI006-E)
420 MOBILE PISTON PUMP CATALOG MANUAL (E-PUPI-TM002-E)
420 MOBILE PISTON PUMP SERVICE PARTS MANUAL (E-PUPI-TP002-E)
TRW, ROSS GEAR DIVISION
HYDRAULIC MOTOR MG, MF, MB, ME SERIES SERVICE PROCEDURE
SAUER SUNDSTRAND
PISTON PUMP SERVICE MANUAL
HYDRAULIC MOTOR SERVICE MANUAL

Page 1
February 2014
420 Series Eaton Pumps
Kit 9900194-008 Shimming Process
Installation Information
Introduction
This shim kit is to replace the crush ring within the pump
housing. If the housing, drive shaft, shaft bearings or end
cover is replaced during servicing, the original crush ring can
no longer be used to assure proper bearing set.
Shimming procedures:
1 Measure the thickness of the existing crush ring.
2 To obtain a starting point, stack shims to a few thou-
sandth of an inch less than the measurement of existing
crush ring. Then insert shims into the housing in the
same location as the removed crush ring.
3 Assemble the housing (**without interface o-ring seals),
shaft bearings, shaft and end cover. Install the end cover cap
screws and torque to 97 +/- 9 lbf.ft.
4 Using a dial indicator, measure drive shaft end play. Target Cap Screws 30
bearing set range is .001" clearance to .002" interference
(preload). Add shims to achieve proper bearing set. If no
movement of the shaft is observed, shims will need to be
removed and steps 3 and 4 repeated.
End Cover 4
5 Finish the assembly of the pump.
Rear Bearing 18
Shaft 1
Crush Ring 2
Front Bearing 16
Shim Kit 9900194-008 2
Housing 14
Eaton Eaton Eaton
14615 Lone Oak Road 20 Rosamond Road Dr.-Reckeweg-Str. 1
Eden Prairie, MN 55344 Footscray D-76532 Baden-Baden
USA Victoria 3011 Germany
Tel: 952 937-9800 Australia Tel: (49) 7221 682-0
Fax: 952 974-7722 Tel: (61) 3 9319 8222 Fax: (49) 7221 682-788
www.hydraulics.eaton.com Fax: (61) 3 9318 5714
2004 Eaton Corporation

All rights reserved
Printed in USA
Document No. E-PUPI-TI006-E
February 2004
Section 6. Fluid
TASKFORCE TIPS INCORPORATE
ANTI-ICING NOZZLES TECHNICAL MANUAL
HARDI INCORPORATE
COLD AND HOT FLUID PUMPS DISASSEMBLY INSTRUCTIONS AND LUBRICANT
F.E. MYERS COMPANY
TWO STAGE CENTRIFUGAL PUMP INSTALLATION, SERVICING AND PARTS MANUAL
MISCO VIP INLINE
PROCESS REFRACTOMETER, INSTRUCTIONAL MANUAL
RECTORSEAL - SOOTOMAGIC
HEATER SOOT REMOVAL INSTRUCTIONS

Page 1
February 2014
_" Anti-icing l De-icing
MANUAL: Nozzles
|_:i_=_:0i_Tl_i)_
INSTRUCTIONS FOR SAFE OPERATION AND MAINTENANCE
INGI manual
IAWARN and receiving proper training
Read instructionmanualbeforeuse. can beof this
Operation
equipment. Call (800) 348-2686 with any questions.
dangerous and is understanding
nozzle without a misuse of this
the
This instruction manual is intended to familiarize ground support crew and maintenance
personnel with the operation, servicing and safety procedures associated with TFT ice-
control nozzles.
This manual should be kept available to all operating and maintenance personnel.
i
_
- BH-HT
I
] B-ER
/'(
__BGH-TYPE2 BH-TYPE2
TASK FORCE TIPS 800.348.2686 http://www.tft.com

Copyright Task Force Tips, Inc. 1999 LIB-205 January 20, 1999 REV 0
TABLE OF CONTENTS
1.0 MEANING OF SAFETY SIGNAL WORDS J!h
2,0 GENERAL INFORMATION
2.1 VARIOUS MODELS AND TERMS
3.0 FLOW CHARACTERISTICS
3.1 TRAJECTORYCHARTSFOR ICE-CONTROLNOZZLES
3.1,1 ANTI-ICINGNOZZLES
3,1.2 DE-ICING NOZZLES
3.1.3 ELECTRICREMOTE NOZZLES
4,0 NOZZLE CONTROLS
4.1 FLOWCONTROLS -_-'-",,-_!
4.1.1 LEVER TYPE FLOW CONTROL
4.1.2 ELECTRICREMOTE NOZZLE
4.2 PATTERN AND FLUSH CONTROL
4.2.1 PATTERN CONTROL
4.2.1.1 MANUAL PATTERN CONTROL
4.2.1.2ELECTRICPATTERNCONTROL
4.2.2 FLUSH CONTROL
4.2.2.1 MANUAL CONTROL
4.2.2.2 ELECTRIC CONTROL
5.0 USE OF ICE-CONTROL NOZZLES
6.0 FIELD INSPECTION
7,0 WARRANTY
8.0 PARTS LIST ....
__
8.1 ICE-CONTROLNOZZLEVALVEDMODELS
8.2 ICE-CONTROLNOZZLE ELECTRICREMOTEMODEL
9.0 ANSWERS TO YOUR QUESTIONS
10.0 INSPECTION CHECKLIST
Copyright TaskForce Tips, Inc. 1999 2 LIB-205 January 20, Igg9 REV 0
1.0 MEANING OF SAFETY SIGNAL WORDS
A This is a safety alert symbol, throughout the text it alerts you to potential personal injury hazards. Obey all safety
messages that follow to avoid possible injury or death.
A safety related message is identified by a safety alert symbol and a signal word to indicate the level of risk
involved with a particular hazard. Per ANSI standard Z535.4-1998 the definition of the three signal words is as
follows:
DANGER indicates an imminently hazardous situation which, if not avoided, will result in
,DANGER death or serious injury.
IAWARN IN GI WARNINGin
death or seriousindicateSinjury.a
potentially hazardous situation which, if not avoided, could result
I"'1
^CAUTION I/ in minor orindicates
CAUTION moderatea injury.
potentially hazardous situation which, if not avoided, may result
2.0 GENERAL INFORMATION

Task Force Tips ice-control nozzles have been specifically designed to apply water, glycol or water/glycol based ice-
control fluids to aircraft exterior surfaces at fluid temperatures up to 210 degrees F (99 degrees C). The proper use of de-
icing agents aids ground support professionals in the removal of ice from aircraft fuselage, landing gear and wing
surfaces. The proper use of anti-icing agents aids ground support professionals in their efforts to prevent ice and snow
from adhering to the wings of aircraft. This may extend holdover times and help make air travel in cold weather conditions
less hazardous. These nozzles are only part of a complete ice-control system. Suitability of a particular nozzle for
applying de-icing or anti-icing fluids must be determined by the end user of the nozzle.
Valved ice-control nozzles have:

Automatic Pressure Control for optimum reach
Slide-Type valve with heat resistant EPDM seat - The valve design controls the flow through the nozzle
while minimizing turbulence that causes shear and degradation of Type II fluids
Pattern Control - This nozzle features a "toothless" bumper to reduce air turbulence, and can be easily
adjusted for any desired spray pattern between a straight stream or wide spray position.
Pistol Grip - The pistol grip and flow control handle are insulated to protect the operator from the high
temperatures generated by fluids passing through the nozzle.
One Twist Flushing - Easily flushable while flowing to clear trapped debris
Warranty- TFT's five-year warranty and unsurpassed service with 24 hour factory turnaround time.
Electric remote control ice-control nozzles have:

Automatic Pressure Control for optimum reach
Sealed electric motor with easy to use manual override
Pattern Control - This nozzle features a "toothless" bumper to reduce air turbulence, and can be easily
adjusted for any desired spray pattern between a straight stream or wide spray position.
Flush - Easily flushable while flowing to clear trapped debris
Warranty - TFT's five-year warranty and unsurpassed service with 24 hour factory turnaround time.
Copyright TaskForce Tips, Inc. 1999 3 LIB-205 January 20, 1999 REV 0
2.1 VARIOUS MODELS AND TERMS
FLOW NOMINAL I PATTERN
MODEL RANGE PRESSURE FLUID COUPLING VALVE CONTROL
I I I I l l I_
BER-HT120 20 / 80 GPM* 50 / 120 PSi* 2/1" and 4 1.5"-9 NH NO ELECTRIC (12-24VDC) i
BER-HT120-HV 20 / 80 GPM* 50 / 120 PSI* _ 2/1" and 4 1.5"-9 NH NO ELECTRIC (24-36VDC)

i i u U i i n
I
BER-HT150 I
10-60 GPM 150 PSi i
1 and 4 1.5"-9NH l
NO 1
ELECTRIC(12-24VDC) I
BER-HT150-HV 10-60 GPM 150 PSI 1 and 4 1.5"-9 NH NO ELECTRIC (24-36VDC)

l l l 1 | l I
I I I _ l I
BER-HT1501
BER-HT1501-HV 20
20 // 80
80 GPM
GPM 50 // 150
50 150 PSi
PSI 1 and
1 and 4
4 1.5"-9 NH
1.5"-9 NH , NO
NO ELECTRIC
ELECTRIC (12-24
(24-36 VDC)
VDC)
I I I I i I I
BER-HT75 10-60GPM 75 PSi 1, and 4 1.5"-9 NH NO ELECTRIC(12-24VDC)

I I I I I I I
I
BER-HT75-HV I
10-60 GPM 1
75 PSi I
1,2 and 4 1.5"-9 NH I
NO I
ELECTRIC (24-36VDC) I
I
BGH-HT-100 1
10-60 GPM I
100 PSi I
1 and 4 1.0"-11.5 NPT I
YES I
MANUAL TWIST I
BH-HT-100 10-60 GPM 100 PSi 1 and 4 1.0"-11.5 NPT I YES MANUAL IVVJS'I __
BGH-HT-120 !20 / 80 GPM* 50 / 120 PSI* 2 / 1" and 4 1.0"-11.5 NPT I YES J MANUAL TWIST
BGH-HT-150 10-60 GPM 150 PSI 1 and 4 1.0"-11.5 NPT YES MANUAL TWIST
BH-HT-150 10-60 GPM 150 PSI 1 and 4 1.0"-11.5NPT YES MANUAL TWIST
BGH-T2-75PD 10-60 GPM 75 PSI 2 and 4 1.0"-11.5 NPT YES MANUAL TWIST
BGH-TYPE2 10-60GPM 50 PSI 2 and 4 1.5"-9NH YES MANUALTWIST
BH-TYPE2 10-60GPM 50 PSI 2 and 4 1.5"-9NH YES MANUALTWIST

BGH-TYPE2-DS 10-60 GPM 50 PSI 2 and 4 1.312"-12 SAE YES MANUAL TWIST
BGH-TYPE2-PD 10-60GPM 50 PSI 2 and 4 1.0"-11.5NPT YES MANUALTWIST

II
* INDICATESCOMBINATIONNOZZLEWITH LOWFLOW FIXEDGALLONAGE / HIGHFLOWAUTOMATICCONTROL SETTINGS
I i Mismatched or damaged threads may cause nozzle to leak heated fluid or uncouple from
I A C A U TI 0 N I hose/piping under pressure and could cause injury. Nozzle must be mated to
hose/piping with matched threads.
0"_ CONT,90
COUPLING SHAPER -k
STREAM /--- STREAM _, _-_
ON OFF SHAPER
'
RUBBER
COUPLIN_
GASKET _==_(_ ' _z
//
,dL,
VALVEDNOZZLE NOZZLEWITHELECTRIC ml_'

and INTEGRAL PISTOL GRIP REMOTEPATTERNCONTROL
FIGURE 1 - COMMON MODELS AND TERMS
@Copyright Task Force Tips, Inc. 1999 4 LIB-205 January 20, 1999 REV 0
3.0 FLOW CHARACTERISTICS
Valved Ice-Control De-icing Nozzles
Flow (Ipm)
0 100 200 300 400
240 I ' I ' 16
220
200
180
_ _/'_ 14
;14o _ I_f_, _ _.._ lo_

120
100 GH- ___: 8
6
= 80
60 ZF:_y]
]/,,_ 4
40 / /r_l _ iI 2
20 _',,_ _'1 BGH-HT120
0 / 0
0 10 20 30 40 50 60 70 80 90 100 110
Flow (GPM)
\excel\fft_boosteAICE-CONTROL_Flow.xlsl_/alved Nozzles]
Valved Type 2 Anti-icing Nozzles

Flow (Ipm)
0 50 100 150 200 250 300
6 A
100 I '
_" 80
"_ 60 - 4
a. 20 - 1
0 I 0
0 10 20 30 40 50 60 70 80 90
excel_fft_booster_lCE-CONTROL_Flow.xls[TYPE2 Nozzles] Flow (GPM)
Electric Remote Nozzles

Flow (Ipm)
0 50 100 150 200 250 300 350 400
160
t,t o , BER-_T150-H_
-HT15
, _--
_ _--
,2
10
loo \ / '_\
_ k _ _ ER'HT120 I '
= 80 /P-- _IBER'HT120"HVl 6 =:
40 /:,//- \IBER-H_ I _ 2
0
, I ,0
0 10 20 30 40 50 60 70 80 90 1O0 110
\excel\tft\booster\lCE-CONTROL_Flow.xls[Electric Remote Nozzles] Flow (GPM)
FIGURE2 - FLOW CURVES
Friction losses may vary due to differences in hoses/piping construction resulting in flows different than those shown.
Flows can be calculated using conventional hydraulics.
These flow curves are for reference only. User must determine suitability of the stream for the particular purpose for
which it is being used. Such factors as fluid to water ratio, manufacturer of fluid, fluid temperature and equipment
used to supply fluid to the nozzle may produce variation from the flows and pressures shown above.
Copyright Task Force Tips, Inc. 1999 5 LIB-205 January 20, 1999 REV 0
3.1 TRAJECTORY CHARTS FOR ICE-CONTROL NOZZLES
3.1.1 ANTI-ICING NOZZLES
PSI
50 PSI VALVED ANTI-ICING NOZZLE _P. ,.LET L.S
CURVEFLOW PRESSURE
REACTION
IJIJ 50 A 10 19 1
14.
,,, 40 B 20 45 4
.) C 30 60 9
z 30 o 40 64 13
_ 20
tC
KGF/CM =
CURVE FLOW PRESSURE REACTION
_10
_-- ____--_____
, .,D A LPM
38 INLET
1.3 KGF
.5
rr
tU 0 B 76 3.1 2.1
> 0 20 40 60 80 100 120 140 c 11o 4.1 4.5

HORIZONTAL DISTANCE (FEET) D 150 4.4 6.3
PSI
75 PSI VALVED ANTI-ICING NOZZLE oPM ,NLET LBS
"-" CURVE FLOW PRESSURE REACTION
m
uJ 5o A 10 5 1
14.
Ill 4n
--rllzF B 20 21 5
fO C 30 49 11
z 30 0 40 55 15
_ c
20 "
<_10 _'__ _ _ "'D LPM INLET KGF
_u
k- 4m_ .,_ _p..B _, A a8 .3 .s
nr U B 76 1.4 2.2
UJ
> 0 20 40 60 80 100 120 140 c 11o 3.4 5.o
HORIZONTAL DISTANCE (FEET) D 150 3.8 7.1
These trajectories,reach and reaction numbers are provided for reference. Actual trajectories, reach and reactions may
vary with wind conditions, fluid type, fluid/water ratio, fluid temperature, pressure and flow at the nozzle. It is the
operator's responsibility to determine that the system provides adequate reach for the intended purpose.
CAUTION, I angles
De-icingtonozzles
some aircraft
operatesurfaces may cause Direct
at high pressures. deformation or damage.
impingement of theDirect
streamstream at _%
at right
shallow angles to sensitive surfaces.
3.1.2 DE-ICING NOZZLES
PSI
100 PSI VALVED DE-ICING NOZZLE GPM ,NLET L-S
50 CURVEFLOW PRESSURE
REACTION
IJJ
=-"40
IJJ A
B 20
40 64
85 8
19
z 30 c 50 9s 2s
,C o 60 loo 31
__'_-"'_ "__ _ j-D LPM KGF/CM
INLET = KGF
10 ..- / _ ,,_' _ CURVEFLOWPRESSURE
REACTION
o
_/C O
I A. \B" A 76 4.4 3.8
IJJ B 150 5.9 8.8
> 0 20 40 60 80 100 120 140 c 190 6.6 12
HORIZONTAL DISTANCE (FEET) D 230 6.9 15
PSi I
120 PSi VALVED DE-ICING NOZZLE GP,., ,NLET L.S
50 CURVE FLOW PRESSURE REACTION
IJJ
I,I. A 20 50 7
_" 40 8 40 81 18
('_ C C 60 105 31
z 30 / D 80 120 44
20 _ _ _ _ "_ KGF/CM'
'"' _"_ _,. _ _, LPM INLET KGF
._ 10 - ,-
or_ / A" _ B"'_\ _ '_, \ CURVEFLOWPRESSURE
REACT.ON
0 A 76 3.4 3.4
"_ IJJ B 150 5.6 8.6
= > 0 20 40 60 80 100 120 140 c 230 7.2 1_
HORIZONTAL DISTANCE (FEET) D 300 8.3 21
PSI
150 PSI VALVED DE-ICING NOZZLE GPM INLET LBS
50 CURVE FLOW PRESSURE REACTION

UJ
U. A 10 40 3
,,, 40 s 2o 83 9
O C 30 114 16
_ D 50 150 31
_1 _" _ _ _ LPM INLET

KGF/CM' KGF
<_10N _'- _ '_ '_ k CURVE

A FLOW
38 PRESSURE
2,8 REACTION
1.5
uJ B 76 5.7 4.3
_o _ 0_

> 20A_ 40_ e 60 80 100 120 140 c 11o z.9 7.6
HORIZONTAL DISTANCE (FEET) D 190 10 15
These trajectories, reach and reactionnumbers are provided for reference. Actual trajectories, reach and reactions may
operator's responsibility to determine that the system provides adequate reach for the intended purpose.
I _CAUTIOI_I I De-icing
angles tonozzles operatesurfaces
at high pressures.
may cause Direct impingement of theDirect
stream at right
I '"1 some aircraft deformation or damage. stream at
/
Copyright TaskForce Tips, Inc. 1999 7 LIB-205 January 20, 1999 REV 0 J
J
3.1.3 ELECTRIC REMOTE NOZZLES
PSI
75 PSI ELECTRIC REMOTE CONTROL GP. ,NLET L.S _

,,'_"
IJJ
ANTI'ICING NOZZLE CURVE
A
FLOW
10
PRESSURE
19
REACT,
2
ON
50 B 20 45 7
uJ
o 40 c 30 60 _2
Z D 50 64 20
30 /C
N 20 _...__ _ ,,,D LPM INLET KGF

o
_ 10
r- 0 I_ A-_>_ B" _= CURVE
A FLOW
38 PRESSURE
1.3 REACTION
1.o
E
uJ B 76 3.1 3.2
> 0 20 40 60 80 100 120 140 c 11o 4.1 5.5
HORIZONTALDISTANCE (FEET) D 190 4.4 9.5
PSI
120 PSI ELECTRIC REMOTE CONTROL GP. INLET ,-,,S
_"
uJ DE-ICING NOZZLE CURVE
FLOW
PRESSURE
REACTION
"'
_._
50 A
B
20
40
so
93
719
"' 40 c 60 lo6 31
o
Z _ ="_ _ _C D 80 120 44
_
o 10 j_-_ _._/ _ _ B" _, _ _ \ "_lt' __ CURVE LPM
FLOW INLET
PRESSURE KGF
REACTION
r- O _ A 76 3.4 3.4
n- S 150 6.4 9.2
>
UJ 0 20 40 60 80 100 120 140 c 230 7.3 15 _
HORIZONTAL DISTANCE (FEET) D 3O0 8.3 21
150 PSI ELECTRIC REMOTE CONTROL GP. INLET

PSI
L,,S i
_"
IJJ
DE'ICING NOZZLE CURVE
FLOW
PRESSURE
REACT,ON
"' 50- A
B
20
40
74
123
9
22
"'
O
40 c 60 136 35
30 _._ _ -'- --- _ .D

--I _ _ LPM INLET KGF
_ ;r"" _,. _. CURVE FLOW PRESSURE REACTION 1
I
tO _ A 76 5.1 4.1
r- 0
tv" B 150 8.5 11
UJ
> 0 20 40 60 80 100 120 140 c 230 94 1_
HORIZONTAL DISTANCE (FEET) D 300 10 23
These trajectories, reach and reactionnumbers are provided for reference.Actual trajectories,reach and reactionsmay
operator's responsibility to determine that the system provides adequate reachfor the intended purpose.
De-icing nozzles operate at high pressures. Direct impingement of the stream at right _
I^
II,=CAUTION I angles to some aircraft surfaces may cause deformation or damage. Direct stream at
4.0 NOZZLE CONTROLS
4.1 FLOW CONTROL
4.1.1 LEVER TYPE FLOW CONTROL
On models that use a bail type valve handle, the nozzle is shut off when the handle is fully forward. The valve
handle has six detent flow positions. These detent positions allow the nozzle operator to regulate the flow of the
nozzle depending on the need or what can be safely and effectively handled
4.1.2 ELECTRIC REMOTE NOZZLES
On models with electric remote control of the shaper there is no built in flow control. Flow control must be
provided for elsewhere in the system.
4.2 PATTERN AND FLUSH CONTROL
4.2.1 PATTERN CONTROL
4.2.1.1 MANUAL PATTERN CONTROL
On models that use a twist type pattern control, a continuously variable pattern from narrow to wide is
available. Turning the SHAPER clockwise as seen from the operating position behind the nozzle moves the
SHAPER to the straight stream position. Turning the SHAPER counterclockwise will result in an increasingly
wider pattern. An indicator band on the nozzle barrel shows which position the SHAPER is in by
progressively uncovering symbols for FLUSHING, WIDE SPRAY and STRAIGHT STREAM.
4.2.1.2 ELECTRIC PATTERN CONTROL j

On models that use an electric pattern control a continuously variable pattern from narrow to wide is
available by operating the electric actuator according to the directions supplied with the actuator control
panel. Extending the SHAPER outwards as seen from behind the nozzle moves the SHAPER to the straight
stream position. Retracting the SHAPER inwards will result in an increasingly wider pattern. The actuator
"free wheels" at stroke ends making limit switches unnecessary. A manual override lever on the electric
actuator when depressed allows the manual override knob to be turned. Turning the knob counterclockwise
as seen from the operating position behind the nozzle extends the SHAPER towards the straight stream
position. Turning the knob clockwise retracts the SHAPERtowards the wide spray position.
J,_CAUTJON
I Ij using
Electric remote
electric nozzle
control. has finger pinch points. Keep fingers away from nozzle when
4.2.2 FLUSH CONTROL

Debrismayget caughtinsidethe nozzle.Thistrapped materialwillcausepoorstreamquality,shortenedreach
and reducedflow.Toremovethistrappeddebristhe nozzlecanbeflushedasfollows:
4.2.2.1 MANUAL CONTROL
While still flowing fluid turn the SHAPER counterclockwisepast the wide spray position (increased
resistanceto turningwillbe felt on the SHAPER as the nozzle goes into flush.) This willopen the nozzle
allowingdebris to pass through. Rotate the SHAPER clockwise and out of flush to continue normal
operation.
J ACAUTION splash toice'cntrl

I Heated the groundfluids
directly
areunder the nozzle.
capable Direct
f causing stream away
burns"when from personnel
flushing' ht fluidwhen
may
flushing.
4.2.2.2 ELECTRIC CONTROL
Whilestillflowingfluid retractthe SHAPERbackwards pastthe wide spray position(as viewedfrom behind
the nozzle)tillit reaches itsstop. This willopen the nozzleallowingdebris to passthrough. When the debris
has been flushed out extend the SHAPERoutwards until it is out of flush as determined by the markings on
the barrel and the force of the stream to continue normal operation. Flushing may also be accomplished in
the manual override mode of operation by moving past the wide spray position. See 3.2.1.2 for instruction
on how to use manual override.
During flush, the nozzle will lose much of its reaction force and reach as the pressure drops. The nozzle
_ operator must be prepared for an increase in reaction, reach and pressure when returning the nozzle from
the flush position to normal operation to retain control of the nozzle and stream.
I'WARN
INGI D ebris innozzlecanresultinineffectivestream.
debris. Flush
Remove all pressure and flow from the nozzle or uncoupling.
before uncouple nozzle to remove
Copyright TaskForce Tips, Inc. 1999 g LIB-205 January 20, 1999 REV 0
5.0 USE OF ICE-CONTROL NOZZLES
IT IS THE RESPONSIBILITYOF THE GROUND CREWMANAGEMENT TO DETERMINEPHYSICALCAPABILITIESAND
SUITABLITYFORAN INDIVIDUAL'SUSEOF THIS EQUIPMENT.
The methodsusedin applyingice-controlfluidsto aircraftarethe responsibilityoftheagencydoingthe ice-control.Many _'
factorscontributeto the propercontrolof ice on an aircraft.The nozzleisonlyone part of a completeice controlsystem.
Flow, pressureat the nozzle,fluid temperature,type of fluid, methodof application,outsideair temperature,aircraft
surfacetemperatureand thelikemustbetakenintoaccountwhendealingwithiceconditions.The propermethodsmust
be determinedby eachagencyfor theirparticularconditions.
Where a nozzle is listedas Type 2 capable, flow and pressuremust be controlledwithinthe ratingof the nozzle to
minimizeshearingdegradationof theType2 fluid.
IN may
IAWARNGI result oftype2anti-icingfluidsfromnozzlesatflowshigherthan50GPMor85psi
Discharge in degradation of the fluid and render it ineffective in preventing a buildup of
ice on aircraft surfaces prior to takeoff. Consult fluid manufacturer's recommended
guidelines.
Rated fluid temperatures at the nozzlemust not be exceeded. Use of saltwater in these nozzles isnot permissible and will
lead to a shortened service life.
Some features of this nozzle that the operator should be aware of are:
Automatic Pressure Control for de-icing - When used for de-icing these nozzles from TFT incorporate a
pressure regulating mechanism, which means the fluid discharge velocity is nearly constant. With a constant
nozzle discharge pressure, the de-icing agent will have optimum reach at all flow settings, thereby reducing
waste due to insufficient range of the stream.
Slide-Type valve with heat resistant EPDM seat - On nozzles with a valve the valve design controls the flow
through the nozzle while minimizing turbulence that causes shear and degradation of Type 2 fluids. Because of
this feature the nozzle can be operated at any handle position, thereby allowing the operator to regulate the
amount of agent being applied. This gives the operator the ability to conserve fluid and minimize waste without
sacrificing reach or range of the stream. Unlike a ball valve, the stainless steel slide valve is not directly in the t_
flow path and will not tighten under pressure, or bind with age. Therefore, it is always easy to operate.
Pattern Control - This nozzle features a "toothless" bumper to reduce airturbulence, and can be easily adjusted
for any desired spray pattern by moving the shaper between a straight stream or wide spray position. This will be
beneficial when applying fluids to sensitive areas of the aircraft.
Sealed electric motor with easy to use manual override - On electric remote models the nozzle is equipped
with a sealed motor/gear housing which prevents contamination of the actuator with dirt and fluids. The actuator
features an easy to use override mechanism to allow manual setting of the pattern or to place the nozzle into flush
mode.
Flushable while flowing - The nozzle shaper when retracted fully puts the nozzle into flush providing an
oversized fluid passageway which allows trapped debris to exitthe nozzle. On manual models an increase in
turning force on the shaper signals the operator that the nozzle is moving into flush.
An inadequate supply of nozzle pressure and/or flow will cause an ineffective stream and
can result in incomplete removal or incomplete protection from the buildup of ice on
flight surfaces which may lead to injury, death or loss of property.Call 800-348-2686 for
assistance.
IAWARN
I--- INGII Ice-control fluid streams
and burn unprotected areand
flesh capable
eyes. ofDo
injury and damage.
not direct Heated
fluid stream streams
or allow cantocling
splash to
cause
injury to persons or property.
IAWARN INGi With handheld

Failure nozzles the nozzle operator must always be positioned to restrain the
torestrainnozzlereactioncancauseinjuryfromlossoffootingand/rwhipping"
nozzle reaction in the event of those changes, In case of whipping retreat from the nozzle
immediately. Do not attempt to regain control of nozzle while flowing fluid. _
IA WARN I NGi downwind. Avoidsplash

Breathing ice-control back.
fluid Consult
fumes canmanufacturer'ssafety
be hazardous to yourguidelines.
health. Avoid working
Copyright TaskForce Tips, Inc. 1999 10 LIB-205 January20, 1999 REV 0

6.0 FIELD INSPECTION
Task Force Tip's Ice-Control Nozzles are designed and manufactured to be damage resistant and require minimal
maintenance. However, as the primary fluid application tool upon which aircraft ice-control depends they should be
treated accordingly.
IAWARN
INGI inspection checklist in sectionlO.O. Any nozzle that fails inspection is dangerous to use
Nozzle mustbeperiodicallyinspectedforproperoperationandfanctionaccordingto
and must be repaired before using.
Performance tests shall be conducted on Ice-Control nozzles after repair, or anytime a problem is reported to verify
operation in accordance with TFT test procedures. Consult factory for the procedure that corresponds to the model and
serial number of the nozzle. Any equipment which fails the related test criteria should be removed from service
immediately. Equipment can be returned to the factory for service and testing.
Factory service is available with repair time seldom exceeding one day in our facility. Factory serviced nozzles are
repaired by experienced technicians to original specifications, fully tested and promptly returned. Any returns should
include a note as to the nature of the problem, who to reach in case of questions and if a repair estimate is required.
Repair parts are available for those wishing to perform their own repairs. Task Force Tips assumes no liability for damage
to equipment or injuryto personnel that is a result of user service.
I A U T IO N I Any
misuse of this product.
alteratins Do not and
t the nzzle alter its
the markings
nozzle or culd
its markings.
diminish safety and cnstitutes a
All Task Force Tip nozzles are factory lubricated with high quality silicone grease. This lubricant has excellent washout
resistance and long term performance. If your operation has unusually hard water, the moving parts may be effected.
The moving parts of the nozzle should be checked on a regular basis for smooth and free operation, and signs of
damage. IFTHE NOZZLE IS OPERATING CORRECTLY, THEN NO ADDITIONAL LUBRICATION IS NEEDED. Any nozzle
that is not operating correctly should be immediately removed from service and the problem corrected.
7.0 WARRANTY
_ Task Force Tips, Inc., 2800 East Evans Avenue, Valparaiso, Indiana 46383 ("TFT") warrants to the original purchaser of its
Ice Control series nozzles ("equipment"), and to anyone to whom it is transferred, that the equipment shall be free from
defects in material an workmanship during the five (5) year period from the date of purchase.
TFT's obligation under this warranty is specifically limited to replacing or repairing the equipment (or its parts) which are
shown by TFT's examination to be in a defective condition attributable to TFT. To qualify for this limited warranty, the
claimant must return the equipment to TFT, at 2800 East Evans Avenue, Valparaiso, Indiana 46383, within a reasonable
time after discovery of the defect. TFT will examine the equipment. IfTFT determines that there is a defect attributable to it,
TFT will correct the problem within a reasonable time. If the equipment is covered by this limited warranty, TFT will
assume the expenses of the repair.
If any defect attributable to TFT under this limited warranty cannot be reasonably cured by repair or replacement, TFT
may elect to refund the purchase price of the equipment, less reasonable depreciation, in complete discharge of its
obligations under this limited warranty. If TFT makes this election, claimant shall return the equipment to TFT free and
clear of any liens and encumbrances.
This is a limited warranty. The original purchaser of the equipment, any person to whom it is transferred and any person
who is an intended or unintended beneficiary of the equipment, shall not be entitled to recover from TFT any
consequential or incidental damages for injury to person and/or property resulting from any defective equipment
manufactured or assembled by TFT. It is agreed and understood that the price stated for the equipment is in part
consideration for limiting TFT's liability. Some states do not allow the exclusion or limitation of incidental or consequential
damages, so the above may not apply to you.
TFT shall have no obligation under this limited warranty if the equipment is, or has been, misused or neglected (including
failure to provide reasonable maintenance) or if there have been accidents to the equipment or if it has been repaired or
altered by someone else.
THIS IS A LIMITED EXPRESS WARRANTY ONLY TFT EXPRESSLY DISCLAIMS WITH RESPECT TO THE EQUIPMENT
ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND ALL IMPLIED WARRANTIES OF FITNESS FOR A
PARTICULAR PURPOSE. THERE IS NO WARRANTY OF ANY NATURE MADE BY TFT BEYOND THAT STATED IN THIS
DOCUMENT.
This limited warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
@Copyright TaskForce Tips, Inc. 1999 11 LIB-205 January 20, 1999 REV 0
8.0 PARTS LIST
8.1 ICE-CONTROL NOZZLE VALVED MODELS
12
27 8\ 7___.[] 9
2,3
15 28 19 3 4 5 29 36 1
10----_% Q# 3O
,32 ,35 _ 17 34,31 11 40 6 2 20 ,33 \
18 21 37
41 14 24 16
___ 13
22
26 12
39
TFT\BOOSTER \PRICE LIST\MI TIGATION.dw(:J
MODEL NUMBER
(a) BGH-TYPE2 (f) BGH-HT100

(b) BH-TYPE2 (g) BH-HT100
(c) BGH-TYPE2DS (h) BGH-HT120
(d) BGHTYPE2-PD (i) BGH-HT150
REF # QTY (e) BGH-T2-75 (j) BH-HT150 DESCRIPTION --_ _!
7
!
1 1 B504 B504 SHAPERWITH BUMPER

2 1 B510 B510 SHAPERGUIDE
3 1 B524 B524 BARRELcoNE ' I
4 1 B560 B560 BAFFLE

5(a,b,c,d) 1 B568 50PSISPRING
WASHER |
5(e) 1 B567 75PSISPRING

WASHER
5(f,g) 1 B565 100PSISPRING
WASHER
5(h) B563 120PSISPRING
WASHER
5(i,j) 1 B566 150PSISPRING
WASHER I
6 1 B594 B594 HIGH-TEMP

NOSECONE I
7 1 B620 B620 VALVEHANDLE I
8 1 B630 B630 CAM PIN , iil_'

9 1 B635 B635 SAFETY PIN I
10 4 B650 B650 DRAG NUBS
Copyright Task Force Tips, Inc. 1999 12 LIB-205 January 20, 1999 REV 0
8.1 ICE-CONTROL NOZZLE VALVED MODELS - cont.
MODEL NUMBER
m !
(a) BGH-TYPE2 1 (f) BGH-HT100

(b) BH-TYPE2 (g) BH-HT100
(c) BGH-TYPE2DS (h) BGH-HT120
(d) BGHTYPE2-PD (i) BGH-HT150
REF # QTY (e) BGH-T2-75 (j) BH-HT150 DESCRIPTION
I l I I I
11 1 B662 B662 SPECIAL

AGENT
SLIDER
I I I I I
12(d,f,g,h,i) 1 I B668 B668 1.0" TAPER PIPE COUPLING

I I ! I I
12(a,b,e) 1 B675N l -- 1 1.5" NH COUPLING ,'i

12(C) ! 1 ' B680DS -- CODE DS COUPLING 1 5/16-12
13 ,
J
1
J
B691 ,
,
B691 ,
i
HIGH-TEMP PISTOL GRIP
W
14 m
1 !
n
B724 '
m
B724 _ DE-ICING
NAMELABEL |
15(a,b,c,d) , 2 ,' B725 _' -- 1 50 PSI TYPE 2 LABEL ,

15 , 2 B726(e) i/ _ j 75 PSi TYPE 2 LABEL
16 I
; 1 ,
B740 I
B740 I
BARREL LABEL I
17 1 1 1 B750 , B750 , VALVE LABEL ,

18 1 B770 B770 PORT PLUG
19 1 B785 ! B785 FLUSH WAVE SPRING
I I I I I
20(f,g) i
1 i
) -- I
B810-1CE-100 !
I
DE-ICING BARREL ASS'Y- 100 PSI
20(h) , 1 1 -- , B810-1CE-120 DE-ICING BARREL ASS'Y 120 PSI

20(i,j) i
1 _
-- i
B810-1CE-150 i
DE-ICINGBARRELASS'Y- 150 PSI I
20(a,b,c,d) i 1 m_ B810-TYPE2 i -- i BARREL ASSEMBLY- 50 PSI I
20(e) I
1 I
! B810-T2-75 I
-- I
BARREL ASS'Y 75 PSI I
21 1 B910 B910 VALVEASSEMBLY

i ii i i |
22 28 V2120 V2120 3/16" DIA. STAINLESS BALL

I ! I I I
23 2 V2120-TORLON V2120-TORLON 3/16" DIA. TORLON BALL
I I I I
24 4 ' V2130-TORLON V2130-TORLON 7/32" DIA. TORLON BALL

i i i i
25 46 V2135 V2135 1/8" DIA. NYLON BALL

_ i i m
26 1 V3040 V3040 1.0" COUPLING GASKET
| m m m
27 _ 1 _ V3130 V3130 1.5" COUPLING GASKET

l m m m
28 m
1 I
V4270 V4270 ,_ WS-128-F-S02 SMALLEY RING i
29 1 V4280 V4280 r WSM-50-S02 SMALLEY RING

| m i i
30 2 VM4195 VM4195 SPRING #C0180-032-0310-S

m m m i
31 1 vo-o3o vo-o3o o-RING-o3o

32 1 VO-127 VO-127 O-RING-127
33 1 VO-128 VO-128 O-RING-128
34 1 VOQ-4124 VOQ-4124 QUADX-4124
35 1 VOQ-4216 VOQ-4216 QUADX-4216
36 1 VOQ-4225 VOQ-4225 QUADX-4225
37 2 VT10-32SS187 VT10-32SS187 #10-32 x 3/16" SOCKET SET SCREW 1

i
38 2 _ VT31E18BH500 VT31E18BH500 5/16-18 x 1/2" BUTTON HEAD i
39 1 I VT37-24SH1.0 i VT37-24SH1.0 3/8-24 x 1.00" SHCS ii
40(f,g,i,j) 1 VT37-24SS750 VT37-24SS750 3/8-24 x 3/4" SOCKET SET SCREW
40(h) 1 -- VT37-24SS150 3/8-24 x 1 1/2" SOCKET SET SCREW
41 1 X405 X405 SWIVEL SCREW
I i i i
@CopyrightTaskForce Tips,Inc. 1999 13 LIB-205January20, 1999REV0

8.2 ICE-CONTROL NOZZLE ELECTRIC REMOTE MODEL
16 10 3 4 5 17 20 1
14 -
15 7 18 23 6 8 2 11
/
13 9
TFT\BOOSTER\ICE- CONTROL- ER.dwg _21 12 22
MODEL NUMBER
Part # For Part # For

12-24 VDC 24-36 VDC
BER-HT75 BER-HT75-HV
BER-HT120 BER-HT120-HV " -- --_
REF # QTY BER-HT1501 BER-HT1501-HV DESCRIPTION i
I
1 1 B504 B504 BUMPER / NO TEETH I
2 1 B514 B510 ERSHAPER GUIDE i

3 1 B525 B524 BARRELCONE
4 1 B560 B560 BAFFLE
5 1 B567 SPRINGWASHER - 75PSI
1 B563 WASHER 20GPM @50PSI
1 B566 B565 SPRINGWASHER -150PSI
1 B562 B562 SPRINGWASHER - 20@50 / 80@150
6 1 B597 B563 SOLIDHIGHTEMP NOSE CONE
7 1 B664 B566 ERT.O.BASE- LASERED
8 1 B727 B594 ICE-CONTROL NAME LABEL
9 1 B740 B620 BARREL LABEL
10 1 B785 B630 FLUSHWAVE SPRING
@Copyright Task Force Tips, Inc. 1999 14 LIB-205 January 20, 1999 REV 0
8.2 ICE-CONTROL NOZZLE ELECTRIC REMOTE MODEL- cont.
MODEL NUMBER
Part # For Part # For

12-24 VDC 24-36 VDC
REF # QTY BER-HT1501 BER-HT1501-HV DESCRIPTION
!
11 1 B810-1CER75 B810-1CER75 BARREL ASSEMBLY -DE-ICING-ER

1 B810-1CER120 B810-1CER120 BARREL ASSEMBLY -DE-ICING-ER
1 B810-1CER150 B810-1CER150 BARREL ASSEMBLY -DE-ICING-ER I
12 1 B935 12 VDC CAST ACTUATOR ASSEMBLY

1 B936 24VDCCASTACTUATOR ASSEMBLY
1
13 4 V2130-TORLON V2130-TORLON HIGH-TEMP PISTOL GRIP 'i

14 46 V2135 V2135 DE-ICING NAME LABEL
1
15 1 V3130 V3130 50PSITYPE2 LABEL

I
16 1 V4270 V4270 BARREL

LABEL ,
17 1 V4280 V4280 VALVE LABEL
I
18 1 VO-030 VO-030 PORT
PLUG
|
19 1 VO-128 VO-128 FLUSHWAVESPRING
!
20 1 VOQ-4225 VOQ-4225 DE-ICINGBARRELASS'Y- 100 PSI 1
21 2 VT25-20SH3.0 VT25-20SH3.2 VALVE ASSEMBLY i

22 1 VT31-18BH1.4 VT31-18BH1.4 3/16" DIA. STAINLESS BALL !
23 1 VT37-24SS750 VT37-24SS750 3/16" DIA. TORLON BALL
9.0 ANSWERS TO YOUR QUESTIONS

We appreciate the opportunity of sewing you and making your job easier. If you have any problems or questions, our toll-
free "Hydraulics Hotline", 800-348-2586, is normally available to you 24 hours a day, 7 days a week.
Copyright TaskForce Tips, Inc. 1999 1 5 LIB-205 January 20, 1999 REV 0
10.0 INSPECTION CHECKLIST
Nozzle must be inspected for properoperationand functionaccordingto this checklistperiodically.
On models with a hand operated valve check that: J_.

1) There is no obvious damage such as missing, broken or loose parts, damaged labels, etc.
2) Coupling is tight and leak free.
3) Valve operates freely through full range of settings.
4) "OFF" position does fully shut off and flow stops
5) Nozzle flow is adequate as indicated by pump pressure and nozzle reaction
6) Shaper turns freely and adjusts pattern through full range
7) Shaper turns into full flush and out of full flush with normal flow and pressure restored.
On models with an electric remote control check that:

1) There is no obvious damage such as missing, broken or loose parts, damage , cked
wiring, etc.
2) Coupling is tight and leak free.
3) Nozzle flow is adequate as indicated by pump pressure and nozzle reach
4) Shaper moves freely and adjusts pattern through full range by electric and manual control.
5) Shaper moves into full flush and out of full flush with normal flow and pressure restored by electric and
manual control
6) Electric remote actuator mountings are tight
7) Manual override controls operate freely and through full range of motion.
Any ice-control nozzle failing any part of the inspection checklist is unsafe. Correct this
I,_WAR,,.GI problem
misuse of before use. Operating a nozzle that fails any of the above inspections is a
this equipment.
TASKFORCE TIPS,Inc.
www.tft.com
2aoo
EastEva,sAv.,u.
800.348.2686
"Val.araiso,
219.462.6161
IN463a3-8 40
Fax219.464.7155
Copyright Task Force Tips, Inc. 1999 LIB-205 January20, 1999 REV 0
HOT FLUID PUMP 463# 821591
-For use with hot or cold fluids (Max. temp. 185 degrees F)
-Exterior finish, Paint Black
-Rubber o-rings in valves
-Rubber diaphragms
-Bearings have grease (High temperature grease is recommended)
-Bottom mounting foot
- 540 RMP (max)
-1-3/8 6 spline drive shaft
-238 Liters per minute at 450 RPM O PSI
DISASSEMBLY INSTRUCTIONS
1. Remove the valve/diaphragm covers (111615) by removing the four bolts (430438)
2. Remove the valves (72094700) from the chambers by removing o-ring (242510). Note the
position of the valves before removal. Intake valves up into cover, pressure valves down into
pump. NOTE: If the valves are removed, reassemble them with new o-ring (242510).
3. Remove diaphragm retainer bolt (430938), and plate (161012).
4. Remove diaphragm (242426) and backing disc (161012).
5. Remove the front pump casing (111547) by removing the three bolts (421083) and prying off.
6. Press the crankshaft assembly slightly toward the open end of the pump until the rod retrainers
(161745) are loose enough to remove the connecting rods (111623).
7. Press out the crankshaft assembly, then press off the carrier bearings (210221) and remove
rod retainers (161745).
8. Press off the rod bearings (210232) and the space ring (331192) can be removed.
NOTE: If new bearing are installed or chemical has leaked into crankcase, repack bearings with a
good quality ball bearing grease, NLGI-2 Grease.
V.I.P.
10
V.I.P. VERY IMPORTANT PROCESS
Inline/Process Refractometer
Instruction Manual
INSTRUCTIONS FOR OPERATION
VIP Inline Refractometer
MISCO Refractometer
3401 Virginia Road Cleveland, Ohio 44122 (USA)
Phone 216-831-1000 Fax 216-831-1195
www.misco.com
2005 MISCO. All rights reserved.
Reproduction of any part of this instruction manual, in any manner whatsoever, without
the written permission of MISCO is strictly forbidden. Information in this document is
subject to change without notice.
Table of Contents
WARNINGS: ........................................................ 2 System Operation ............................................ 18
A Brief Introduction to Refractometers ............ 3 Operating the System ................................. 18
Bending Light................................................ 3 Component Maintenance & Service............... 20
The History of Refractometers...................... 5 Before Removing Sensor Head .................. 20
About Your New VIP Inline Refractometer....... 7 Cleaning the Sensor Head Optic ................ 21
Refractive Index............................................ 8 Error Code & Error Messages ......................... 23
Temperature Compensation......................... 8 Error Codes ................................................ 23
Component Descriptions................................... 9 Error Messages .......................................... 24
Sensor Head................................................. 9 Specifications ................................................... 25
Control Unit................................................. 10 Legal .................................................................. 27
Sensor Cable.............................................. 11 Warranty ..................................................... 27
Power/Relay Harness................................. 11 Regulatory Notices...................................... 28
Remote Display (optional) .......................... 11 Patents, Trademarks, and Copyrights ........ 29
Additional Features..................................... 11 Record of Revisions ......................................... 30
System Installation........................................... 12
I.) Planning the Installation ......................... 12
II.) Mounting the Control Unit...................... 13
III.) Installing the Sensor Head ................... 14
IV.) Connecting the Power/Relay Harness . 15
V.) Initial System Test................................. 16
VI.) Route & Connect the Sensor Cable..... 16
VII.) Final System Test ............................... 17
Conventions Used in This Manual
WARNING: Important operation or safety information. Pay particular attention to this symbol; it
indicates a potential for property damage or personal injury.
NOTE: Indicates special information or tips that help you make better use of your refractometer.
WARNINGS:
OBTAIN A MATERIAL SAFETY DATA SHEET (MSDS) FOR EACH FLUID YOU CHOOSE TO TEST AND READ
AND FOLLOW THE SAFETY AND HANDLING PRECAUTIONS FOR THAT FLUID. PAY PARTICULAR
ATTENTION TO WARNINGS CONCERNING VENTILATION, PROTECTIVE CLOTHING, EYE PROTECTION AND
WASTE DISPOSAL.
_________________________________________________________________
READ THIS INSTRUCTION MANUAL COMPLETELY BEFORE USE. PAY PARTICULAR ATTENTION TO THE
SECTIONS ON INSTRUMENT INSTALLATION, CARE, AND MAINTENANCE. USE THE INSTRUMENT ONLY IN
ACCORDANCE WITH THIS MANUAL.
_________________________________________________________________
MEASURING STRONG ACIDS OR BASES MAY DAMAGE THE SENSOR HEAD AND OPTICS. CHECK WITH
MISCO TECHNICAL SUPPORT FOR CHEMICAL COMPATIBILITY.
_________________________________________________________________
NEVER USE STRONG CLEANING SOLUTIONS OR SOLVENTS TO CLEAN THE SURFACES OF THE CONTROL
UNIT.
_________________________________________________________________
MAKE CERTAIN THAT THE CONTROL UNIT IS POWERED OFF BEFORE SENSOR HEAD CABLE IS
CONNECTED OR DISCONNECTED. DAMAGE TO THE SENSOR HEAD CAN RESULT IF THE SYSTEM IS
POWERED.
___________________________________________________________
MAKE CERTAIN THAT THE USER-SUPPLIED POWER SUPPLY MATCHES THE VOLTAGE MARKED ON THE
CONTROL UNIT (AND/OR THE WIRING HARNESS) AND THAT IT CAN SUPPLY AT LEAST 0.5 AMPS. FAILURE
TO MATCH THE VOLTAGE MAY CAUSE SERIOUS DAMAGE TO THE INSTRUMENT.
___________________________________________________________
THE SENSORS AND CONTROL UNITS ARE MATED TOGETHER AND IDENTIFIED BY NUMBER. MAKE SURE
THAT THE NUMBER ON THE SENSOR AND THE NUMBER ON THE CONTROL UNIT MATCH BEFORE
CONNECTING THE TWO COMPONENTS TOGETHER. ATTACHING THE WRONG SENSOR AND CONTROL
UNIT TOGETHER WILL CAUSE INACCURATE READINGS AND MAY RESULT IN DAMAGE TO BOTH
COMPONENTS.
___________________________________________________________
FLUID PRESSURE SHOULD NOT EXCEED 10.34 BAR (150 PSI) AND THE TEMPERATURE SHOULD BE IN THE
RANGE -28 C TO 100 C (-20 F TO 212 F).
___________________________________________________________
THIS DEVICE CONTAINS NO USER-SERVICABLE PARTS. ALL REPAIRS AND SERVICE MUST BE
PERFORMED BY A MISCO CERTIFIED REPAIR FACILITY. ANY ATTEMPT TO MODIFY OR REPAIR THE
INSTRUMENT WILL VOID THE WARRANTY AND MAY RESULT IN PERMANENT DAMAGE TO THE
INSTRUMENT.
___________________________________________________________
DO NOT TOUCH EXPOSED SENSOR HEAD WITH BAREHANDS; IT MAY BE HOT AND CAUSE BURNS.
Section
M I S C 0 V I P I N L I N E R E F R A C T O M E T E R
1
A Brief Introduction to
Refractometers
This brief introduction on measuring refractive index will go
a long way in helping you to understand how this instrument
operates as well as provide a little background information on
its history.
N
early a century and a half after their introduction, refractometers have
come a long way in terms of usefulness, though their principle of
operation has changed very little. Refractometers still remain essential
instruments for fluid measurement, quality control, and process
control applications.
Refractometers are optical instruments designed to measure the refractive index

of a solution. Refractive index is a dimensionless quantity expressed as the ratio
of the speed of light in air to the speed of light in a fluid. Roughly speaking, it is
the degree to which light bends when it enters a solution.
Refractive index is a fundamental physical property of a substance and once

measured, it can often be used as a basis for conversion into other physical
properties such as percent concentration, boiling point, freeze point, specific
gravity, etc.
Bending Light
Optics have historically been one of the most fundamentally applied areas of
physics. This is as true today as at any other time in the last 500 years. From the
discoveries by Roemer, Snell, and Newton in the 17th and 18th centuries, to the
development of lasers, light emitting diodes, and fiberoptics in the 20th century,
the field of optics continues to challenge scientists and spawn entire new
industries.
3
One of the most elementary phenomena in optics is refraction, the apparent

change in direction that occurs when light passes from one transparent medium
into another with a different optical density.
Very nearly four centuries ago, Danish astronomer, Ole Roemer, determined that
light travels at approximately 186,000 miles per second (~300,000,000 meters per
second) in space. A short time later, Willebrord Snell, a Dutch physicist,
discovered that the speed of light depends on the medium through which it
passes. In water this speed is roughly 140,000 miles per second (~255,000,000
meters per second) and in glass, approximately 124,000 miles per second
(~200,000,000 meters per second).
Snell discovered that when light crosses an interface between a less-dense

medium, such as air, to an optically denser medium, such as water, it will appear
to bend. It is the difference in refractive index of the two materials that causes the
light to be bent. This bending takes place toward the normal, which is an
imaginary plane running perpendicular to the interface between the two materials.
One example of this is the apparent bending of a pencil when it is immersed in a

glass of water. The bending appears to take place at the surface of the water, or
precisely at the point where there is a transition of density. Obviously, the pencil
is not really bending, but the light forming the image of the pencil is being bent as
it passes from the water (a medium of higher density) to the air (a medium of
lower density).
With respect to the refractive index of fluids, Snell determined that the refractive
index was related to the speed of light in air divided by the speed of light in the
fluid. He held that the refractive index of the fluid could be accurately determined
by the degree to which the light was bent when entering the solution. The greater
the refractive index of the fluid, the more the light will be bent.
This all sounds very straight forward and simple; however, there are a number of
things that complicate matters. The amount light bends when entering a fluid
depends, not only on the wavelength of light, but also on the temperature of the
fluid. Since fluids tend to be dispersive mediums, different wavelengths of light
will bend at different rates within the fluid. This means that each component
wavelength of a beam of white light will be refracted at a different angle, much
like white light projected through a prism. The refractive index measurement of
most fluids is made at a single wavelength of light. Most commonly this
wavelength is the Sodium D-Line (589.3 nm).
Further, since refractive index is directly related to the density of a substance,

changes in density will have an increasing or decreasing effect on refractive index.
Nearly all materials expand when heated (become less dense) and contract when
cooled (become more dense). To counteract this uncertainty, most refractive
index measurements are made at a reference temperature which is typically 20
or 25 C.
4
Keeping these key constraints in mind, it is imperative to properly record the

wavelength and temperature at which the refractive index reading was observed.
Without this additional information, the refractive index value alone is
meaningless. The correct notation for refractive index is n. The Sodium D-Line
is notated as D, and the temperature is typically noted as an integer. The
refractive index of water at 20 C, measured at the Sodium D-Line, would be
recorded as nD20.
The History of Refractometers

In 1621, Willebrord Snell determined the relationship between different angles of
light as it passed from one medium to another, but it would take nearly 250 years
more before Ernst Abbe would make use of Snells research to devise an
instrument capable of directly measuring refractive index.
Although Abbe is the undisputed father of refractometry, he is probably best

known for the advances he made in glass composition and formulation, optical
theory, microscopic imaging, and the design and fabrication of advanced optical
systems.
Abbe was a brilliant mathematician and physicist who was born into an
impoverished family in Eisenach, Germany in 1840. He obtained undergraduate
degrees in math and physics from the University of Jena and later received a
Ph.D. in thermodynamics.
Abbe joined the faculty at the University of Jena

where he taught physics until meeting Carl Zeiss, a
well known German industrialist and microscope
manufacturer, in 1866. The two became fast friends,
and Zeiss soon made Abbe the research director of
Zeiss Optical Works.
Abbe is credited with inventing the refractometer in

1869, although he didnt write about it for another five
years. In 1874, Abbe published a paper in which he
first described the theory and equipment necessary to
measure refractive index by total reflection using
prisms, the principle upon which most of todays
refractometers are based. Abbe also recognized the
dependence of refractive index on temperature and developed a refractometer
with heatable prisms and a prism thermometer. He also developed a method to
adjust for the color dispersion of samples.
Refractometers were first used internally at Zeiss until they were introduced as
products around 1881. Zeiss and Abbe worked very closely together until 1888,
5
when Zeiss died at the age of 72. Abbe then took control of the company and ran
it until his own death in 1905.
With only minor modifications, the Zeiss Company dominated the refractometer
market for nearly half a century with little or no competition. It was the
combination of the explosive growth of science and industry after World War I,
together with the expiration of the original Abbe patents, which led a number of
other companies around the world to enter the refractometer market with
instruments based on Abbes design.
After World War II, several companies introduced the first inline refractometers.
These instruments were rather crude by todays standards. The fluid flow was
directed through a housing that contained traditional optical elements. An
eyepiece on the housing magnified the point that a shadow-line crossed a tiny
internal scale.
Although these first inline instruments eliminated the need for manual fluid
sampling and testing, they did not provide a signal output for recording or
process control. It wasnt until the 1970s, that the first process control
refractometers were developed that provided digital readouts and signal outputs.
Since that time, inline refractometers have continued to evolve and are becoming
more and more common for many fluid measurement, quality control, and
process-control applications.
6
Section
M I S C O V I P I N L I N E R E F R A C T O M E T E R
2
About Your New
VIP Inline Refractometer
The MISCO VIP (Very Important Process) Refractometer is an
inline/process control refractometer that incorporates the latest
advances in refractometer sensor technology and is designed to be
mounted directly into a pipeline or tank.
T
he MISCO VIP is designed for the rapid continuous monitoring of fluid
properties. The instrument will automatically compensate for temperature with
computer precision, and when used and cared for properly, will provide years of
trouble-free service. Integration into fluid handling equipment will help to enhance
and standardize fluid quality control. The system capabilities include:
Continuous monitoring and digital display of fluid properties

Stainless steel sensor head
Fluid temperature measurement
Single 4-20 mA output (second 4-20 mA output is optional)
OPTION: One to three customer-specified relay outputs, to drive high-load external relays
OPTION: Two additional relays can be added for a total of five relays, if needed
The instruction manual is meant as a general manual for features common to all VIP Inline
Refractometers. Please read the accompanying Specifications Page for detailed information
concerning your particular model. This manual will help you maximize the usefulness of
this instrument and MUST be read thoroughly before use. If you have any questions,
please call MISCO technical support at (216) 831-1000.
7
Refractive Index
Although your particular refractometer may have special scales and may not display
refractive index directly, the measurement of refractive index is the underlying principle
behind all measurements.
Refractive index is a physical property of a substance and has become a valuable method
for determining fluid concentrations. Refractive index is actually a measure of the speed of
light. In liquids, it relates to the difference between the speed of light in air to the speed of
light in the liquid, or how much the light is slowed as it travels through the liquid. The
MISCO VIP Inline Refractometer is able to accurately determine extremely small changes
in the speed of light (or fluid concentrations).
Temperature Compensation
It is well know that substantially all materials expand when heated (become less dense) and
contract when cooled (become more dense). As the temperature of a liquid decreases, it
becomes more dense, and the light moving through it is slowed. Although this thermal
effect is small for solids, the change in density for liquids is substantial.
Automatic temperature compensation ensures that concentration readings of aqueous

(water soluble) solutions will be accurate with respect to the samples temperature. The
MISCO VIP Inline Refractometer is able to automatically sense and correct for differences
in the temperature of the sample relative to a reference temperature, which is usually 20C.
Warning
Always read and follow the safety and handling precautions in the Material Safety Data Sheet
(MSDS) for the fluid you are testing. Pay particular attention to recommendations on wearing
protective equipment and sample disposal.
8
Section
3
Component Descriptions
It is important to learn the names and function of each of the
VIP components and to understand how they interrelate.
T
he VIP Inline Refractometer should be thought of as an integrated system that
is composed of a number of separate components. A Central
Processor/Control Unit (Control Unit) houses the main electronic assembly
and display. The Control Unit is supplied with power through the Power
/Relay Harness, which also carries the relay and 4-20 mA outputs. The Control Unit is
connected, by means of a heavy industrial cable, to a remotely mounted Sensor Head.
Each of these parts is described in more detail below:
Sensor Head
The Sensor Head of the MISCO VIP Inline
Refractometer is the active, pipeline or tank-mounted
portion of the system, which measures the refractive
index of the fluid. The actual measurement takes place
on the surface of the optical element (Optic) on the
face of the Sensor Head. The fluid mixture in direct
contact with this surface will be detected through observation of the fluids
characteristic index of refraction. Sophisticated internal processing performed by the
custom microcontroller, integrated into the Control Unit, calculates the physical
property of interest, compensates for temperature effects, and displays the reading on
the Control Unit display.
The watertight Sensor Head houses a precision Optic element, custom light source,
photo-detectors, and the amplification circuitry used to make measurements. The
stainless-steel body has either 1 NPT threads or a Sanitary Tri-Clamp design. The
Sensor Head unit is sealed with O-rings to protect against intrusion of water or other
foreign objects and is connected to the Control Unit by a heavy-duty industrial data
cable. The Sensor Head is self-powered and does not require a separate power
connection.
9
Control Unit
The NEMA IV watertight Control Unit performs all the
communication with the Sensor Head as well as signal
and data processing. It also serves as an interface to the
outside world through the LCD display, or through
signals sent to electronic data loggers, PLCs, or
automated pump and valve units.
The front panel of the Control Unit houses a backlit

LCD display, a power indicator, and three buttons. The
display will show the fluid property, or fluid
temperature, as well as any applicable error messages.
The buttons will power the Control Unit on and off, switch the readings between
scales, and show the fluid temperature. The following controls and indicators are
available on the front of the Control Unit:
The POWER button (if equipped) turns unit on and off.
The SELECT SCALE button switches between scales.
The TEMPERATURE button displays the current fluid temperature.
The POWER INDICATOR is a green light that will be illuminated when the unit is powered.
One line x 16-character-illuminated LCD DISPLAY.
NOTE: THE FLUID TYPE BUTTON MUST BE MANUALLY SET TO MATCH THE SCALE TO THE
TYPE OF FLUID IN THE FLUID HANDLING SYSTEM. FAILURE TO DO SO WILL RESULT IN
INACCURATE READINGS.
When displaying a reading on the MISCO VIP Inline Refractometer, the Control Unit
will indicate the unit of measure (Brix, % concentration, freeze point, etc.) together
with the measured value.
Pressing and holding the TEMPERATURE button will display the fluid temperature
at the Sensor Head. When released, the system will again display the unit of measure
and measurement value. The unit of measure for temperature can be changed between
degrees Celsius or Fahrenheit only at the factory.
The Control Unit also provides connectors for the Sensor Head Cable and the
Power/Relay Harness. It may also provide an optional connector for a remote LCD
display. These connectors are either splash proof or watertight.
10
Sensor Cable
A 19-pin, watertight harness connects the Sensor
Head to the Control Unit. It carries the power and
communication lines necessary for the Sensor
Head operation. The Sensor Head is watertight to
IP 68/NEMA 6P standards. Although the
connector at the Sensor Head end is watertight,
MISCO recommends against fully submerging the Sensor Head in fluid. The standard
cable length is 12-foot; however, optional cable lengths of 6-foot and 36-foot are
available. DO NOT attempt to shorten or lengthen the Sensor Cable.
WARNING: ENSURE THAT THE MISCO VIP INLINE REFRACTOMETER IS POWERED
OFF BEFORE THIS HARNESS IS CONNECTED OR DISCONNECTED. DAMAGE TO
THE SENSOR HEAD CAN RESULT IF THE SYSTEM IS ON WHEN IT IS PLUGGED IN.
WARNING: THE SENSORS AND CONTROL UNITS ARE MATED TOGETHER AND
IDENTIFIED BY NUMBER. MAKE SURE THAT THE NUMBER ON THE SENSOR AND
THE NUMBER ON THE CONTROL UNIT MATCH BEFORE CONNECTING THE TWO
COMPONENTS TOGETHER. ATTACHING THE WRONG SENSOR AND CONTROL
UNIT TOGETHER WILL CAUSE INACCURATE READINGS AND MAY RESULT IN
DAMAGE TO BOTH COMPONENTS.
Power/Relay Harness
The small 8-pin Power/Relay Harness connects the MISCO VIP Inline Refractometer
to an external 24VDC (or optional 12VDC) power supply. It also carries the relay and
4-20 mA outputs and is weatherproof to IP 68/NEMA 6P standards.
Remote Display (optional)

The MISCO VIP Inline Refractometer can be configured when ordered to drive a
remote LCD display. This display will show exactly what is being shown on the main
display, but in a smaller enclosure that can be installed in a more convenient location.
Additional Features
In the event that your particular VIP Inline Refractometer has any additional or unique
features, please read the special Addendum, located at the end of this manual, for
instructions on using and implementing these features.
11
Section
4
System Installation
It is important to carefully follow the steps in this section to ensure
the proper installation and operation of the VIP Inline
Refractometer.
C
areful thought and planning will go a long way in easing the pains associated
with installing your new inline refractometer. Please read this section
completely before attempting to install or operate this equipment. Each step
of the process is essential for maximizing the accuracy of your readings,
extending the service life of the equipment, and preventing damage during the
installation process.
I.) Planning the Installation

Follow these guidelines when planning for the initial installation of this equipment:
1) If the MISCO VIP Inline Refractometer will be used to control external

equipment, such as recorders, blenders, mixers, PLCs, etc., this equipment
should be installed first.
2) Plan the installation location for the MISCO VIP Inline Refractometer Sensor
Head. This location should be:
a) Downstream of the pumps, blenders, mixers, and fluid heaters.
i) If the refractometer is being used in a loop to control blenders or

dosing pumps, locate the Sensor Head as close to the dosing point as
possible to get immediate feedback of fluid concentration changes.
b) Preferably at the end of a straight run of pipe to allow fluid turbulence and
air bubbles to settle.
c) In an area with the highest operational temperature and pressure to help

minimize coating of the Sensor Optic.
12
i) Most fluids are more soluble at higher temperatures and have lower
viscosities.
ii) Fluid pressure should not exceed 10.34 bar (150 psi) and the
temperature should be in the range -28 C to 100 C (-20 F to 212 F).
d) Where the fluid is well-mixed, not changing temperature rapidly, and

preferably in the smallest diameter of pipe (highest velocity) possible.
e) Where the sensor can be mounted in a T-Fitting at 30 to 90 from vertical

to minimize air bubbles or sediment buildup.
i) Isolate the T-Fitting with shutoff valves so that the Sensor Head can
be removed for cleaning, maintenance, and calibration.
ii) Allow for a suitable petcock close to the Sensor Head for taking fluid
samples and/or draining the pipe.
iii) It may be advantageous to install the Sensor Head on a parallel bypass

pipe so that flow past the Sensor Head can be stopped without
stopping the main process stream.
f) If mounted on mobile equipment: The Sensor Head should be protected

from debris kicked up by tires or splashed snow and slush.
g) If tank-mounted: Mount in a region where the fluid is well-mixed and

there are a minimum of air bubbles. The Sensor Optic must be protected
from ambient light.
II.) Mounting the Control Unit

1) To maximize the performance and reliability of the system, select an
installation location for the Control Unit using these guidelines:
a) Securely mount the Control Unit vertically, in a protected location, where

temperature changes are minimized.
i) Bolts and lock washers are provided for mounting to four threaded
holes on the rear of the Control Unit.
ii) DO NOT DRILL ANY HOLES IN THE CONTROL UNIT.
b) Although the electronics will operate accurately between -28 C to 65 C (-

20 F to 150 F), the optimum operating range is between 4 C to 32 C
(40 F to 90 F).
13
c) Keep in mind that the standard distance between the Control Unit and
Sensor Head is 12-feet. Extra-length cables are available that can span a
distance of 36-feet.
III.) Installing the Sensor Head

1) Clean the Sensor Head:
NOTE: A CLEAN OPTIC IS ESSENTIAL FOR ACCURATE
READINGS.
i) Clean the optic surface on the Sensor Head with cotton swabs
dampened with either isopropyl alcohol or common glass cleaner.
ii) Dry the optic surface well with soft clean cloth.
iii) Check the optic surface for smears or water spots.
2) Install Sensor:
a) NPT Thread Sensor Head:
(1) To create a watertight seal, wrap the sensor threads with

Teflon tape.
NOTE: DO NOT USE PIPE DOPE BECAUSE IT MAY
ACCIDENTALLY CONTAMINATE THE OPTIC SURFACE.
(2) Insert the threaded end of the sensor into the mating female
fitting and tighten hand-tight. Use an appropriate wrench on
the flats on the rear of the Sensor Head to gently tighten the
Sensor Head only an additional quarter turn.
NOTE: DO NOT OVER TIGHTEN THE SENSOR HEAD AND
DO NOT TIGHTEN THE SENSOR HEAD USING THE
CONNECTOR ON THE BACK OF THE SENSOR.
b) Sanitary Tri-Clamp Sensor Head:
(1) Use a specially designed Sanitary Tri-Clamp gasket that is

chemically compatible with the fluid that you intend to test.
NOTE: CHECK GASKET FOR SIGNS OF WEAR AND/OR
REPLACE EACH TIME SENSOR HEAD IS REMOVED FOR
MAINTENANCE OR CLEANING.
(2) Apply ring clamp and secure it by turning the locking nut
hand-tight only. DO NOT USE TOOLS.
14
IV.) Connecting the Power/Relay Harness

1) Route, but do not connect, the Power/Relay Harness wires through a
protected pathway to a suitable external power supply and to any relays.
2) Before connecting any wires to the power supply:
a) Make certain that the power supply is turned OFF.
b) Make certain that Power/Relay Harness is NOT connected to the Control

Unit.
NOTE: MAKE CERTAIN THAT THE USER-SUPPLIED POWER SUPPLY
MATCHES THE VOLTAGE MARKED ON THE CONTROL UNIT (AND/OR THE
WIRING HARNESS) AND THAT IT CAN SUPPLY AT LEAST 0.5 AMPS. FAILURE
TO MATCH THE VOLTAGE MAY CAUSE SERIOUS DAMAGE TO THE
INSTRUMENT.
c) Connect all power and relay wires using commercially available waterproof
connectors or soldered together and properly protect from the elements.
d) Connect the wires as indicated in the diagram below:
PIN# Function Wire Color Note

1 Power Input (+) RED 1&2
2 Power Supply Ground (-) BLACK
3 Relay 1 (+) WHITE 3
4 Relay 3 (+) ORANGE 3
5 4 - 20 mA (+) YELLOW
6 4 - 20 mA (-) GREEN
7 Relay 2 (+) BLUE 3
8 Relay Ground (-) BROWN 3
Notes:
1. Power supply MUST BE 24 VDC or 12 VDC depending on how the
instrument was ordered. Power requirement will be marked on the Control
Unit and/or the Power/Relay Harness.
2. Pin One is marked with a molded dot on the plastic connector.
3. When energized (closed), the relay provides a 12 VDC, 450 mA, source.
15
V.) Initial System Test

1) With the Sensor Head Disconnected:
a) Plug the Power/Relay Harness into the Control Unit and tighten hand-
tight.
b) Turn the external power supply ON.
c) Push the POWER button to power-on the instrument.
d) The screen should illuminate and briefly display the words, MISCO VIP
Inline.
e) The display should then alternate between Wiring Open and Check
Sensor.
f) Turn the Control Unit OFF by pressing the POWER button.
VI.) Route & Connect the Sensor Cable

1) Route the Sensor Head Cable between the Control Unit and the Sensor Head
following these guidelines:
a) Avoid contact with surfaces hotter than 220F.
b) Adequately secure the harness to relieve strain on the end connectors.
c) Allow at least a 4 bending radius for the harness.
2) Connect the Sensor Head Cable to the Sensor Head and to the Control Unit.
WARNING: MAKE CERTAIN THAT THE CONTROL UNIT IS POWERED OFF
BEFORE SENSOR HEAD CABLE IS CONNECTED OR DISCONNECTED. DAMAGE
TO THE SENSOR HEAD CAN RESULT IF THE SYSTEM IS POWERED.
a) Tighten the harness connectors hand-tight only. DO NOT USE TOOLS.
16
VII.) Final System Test

1) Fill system with fluid of known type, strength, and temperature and circulate
past the Sensor Head.
2) Power the MISCO VIP Inline Refractometer ON and allow time for it to
equilibrate with the fluid.
3) Hold the TEMPERATURE button down and confirm that the displayed
temperature is the same as the fluid temperature at the Sensor Head.
4) Press the SELECT SCALE switch until the correct unit of measure is
displayed on the screen.
5) Check that the concentration displayed on the Control Unit display matches
the strength of the fluid as determined by using a MISCO Palm Abbe Digital
Refractometer, or other high precision refractometer.
a) Make sure to check the calibration of the reference refractometer

beforehand.
6) Run the MISCO VIP Inline Refractometer through the range of fluid
concentrations that the system is likely to see during normal operation.
a) Test all relays (if any) to see that they trip under the proper conditions. If
they do not trip as expected, check the wiring to make sure that they were
not misrouted.
b) Check the 4-20 mA output to ensure that it is properly supplying current.
17
Section
5
System
Operation
Once properly installed and tested, the VIP Inline Refractometer
will provide continuous measurements and process control.
O
nce set up and running, the VIP Inline Refractometer should need very little
user intervention. Keep in mind that the sensor window will need to be
cleaned on a periodic basis. The interval between cleanings will be based on
your accuracy requirements, the type of fluid being tested, the cleanliness of
the fluid, and your experience with the system. See Section 6, for more information.
Operating the System

1. Turn the MISCO VIP Inline Refractometer ON using the POWER button on
the face of the Control Unit.
2. The system should briefly display MISCO VIP Inline and then begin to
display fluid readings using the unit of measure on the current scale.
a. If the sensor is in air, or if no fluid is in the pipe in front of the sensor

optic, the display will read AIR IN SYSTEM.
3. The Processing/Control Unit will start sending signals to the relays, and the 4-
20mA outputs, as soon as the system is powered on and a valid initial reading
is internally confirmed.
a. In the time between powering on and the initial reading confirmation,

the relay outputs will be turned off and the 4-20mA outputs will be set
to 4mA.
4. In the event that an error is detected by the internal self-test circuitry, the
system will show either an error code or an error message.
18
a. The fluid property or temperature information will not be displayed

when an error is detected.
b. All relay outputs will be turned off when an error is detected and the
4-20mA outputs will be set to 4mA.
NOTE: Errors in measuring fluid temperature (due to rapid fluid temperature changes, inadequate fluid
mixing, etc.) can lead to significant errors in reading the true fluid concentration of a fluid. Also, the addition
of significant amounts of contaminants to the fluid (salt, oils, surfactants, etc.) could also affect the
accuracy of readings.
19
Section
6
Component
Maintenance & Service
Properly maintaining the VIP Inline Refractometer components
will maximize the accuracy and system performance while
extending the useful life of the equipment.
T
he sensor window should be cleaned on a periodic basis to ensure optimal
performance and accuracy of the system. A 30-day cleaning interval is initially
recommended. This period can be increased or decreased depending on the
type of fluid, the application, and the users experience. The optic should also
be cleaned if the unit is displaying erratic or suspect readings.
Since there is no effective method to calibrate the VIP Inline Refractometer in

the field, it is recommended that the Control Unit and Sensor Head be
returned to MISCO annually for a factory calibration traceable to NIST. Please
call for details.
Before Removing Sensor Head

Prior to removing the Sensor Head after installation, several key safety precautions
should be followed to avoid personal injury or damage to property:
1) Wear protective eyewear and clothing adequate for protection from process
fluids.
2) Do not touch exposed Sensor Head with bare-hands; it may be hot and cause
burns.
3) Make certain that the flow past the Sensor Head has been stopped and/or
diverted.
4) Make certain that the pipe to which the Sensor Head is mounted is drained
and not under pressure.
20
5) Loosen any clamps slowly and cautiously and be prepared to retighten if

necessary.
6) Be prepared to catch spillage from the pipe.
7) Tag all diversion valves and switches so that flow is not inadvertently restarted
before Sensor Head is reinstalled.
a) It may be a good idea to have a maintenance plug to seal the system in the
event that the Sensor Head is sent away for maintenance.
Cleaning the Sensor Head Optic

1) Turn POWER to the unit OFF!
2) Shut off the flow of fluid past the sensor and drain all residual fluid from pipe.
3) Carefully remove the Sensor Head Cable and remove the Sensor Head from
the pipe fitting.
4) Thoroughly clean the face of the Sensor Head.
5) Clean the Sensor Head Optic using a Q-Tip swab dipped in alcohol or glass
cleaner.
6) Use a light to inspect the lens to assure that there is no streaking or residue on
the sensor window.
7) NPT Threaded Sensor Head
a) Remove old Teflon tape and clean the threads.
b) Rewrap the pipe thread with new Teflon tape.
i) DO NOT USE PIPE DOPE.
c) Replace the Sensor Head in the fitting carefully and hand-tighten.
d) After hand tightening, use the proper size wrench on the flats and tighten
only an addition quarter turn.
8) Sanitary Tri-Clamp Sensor Head
a) Check gasket and replace if needed.
9) Ensure that the drain is CLOSED.
21
10) Reopen valves to allow flow past sensor.
11) Turn Power to the unit ON.
WARNING: MAKE CERTAIN THAT THE CONTROL UNIT IS POWERED OFF BEFORE SENSOR HEAD
CABLE IS CONNECTED OR DISCONNECTED. DAMAGE TO THE SENSOR HEAD CAN RESULT IF THE
SYSTEM IS POWERED.
22
Section
7
Error Code
& Error Messages
Self-diagnostic software built into the VIP Inline Refractometer is
able to sense and diagnose most system failures and report specific
fault codes to the operator.
T
he MISCO VIP Inline Refractometer displays errors in two ways. Uncommon
errors are shown as Error #X on the display, where the error number and its
cause are listed below. More common errors are clearly spelled out in full text
on the screen.
Error Codes
Error # Error Error Cause(s)
0 N/A Multiple Errors Detected in System
Damaged wire harness.

LED X Inoperative
17 Damaged connector.
X = LED Segment
Sensor Head failure.
Poor ground shield connection on wire harness.

15 Optical data too noisy
Background light too noisy/bright.
22 Displayed number too large Number larger than 999 cannot be shown on display.
23 Displayed number too small Number smaller than -99 cannot be shown on display.
23
Error Messages
Error Message Problem
Conc. High
(alternating with) Fluid is more concentrated than the MISCO VIP Inline
Fluid Concentration Refractometer can accurately read.
Above Upper Limit
Fluid Too Cold

(alternating with) Fluid temperature below system range.
Fluid below -20F
Fluid Too Hot

(alternating with) Fluid temperature above system range.
Fluid above 212F
Air in System The Sensor optic is uncovered and is exposed to air.
Wiring Open
Sensor Head disconnected / major Sensor Head-to-Control Unit
(alternating with)
harness fault
Check sensor
24
Section
8
Specifications
7.0"
4.0"
4.65
2.83
" .4 "
3"
.75
"
LCD
11.0" ON/OF
F
SELEC
ETHYLENE
T
PROPYLENE
GLYCOL/
PUSH
FLUID
FOR
TEMP
DISPLAY
GLYCOL
SENSOR HEAD CONNECTION
PART MATERI OTHER SIZ

PART
NAME AL MATERIAL REQD PER
SPECIFICATION E
REQ
NO REQ NEXT USED PART
FINIS SCAL
NON
PER
D D ASSY ON
1.42
ASSY
H: E:
E
" DRAWN
BY
ENGINE
ER
1.26 DECIMAL .XX +/-

03
PRODUCTI
ON
ANGULAR +/- 2.0 Q
" INTERNAL RADII
DEG
015/ 025
SOFTWACLARIS CAD
A
FINA
APPROV
L
VER
RE ED
:
CA 2.0V3
FIL
D
A
E:
SUPERSED S
ES: DWG NO
H
RE CONTRA NO
CHANG DAT B EN PRO Q FINA NUMBE
V A L CT
E E Y G D R:
NOTICE - THIS DRAWING IS THE PROPERTY OF MISCO., AND ANY DISCLOSURE OF ITS CONTENTS TO OTHERS IS GIVEN IN CONFIDENCE. IT MUST NOT BE
WHOLE OR IN
REPRODUCED ORPART OR IN
COPIED USED IN ANY WAY EXCEPT WITH SPECIFIC APPROVAL AND PERMISSION OF MISCO, 3401 Virginia .
Rd Cleveland Ohio 44122
Mechanical Dimensions
Control Unit:
Approximate Size (W x H x D): 17.8 x 27.9 x 10.6 cm (7 x 11 x 4 in.)
Approximate Weight: 4.5 kg (10 lbs.)
Sensor Head:
Size (Diameter x Height): 5.1 cm x 7.6 cm (2 x 3 in.)
Approximate Weight:: 0.5 kg (1 lbs.)
Material: Stainless Steel
Optic Material: Glass or Sapphire
Head Connection Fitting:
Type I: 1 NPT Thread, Male
Type II: 1 Sanitary Tri-Clamp
25
Acceptable Fluid Limits
Refractive Index Span: 1.333 to 1.395

Corresponding Brix Span: 0.0 Brix to 37.0 Brix
Fluid Color: Any color, substantially transparent
Fluid Temperature Range: -28 C to 100 C (-20 F to 212 F)
Max. Fluid Pressure: 10.34 bar (150 psi)
Electrical Requirements
Power Supply Input: 24VDC Standard (12VDC Optional)

500 mA Minimum
Sensor Cable: 19-pin round connector, watertight to IP 68/NEMA 6P
36 foot maximum.
Relay/Power Harness: 8-pin round connector, watertight to IP 68/NEMA 6P
No maximum length.
Environmental Requirements
Control Unit
Operational Temperature: -28 C to 65 C (-20 F to 150 F)

Weather: NEMA IV Compliant
Sensor Head
Operational Temperature: -45 C to 100 C (-50 F to 212 F)
Max. Rate of Temp Change: 38 C (100 F) per minute
Max. Pressure: 10.34 bar (150 psi)
Weather: Watertight Complete immersion not recommended
26
Appendix
i
Legal
The following legal notices relate to the warranty provisions, software license, patents, trademarks,
copyrights and regulatory issues.
Warranty
A. What is covered and for how long:
Any defect in material and/or workmanship from use, in accordance with the Instruction
Manual, is covered for one year from the date of purchase. It is your responsibility to report any
claims for warranty within ten days of detecting a defect.
B. Who gets this Warranty:
This warranty is limited to the original end user of products purchased in the United States.
C. What we will do:
If your MISCO product is defective, we will repair it or, at our option, replace it at no charge to
you. If we repair your MISCO product, we may use new or reconditioned replacement parts. If
we choose to replace your MISCO product, we may replace it with a new or reconditioned one
of the same or similar design.
D. Limitations:
EXCEPT AS SET FORTH ABOVE, NO WARRANTY OF MERCHANTABILITY

OR FITNESS FOR A PARTICULAR PURPOSE, OR OTHER WARRANTY,
EXPRESS, IMPLIED OR STATUTORY, NOR ANY AFFIRMATION OF FACT
OR PROMISE IS MADE BY MISCO WITH RESPECT TO THE GOODS WHICH
ARE SOLD PURSUANT HERETO. MISCO SHALL NOT BE LIABLE FOR
INCIDENTAL OR CONSEQUENTIAL LOSSES, DAMAGES OR EXPENSES,
DIRECTLY OR INDIRECTLY ARISING FROM THE SALE, HANDLING, OR
USE OF THE GOODS, OR FROM ANY OTHER CAUSE RELATING
THERETO, AND MISCOS LIABILITY HEREUNDER, IN ANY CASE, IS
EXPRESSLY LIMITED TO THE REPAIR AND/OR REPLACEMENT (IN THE
FORM ORIGINALLY SHIPPED) OF GOODS NOT COMPLYING WITH THIS
AGREEMENT OR, AT MISCOS ELECTION, TO CREDITING BUYER WITH
AN AMOUNT EQUAL TO THE PURCHASE PRICE OF SUCH GOODS,
WHETHER SUCH CLAIMS ARE FOR BREACH OF WARRANTY,
NEGLIGENCE, OR OTHERWISE.
27
E. How to obtain Warranty Service:
To obtain warranty service for your MISCO product, you must provide proof of the date and
place of purchase of the product, and you must have completed and returned the Warranty
Registration Card to MISCO, or you must have completed the online warranty registration on
the MISCO website.
You may obtain service by returning the product (shipping prepaid) to:
MISCO, 3401 Virginia Road, Cleveland, Ohio 44122 (USA) - Attention: Service Department
Be sure to include your name, address, telephone number, proof of date and place of purchase
and a description of the operating problem. After repairing or, at our option, replacing your
MISCO product, we will ship it to you at no cost for the parts and labor, but you will have to
pay a minimum of $10.00 for shipping and handling charges.
F. What this Warranty DOES NOT Cover:
Damage or defects resulting from accident, misuse or abuse, material incompatibility, damage
from corrosive fluids, damage while in transit to our location, damage resulting from alterations,
problems caused by electrical power, damage caused by unauthorized repair or modification of
the product or affixing of any attachment not provided with the product, damage by fire, flood
or act of God, damage caused by usage not in accordance with this Instruction Manual, or
damage from failure to perform preventative maintenance.
The above is your exclusive remedy under this warranty. This Warranty is the only one we will
give on your MISCO product, and it sets forth all our responsibilities regarding your MISCO
product. There are no other express warranties.
Regulatory Notices
Federal Communications Commission (FCC) Statement
This equipment has been tested and found to comply with the limits for a Class A digital device,
pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable
protection against harmful interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio frequency energy and, if not
installed and used in accordance with the instruction manual, may cause harmful interference to
radio communications. Operation of this equipment in a residential area is likely to cause
harmful interference in which case the user will be required to correct the interference at his
own expense.
This device complies with Part 15 of the FCC Rules. Operation is subject to the following two
conditions: (1) this device may not cause harmful interference, and (2) this device must accept
any interference received, including interference that may cause undesired operation.
European Standard Statement:
This product has been tested and found to comply with the limits for Class A Information
Technology Equipment according to European Standard EN 55022. The limits for Class A
equipment were derived for commercial and industrial environments to provide reasonable
protection against interference with licensed communication equipment.
This is a class A product. In a domestic environment this product may cause radio interference
in which case the user may be required to take adequate measures.
28
Industry Canada Compliance Statement:
This Class A digital apparatus complies with Canadian ICES-003.
Cet appareil numrique de la classe A est conform la norme NMB-003 du Canada.
Statement for CISPR 22 Edition 2 Compliance: Warning: This is a Class A product. In a

domestic environment this product may cause radio interference in which case the user may be
required to take adequate measures.
CE Mark / UL Listing
This device has not been tested for compliance with European Union CE standards and is not
UL Listed.
Patents, Trademarks, and Copyrights

This technology is protected by United States Patent No. 5,596,320.
Copyright 2005 MISCO. All rights reserved.
Trademarks used in this manual:
MISCO, Palm Abbe, VIP Inline Refractometer, Very Important Process Refractometer, MVP Inline
Refractometer, and Most Valuable Process Refractometer, are trademarks of MISCO Products Division of
the Mercury Iron & Steel Co.
Other trademarks and trade names may be used in this document to refer to either the entities claiming the
marks and names or their products. MISCO disclaims any proprietary interest in trademarks and trade
names other than its own.
29
Appendix
ii
Record of Revisions
Date Section Change
30
SOOTOMAGIC
THROW-IN SOOT REMOVER
DESCRIPTION
SOOTOMAGIC is the original soot stick. SOOTOMAGIC destroys soot by high

temperature ignition, catalytic low temperature ignition and a residual soot removal coating that
works even after the stick is consumed.
CHARACTERISTICS
* Removes insulating soot * Contains no lead
* Non-corrosive * Non-explosive
* Fits through all combustion chamber openings.
APPLICATIONS
SOOTOMAGIC is used to remove insulating soot from oil burners. Place stick through combustion
chamber port. One SOOTOMAGIC stick is good for up to 400 sq. ft. of radiation.
PACKAGING
Code Size Qty./Case Lbs./Case Cu. Ft./Case
68332 lb. Stick 48 14 0.36

SOOTOMAGIC THROW-IN SOOT REMOVER
INSTRUCTIONS
READ ALL DIRECTIONS, MSDS AND WARNINGS ON LABEL BEFORE USING
One SOOTOMAGIC stick is good for up to 2.4 hp or 4.5 sq ft heating surface.
1. Run burner until chamber is hot.

2. Throw unopened pack through peephole.
3. Keep inspection doors and ports closed.
For additional technical information, call Toll Free 1-800-231-3345
PRECAUTIONS
FOR CHEMICAL EMERGENCY, SPILL, LEAK, FIRE, EXPOSURE OR ACCIDENT,

CALL CHEMTREC - DAY OR NIGHT 1-800-424-9300
PRECAUTIONS: Harmful if swallowed. Wash hands after handling.

KEEP OUT OF REACH OF CHILDREN.
FIRST AID: For any overexposure get immediate medical attention after first aid is administered.
Skin: Wash with soap and water. Eyes: Flush with clean water for 15 minutes.
Ingestion: Call physician.
For additional information, refer to Material Safety Data Sheet.
SPECIFICATIONS
Wt/Gal @ 77F Solid

Flash Point SETA CC None
Color Dark Powder
Shelf Life 2 years
Suggestions and recommendations covering the use of our products are based on our past experience and laboratory findings. However, as we
have no control as to the methods and conditions of application, we only assume responsibility for the uniformity of our products within
manufacturing tolerances.
LIMITED WARRANTY
Rectorseal makes the Limited Express Warranty that when the instructions for storage and handling of our products are followed we warrant our products to be free from defects. THIS
LIMITED EXPRESS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER EXPRESS OR IMPLIED WARRANTIES, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, AND OF ANY OTHER OBLIGATION ON THE PART OF RECTORSEAL. The sole remedy for breach
of the Limited Express Warranty shall be the refund of the purchase price. All other liability is negated and disclaimed, and Rectorseal shall not be liable for incidental or consequential
damages.
MANUFACTURED IN U.S.A. BY
Rectorseal 2601 Spenwick Drive Houston, Texas 77055
Telephone: 713/263-8001 or 800/231-3345 Fax: 713/263-7577 or 800/441-0051
www.rectorseal.com H-02
Section 7. Miscellaneous
DAVID CLARK COMPANY INCORPORATE
SERIES 3800 INTERCOM SYSTEM INSTALLATION/OPERATION INSTRUCTIONS
MODELS H3332, H3392 PARTS LIST
ANSUL FIRE PROTECT
INSTALLATION, RECHARGE, INSPECTION AND MAINTENANCE
TROUBLESHOOTING, AND PROGRAMMING
SAGE FLOW MONITOR
INSTALLATION, OPERATION, AND BATTERY REPLACEMENT PROCEDURES
SIGNET FLOW TRANSMITTER
TRANSMITTER INSTRUCTIONS, AND ELECTRICAL INSTRUCTIONS
MILLER
LANYARD AND SHOCK ABSORBER INSTRUCTIONS
GENERAL REQUIREMENTS
JBT AEROTECH
DEICING MONITOR
GENERAL OPERATING INSTRUCTIONS AND PARTS SALES
ACCESIBLE TECHNOLOGIES, INC.
AIR FIRST SUPERCHARGER, OPERATION AND MAINTENANCE
AIRTRONIC/ESPAR HEATER SYSTEMS
TECHNICAL DESCRIPTION, INSTALLATION, OPERATING AND MAINTENANCE
INSTRUCTIONS, TROUBLESHOOTING AND REPAIR, HEATER PARTS
CLARSON
TECHNICAL DOCUMENTATION AND OPERATING INSTRUCTIONS
5-7
MANUFACTURERS APPENDICES
Page 1
February 2014
ANSUL, INSTALLATION, CHECKFIRESC-N
RECHARGE, ELECTRIC
INSPECTION, AND DETECTION AND
MAINTENANCE ACTUATION
MANUAL SYSTEM
BB
002750
This manual is intended for use with the CHECKFIRE SC-N
Electric Detection and Actuation System.
Those who install, operate, inspect, or maintain this system
should read this entire manual. Specific sections will be of par-
ticular interest depending upon one's responsibilities.
As with all electro-mechanical equipment, the electric detection
and actuation system needs periodic care to provide maximum
assurance that it will operate effectively and safely. Inspection fre-
quency should be based on the requirements of the equipment on
which the system is installed and the environment in which the
equipment will operate. On equipment working 24 hours/day,
seven days/week, maintenance should be performed on the
detection and actuation system at 250, 500, and 1000-hour inter-
vals. On equipment that does not work continuously, maintenance
should be performed at least every six months.
The application and use of the CHECKFIRE SC-N system is lim-
ited to the application and uses described in this manual. For
other applications, contact your local Ansul distributor or the Ansul
technical representative in your area.
ANSUL is a registered trademark and CHECKFIRE is a trademark.

TABLE OF CONTENTS
SECTION PAGES SECTION PAGES
SAFETY PRECAUTIONS 1 INSPECTION AND MAINTENANCE 25 - 26

DailyInspections 25
TOTAL SYSTEM DESCRIPTION 2 Maintenance 25 - 26
SYSTEM COMPONENTS 3- 6 TROUBLESHOOTING 27- 30

Control Module 3 Diagnostics 27
Manual/Automatic Actuator 3 History Buffer 27
LT-5-R Cartridge 3 Troubleshooting Table 28 - 30
Mounting Brackets 4
Splicing Device 4 PROGRAMMING 31 - 34
Linear Detection Wire 4 PC Programming 32
Thermal Spot Detector 4 Explaining the Menu 32 - 34
Pneumatic/Linear Detector 5
Squib 5 APPENDIX 35- 39
Squib Cable 5 Release Circuit Test Module Instructions 35
Battery 5 Component Index 36 - 37
Pressure Switch - Weatherproof 6 Detection Wire Fluid Resistance Capability 38
Check Valve 6 Warranty 39
RemoteHigh LevelAlarm 6
Release Circuit Test Module 6
USERINTERFACE 7- 9
Field Terminations 7
FrontPanelIndicators 8
PowerConnections 9
FrontPanelButtons 9
BatteryReplacement 9
Enclosure 9
Cover Removal 9
Strain Relief Installation 9
Mounting 9
SYSTEM PLANNING - 10 - 11
Hazard Identification 10
Pre-installation Guidelines 10 - 11
INSTALLATION 12- 22
InstallationMaterials 12
Mounting Bracket Installation 12
Mounting to Existing CHECKFIRE SC Bracket 13
Manual/Automatic Actuator Installation 13
and Connection
ControlModuleMounting 14
Remote High Level Alarm Installation 14
Shutdown Device Connection 15
Detection Wire Installation 15 - 16
Thermal Detector Installation 16 - 17
Pneumatic/Linear Detector Installation 18
SquibLeadConnector 18
ExternalPower Connection 15
Optional Pressure Switch/Electric Pull Station 19
Function Test 19- 20
Placing the System in Service 21 - 22
INCASE
OFFIRE 23
RECHARGE 24
SAFETY PRECAUTIONS
9-1-98 Page 1
SAFETY PRECAUTIONS
For the protection of personnel and equipment being installed, this

manual contains WARNING and CAUTION statements which are
listed in the steps which they apply. These warnings and cautions
are also listed here so that the manual user can become familiar
with them before performing any procedures.
WARNING
In case of fire, evacuate area to lessen the risk of injury from

flames, heat, hazardous vapors, explosions, or other hazards
that may be created.
WARNING
The squib is an explosive device. Do not attach connector until

squib is installed in actuator body. If the squib is actuated out-
side of the actuator body, possible personal injury could result.
Manual pneumatic actuation will result in immediate system

discharge which may obscure vision. Make certain vehicle is
stopped safely before manually actuating the system. Manual
actuation will bypass all auxiliary shutdown and alarm func-
tions.
I
The fire suppression system could be accidentally actuated

causing the release of agent if the squib or nitrogen cartridge
is installed before the appropriate installation step is reached.
The control module could be damaged and the fire suppres-

sion system may not operate if the squib spring (shunt) is not
removed before installing the squib connector.
The fire suppression system will discharge dry chemical if the

cartridge is installed when operating the strike button. Do not
install cartridge unless puncture pin is fully retracted with ring
pin inserted and visual inspection seal installed.
Discharged lithium batteries may contain significant amounts

of unused energy and should be handled with care. Do not
compact for disposal. Before disposal, each battery must be
fully discharged and electrically isolated by enclosing in a plas-
tic bag and sealing the bag. Do not dispose of in fire. Check
applicable solid waste disposal regulations for proper disposal
of more than one battery. I
TOTAL SYSTEM DESCRIPTION
9-1-98 Page 2
TOTAL SYSTEM DESCRIPTION The control module may be installed where the ambient tempera-
The complete CHECKFIRE SC-N system is composed of compo- ture is between -40 F to 140 F (-40 C to 60 C).
nents which are combined to provide automatic fire detection and The CHECKFIRE SC-N Detection and Actuation System is
actuation for equipment hazard areas. The electric detection and approved by Factory Mutual Research Corporation (FMRC).
actuation system is designed for use only with Ansul fire suppres-
sion systems requiring pneumatic input as a means of actuation. Circuits
In addition to the mechanical pneumatic means of operating the The first initiating circuit is the supervised detection circuit
suppression system, the CHECKFIRE SC-N also provides an designed to be connected to linear (wire) and/or spot type thermal
automatic and manual electric means to perform the same detectors that provide a contact closure input to initiate a fire
function, detected condition. The second initiating circuit is designed to
The CHECKFIRE SC-N system is typically used with an Ansul accept a contact closure type of actuating device such as an elec-
A-101 Vehicle Fire Suppression system for 24-hour protection of tric manual pull station or a pressure switch. The initiatingcircuits
equipment. The system is particularly suited for the protection of are low impedance and designed to eliminate nuisance alarms
equipment that is subjected to extreme environmental and physi- associated with contact bounce.
cal conditions such as vehicles used in forestry, mining, agricul- Two field programmable time delays provide timing of shutdown
ture, construction, public transportation, public utilities, land fill, and release functions associated with the operation of the detec-
and waste disposal, tion and electric manual pull/pressure switch initiationcircuits.
Some of its features include linear (wire) and/or spot (thermal) 1) DETECTION INITIATING CIRCUIT
detection, supervised circuitry, internally powered, adjustable
shutdown and discharge time delays, auxiliary relays, and one- The detection circuit consists of two time delays:
button operation. The first time delay is field programmed to assign the time
CHECKFIRE SC-N Electric Detection and Actuation System con- between alarm (initiation of the detection circuit)and the oper-
sists of the following components: ation of the shutdown relay. The first time delay is field pro-
1. Control Module grammable for 5, 10, 20, or 30 seconds.
2. Manual/Automatic Actuator The second time delay is field programmed to assign the time
3. Mounting Bracket between the completion of the first time delay (when the shut-
4. Detection Wire down relay operates) and the operation of the release circuit.
5. Thermal Detectors The second time delay is field programmable for 0, 10, 20, or
6. Pneumatic/Linear Detection 30 seconds.
7. Squib
LT-5-R(not shown) 2) ELECTRIC MANUAL PULL/PRESSURE SWITCH FEED-
8. Cartridge
9. CheckValve(notshown) BACKINITIATINGCIRCUIT
10. Remote High Level Alarm (not shown) The second initiating circuit is field programmable to be used
11. Squib Circuit Test Module (not shown) as either an electric manual pull or pressure switch feedback
2 _ circuit. If selected as an electric manual pull circuit, its opera-
tion will override the first time delay function and initiate a sec-
ond time delay condition, causing the shutdown relay to
1 immediately operate and system release to occur upon com-
3 ulecan befield programmedto shortenthe secondtime delay

when a manual actuation occurs. The time delay options
pletion of with
available the second time manual
the electric delay. Additionally,
actuation arethe0, control
10, 20, mod-
and
30 seconds, with the condition that it can only be less than or
equal to the programmed time delay of the detection circuit.
..t4"" Selection of the second initiating circuit as a pressure switch

.I feedback circuit will result in the operation of the alarm relay
Ij" and shutdown relay immediately upon receiving the signal.
4 =- _ _ cur because the system will already have been pneumatical-

6 ly actuated from the manual pneumatic actuator.
When this initiating circuit has operated, the Alarm and
_ t_X,, 5 The release
Release circuit
LED's, will with
along not be
the initiated from thiswill
audio sounder, feedback cir-
pulse until
the pressure switch is reset and then the control panel is reset.
oo2998 3) A "DELAY" button is available for the operators use. Operation
of the "DELAY" button will restart the first time delay cycle if
The control module can be used as a self contained system, pow- initiated while the first time delay is active. Once the second
ered by its own internal lithium battery. This allows the detection time delay has started, operation of the "DELAY" button has
system to operate around-the-clock without use of external power, no affect. The "DELAY" button also serves the dual function of
Optionally, external power can be connected to the control module silencing the auxiliary alarm relay. The silence function is only
with the internal power also connected, which results in a system effective 30 seconds or more after release or pressure switch
with battery back-up. When connected to an external 12/24 VDC feedback operation has occurred.
supply with the internal battery also connected, the external power
source becomes the primary supply, while the internal power
source is maintained in a stand-by mode of operation.
SYSTEM COMPONENTS
9-1-98 Page 3
CONTROL MODULE MANUAL/AUTOMATIC ACTUATOR

The Control Module, Part No. 423504, is the basis of the The manual/automatic actuator, Part No. 24479, provides a manu-
CHECKFIRE SC-N detection system. The module cover and back al and automatic means of fire suppression system actuation. By
box is made of durable Noryl SElgfN3 material with a flammabili- pullingthe ring pin and strikingthe red button, manual system actu-
ty ratingof UL94 V-1. The back box contains the field interface ter- ation can be accomplished. The system is automatically actuated
minal block, battery, and field wiring entrance ports. The cover by use of a squib. When the detection circuit is activated, the con-
assembly contains the control PC board assembly, sounder, oper- trol module will direct the electrical current to the squib, causing it
ator interface panel, and environmental seal. The enclosure meets to actuate. The pressure generated from the squib actuation forces
International Standard IEC 529 requirements for dust and water the puncture pin down automatically.
spray in all directions. Mounting pads allow mounting to any suit- A 1/4 in. NPT street elbow is supplied with the actuator for conve-
able flat surfaces. Steel mounting brackets are also available, nient connection of the 1/4 in. actuation line to the fire suppression
All circuitry, relays, switches, and LED's are contained on a single system. See Figure 2.
PC board. A board mounted receptacle mates with the plug-in ter- STRIKE
minal block mounted in the back box. A high pitch sounder is BUTTON
threaded into the cover and plugged into the PC board. The PC RING
board is encapsulated to provide added protection against tools- PIN
ture and dust. An RS232 interface cable connector is provided for
field programming from a PC and for data retrieval from a trouble
and alarm history buffer. The PC board assembly contains a DIP
switch for optional manual programming functions without the use
of a PC. See Figure 1. SQUIB
1/4 IN. NPT TO -- PORT
LINE
V,, j
V _--"
ACTUATION
FIGURE 2
0OO85O
LT-5-R CARTRIDGE
factory-filled with nitrogen to 1800 psi at 70 F (124 bar at 21 C).

The LT-5-R
The cartridgecartridge,
is installed
Part in
No.the6979,
manual/automatic actuatorthat
is a pressure vessel and
is
provides the pressure required to actuate the connected fire sup-
_ pression system. Following operation, the cartridge must be
_ replaced. See Figure 3.
FIGURE 1 ____ SAFETY
002755 _ SHIPPING CAP

- CARTRIDGE
FIGURE 3
OO0851
SYSTEM COMPONENTS
9-1-98 Page 4
MOUNTING
BRACKETS LINEARDETECTION
WIRE
The CHECKFIRE SC-N Detection and Actuation System offers The linear detection wire consists of two spring steel conductors
three types of steel mounting brackets, which are separated by a heat-sensitive insulator.At the tempera-
ture rating of the wire, 356 F (180 C), the insulator melts, allow-
The first type, Part No. 423525, is a combined bracket for mount-
ing the control module and the pneumatic actuator together. See ing the two conductors to make contact. This contact provides
electrical continuity between the two conductors. The linear detec-
Figure 4. tion wire is supplied in lengths of 100 ft. (30.5 m), Part No. 71230,
The second type, Part No. 423528, is an individual bracket for or 500 ft. (152.4 m), Part No. 71231, and must be ordered sepa-
mounting the control module separate from the pneumatic actua- rately. See Figure 6.
tot. Note: When ordering this bracket, it is also necessary to order
the pneumatic actuator bracket, Part No. 419772. See Figure 4. _ INSULATED
a SC-N module to any existing CHECKFIRE bracket except CONDUCTORS

The thirdG.
CT/CT+ type,
See Part No.4.423531, is a retrofit bracket for mounting
Figure _ SPRING
STEEL
All brackets can be fastened by either bolting or welding. Brackets FIGURE 6

are painted with red enamel paint, oo0855
Thermal detectors are normally open, contact closure devices.

The fixed temperature design of these detectors will cause the
contacts to close when the temperature of the surrounding air
THERMAL
reaches theSPOT
set point
DETECTOR
temperature of the detector. See Figure 7.
WITHOUT PROTECTIVE
MOUNTING TUBING,PARTNO.
BRACKET, _ 416762
PART NO. CABLE CLAMP WITH
CABLE CLAMP
416221 PROTECTIVE TUBING,
PART NO. 416214
PART NO. 423531

002757
SPOT
DETECTOR
C O__IIE T RETROFITBRACKET
t Thermal detectors are available in three preset temperatures

FIGURE as
000856
7
shown below. Each temperature rating is stamped on the detector.
Rated Maximum
MODULE
PART NO.BRACKET
423528 ACTUATOR
PART NO. BRACKET
419772 Operating Continuous
oo_8 ooo_ Temperature Use Temperature Detector
FIGURE 4 F (C) F (C) Color Part No.
270 (132) 234 (112) Blue 416218
SPLICING DEVICE 325 (163) 280 (137) Red 416219
A remote splicing device, Part No. 71820, is required for detection 360 (182) 312 (155) Red 416220
wire connection between the control module and the linear detec-
tion wire. The splicing device is designed with terminal screws to
allow a connection interface between standard cable and linear
detection wire. When the splicing device is used in the system,
special sealing compound or tape is required to make a proper
seal. See Figure 5.
FIGURE 5
0O0854
SYSTEM COMPONENTS
9-1-98 Page 5
PNEUMATIC/LINEAR DETECTOR SQUIB CABLE- OPTIONAL 15 FT. (4.6 m)

The pneumatic/linear detector, Part No. 416113, consists of 35 ft. The standard cable, Part No. 79062, is 20 in. (51 cm) and is
(10.7 m) of gas filled stainless steel tubing connected to a small included with the control module shipping assembly. The optional
pressure responder. When the gas in the tubing heats up, the squib cable, Part No. 422747, is required to supply an electrical
increase in pressure operates the responder, thus closing the signal from a remote module to the squib located in the actuator
detection circuit of the control module. The pneumatic/linear detec- body. The squib cable is 15 ft. (4.6 m) and can be cut to whatever
tot will operate at a temperature of 900 F (482 C) over 12 in. (31 length is required. See Figure 10. The maximum allowable cable
cm) or 300 F (149 C) over the total length. The detector assem- length from controller to actuator is 15 ft. (4.6 m).
bly connects to the control module by means of a special wire
assembly which is supplied with the detector assembly. See Figure
8.
DETECTOR _--
FIGURE 10
001058
BA'I-rERY
=__ RESPONDERESPONDER
The CHECKFIRE SC-N control module uses one 3.6 VDC lithium
battery, Part No. 423520. All power required to run the detection
system can be provided from this battery. Note: External power
connections are also provided to connect to vehicle power. The
battery must be replaced annually or when the YELLOW Battery
LED and the Audio Alarm are pulsing. See Figure 11.
CONNECTION TO
CONTROL MODULE FIGURE 8 ._

000857
SQUIB
The squib assembly, Part No. 54919, is an electrically-actuated

component containing a small charge of powder. When the circuit ---"
is closed to the squib, a small internal wiring bridge heats up,
causing ignition of the squib. This generates pressure, which
forces the puncture pin of the actuator through the seal in the
nitrogen cartridge. See Figure 9.
FIGURE 11
........ WARN.IN_
......... o02_9
UEV I_,l.. '../UI_I I/'tll_lO AFLUOIYE
CHARGE.
DONOTREMOVESHUNT END-OF-LINE RESISTOR

UNTILREADYTO CONNECT
iNTO
ELECTRICAL
SYSTEM. The End-Of-Line Resistor Assembly, Part No. 426461 (Package of
10), is required for supervision of the external input circuits. The
package consists of 10 each of the required components to
FIGURE 9
OOO858 assemble 10 of the resistor assemblies. See Figure 12.
___RNA/NC_/E _- F LOuCTK
_CAP _ViT_IHM_RLKBoLHOMC
K
FIGURE 12
003050
SYSTEM COMPONENTS
9-1-98 Page 6
PRESSURESWITCH- Weatherproof CHECK VALVE

The 1/4 in. check valve, Part No. 25627, is installed in the actua-
tion line between the manual/automatic actuator and the pneu-
matic actuator on the connected fire suppression system. This
check valve allows actuation pressure to flow to the fire suppres-
sion system, but does not allow pressure from other actuation
devices to back up into the manual/automatic actuator of the
CHECKFIRE SC-N system. See Figure 14.
Other actuation devices in the fire suppression system also
require check valves to be installed in the same fashion. This pre-
vents pressure from escaping through an actuator whose car-
tridge was inadvertently removed.
1/4 IN. NPT

(BOTH ENDS)
1 5/8 IN.
TOBEADDED
LATER
FIGURE 14
000899
REMOTE HIGH LEVEL ALARM

The remote high level alarm, Part No. 79559, is intended for those
installations where the noise level or operating conditions may
prevent the operator from recognizing the control module alarm
condition.This device is connected through the alarm relay of the
control module to a separately fused power source. It is capable
of 102 decibels at 6 to 30 volts, 0.3 amp maximum at a tempera-
ture range of -40 F to 170 F (-40 C to 76.7 C). See Figure 15.
FIGURE 15
000861
RELEASE CIRCUIT TEST MODULE

The release circuittest module, Part No. 423541, is used in place of
.o the squib during test procedures to simulate squib actuation or gas
motor actuation on CHECKFIRE MP systems (indicator lamp on). It
is also used when verifying time delay durations. See Figure 16.
FIGURE 13
oo_ooo
FIGURE 16
O03O15
USER INTERFACE
9-1-98 Page 7
USER INTERFACE Shut Down Relay Circuit (Terminals No. 14, No. 15, and No. 16)
This section is designed to give the user overall information on all Cable must be round jacketed, with an O.D. of 0.13 in. to 0.25
features and components pertaining to the CHECKFIRE SC-N in., suitable for the intended usage
Control Module itself. 3 amp maximum load
Relay specification: 4A 250VAC, 3A 30VDC resistive
FIELD TERMINATIONS Normally open, normally closed set of contacts
External Power Circuit (Terminals No. 1 and No. 2) Form "C" contact arrangement
12 to 24 VDC Contacts shown in normal condition - No. 14 (N.O.), No. 15
(Common), No. 16 (N.C.)
Polarity must be considered -Terminal No. 1 (+), Terminal No.
2 (-) Terminal
Block
3 amp inline fuse must be used in the positive side Terminal connections are sized for 12 - 24 AWG
Cable must be round jacketed, with an O.D. of 0.13 in. to 0.25 Terminal is labeled from left to right, No. 1 through No. 16
in., suitable for the intended usage The terminals are designed as follows:
Detection Circuit (Terminal No. 3 and No. 4) 1. + Ext. 12/24 VDC Battery
Cable from splicingdevice must be round jacketed, with an O.D. 2. - Ext. 12/24 VDC Battery
of 0.13 in. to 0.25 in., suitable for the intended usage 3. + Detection Input
Polarity need not be considered 4. - Detection Input
5. + Manual Input
Manual Pull/Pressure Switch Circuit (Terminals No. 5 and
No.6) 6. - Manual Input
7. + Release Output
Can be set up for either manual pull input or pressure switch
feedback input 8. - Release Output
When set up for pressure switch feedback input, operation does 9. Trouble Common
not discharge system 10. Trouble N.O.
Polarity need not be considered 11.Alarm N.O.
Cable from splicing device must be round jacketed, with an O.D. 12. Alarm Common
of 0.13 to 0.25 in., suitable for the intended usage 13. Alarm N.C.
14. Shutdown N.O.
Release Circuit (Terminals No. 7 and No. 8) 15. Shutdown Common
Polarity must be considered - Terminal No. 7 (+), Terminal No. 16. Shutdown N.C.
8 (-)
15 ft. maximum cable length between control module and pneu-
matic actuator
Cable from splicing device must be round jacketed, with an O.D.
of 0.13 to 0.25 in., suitable for the intended usage
Trouble Relay Circuit (Terminals No. 9 and No. 10)

Cable must be round jacketed, with an O.D. of 0.13 in. to 0.25
in., suitable for the intended usage
3 amp maximum load
Contacts are normally open in the powered, non-trouble condi-
tion. Contacts close upon trouble
Alarm Relay Circuit (Terminals No. 11, No. 12, and No. 13)
Cable must be round jacketed, with an O.D. of 0.13 in. to 0.25
in., suitable for the intended usage
3 amp maximum load
Normally open, normally closed set of contacts
Form "C" contact arrangement
Contacts shown in non-alarm condition - No. 11 (N.O.), No. 12
(Common), No. 13 (N.C.)
USER INTERFACE
9-1-98 Page 8
FRONT PANEL INDICATORS (See Figure 17) Release Trouble (Yellow)

The Yellow Release LED and the audio will pulse at a rate of once
Battery Trouble (Yellow) every 10 seconds when a trouble condition is detected in the
LED pulses once every 10 seconds when indicating battery release circuit.The control module will return to normal when the
trouble trouble condition is cleared.
The yellow battery trouble LED will pulse when a low power con- The Release trouble will also pulse after the system has complet-
dition is detected in either of the connected supplies (internal or ed a discharge cycle or a pressure switch feed back signal has
external). If only one power source is used, the control module been received. The trouble signal in this condition is used to indi-
will automatically ignore the unconnected circuit upon resetting cate a recharge of the fire suppression system is necessary. A
the control module. If a power source is once connected and Release trouble under either of these conditions can only be
recognized, a subsequent loss of that power source will be rec- cleared by resetting the control module.
ognized as a Battery Trouble condition.If a power source is once
connected, recognized, and then disconnected, the disconnect- Detection Trouble (Yellow)
ed supply can be ignored by operating the RESET button. The Yellow Detection Trouble LED and the audio pulse once every
10 seconds when the control module detects a trouble in the
Power Normal (Green) detection circuit. The control module will automatically return to
LED pulses once every 3 seconds when indicating normal normal when the trouble is cleared.
power
The green Power Normal LED pulses "on" once every 3 sec- Sounder (Audio)
onds indicating power is normal from both sources of input The sounder gives the audio indication for all alarm and trouble
power. If the power drops below an acceptable level from either outputs. The sounder will pulse at the same rate as the visual cor-
the internal or external source of input power, the green Power responding LED.
LED will be extinguished. If only one source of power is used, The sounder gives the audio indications of the various outputs.
the green Power LED will extinguish when the voltage level
drops below an acceptable level. The sounder is rated at 85 Db at 10 feet.
The pulse rates are as follows:
Alarm (Red) Alarm - Time Delay 1 = 2 pulses per second
The alarm LED will flash if an alarm condition exists. An alarm Time Delay 2 = 4 pulses per second
condition is caused by operation of the detection circuit or oper-
ation of the manual pull/pressure switch input circuit.The alarm Trouble - 1 pulse per 10 seconds
condition will continue until the source of the alarm is removed Loss of Power- 1 pulse per 10 seconds
and the control module is reset. Release Circuit Fired - 4 pulses per second for 30 seconds, then
DETECTION CIRCUIT ACTIVATION MODE - Upon receipt of 1 pulse per 10 seconds
an inputto the detection circuit, the Alarm LED and the sounder Low Battery - 1 pulse per 10 seconds
will pulse at a rate of 2 times per second and will continue at this
rate until the first time delay period has expired.
After the first time delay, a second time delay mode is initiated. I1Oil !1o
This causes the LED and sounder to pulse at a rate of 4 times "'r (_
"F _ 0 / SOUNDER
After discharge, the LED and sounder will continue to pulse at a

rate of 4 times per second for 30 seconds. After that, it will
per second.
switch to the trouble mode and pulse once every 10 seconds. YELLOW I ir _"_---_
ATTERY _'_
po_R_._ _ GREEN
ELECTRIC MANUAL RELEASE MODE - The first time delay RED I -_M
,_1_ DETI:CTION
mode will be by-passed and the LED will pulse at a rate of 4 YELLOW
_ ._--I._IIQRI:LEASE
pulses per second. After the time delay setting is reached, it will I ,.-_.,
pulse another 30 seconds at the same rate. After that, the con-
trol module will go into the post-discharge mode, at which time LL-J
the Alarm LED and Release LED will pulse at a rate of one pulse i_
per 10 seconds. OL ,J0
PRESSURE SWITCH CIRCUIT (FEED BACK) ACTIVATED " u_J.ru.--.u _ "
MODE - When this mode is actuated, the Alarm LED will pulse __:_l
a minimum of 30 seconds at 4 pulses per second. The control
module will then go into the post-discharge mode and the Alarm
and Release LED will pulse at a rate of one pulse per 10 sec- FIGUREO0276O
17
onds.
USER INTERFACE
9-1-98 Page 9
POWER CONNECTIONS
Internal _
The 3.6 VDC internal lithium battery is connected to the control O _
module by a removable type plug. The battery must be replaced _r_.. _
annually or when the Yellow Battery LED and sounder are pulsing.
A label is attached near the battery mounting location for record- l
ing the installation date. | eB,rrE,YPO_,e|
I n" /
l ,0_Ec_,o, i
Discharged lithium batteries may contain significant amounts DELAY BUTTON
compact for disposal. Before disposal, each battery must be

fullyunused
of discharged and and
energy electrically isolated
should be by enclosing
handled with care.in Do
a plas-
not BUTTON -- 1
tic bag and sealing the bag. Do not dispose of in fire. Check (Z) (Z)j
applicable
of more thansolid
onewaste
battery.disposal regulations for proper disposal FC_ _1_ I1
FIGURE 18
External 0oo278o
The external power circuit can be between 12 to 24 VDC. The cir-
cuit must be fused at the source on the positive line. The external BA'n'ERY REPLACEMENT
power source is connected to the module terminal block on termi- While in use, the battery requires replacement every year or
nals No. 1 (+) and No. 2 (-). when the Yellow Battery LED and sounder are pulsing
Both power sources, internal and external, should be utilized The shelf life of the battery is 8 years
whenever possible. This will always give the fire suppression sys- Control Module contains a label for recording battery replace-
tern a battery back-up when one of the sources are removed for ment date
whatever reason. Make certain used battery is disposed of properly
FRONT PANEL BUTTONS (See Figure 18) ENCLOSURE
Delay The enclosure is watertight. It meets the requirements of

International Standard IEC 529, "Degrees of Protection
Pushing the "DELAY" button during the first time delay cycle will Provided by Enclosures" for an IP 66 rating
restart the time delay cycle. If the second time delay cycle has
already started, the "DELAY" button will have no effect. COVER REMOVAL
The "DELAY" button can also be used to check the diagnostics The cover is attached with 4, captive, slotted screws
function. By depressing the delay button when the system is in
the trouble condition, the LED's will flash a pattern code. Each When removing and installingcover, make certain seal is always
pattern code indicates a certain type of trouble. The code pat- correctly in place and not twisted
tern is prioritized. The first trouble must be fixed before address- Seal should always be kept clean
ing the next one. Once the first trouble is taken care of, depress- A small amount of silicone lubricantwill improve the seals effec-
ing the "DELAY" button will cause the LED's to indicate the code tiveness.
for the next trouble, if there is one. When the "DELAY" button is
pressed, three short audio and visual indications will acknowl- STRAIN RELIEF INSTALLATION
edge the switch has been depressed properly.
Always use Dow Coming 737 RTV Sealant or equal on all strain
In a post discharge condition, pressing the DELAY button will relief and plug male threads
silence the alarm relay if the alarm relay has been programmed
to silence. MOUNTING
Reset There are four types of mounting options available for the
The "RESET' button is used to re-initialize the control panel. CHECKFIRE SC-N Control Module.
When depressed, it providesan indicationthat all LED's and the Control Module can be mounted without a bracket. It has mold-
sounder are functional, ed-in mounting tabs on the back box. Note: Surface must be
suitable.
It is used to upload the manual programming into the control
module. Control Module can be mounted on a combined bracket which
will allow both the module and the actuator to be mounted
If trouble(s) has not been cleared, the trouble indication will together.
reappear after the RESET button is pressed. Control Module can be mounted on its own bracket and the
When the "RESET' button is pressed, three short audio and actuator can be also mounted on its own bracket, with a maxi-
visual indications will acknowledge the switch has been mum release cable length of 15ft.
depressed properly. Control Module can be mounted to an existing CHECKFIRE SC
bracket by the use of a retrofit bracket.
The Control Module should never be mounted in an area which is
subject to pressure washing or steam cleaning.
SYSTEM PLANNING
9-1-98 Page 10
HAZARD IDENTIFICATION
Before the CHECKFIRE SC-N Electric Detection and Actuation The CHECKFIRE SC-N controlmodulecontains3 amp 30VDC
Systemis installed,the hazardstobe protectedmustbe identified, shutdownrelay contacts to facilitate connectionof shutdown
These hazard locationsdeterminewhere the detectionwire or devices recommendedby the vehicle manufacturer.Example:
thermal detectorsand the fire suppressionsystem nozzles are openingor closingof coolantover-temperaturealarm will bring
required.Whilethe agent nozzlesinexistingfire suppressionsys- about properlysequencedengine shutdownon many vehicles.
terns will pointout the hazard areas, the followinginformation Consultvehiclemanufacturerfordetails.
shouldstillbe reviewedto bestdeterminedetectionrequirements.
If an entirefiresuppression/detection
systemistobe installed,this Alarm Application
informationis vital in determiningproperplacementof discharge Even with an effectivefire suppression/detection package,the
nozzlesand detectiondevices, vehicle must be evacuatedat the earliestpossiblemomentto
assure passengerand operatorsafety.Most vehiclestend to be
Fire Hazard Definition very noisy,and on some, theoperatorcannotsee the entirevehi-
A fire hazard is anyarea where an ignitionsource(hightempera- cle and oftenisn'taware thata fire exists.Therefore,a highdeci-
ture or sparks)and fuel (flammable materials)may be found in bel alarmshouldbe providednear the operatorto signalthatthe
closeproximity, controlmodulehas receiveda detectionsignal.
Examplesof ignitionsourcesare engines,exhaust piping, tur-
bochargers, battery compartments, electrical system equipment, PRE-INSTALLATIONGUIDELINES
torque converters, transmissions, hydraulic pumps, parking BeforeactuallyinstallingtheCHECKFIRESC-N ElectricDetection
brakes,and frictionfromdebrispackedaroundparts, and ActuationSystem, reviewall of the followinginformationand
Occasionally othercomponentsmay reachhightemperaturesdue plan (sketch)the systemlayout.This willhelpto avoidany unfore-
to malfunction.The potentialdangerfromthesecomponentsmust seen installationproblems.Once an acceptablelayouthas been
alsobe examinedduringhazardidentification. A parkingbrakeleft determined,recordand keepit for futurereference.
engagedis an example of a potentialhigh temperaturesource. Control Module and Actuator Location
Temperaturesin excess of the detectionwire or thermaldetector
ratingswillcausethe detectionsystemto activatetherebyactuat- 1. The controlmoduleandactuatormustbe mountedin full view
ingthe fire suppression
system, and accessibletothe operator.They mustbe positionedwith-
in arms reachof the operatorto enable manualoperationof
The above mentionedheat sourcescan cause fire when they the red strike buttonon the manualactuatoras well as the
come in contactwith flammablematerialssuch as leakingfuel: "Delay"button(to extendtimedelay) on the front of the con-
either broken fuel lines, slow leaks, broken hydraulic lines, or a trol module.
ruptured fuel tank. Type of Class A materials are part of the vehi-
cle itself such as electric wiring insulation, padding, plastic parts, 2. The location must be suitable for bolting or welding if bolting
the packages on the vehicle, or debris due to poor maintenance, is impractical. The mounting surface must be flat to avoid
These materials can contribute to the rapid buildup or spreading strain on the mounting bracket.
of fire. 3. There must be room enough to allow for proper wiring con-
nection to the control module and to install the actuation line
Other Considerations from the fire suppressionsystem to the manual/automatic
Be aware that the propagationof fire from one area to another actuator.Also,the moduleand actuatorshouldbe accessible
maycause a hazardto be largerthanoriginallydetermined.Liquid for periodicinspectionand maintenance.The components
fuel may spray, splash, or flow carryingthe fire some distance shouldbe mountedin a locationthatwillnotinterferewithnor-
from the startingpoint.Radiation,sparks, or conductionthrough real equipmentmaintenance.
metalcancarry heat to an area wherethe dangerof fire wouldn't NOTICE
normallyexist. The ambienttemperaturein the mountingenvi-
Also,considerthe fire historyof the equipmentbeingprotectedor ronmentmustnotfallbelow-40 F (-40 C) nor
of similarequipment.This informationmay be availablethrough exceed 140 F (60 C).
companyrecordsor vehicleoperatorsmay have had first hand
experienceenablingthemtoidentifythe locationsof previousfires Linear DetectionWire Routing
as well as specialhazardssuchas a hydraulichosethatfrequently The lineardetectionwirewillbeginat thedetectionsplicingdevice
ruptures, and willbe routedthroughthe predeterminedhazard areas.The
Eachhazardthat isidentifiedmusthavebothfire suppressionsys- detectionwire need onlybe routedthroughthe hazardarea. From
tem fixednozzlesand detectionwireor thermaldetectors, the controlmoduleto the hazard area, standard16 AWG wiring
can be used.Thiswiringis then connectedto the detectionwiring
EquipmentShutdown by means of a splicing device, Part No. 71820. At the end of the
Another factor to examine is equipment shutdown.Provisions detectionwire, an end of line resistorassembly,Part No.426461,
shouldbe madeto shutdownany components thatcouldpossibly willbe installed.The detectionwireshouldbe installedas closeto
add to the intensityof the fire (fuel pumps, hydraulic pumps, the hazardas possible,takingintoconsideration therequirements
engine,etc.) or any componentsthat couldpossiblyre-ignitethe listedin the followingsteps:
fire once it has been suppressed (battery, electricalsystem). 1. A splicingdevice,Part No. 71820, mustbe usedfor detection
Althougha properlyinstalledfire suppression/detection
systemis wiretermination.Detectioncircuitwiringfromthe controllerto
the primarymeansof protectingequipmentfrom fire, an effective the splicingdeviceshouldbe standard16 AWG twistedwire.
fire protectionpackage also includesprovisionsfor equipment
shutdown.
SYSTEM PLANNING
9-1-98 Page 11
PRE-INSTALLATION GUIDELINES (Continued) System Layout

Detection Wire Routing (Continued) Once the system components have been selected and their Ioca-
2. The total length of detection wire must not exceed 750 ft. tions
sketchhave beeninclude
should determined, sketchofthe
the location thelayout of the system.
components, This
as well as
(229 m). If possible, it should be run continuously. Splices are
acceptable when they are kept to a minimum and when they the proposed detection wire routing, thermal detector locations,
are made in accordance with the splicing technique found on and pneumatic actuation hose routing. Also, indicate areas where
Page 16 of Installation Section. the
ablewire must pass through
hazardbulkheads soThis
thatsketch
there is an accept-
routingfrom one to the next. should be as
An end-of-line resistorassembly, Part No. 426461, is required precise as possible to avoid any unforeseen installation problems
on the end of the linear detection wire. later.
3. Do not install the wire within 12 in. (30 cm) of a temperature
source of 356 F (180 C) or greater (engine block, exhaust
manifold, turbochargers, brake grids, etc.).
4. Avoid routing detection wire directly across an opening.
Where possible, install detection wire above the hazard area
or around the perimeter of a hazard compartment to react to
escaping heat. Do not allow struts, frame members, etc. to act
as heat shields between the hazard and the detection wire.
5. Avoid areas where the detection wire may be damaged, such
as outside the vehicle, near moving parts, in areas where
debris may be thrown by wheels, or in the way of maintenance
personnel.
6. To reduce its accessibility to damage, use only as much
detection wire as is necessary to cover the hazard area.
Thermal Detector Selection and Placement

Thermal detectors are used when single point detection is
required. They are selected by temperature range relative to the
hazard temperature. The table below indicates the thermal detec-
tor rated operating temperature required according to the maxi-
mum hazard temperature.
Maximum
Rated Continuous
Operating Use
Temperature Temperature Detector
F (oc) F (C) Color PartNo.
270 (132) 234 (112) Blue 416218
325 (163) 280 (137) Red 416219
360 (182) 312 (155) Red 416220
The placement of thermal detectors should be based on the fol-
lowing requirements:
1. They can be wired directly to the control module using
approved cable. Cable must have a temperature rating of
392 F (220 C) minimum, 16-18 gauge, two conductor with
drain, with an O.D. of 0.13 in. to 0.25 in. (0.3 to 0.6 cm). Again,
placement of the detectors should allow for incoming and out-
going wire connections. At the end of the detection circuit, an
end of line resistor assembly, Part No. 426461, must be
installed.
2. Secure the detector with the provided bracket and clamps.
Pressure Switch
Mount pressure switch in a location which is not subject to dam-

age. Switch must be mounted in an area in which it can be easily
reset after system actuation. See Section I, Components, for elec-
trical rating of switch contacts. When running the actuation hose
to the switch, make certain hose does not run through any areas
which could cause damage to the hose. Make certain hose is
securely supported and not subjected to vibration.
INSTALLATION
9-1-98 Page 12
eorenst theS
not edetectona
ste
INSTALLATION
Planning portion of this manual should have been reviewed for
oa cuara c tonresu,nonas st
read the procedure before installing each component to become
familiar with the correct installation steps as they apply to the par-
NOTICE
@_..
__.
system should be installed before the detection (_.,_

and actuation
ticular application system.
and sketch. _ .. _'-
For ease of installation, the fire suppression _O II q ''_
INSTALLATION MATERIALS
All hardwareand tools should be on hand before beginningthe
installation. Check the Component Index, Pages 35-36, to make FIGURE 19
certain all necessary system components are available. 002761
Material to be supplied by the installer includes: Welding

- Ample cable ties or 1/4 in. (6 mm) clamps to guide and support NOTICE
the detectionwire. Never weld on the vehicle frame without first
- Non-wire braid hose (1/4 in.) to be used as a protective cover- consulting the owner and vehicle manufacturer.
ing for the detection or power wire at points of securement and 1. Carefully mark the location of the bracket.
when passing through bulkheads. 2. Clean the mounting bracket and mounting surface using a
- Actuation line (1/4 in. hydraulic hose) and fittings to connect the wire brush until clean steel surfaces are available for welding.
electric detection and actuation system actuator to the fire sup-
pression system. (See applicable Ansul Fire Suppression 3. Secure the bracket to the mounting surface using 1/8 in.
Systems installation manual for additional details.) (3 mm) fillet welds at the top, bottom, and both sides. See
Figure 20.
Tools required to perform the installation include: 4. Remove all weld spatter from the bracket and mounting sur-
- Drill and Drill Bit Set (or welding equipment) face.
- 1/8 in. Blade Screwdriver 5. Prime and paint the exposed bare metal of the bracket and
- 1/4 in. Blade Screwdriver mounting surface.
- Phillips Screwdriver
- Standard Sidecutters
- Small Sidecutters (1/4 in. cut) _
- Wire Stripper q_ WELD
- Low Wattage Soldering Pencil (35 watt) WELD

-- Rosin Core Solder (60/40)
- Rubberized Electrician's Tape
MOUNTING BRACKET INSTALLATION
Three mounting bracket options are available: ,__._

Mounting control module and pneumatic actuator on same _._"
bracket
Separate bracketsfor control module and pneumatic actuator FIGURE20

002762
Control module retrofit bracket to existing CHECKFIRE SC

bracket
Bolting
1. Using the bracket as a template, carefully mark the location of
the bracket mounting holes.
2. Center punch the premarked hole locations and drill 3/8 in.
(10 ram) holes through the mounting surface.
3. Secure the bracket to the mounting surface using appropriate
length of 5/16 in. (8 ram) bolts with flat washers, Iockwashers,
and nuts. See Figure 19.
INSTALLATION
9-1-98 Page 13
MOUNTING TO EXISTING CHECKFIRE SC BRACKET Installing The Fire Suppression System Actuation Line
In some cases, retrofitting to an existing CHECKFIRE SC system Install 1/4 in. actuation hose from lower outlet on actuator to
may be an option To accomplish this, use retrofit bracket, Part No. pneumatic actuator on fire suppression system using a check
423531. This bracket can be mounted directly to the existing SC valve at the intersection of each actuation device branch line. See
bracket. See Figure 21. Figure 23.
The CHECKFIRE SC-N System output (using /T-5-R cartridge)
can pressurize up to 75 lineal ft. (22.8 m) of 1/4 in. actuation line
with up to eight tanks and/or accessories Check valves are used
to protect against pressure loss if one or more actuator cartridges
are removed or damaged; and by isolating each branch line, they
o reduce the overall lineal length of actuation line.
@'_E)
The fire suppression system could be accidentally actuated
installed at this time. Do not install these components until the

appropriate installation step is reached.
___4 causing the release of agent if the squib or LT-5-R cartridge is

NUTS AND BOLTS INCLUDED
FIGURE 21 = ACTUATION
o02763 SYSTEM
...,a
WITH RETROFIT BRACKET _ DETECTION AND
MANUAL/AUTOMATIC ACTUATOR INSTALLATION AND f_5o FT.
CONNECTION
I_ (15.2 m)
I_ ACTUATIO
Mounting CHECK _ N LINE
PRESSURE
actuatorthroughholein mountingbracket. VALVES _ _ RELIEF
1 Remove jam nut from lower threads of actuator and slide _"_,,,,,C-Y _ VALVE
ule and that actuation line outlet is accessible.

ACTUATIO
3.
2. Reinstall jam nutsoand
Rotate actuator thattighten
upper firmly. (SeeisFigure
squib inlet facing 22.)
control rood- NLINE _ _._m, tl I I
4. Install ring pin but do not attach seal at this time. 50FT. _ j
MANUAL SUPPRESSION
ACTUATOR SYSTEM
'___ FIRE
FIGURE 23
002772
ACTUATION LINE
JAMNUT
OUTLET _ __::_
FIGURE 22
002764
INSTALLATION
9-1-98 Page 14
MOUNTING THE CONTROL MODULE 2. Wire the alarm to the control module in accordance with the
The CHECKFIRE SC-N Control Module can be mounted to either diagram in Figure 25 using 20 AWG wire. Make certain the
a flat, rigid surface or utilizing one of the three bracket options, jumper is installed between
Certainthealarm
HI and LO terminals ononly
the
alarm terminal block. models may have
If mounting the control module to a flat, rigid surface, use the one positiveterminal in which case a jumper is not used. The
appropriate fasteners, ends of stranded wire must be tinned with 60/40 rosin core
If mounting the control module to the SC-N bracket, complete the solder, using a low wattage soldering pencil, before installa-
tion. On the terminal block at the control module, install the
following steps: wires to Terminals 11 (NO) and 12 (C).
1. With the bracket securely mounted, position the holes in the
control module mounting flanges over the threaded studs on NOTE: Use 0.13 to 0.25 in. diameter roundjacketed cable to
the bracket. Using the supplied mounting hardware, securely maintain water tight integrity of control module strain
fasten the control module to the bracket with four lock wash- reliefs.
ers and nuts.
ALARM RELAY
2. If utilizing the SC retrofit bracket, first fasten the retrofit brack- |
et onto the existing SC bracket by using the supplied fasten-
ers. With the SC retrofit bracket securely fastened, position I NO
'c NCI _
GROUND
CHASSIS
the holes in the control module mounting flanges over the _(_)!o!_i(2)101(_l FUSED LEAD
SIDE (FUSE ONNON-CHASSIS
AT LOAD X 1.25, NOT
threaded studs and securely fasten. I 1111121131 I I TO EXCEED 3AMPS)
I
Remove the cover from the control module. If the internal 3.6 I \
VDC battery is in place, disconnect the wire plug until the \
ALARM \
field wiring is complete. TERMINAL
\ \ VEHICLE
If the strain relief(s) and plug(s) are not in place, coat the male BLOCK ___ \ POWER
threads with Dow Coming 737 RTV Sealant or equal and install in
holes of module back box.
At this point, the external field wiring can be installed.
LEAVE
JUMPER
IN
PLACE (WHEN ---_J_|

EQUIPPED) I_
I
I
_O CUE4-
REMOTE HIGH LEVEL ALARM INSTALLATION
1. Using the alarm as a template, carefully mark the location of FIGURE 25

the four mounting holes. Use either the bottom or rear set of 000869
mounting holes depending on the mounting location. Secure

the alarm using appropriate length of 5/16 in. bolts with lock
washers and nuts. See Figure 24.
FIGURE 24
00O868
INSTALLATION
9-1-98 Page 15
SHUTDOWN DEVICE CONNECTION DETECTION WIRE INSTALLATION
1. Install the shutdown device in accordance with manufacturer's Mounting

instructions. Also check with vehicle manufacturer to make 1. Using the system layout sketch, investigate each point where
certain the appropriate shutdown device is being used. The the wire will be secured to the vehicle. Keep in mind all the
device must not exceed the relay contract rating of 3 amp @ guidelines in the System Planning Section. Do this on a vehi-
30VDC resistive, cle that has been operated recently to avoid securing the wire
2. Terminals 14 (NO), 15 (C), and 16 (NC), are the shutdown too close to extremely hot components.
relay terminals on the control module. Figure 26 illustrates a 2. After the vehicle has cooled, loosely route the wire from the
typical wiring diagram for a normally closed circuit. Figure 27 start of the hazard throughout the proposed path through the
shows a typical normally open circuit. The ends of stranded hazard areas. If splicing is required, see Splicing, Page 16, for
wire should be tinned with 60/40 rosin core solder, using a low detailed information.
wattage soldering pencil, before connection to the control
terminals. 3. Secure the detection wire by completing the following steps:
See Figure 28.
NOTE:Use 0.13 to 0.25 in. diameter round jacketed cable to
maintain water tight integrity, a. Start at the beginning of the detection wire leading into the
SHUTDOWN
RELAY hazard area. Secure the detection wire every 12 to 18 in.
I (30 to 45 cm) using black nylon cable ties, Part No. 56691,
I and protective coverings, Part No. 56692, at points of
I NO C NCI FUSED LEADONNON-CHASSIS securement. Secure more often if necessary. Attach the
1010101010101 SIDE
NOT (FUSE
TO ATLOAD
EXCEED X1.25,
3 AMPS) wire to mounting surfaces, decks, struts, etc., always keep-
I I I 11411_1161 _ ing System Planning guidelines in mind.
NOTICE
I --O 4- Do not kink the wire by bending it in sharp
turns of 2 in. (5 cm) or less. Remove enough
VEHICLE
SOURCE try to stretch the wire in any way. Do not

attach detection wire to commonly removed
SHUTDOWN _--
DEVICE O -- or replaced equipment.
_[ POWER slack to avoid droops in the line, but do not
(BY OTHERS)
GROUND
_ CHASSIS
Detection wire must never be routed through a hole or
FIGURE 26 near sharp edges without being properly protected.
0oo_7o Failure to protect the wire from being cut or abraded
SHUTDOWN
RELAY could cause it to short, causing a false discharge.
I
passes
,I'NO C NCI! FUSED LEAD ON NON-CHASSIS b. Secure the wire at least once immediately before it
SIDE(FUSEATLOADX1.25, through a hole in a vertical or horizontal surface. At the
1010101010101 NOTTOEXCEED 3 AMPS) hole, a 1/4 in. (6 mm) rubber sleeve, Part No. 56692, or a
[ 1 ! 1141,51,61 _ special grommet to fit the hole should be used to protect
the wire from wear due to vibration. Tape the hose to the
I --O 4- wire using electrician's tape to keep it from shifting. This
VEHICLE hose protection should also be used at locations where the
SOURCE or sharp corners.

SHUTDOWN =--
DEVICE O m 1/4 IN.
POWER wire would rub against other hard surfaces, rough edges,
RUBBER SLEEVE
[_ CHASSIS
' GROUND
ou. ,Ol BOTH ENDS
FIGURE 28
0OO872
INSTALLATION
9-1-98 Page 16
DETECTION WIRE INSTALLATION (Continued)

Splicing
If possible, the detection wire should be run in a continuous piece. 5. Starting at the outer jacket, wrap the entire splicing area in
However, if splices are required, they must be made using the fol- rubberized electrician's tape. An acceptable brand is 3M
lowing technique. See Figure 29. Super33+. Make certain the tape is sufficiently overlapped so
that the leads and the splicing device are completely covered.
1. Strip off about 1 1/2 in. (3.8 cm) of the detection wire outer
jacket to expose the internal leads. 6. Route the 16 gauge wire from the splicing device, through the
2. Cut leads to make certain they are of equal length. Then,strip strain relief, to the terminal strip in the control module. Make
off 1/2 in. (13 ram) of insulation from each of the internal certain wire is not exposed to damage. See Figure 30.
spring wires. 7. On the terminal block at the control module, install the wires to
3. Loosen the terminal screws on the special splicing device, terminals No. 3 and 4. See Figure 30. Note: It is not necessary
Part No. 71820. Insert the two incoming detection wires into to be concerned about polarity when installing these wires.
one end of the splicing device and the two outgoing leads into DETECTION A _..-...---r-r"
the other end so that the exposed wires overlap as shown in _ _-_--_'_ II
4. Tighten the terminal screws until the wire is secured.

5. Starting at the outer jacket, wrap the entire splicing area in
rubberized electrician's tape. An acceptable brand is 3M
Super 33+. Make certain the tape is sufficiently overlapped so
that the leads and the splicing device are completely covered.
F igure29. __[3E]0__11
OUTGOING
1/2 IN. 17"

(1.3cm) I I ._ _,
002765
13!8]llmNi "-_ SDPLII_N

G FIGURE 30
THERMAL DETECTOR INSTALLATION
When installing the Ansul spot detectors, use only components
approved by Ansul. These components consist of the following:
E --Mounting Bracket Shipping Assembly, Part No. 416221 -
ENTIRE
SPLICE Consists of one mounting bracket.
INCOMING LEADS -- Detector Clamp Package Shipping Assembly, Part No. 416214
(for use with protective tubing) - Consists of (2) cable clamps,
FIGURE29
000873 (2) 1/4-20 x 1/2 in. socket head screws, (4) flatwashers,
(2) spacers, and (2) 1/4-20 x 5/8 in. socket head screws.
Wiring - Detector Clamp Package Shipping Assembly, Part No. 416762
Once the detection wire has been routed and secured in the haz- (for use without protective tubing) - Consists of (2) cable
ard area, complete the following steps: clamps, (2) 1/4-20 x 1/2 in. socket head screws, (4) flatwashers,
and (2) 1/4-20 x 5/8 in. socket head screws.
1. Install an end of line resistor assembly, Part No. 426461, to
the far end of the detection wire. See instructionsheet includ- - Detector Connector Package Shipping Assembly, Part No.
ed with end-of-line resistor shipping assembly for assembly 416213 - Consists of (2) connector housings, (6) pins, and
details. (2) heat shrinkable sleeves.
2. Near the area where the detection wire enters the hazard - Protective Tubing Shipping Assembly, Part No. 416215 -
area, cut the detection wire as described in Steps 1 and 2 in Consists of 100 ft. (30.5 m) of tubing.
Splicing. -Multi-Conductor Cable, Part No. 417055 - Cable must be
purchased by installer and must have a temperature rating of
3. Loosen the terminal screws on the splicing device, Part No. 392 F (220 C) minimum, 16-18 gauge, two conductor with
71820. Insert the two incoming detection wires into one end of
the splicingdevice as shown in Figure 29. drain, minimum O.D. of .230 in. (.58 cm).
- AMP crimping tool, Part No. 416784.
4. Strip approximately 1 1/2 in. (3.8 cm) of outer jacket and
1/2 in. of internal inner insulation from the 16 gauge wire
which will run from the splicing device to the control module.
Insert these leads into the outgoing side of the splicing device
so that the exposed wires overlap as shown in Figure 29.
There is no need to be concerned about polarity between the
mating wires. Once the wires are inserted properly, tighten the
splicing device screws until the wire is secured.
INSTALLATION
9-1-98 Page 17
THERMAL DETECTOR INSTALLATION (Continued)
To properly install the thermal detector, complete the following:

1 Secure the mounting bracket(s)near the hazard. Make certain | ,.,, I' "NIr
(.6crn)
_
CRIMP
flame.the
bracket does not shield the detector from the heat or _', J' _ ' I A_I
bracket using (2)two flatwashers and (2) two 1/4-20 x 5/8 in. [r-= (3.2crn) =1 _'_
socket head screws supplied in detector clamp package. See 3
2. Attach
theFigure
31.
the correct temperature range spot detector to I- 1 1/4 IN. "_'=__
jill _"__ _
RUBBER PINS 3 _
cLAP
s
CABLE ,_
PROTECTIVE _. A
MOUNTING TURIN-- _ "_""'_

SLEEVES
BRACKET RUBBER _ _,,,,_,
// :r(__ -_/J._J-- \ 1/4-20

x1/2 WIRE
// _. __,_,%v P,NS SOCKET
HEAD
j SCREW
dl,jJ
- / SOCKET HEAD
SPOT SCREW (2) []
DETECTOR
FIGURE 31
000875
3. Starting at the Ansul CHECKFIRE Control Module, measure __

and route the cable to the first detector. Note: If protective tub-
ing is to be used, make certain cable is run through it between POSITION
SHRINK AFTER
HEAT
each detector. TUBING I 3/6-1/2 IN.

4. The circuit cable is 3 conductor. It consists of two insulated (.9-1.3 cm)
wires and one bare ground wire. Cut all wires equal in length
and strip the outer jacket and inner sheath back 1 1/4 in.
(3.2 cm). Note: Make certain not to cut into the insulation on
the two insulated wires or cut into the bare ground wire See FIGURE 32
Figure 31. 0oo876
5. With the outer jacket and sheath cut back, strip the insulation 13. Complete this process on each detector in the system.
on the two inner wires 1/4 in. (.6 cm). See Figure 32. 14. Attach the ground wire to the vehicle ground. Do this by
6. Slide the rubber sleeves from the AMP connector over the 3 mounting a sealed junction box in a convenient, protected
wires. The small end of the sleeves must be toward the striped location. The box must be mounted to a rigid support. Run the
end of the wires. See Figure 32. detection circuit cable to the box and attach to grounding
7. Slide a piece of heat shrinkable tubing onto the cable. See screw. See Figure 33.
Figure 32. 15. Attach the end-of-line resistor assembly, Part No. 426461.
8. Crimp the pins onto all three wires, using AMP crimping tool, See Figure 33. See instruction sheet included with end-of-line
AMP part No. 90277-1. See Figure 32. This tool is required for resistor shipping assembly for detailed assembly information.
proper crimping. It can be purchased through your local elec- 16. Run cable to the terminal strip at the control module. Make
tronics distributor or is available through Ansul as Part No. certain cable is not subject to damage. Install cable to termi-
416784. nals3 and4.
9. Press the pins into the connector housing. The two insulated I_
hole 1. Make certain each locks into place. The bare ground
wire
wiresmust go holes
go into into hole
2 and1 3but
andit the
makes
bareno difference
ground whichinto
wire goes of (/"__ I_ E.O.L.RESISTOR
the two insulated wires goes into hole 2 or 3. See Figure 32. \ _ ] I_ ASSEMBLY' ......
L_HUUINU
\ IV I PART NO. 426461 WIRE
10. Press the rubber sleeves into the connector holes. TECT _'--_I_
ION ""_----_I_L_:_ \\ _'\
11 Fit the heat shrinkable tubing over the connector so it covers DE
approximately 3/8 in. to 1/2 in. (.9 cm tol.3 CIRCUIT3UIT
cm)of the con- _
the tubing onto the connector and cable to form a tight, water-
proof fit. See Figure 32.
12. Coat the O-ring on the detector with silicon grease, then snap
hector.
the Heat the
connector tubing
onto with an approved
the mounted heatsecure
detector and gun, shrinking
cable to ___
detector bracket using appropriate cable clamp and 1/4-20 x JUNCTION
BOX
1/2 in. socket head screw supplied in detector cable clamp FIGURE 33
package shipping assembly. _7_
INSTALLATION
9-1-98 Page 18
PNEUMATIC/LINEAR DETECTOR INSTALLATION SQUIB LEAD CONNECTOR
The pneumatic/linear fire detection system, Part No. 416113, is a Squib connector cable assembly, Part No. 79062, is supplied with
Systron Donner Model 808-DRV. This detection system is the CHECKFIRE SC-N shipping assemblies (Part No. 423500and
completely compatible with the Ansul CHECKFIRE SC-N control 423538). The cable assembly is precut to 20 in. (51 cm) to reach
module, betweenthe actuatorassemblyand the control moduleon a stan-
Each detection system is shipped with a detailed Installation, dard bracket. An optional connector assembly, Part No. 422747, is
Maintenance Manual. 15 ft. (4.6 m) long and it can be cut to any length required to make
the connection between the control module and the pneumatic
When installation the pneumatic/linear detection system to an actuator.
Ansul CHECKFIRE SC-N control module, use connector/cable
assembly, Part No. 416216, and install per Figure 34. If the control module and pneumatic actuator are mounted on the
same bracket, the squib connector included with the control mud-
NOTE: Attach end-of-line resistor assembly by following the ule shipping assembly should be used and no cutting to length is
detailed steps listed on the instruction sheet included with the end- required.
of-line resistor shipping assembly.
MULTIPLE DETECTORS
OUT DO not attach squib connector to live squib at this time. If squib
CONTROL _ is connected, the squib could be actuated accidentally during
TERMINAL PARTNO.426461
BLOCK 4.7 K, 1/8 W
1. Locate the squib connector end of the assembly at the squib

BLUE inlet port on the pneumatic actuator. Route the cable from that
GREEN
MODULE _ EjL RESISTORASSEMBLY, installation.
IGRi EN I I= I :1IORANGE-
BLuERED I l - IBLUE
GREEN RED I , I ORANGEI
I I 2. Leaving
controllcatin'
themodule.
athrough
little slack,
See
the Figure
cut
strain
off 35.
relief,
excesstocable.
the terminal strip at
ABCO
A 808-DRV
[_ renernaire
noa
red/green leads to Terminal 8 on the control module. See
Figure 35.
securely fasten the black/white leads to Terminal 7 and the
OUT
[__L_.]
SINGLE
CONTROL
DETECTOR II
JL RED/ I WIRE
( _ TERMINAL BLOCK EOL RESISTOR GREENI ....
41 ASSEMBLY,
PART NO. 426461
4.7 K, 1/8 W
ORANGE
i. ODUL
lAB CDI
4. Attach the release circuit tester, Part No. 423541, at this time.
002767
This will be required when performing the functional test, start-

608-DRV ing at Page 19.
FIGURE 34
001059
INSTALLATION
9-1-98 Page 19
EXTERNAL POWER CONNECTION Depress the "RESET" button on the control module. This will set
In some cases, the customer may prefer external power input from the module to normal. Reset will be acknowledged by the control
the vehicle battery, module with short pulses from the sounder.
This external power is wired into the control module terminal strip At this point, the GREEN Power LED should be the only LED
on Terminals No.1 (+) and 2 (-). See Figure 36. See Component pulsing.
Index in Appendix Section for list of Power Wiring and Battery NOTICE
Connection Assemblies. When performing any of the functional test,
make certain the release circuit tester, Part No.
EXTERNAL
12/24VDCCIRCUIT 423541, is attached to the squib lead connector.
TERMINALS 1 (+) AND 2 (-)
__-_------'- The following tests will verify that the system will operate upon
+- fire condition) or when actuated using an electric pull station. The

accuracy of the time delay setting(s) will also be verified during this
test. If the system is connected to a vehicle shutdown device, the
vehicle should be left running during this test to verify that the shut-
1___i_!CI[31_]_ I receiving
down device an electrical signalIf from
is functioning. noted aresults
detection
are device (simulated
not attained, refer
_ !1 J' I_ to the Troubleshooting Section of this manual for corrective action.
External Power Circuit Test
Check the external power circuit by disconnecting the fuse and
checking to see that a power trouble is present. Replace the fuse
and check to see that the control module returns to normal.
Detection Circuit Functional Test

NOTICE
TOVEHICLE
BATTERY Before conducting the functional test, each time
FIGURE 36 delay setting must be known.
002768
1. Using a short length of insulated wire stripped at both ends,
OPTIONAL PRESSURE SWITCH/ELECTRIC PULL STATION hold one end of the wire to Terminal 3 and hold the other end
to Terminal 4. See Figure 38.
The pressure switch circuit must be wired to Terminals 5 and 6 on
the control module terminal strip. The pressure switch circuit must DETECTION
CIRCUIT
also have an end of line resistor assembly, Part No. 426461, TERMINALS3AND_
installed in the circuit. See Figure 37. .-T"E"'-'---__,P_"_4 JUMPER

-1311 /_
NOTE: If pressure switch/electric pull station circuit is not used, a II if"
"4"" / I
4.7 k ohms resistor must be connected across terminals i IITilI_, D[glg[]I]313_EE]FID I
inside the control module. I _ / DETECTION
PRESSURE SWITCH/ELECTRIC L._ _ CIRCUIT
POLLTT,ONO, OU'T-
TERMINALS 5 AND 6 I WIRING
@ NOTALL O0277O
ONSMUST Hold the wire on the terminals for a time which is shorter than
BEWATERTIGHT. the time programmed in for the first time delay.
PRESSURE SWITCH
FIGURE 37
002769
FUNCTION TEST
Before conducting the following FUNCTION TEST, connect the
internal battery to the front cover using the battery extender cable
assembly, Part No. 426604, and connect the Extender Test Cable
Assembly, Part No. 426601, to the terminal strip inside the back
box and the mating terminal strip inside the cover. (The Extender
Test Cable Assembly allows separation of the cover from the back
box while maintaining circuit integrity.
INSTALLATION
9-1-98 Page 20
FUNCTIONTEST (Continued) ImmediateReleaseOption

Detection Circuit Functional Test (Continued) 1. Using the jumper wire, hold the wire on Terminals 5 and 6.
This is the pull stationcircuit. If the circuit was programmed for
The following will take place while the jumper wire is being held on immediate release, the following will take place:
the terminals:
The RED Alarm LED and the sounder will pulse at a rate of
The RED Alarm LED and sounder will pulse at a rate of two
four times per second
times per second
The first time delay cycle will start The alarm relay will operate (latching)
The alarm relay will activate (non-latching) The shutdown relay will operate (latching)
The release circuit (squib) will activate, causing the
After verifyingthe above, remove the jumper wire. The control GREEN LED on the squib tester to illuminate
module will reset to normal (as long as the cycle for Time
Delay No. 1 has not been exceeded). Normal is when only the 2. Reset squib test module by pressing the reset button on the
GREEN Power LED is pulsing and no other LED's or the tester. Do not disconnect the test module at this time,
Audio Alarm are operating. Also, the alarm relay will return to 3. Push the "RESET" button on the CHECKFIRE SC-N Control
normal. Module and the module will return to the normal condition.
2. This next test will verify the settings of the time delays. Again, 4. If required, make certain to reset any auxiliary shutdown
hold the jumper wire on Terminals 3 and 4. Continue to hold devices.
the jumper wire on these terminals until the second time delay
has started. Once the second time delay has started, the Shutdown/Time Delay/Release Option
jumper wire can be removed. 1. Using the jumper wire, hold the wire on Terminals 5 and 6.
The following will take place while the jumper wire is being This is the pull stationcircuit. If the circuit was programmed for
held on the terminals: shutdown/time delay/release, the following will take place:
The RED Alarm LED and sounder will pulse at a rate of two The RED Alarm LED and sounder will pulse at a rate of four
times per second times per second
The first time delay cycle will start and time through its The alarm relay will operate immediately (latching)
cycle The shutdown relay will operate immediately (latching)
The alarm relay will activate (non-latching) A single time delay cycle will start (during test, verify length
After the first time delay has completed its cycle, the following of delay)
will take place: After the single time delay cycle is completed, the release cir-
The RED Alarm LED and sounder will pulse at a rate of four cult (squib) will actuate, causing the GREEN LED on the squib
times per second tester to illuminate.
The second time delay cycle will start and time through its 2. Reset squib test module by pressing the reset button on the
cycle tester. Do not disconnect the test module at this time.
The alarm relay will activate (latching) 3. Push the "RESET" button on the CHECKFIRE SC-N Control
Module and the module will return to the normal condition.
The shut-down relay will activate (latching), causing vehi-
cle shutdown 4. If required, make certain to reset any auxiliary shutdown
devices.
At the end of the second time delay cycle, the release cir-
cuit (squib) will activate, causing the GREEN LED on the Pressure Switch Option
squib tester to illuminate. 1. Using the jumper wire, hold the wire on terminals 5 and 6. This
3. After the jumper wire has been removed, reset squib test is the pressure switch circuit. The following will take place:
module by pressing the reset button on the tester. Do not dis- - The alarm relay will operate (latching)
connect the test module at this time.
The shutdown relay will operate (latching)
4. Push the "RESET" button on the CHECKFIRE SC-N control
module and the module will return to the normal condition. The RED alarm LED and the sounder will pulse at a rate of
four times per second.
5. If required, make certain to reset any auxiliary shutdown
devices. 2. Push the "RESET" button on the CHECKFIRE SC-N Control
Module and the module will return to the normal condition.
Pressure Switch/Manual Pull Initiating Circuit 3. If required, make certain to reset any auxiliary shutdown
During the programming requirements of the pressure devices.
switch/manual pull circuit, two options are available. The first
option allows the circuit to be programmed for immediate release
and the second option allows for shutdown/time delay/release. If
choosing the shutdown/time delay/release option, the program-
ming will also require a length of time delay to be chosen.
When performing this functional test, it is necessary to know
whether the first or second option was programmed into the
module.
INSTALLATION
9-1-98 Page 21
PLACING THE SYSTEM IN SERVICE c. Remove test module from squib connector and firmly hand
tighten squib connector unto squib. See Figure 41.
After all testing has been successfully completed, the system may
be placed in service.
Make certain cartridge is not installed when completing the
following steps:
1. Install squib by completing the following steps: _ HAND
TIGHTEN
The squib is an explosive device. Do not attach connec- J_ I

tor onto squib until squib is installed in actuator body. If
the squib is actuated outside of the actuator body, possi-
ble personal injury could result.
a. Screw squib into upper-right inlet hole in actuator body and

wrench tighten. See Figure 39.
UIB
FIGURE 41
002771
NOTICE
When the squib connector is removed from
the test module, the control module YELLOW
Release Trouble LED and Sounder will tem-
porarily pulse. This will stop when squib is
connected.
FIGURE 39
0OO882
b. Unscrew protective cap from squib and remove spring Make certain cartridge is not installed at this time. The fire
(shunt). Retain these components for possible future use. suppression system will discharge dry chemical if the car-
See Figure 40. tridge is installed when operating the strike button.
CAUTION 2. Push "RESET" button on CHECKFIRE SC-N Control Module

to reset system. Note: Depress "RESET" button for at least 3
The control module could be damaged and the fire seconds.
suppression system may not operate if the squib 3. Pull ring pin and push strike button on manual/automatic actu-
spring (shunt) is not removed. Always remove cap and ator several times to ensure smooth movement.
spring (shunt) before installing squib connector.
4. Install LT-5-R cartridge, Part No. 6979, into manual/automatic
actuator by completing the following steps. See Figure 42.
a. Make certain puncture pin is fully retracted and insert ring
pin through actuator body into puncture pin shaft. Attach
visual inspection seal, Part No. 197.
-- SPRING
(SHUNT) b. Remove shipping cap and weigh cartridge before installing.
_. PROTECTIVE Replace if weight is 1/4 ounce (7.1 g) or more below weight
CAP stamped on LT-5-Rcartridge, Part No. 6979.
'_ c. Screw cartridge into actuator body and hand tighten.
FIGURE 40
000883
INSTALLATION
9-1-98 Page 22
PLACING THE SYSTEM IN SERVICE (Continued)

6. If a vehicle shutdown device is NOT installed, affix the "WHEN
FIRE ALARM SOUNDS" nameplate, Part No. 71086, near the
RINGPINNED operator's line of vision. See Figure 44.
AND SEALED
WHEN FIRE ALARM SOUNDS

THIS VEHICLE IS EQUIPPED WITH AN AUTOMATIC
FIRE DETECTION, ALARM AND SUPPRESSION SYS-
TEM. WHEN FIRE ALARM SOUNDS, BRING EQUIPMENT
TO A SAFE STOP. SHUT OFF ENGINE, AND EXIT.
TO MANUALLY OPERATE, PULL RING PIN AND PUSH
RED PALM BUTTON ON ACTUATOR.
FIGURE 44
OOO887
LT-5-R CARTRIDGE,
PART NO. 6979
FIGURE 42
000885
5. If a vehicle shutdown device is installed and the shutdown

time delay is being used, complete the following steps: See
Figure 43.
a. Affix the "IN CASE OF FIRE" nameplate, Part No. 79060,
near the operator's line of vision.
b. Using Label No. 79404, cut along the dotted line to remove
the required number square.
c. Peel the protective backing from the number square to
expose the adhesive.
d. Place the number square on the space provided in the third
sentence of Label No. 79060: 'THIS VEHICLE WILL
AUTOMATICALLY SHUTDOWN AFTER SECONDS
WHEN FIRE ALARM SOUNDS

THIS VEHICLE IS EOUIPPEO WITH AUTOMATIC DETEC-
TION. ALARM, FIRE SUPPRESSION SYSTEM, AND ENGINE
SHUTDOWN DEVICE. WHEN FIRE ALARM SOUNOS. BRING
EQUIPMENT TO A SAFE STOP, SHUT OFF ENGINE, AND
EXIT. THIS VEHICLE WILL AUTOMATICALLY SHUT DOWN
AFTER_ _h_SECONDS. TO AVOID UNWANTED VEHICLE
SHUTDOWN, IMMEDIATELY PUSH AND RELEASE
TESTICOI_ROL SUTTON. THIS WILL EXTEND THE SHUT-
DOWN DL=_Y FOR THE TIME INDICATED ABOVE. CON-
TINUE TO _SH AND RELEASE AS NECESSARY.
TO MANUAIY OPERATE: PULL RING PiN AND PUSH RED
PALM BUT_IIN ON ACTUATOR.
I L*mt.o *le_,
,___,!q,__.,___
CUT OUT TIME DELAY
SETTING AND PLACE
IN SPACE ON LABEL
NO. 79O6O
[-I-+:.........
LABELNO. 79404
FIGURE 43
000886
IN CASE OF FIRE
9-1-98 Page 23
Read these precautions carefully until they are clearly understood. Manual System Actuation
All equipment operators or anyone who has any responsibility for The system can be actuated manually by pullingthe ring pin and
the equipment should fully understand how the CHECKFIRE striking the red button on the manual/automatic actuator as shown
SC-N Detection and Actuation System operates. Every operator in Figure 45. Again, bring the equipment to a safe stop, shut offthe
should be fully trained in these procedures, engine, manually actuate the system, move a safe distance from
1. When the system alarm sounds, bring the equipment to a safe the vehicle, and stand by with a hand portable extinguisher.
controlled stop, shut off the engine, and exit. (Equipment left
running may add fuel to the fire or reignite the fire with heat or
sparks.)
Automatic Equipment Shutdown-The CHECKFIRE SC-N Manual actuation will result in immediate system discharge
system is equipped with a shutdown relay and time delay. If a which may obscure vision. Make certain vehicle is stopped
shutdown device is connected to the system, all responsible safely before manually actuating the system. Manual actuation
personnel should understand shutdown device operation and will bypass all auxiliary shutdown and alarm functions.
the length of the time delay (in seconds). If the DELAY button
(on the control module cover) is pushed and released before 2
the end of the shutdown time delay period, the time delay will
automatically repeat itself. This delay can be repeated (using _ STRIKE
the DELAY button) as many times as is necessary to stop the V BUTTON
vehicle safely before it shuts down. (The DELAY button can
also be held in indefinitely to delay shutdown - the shutdown
delay will then restart after the button is released.)
2. Move away from the equipment taking a hand portable extin- PULL
RING
guisher
alongif possible. 1 PIN
In case of fire, evacuate area to lessen risk of injury from

flames, heat, hazardous vapors, explosions, or other
hazards that may be created.
Stand by with a hand portable extinguisher to guard against

any fire that may reignite after the fire suppression system has FIGURE 45
been discharged. Remain alert until the equipment cools and _3
the possibility of reignition is no longer a threat.
RECHARGE
9-1-98 Page 24
For continued protection, the CHECKFIRE SC-N Detection and

Actuation System and the fire suppression system must be
recharged immediately after operation.
Before performing the recharge steps, determine the cause of the UPPERPORTION
system discharge. OFBODY
1. Remove the 4 screws holding the cover to the back box and
remove the cover.
BASE
2. Remove the battery from the back box. Note: If system con- OFSTEM
tains optional vehicle power, also disconnect the wire leads at LUBRICATE O-RING
WITH SILICONE GREASE
the vehicle battery.
3. Remove the empty LT-5-R cartridge from the manual/auto- PUNCTURE
PIN
matic actuator.
5. If the system was automatically actuated - Unscrew the _ _ SPRING

4. squib
proceedlf
the systemto
leadstepWaS7,
connector.
manually
Remove
actuatedthe
- Skip
squib
stepsfrom
5, 6, and
the RESET
__1 _-'---r
manual/automatic actuator. POSITION "_
6. Clean and lubricate the manual/automatic actuator by com- 1/16IN.(1.6ram)

plating the following steps. See Figure 46 1/16(1.6ram) ,,4_ ACTUATOR
BODY
NOTICE
If the system was actuated manually and the APPROXIMATELY
_
squib was not actuated, cleaning is not neces-
sary. FIGURE46
OOO888
a. Remove jam nut and slide actuator out of mounting bracket. NOTICE
b. Unscrew upper portion of actuator body. When puncture pin is fully reset, cutting point of
c. Using a pencil eraser, apply pressure to the bottom of the pin will be located approximately 1/16 in.
puncture pin. This will force the puncture pin and spring out (1.6 ram) below threads in lower actuator body.
of the actuator body. 7. In the case of a fire, replace all linear detection wire and spot
d. Thoroughly clean carbon deposits from base of stem, detector cable. See Section III, Installation, for instructions.
puncture pin, spring, and inside surface of actuator body. 8. Recharge the fire suppression system in accordance with the
e. After all components are clean and dry, liberally lubricate corresponding manual.
O-rings with a good grade of extreme temperature silicone 9. Test the system and place into service by completing the
grease, steps listed under "FUNCTIONALTEST,"Pages 19-20.
f. Reassemble actuator, reinstall into bracket, and securely 10. Record date of recharge on a tag or in permanent record file.
tighten jam nut. Notify operating personnel that the system is back in service.
g. Pull ring pin and push strike button several times to spread i
grease and ensure free movement of puncture pin. !
h. With strike button in the up position, insert ring pin through i
actuatorbodyinto puncturepin shaft.Installvisualinspec-
tion seal, Part No. 197.
INSPECTION AND MAINTENANCE
9-1-98 Page 25
To ensure the CHECKFIRE SC-N Electric Detection and Actuation 7. If thermal detectors are used, check that they are securely
System will operate as intended, proper inspection and mainte- mounted and have not corroded or been damaged.
nance procedures must be performed at the specified intervals. NOTICE
If a vehicle shutdown device is installed, the
DAILY INSPECTIONS vehicle should be running at this time to verify
The vehicle operator must check the system daily by visually ver- that the device is functioning properly.
ifyingthat the GREEN power LED is flashing and no other LED is 8. If external power is used, measure the voltage at terminals
illuminated.Also, no audio alarm should be sounding. If any other 1 and 2 to ensure that the 12/24 VDC is present. Check mon-
conditions exist, contact the local authorized Ansul distributor or itoring of the external power by removing the in-line fuse and
whoever has been trained and authorized by Ansul to perform checking to see that a power trouble condition is present.
inspection and maintenance checks. Replace fuse and depress the RESET button on the control
MAINTENANCE module.
9. Check first time delay - Alarm to Shutdown - Using a short
To give maximum assurance that the system will operate as length of insulated wire stripped at both ends, hold one end of
intended, maintenance must be performed at six-month intervals the wire to Terminal 3 and the other end to Terminal 4 on the
or sooner depending on the operating environment or mainte- control module. See Figure 47.
nance schedule. Maintenance should be performed by an autho-
rized Ansul distributor or someone who has been trained and DETECTION
CIRCUIT
authorized by Ansul to perform maintenance checks. TERMINALS
3 AND4_ "
JUMPER
1. Check all mounting bolts for tightness or corrosion. - 3-_"__"-4
I;\!l /
actuator, install shipping cap, and set aside in a safe location.
2. Remove the LT-5-R cartridge from the manual/automatic
I _
DI-IFI_
J DETECTION
DE]
1
L_,. _ CIRCUIT 1.-
Cartridge must be removed before continuing with the ._ _ L.

following steps or accidental system actuation will take ,_ l
place when squib is actuated.
Do not actuate squib unless it is installed in actuator

body. If the squib is actuated outside of actuator body, it FIGURE 47
will detonate causing possible personal injury. 0o2_0
3. Five Year Squib Replacement-The squib must be replaced Using a jumper wire, temporarily short Terminals 3 and 4,
removing the jumper before the end of the first time delay
after being in service for five years. (The month and year of cycle. This will test the non-latching function of the first time
manufacture is stamped on the squib hex surface.) Proper delay. While the wire is being held in place, the RED Alarm
disposal of the squib is accomplished by actuating the squib LED will pulse and the sounder will operate.
within the actuator body. If this is required, skip Steps 4 and 5
which deal with installing the test module in place of the squib. Remove the jumper wire. At this point, both the RED Alarm
By skipping steps 4 and 5, the squib will be actuated during LED and the sounder will stop pulsing and the first time delay
the following test procedures, will recycle back to zero. The control module will return to nor-
mal with only the GREEN Power LED on.
10. Check second time delay - Shutdown to Discharge -
Once again, hold the wire on Terminals 3 and 4. The RED
Make certain the cartridge is removed from the actuator. Alarm LED and the Audio Alarm will pulse. Hold the wire on
Failure to do so will cause system discharge when squib the terminals for a period longer than what the first time delay
is actuated, is set up for. While holding the wire on the terminals, time the
length of the first time delay to verify that it is the same as
4. Remove the squib lead connector from the squib, what it was set for.
5. Hand tighten the squib lead connector onto the test module, At the end of the first time delay cycle, the pulse rate of the
Part No. 423541. Audio Alarm will change. This will start the cycle of the second
time delay. At this point, the timing cycle is latched, and the
6. Inspect the detection and interconnecting wiring as follows:
wire jumper need not be held on the terminals. Also at this
a. Check for wear due to vibration at penetrations, around point, the shutdown relay will operate, causing the vehicle to
corners, etc. shutdown.
b. Check for damage from direct impact or other abuse. Time the length of the second time delay to confirm that it is
c. Check for tightness at points of securement. Make certain the same as what has been set.
fasteners have not come loose which would allow the wire When the second time delay cycle is completed, the release
to sag or shift, circuit will activate causing the GREEN LED on the test mod-
ule to illuminate or in the case of the five year squib replace-
ment, the squib will fire.
INSPECTION AND MAINTENANCE
9-1-98 Page 26
MAINTENANCE (Continued) 17. Yearly - Remove control module cover screws and replace
11. (If used) Reset test module by pressing the reset button on the internal 3.6 VDC lithium battery, Part No. 423520. Record date
tester. Do not disconnecttest module at this time. of new battery installation on label located near battery.
Reinstall control module cover and depress "RESET' button.
12. Complete the following steps only if the squib has been actu-
ated. Otherwise, go to Step No. 13.
a. Unscrew the squib lead connector from the squib and
remove the squib from the actuator body. Contact your local waste management company for informa-
b. Clean manual/automatic actuator by referring to Step 6 on tion concerningthe correct disposal of lithiumbatteries.
Page 24 in Recharge Section.
18. Reinstall LT-5-R cartridge, Part No. 6979, by completing the
c. Screw replacement squib into the upper-right hole in the
actuator body and wrench tighten, following steps:
d. a. Make certain puncture pin is fully retracted and insert ring
pin through actuator body into puncture pin shaft. Attach
visual inspection seal, Part No. 197.
The control module could be damaged and the fire sup- b. Remove shipping cap and weigh cartridge before installing.
pression system may not operate if the squib spring Replace if weight is 1/4 ounce (7.1 g) or more below weight
(shunt) is not removed. Always remove cap and spring stamped on LT-5-R cartridge. (Shipping Part No. 6979).
(shunt) before installing squib connector, c. Screw cartridge into actuator body and hand tighten.
Unscrew protective cap from replacement squib and 19. Reset any auxiliary shutdown and alarm equipment in actor-
remove spring (shunt). Retain these components for possi- dance with manufacturer's instructions.
ble future use. 20. Record date of maintenance on an affixed tag or in a perma-
e. Line up index slot in squib lead connector with index tab on nent record file.
squib. Then, hand tighten squib lead connector onto squib.
13. Unscrew the squib lead connector from the test module.
NOTICE
When squib lead connector is removed from test
module, the YELLOW Release LED and the
audio alarm on the control module will
temporarily pulse. This will stop when squib is
connected.
14. Line up index slot in squib lead connector with index tab on
squib. Then, hand tighten squib connector onto squib.
15. Push "RESET" button on CHECKFIRE SC-N Control Module
to reset system.
The fire suppression system will discharge dry chemical if

the cartridge is installed when operating the strike button.
Do not install cartridge at this time.
16. Pull ring pin and push strike button on manual/automatic actu-
ator several times to ensure smooth movement.
NOTICE
If lever does not operate smoothly, clean and
lubricate internal components by completing
Step No. 6 on Page 24 in Recharge Section.
TROUBLESHOOTING
9-1-98 Page 27
DIAGNOSTICS Below is a listing and explanation of each type of recorded fault:

The diagnostics feature offers a means to pinpointvarious trouble Programmed- This indicates any time the unit is pro-
symptoms by displaying a flashing code on the control module grammed or a programming change has been
status LED's. made.
If there is more than one trouble at a time, the system will display Switch Enabled - This indicates that the manual programming
them in a pre-set priority, switch is enabled and the program settings
In multiple trouble situations, the first trouble must be cleared are being taken from the program switch set-
before the system will display the next one. tings.
The system must be in the trouble mode in order to display the Init Bad Log - This indicates that an error has been detect-
diagnostics codes, ed in the datalog. If this occurs, the datalog is
With the system in the trouble mode, depress the "DELAY" button, automatically cleared and reset.
With the "DELAY" button depressed, the trouble codes will be indi- Bad Checksum - Indicates that an error has been detected in
cated on the LED's. the E-Prom. If this occurs, the factory default
program settings are restored.
LED Code Trouble Soft Reset- Indicates that the Reset button has been
depressed. The clock is not reset during a soft
Yellow Battery LED flashing Internal battery disconnected reset.
Yellow Battery LED flashing External battery disconnected +12 (24V) Low - Indicates that the external power input volt-
Red Alarm LED flashing age has dropped below a "Normal" threshold
level and is in need of servicing.
Yellow Release LED flashing Release circuit is open
+12 (24V)Fault- Indicates external power input voltage has
Yellow Release LED flashing Release circuit has operated dropped below the minimum operating
Red Alarm LED flashing threshold or the external power has been dis-
connected.
Yellow Detection LED flashing Detection circuit is open Int Batt Low- Indicates the internal battery voltage has
Yellow Detection LED flashing Electric manual pull station dropped below a "Normal" threshold level and
Red Alarm LED flashing circuit is open requires servicing.
Int Batt Fault - Indicates that the internal battery voltage has
HISTORY BUFFER dropped below the minimum operating
The CHECKFIRE SC-N control module is programmed to record threshold or the battery has been
faults, alarms, and programming changes in a numerical disconnected.
sequence. The module will store approximately 50 recorded Detection TD1- Indicates thattheTime Delay 1 sequence has
events. If the number of events exceeds 50, the earlier events will been initiated. This occurs as a result of oper-
be erased to make room for the later ones. ation of the detection circuit.
A sample History Buffer screen appears as follows: Detection TD2- Indicates the start of the Time Delay 2
Event Number Event sequence as a result of a detection input.
0 Programmed Time (dddd:hh:mm:ss) Manual TD - Indicates the start of the time delay as a result
1 Detection TD1 0000:00:01:46 of the manual input circuit being initiated.
2 Delay Engaged 0000:00:01:52 Pressure Switch- Indicates activation of the pressure switch
3 Delay Released 0000:00:02:15 input circuit.
4 Detection TD2 0000:00:02:25
5 Squib Release 0000:00:02:35 Delay Engaged- Indicates the delay button has been
6 Soft Reset 0000:00:05:10 depressed during TD1 of an alarm condition.
7 All Clear 0000:00:05:13 Delay Released- Indicates the time the Delay button was
8 Int Batt Low 385:12:24:32 releasedafter initiating.
9 Int Batt Fault 405:20:32:07 Detection Fault- Indicates an open circuit in the detection
The recorded event indicates which circuit had a fault or an alarm circuit.
recorded. Along with the type of fault or alarm, the history buffer Manual Fault - Indicates an open in the manual pull or pres-
also records the time, relative to the first event. New events are sure switch circuit.
recorded by days: hours: minutes: seconds that have transpired
from the last event. If power is removed and then restored, the Squib Fault- Indicates an open in the squib circuit or that
counter starts over at 0000:00:00:00. the squib has fired.
Squib Release - Indicates that the control module has fired the
squib.
Unknown- Indicates an unexplainable event in the con-
trol module circuitry.
TROUBLESHOOTING
9-1-98 Page 28
TROUBLESHOOTING TABLE
The following table designates normal operating and trouble conditions for the CHECKFIRE SC-N Detection and Actuation System.
Green Yellow Yellow Yellow

Power Power Red Detection Release Audio Alarm Shutdown Trouble Agent
Condition Normal Fault Alarm Fault Fault Alarm Relay Relay Relay Release
battery
normal pulsing off off off off off normal normal normal off
modulenormal onceevery
external
power 3 seconds
notused
batterynormal pulsing off off pulsing off pulsing normal normal transferred off
detection fault onceevery onceevery onceevery
externalpower 3seconds 10seconds 10 seconds
not used
batterynormal pulsing off off off pulsing pulsing normal normal transferred off
releasefault onceevery onceevery
external power 10seconds 10 seconds
not used
batterynormal pulsing off off pulsing pulsing pulsing normal normal transferred off
detection fault onceevery onceevery onceevery
releasefault 10seconds 10seconds 10seconds
external power
not used
batteryfault off pulsing off off off pulsing normal normal transferredoff
externalpowernormal onceevery onceevery
module normal 10seconds 10seconds
batteryfault off pulsing off pulsing off pulsing normal normal transferred off
externalpowernormal onceevery onceevery onceevery
detectionfault 10seconds 10seconds 10seconds
batteryfault off pulsing off off pulsing pulsing normal normal transferredoff
releasefault onceevery onceevery onceevery
externalpowernormal 10seconds 10seconds 10seconds
batteryfault off pulsing off pulsing pulsing pulsing normal normal transferredoff
detectionfault onceevery onceevery onceevery onceevery
releasefault 10seconds 10seconds 10seconds 10seconds
external power normal
alarmdetected pulsing off pulsing off off pulsing transferred normal normal off
alarmtoshutdown onceevery twice twiceevery
period- TD1 3seconds every second second
externalpowerfault off pulsing off pulsing pulsing pulsing normal normal transferred off
detectionfault onceevery onceevery onceevery onceevery
manualpullcircuitfault 10 seconds 10 seconds 10 seconds 10seconds
release fault
battery normal
batteryfault off pulsing off off off pulsing normal normal transferred off
externalpowerfault onceevery onceevery
10seconds 10seconds
batteryfault off pulsing off pulsing off pulsing normal normal transferred off
externalpowerfault onceevery onceevery onceevery
detectionfault 10seconds 10seconds 10seconds
TROUBLESHOOTING
9-1-98 Page 29
TROUBLESHOOTING TABLE (Continued)

batteryfault off pulsing off pulsing off pulsing normal normal transferredoff
externalpowerfault onceevery onceevery onceevery
detectionfault 10 seconds 10 seconds 10 seconds
manual pull circuit fault
batteryfault off pulsing off pulsing pulsing pulsing normal normal transferredoff
externalpowerfault onceevery onceevery onceevery onceevery
detection fault 10seconds 10seconds 10seconds 10seconds
manual pull circuit
fault
release fault
manualpullcircuit pulsing off pulsing off off pulsing transferred transferred normal off
activated once every 4times 4times
prerelease period 3 seconds persecond persecond
(manual release
time delay)
pressureswitch pulsing off pulsing off off pulsing transferred transferred normal off
activated (0to 30 onceevery 4times 4times
seconds 3 seconds persecond persecond
after activated)
pressureswitch pulsing off pulsing off pulsing pulsing transferred transferred transferred off
activated onceevery onceevery onceevery onceevery
(post30+seconds 3 seconds 10seconds 10seconds 10seconds
period)
shutdownto release pulsing off pulsing off off pulsing transferred transferred normal off
period once every 4times 4times
(2ndtimedelay) 3seconds persecond persecond
O- 30 seconds pulsing off pulsing off off* pulsing transferred transferred transferred fired
afterrelease onceevery 4 times 4 times
3seconds persecond persecond
30+ seconds pulsing off pulsing off pulsing pulsing transferred**transferred transferred fired
after release onceevery onceevery onceevery onceevery
3 seconds 10seconds 10seconds 10seconds
manualpull pulsing off off pulsing off pulsing normal normal transferredoff
circuitfault onceevery onceevery onceevery
battery normal 3seconds 10seconds 10seconds
manualpull pulsing off off pulsing off pulsing normal normal transferred off
circuitfault onceevery onceevery onceevery
detection fault 3seconds 10seconds 10seconds
battery normal
manualpull pulsing off off pulsing pulsing pulsing normal normal transferredoff
circuitfault onceevery onceevery onceevery onceevery
detectionfault 3 seconds 10seconds 10seconds 10seconds
release fault
battery normal
TROUBLESHOOTING
9-1-98 Page 30
TROUBLESHOOTING TABLE (Continued)

externalpowerfault off pulsing off off off pulsing normal normal transferredoff
battery
normal once every once every
10seconds 10seconds
externalpowerfault off pulsing off pulsing off pulsing normal normal transferred off
detectionfault onceevery onceevery onceevery
battery
normal 10seconds 10seconds 10seconds
batteryfault off pulsing off off off pulsing normal normal transferred off
noexternal power once every once every
module normal 30seconds 30seconds
batteryfault off pulsing off pulsing off pulsing normal normal transferredoff
detectionfault onceevery onceevery onceevery
externalpower 10seconds 10seconds 10seconds
not used
manualpull pulsing off pulsing off off* pulsing transferred transferred transferred fired
circuit
activated onceevery 4times 4times
(0-30seconds after 3 seconds persecond persecond
system activation)
pressureswitch pulsing off pulsing pulsing pulsing pulsing transferred transferred transferred off
activateddetection once every onceevery onceevery onceevery once every
fault (30+seconds 3 seconds 10seconds 10 seconds 10 seconds 10seconds
after system
activation)
* Willpulseif circuitopensas a resultfrom release

** Can be silenced at this time
PROGRAMMING
9-1-98 Page 31
PROGRAMMING
The SC-N control module can be manually programmed by using Switch No. 1
the manual programming switch located on the control module PC If this switch is ON (Enable), it disables programming through a
board or it can be programmed from a PC through an RS232 inter- PC and enables the manual programming switch. If switch No.
face cable. 1 is on, the operation of the control module will correspond to
A number of settings can be programmed into the SC-N control the settings of the other manual programming switches
module: If this switch is OFF (Disable), the operation of the control rood-
Select initiatingcircuit No. 2 to operate as either an electric man- ule will correspond to the settings of the PC program
ual pull circuit or pressure switch feedback circuit
Switch No.2
If selected as an electric manual pull circuit, it can be pro-
grammed as either shutdown/immediate release or This switch is used to select initiating circuit No. 2 to operate as
shutdown/time delay/release either an electric manual pull or a pressure switch feedback
Alarm to Shutdown (Time Delay 1) can be programmed for 5, ON = Pressure Switch Feedback
10, 20, 30 seconds OFF = Electric Manual Pull
Shutdown to Release (Time Delay 2) can be programmed for 0,
10, 20, 30 seconds Switch No. 3
The SC-N control module is factory programmed with the follow- This switch is shutdown/immediate
used to select either release
the shutdown/time
release or the mode for thedelay/
elec-
ing defaults: tric manual pull input
First time delay (Alarm to Shutdown) = 10 seconds
This switch is only active if the switch No. 2 is in the OFF posi-
Second time delay (Shutdown to Release) = 10 seconds tion
Manual Pull = Shutdown, Time Delay (10 seconds), Release
If switch No. 3 is set to ON, then operation of the electric man-
Manual Programming Switch = Disabled ual pull station will cause the control module to go through a
If the factory defaults are acceptable, no additional programming shutdown/time delay/release sequence. The time delay cycle
is required. However, the factory program is only active if the man- will be whatever is programmed on switches No. 6 and 7
ual programming switch is disabled. If set to OFF, operation of the electric manual pull station will
cause the control module to activate will go to the shutdown and
Manual Programming Switch immediately operate the circuit
The manual programming switch is a PC board mounted, switch
package containing 7 switches. See Figure 48. To manually pro- Switch No. 4 and 5
gram the SC-N control module, each individualswitch must be set These two switches set the cycle time for time delay 1 (Alarm to
in the correct position. Shutdown)
. . _ Switch No. 4 ON / Switch No. 5 ON = 5 seconds
RS-232
SERIAL _ _ O Switch No. 4 OFF / Switch No. 5 ON = 10 seconds
CONNECTION Switch NO. 4 OFF / Switch No. 5 OFF = 30 seconds

INTERFACE
CABLE _ _ Switch NO.4 ON / Switch No. 5 OFF = 20 seconds
MANUAL INTERNAL Switch No. 6 and 7
PROGRAMMING
_ BATTERY
SWITCHES CONNECTION These two switches set the cycle time for time delay 2
(Shutdown to Release)
Switch No. 6 ON / Switch No. 7 ON = 0 seconds
![ ............. Switch No. 6 OFF / Switch No. 7 ON = 10 seconds
Switch No. 6 ON / Switch No. 7 OFF = 20 seconds
INSIDE
OF Switch NO. 6 OFF / Switch No. 7 OFF = 30 seconds
COVER =1__ After all switches have been set, the "RESET' button on the con-
trol module must be depressed. If this is not done, the switch set-
tings will not be entered into the program.
FIGURE 48
002795
NOTICE
Do not remove see-through cover on switch.
Switch position(s) can be moved by using a
blunt, not sharp, object. Do not damage switch
cover.
PROGRAMMING
9-1-98 Page 32
PCPROGRAMMING Inputs
PC programming is another means of setting up the SC-N Control The program inputs will be explained individually.
Module to the required options.
One advantage of using the PC programming approach versus
the manual programming switch feature is, with the PC, the mod-
ule can be programmed to have a shorter time delay period when
using the manual electric pull station than what is programmed
into the second time delay cycle of the detection circuit. When This input is to set the length of time for the time delays.
using the manual programming switch feature, the electric manu- Time Delay 1 (Alarm to Shutdown cycle): This time delay can be
al pull time delay will automatically correspond to the setting of the programmed for 5, 10, 20, or 30 seconds.
second time delay cycle of the detection circuit.
Time Delay 2 (Shutdown to Release cycle): This time delay can be
The control module is field programmed through a PC computer programmed for 0, 10, 20, or 30 seconds.
using an RS-232 serial interface cable. The interface cable kit is
available as Part No. 423524.
The internal 3.6 volt lithium battery must be installed in the
control module prior to programming.
EXPLAINING THE MENU

When programming the CHECKFIRE SC-N control module, only This input allows for the selection of initiating circuit No. 2 to be
one menu screen will appear on the computer. All programming used as either manual pull or pressure switch input.
will be done using this screen. Before starting to program, the If choosing manual pull, two options are available: Shutdown/Time
menu setups and control options will be explained. Delay/Release option or Shutdown/Immediate Release. If choos-
The following menu screen will appear when following the pro- ing the Shutdown/Time Delay/Release option, then the program
gramming steps: Note: The underlined letter or symbol represents will not allow selection of a time delay that is greater than the time
the key to press to initiate the action. Programmable settings are delay selected for time delay No. 2 in the detection set-up. If
shown as bold text. choosing the Shutdown/Immediate Release option, then no time
delay cycle is available.
If choosing the pressure switch input, no options are available.
When doing manual programming, the Manual Programming

switch must be Enabled
When doing PC programming, the Manual Programming switch

must be Disabled
Command Keys
Command keys are used to select the different inputs to be pro-
grammed and execute various computer operations. The com-
mand keys are explained individually.
The down arrow command key moves the cursor down to the next
input line. The input which the cursor is on will be highlighted.
The up arrow command key moves the cursor up to the input line
above where it presently is. The input which the cursor is on will
be highlighted.
The right arrow and left arrow command keys allow for the selec-
tion of available settings on a particular input line. Example:
Changing the number of seconds of each time delay cycle;
Changing the Manual Release Input from Manual Pull to Pressure
Switch.
PROGRAMMING
9-1-98 Page 33
EXPLAINING THE MENU (Continued) ;;;_, _..... __;_ _,_...... _ ..........

Commands
(Continued)
The T key is used to test the communications between the control
module and the computer. When this key is depressed, the pro-
..........
.....
,_o,, _o,_ gram will indicate the status between the module and the comput-
The U key is used to load the inputs from the menu screen to the er as either Successful communications or No communica-
control module. After all input selections have been made on the tions.
menu screen, depress the U key to install those inputs into the If the status is No communications, check the connection of the
controller memory. Wait for verification, and then depressany key. RS-232 serial interface cable and repeat the test.
Communications will not be established until the status line reads
"Successful
communications".
The
to theDmenu
key isscreen.
usedtoThis
download the used
is mainly inputsfromthe
to determinecontrolmodule
the settings
that are presently programmed in the control module. This will not The S key is used to change the user password. The program disc
change what is programmed in the controller, is factory programmed with a password of 111111. If a new pass-
word is desired, type S. The status will indicate: Enter new pass-
word:
The V key is used to determine the status of the control module Type in the new password and press Enter. The new password will
now be saved in the program.
inputs. By pressing the V key, the program will verify if what is
the
showncontrol module.
on the The status
menu screen isthe will
same indicate
as whateither verificationin
is programmed
pass or verification fail. If verification fail is indicated, download
setup from controller to determine what is presently programmed The X key is used to exit out of the program. By pressing the X
in the control module, key, the computer will close the program.
Programming
Note: The internal 3.6 VDC battery must be plugged in to the
The F key is used to view what the default settings are from the control module before programming. Also, before PC pro-
factory. By depressing this key, and viewing the settings, the rood- gramming, make certain the DIP Switch No, 1 is set to Disable
ule will not be changed from what is presently programmed. In (OFF).
order to change the module back to the factory default, after view- While programming, with the cover assembly removed from the
ing, depress the U key to upload the settings into the module, back box, it is normal for the sounder and the LED's to pulse once
every 10 seconds. This will stop when the programming is com-
pleted The
Note: andinternal
the computer andbeinternal
battery can battery without
disconnected is disconnected.
interfering
with the program in the module.
The history buffer datalog is a sequential listing of events that
have taken place over the life of the control module. The datalog Step No. 1 - Attach the RS-232 interface cable between the
will record events such as trouble, alarm, and programming. The computer and the CHECKFIRE SC-N control mod-
list of history events that have taken place will be displayed on the ule and turn on the computer.
screen. The history buffer will record approximately 50 events. If Step No. 2 - Insert programming disc in "A" disc drive and bring
more than 50 events take place, the oldest events will be erased up disc.
to make room for the most recent events.
Step No. 3 - Double click on the "A" drive icon.
The R key is used to download the events stored in the control
module to a file in the computer. To view the events, first, exit the Step No. 4 - On the next screen, double click on the "Setupsc"
menu screen by depressing X. The next screen will show three icon.
files, one being the datalog file. Double click on the datalog icon. Step No. 5 - The program screen will now ask for the password.
This will open the datalog file for viewing. Type in 111111 and depress Enter. The password
can be changed later by using the Security pass-
wordprogram
Step No. 6 - The change will
input.
ask for the correct communica-
The C key is used to clear all the history events recorded in the tion port to address. Not knowing the type of corn-
control module history buffer. After the C key is depressed, the puter being used, it is necessary to, by trial and
menu screen will indicate the datalog is cleared. From this point error, find the correct port. Type 1. If this is not the
on, all new events will start to be recorded, correct port, the program will respond with: Failure
to connect to comm port - Press 1 to retry or 2
to Exit.
PROGRAMMING
9-1-98 Page 34
EXPLAINING THE MENU (Continued) Step No. 13 - Depress the "RESET" button on the control rood-
Programming (Continued) ule.
Step No. 7- Press 1 and then select another comport (2,3,4). Step No. 14- At this point the programming is complete.
When the correct port is chosen, the program will Disconnect
the control the RS-232
Theserial interface cable from
module. module will continue to
respond momentarily with, "Reading Settings From
Controller," after which the main menu will appear pulse once every 10 seconds. Disconnecting the
internal module battery will silence the module.
on the screen. The internal programming will remain intact. The
module is now ready to be installed and wired.
Step No. 15 - if all programming is complete, the program can be
exited and the PC can be shutdown.
Step No. 8 - If the settings shown are acceptable, no additional

programming is necessary. Go to Step No. 13.
Step No. 9 - By the use of the up arrow key (1")or the down
arrow key ($), move to the Setup input requiring
change.
Step No. 10- To change an input, use the Change keys (< >).
By depressing either the (_-) key or the (--_) key,
the input which is highlighted will change. Each
time the key is depressed, a new selected input will
appear. For example, if the Detection Setup Time
Delay 1 is highlighted, and the number of seconds
indicated is 5, by depressing the (_) arrow once,
the time will change to 10. By continuing to
depress the (_) arrow, the time will change to 20,
30, and then back to 5. When the correct time is
reached, stop.
Step No. 11- Scroll to each Setup by using the Next ($) or
Previous (1") keys and make what ever changes
are necessary by using the Change (< >) keys.
Step No. 12 - After all inputs are selected, depress the U key.
This will upload the inputs shown on the menu
screen to the control module. The status will indi-
cate: Verification pass - hit any key. Then press
any key.
RELEASE CIRCUIT TEST MODULE INSTRUCTIONS
9-1-98 Page 35
O "P O
BATTER
Y
LOW
SQUIB/
I Osc
OFF SWITCH
0 0 0
PASS FAIL READY
k.._
FIGURE 49
003016
Operation is as follows:
1. The receptable on the tester mates with the connector on the
gas motor actuation cable, Part No. 416129, used with the
CHECKFIRE MP. A test adapter is provided for testing units
with squib actuator cables, Part No. 79062 or Part No.
422747.
2. A three-position slide switch is located on the side of the
enclosure to select the type of output to test (squib or gas
motor) and the third position is "OFF."
3. Steps for operation are:
a. With slide switch, select type of output to be tested. This
will also turn the unit on.
b. Press the reset button on the tester. This will illuminate the
"READY LED" if it is not already illuminated.
c. Connect to control unit actuator cable.
d. Proceed with activating output.

e. Once the unit activates, the unit tester will indicate a
"PASS" or "FAIL" status resulting from the test.
f. The tester can then be reset by pressing the RESET but-
ton, which will prepare it for the next test.
APPENDIX
9-1-98 Page 36
COMPONENT INDEX
Part Shipping Weight

No. Assembly Ib__, (kg)
Main Assemblies
423500 CHECKFIRE SC-N Electric Detection and Actuation 10 (4.5)
System Includes:
423504 Control Module (module contains nuts and
washers for mounting to bracket)
24479 Manual/Automatic Actuator
423525 Combined Mounting Bracket
79062 Squib Cable with Connector
6979 Nitrogen Cartridge, LT-5-R
25627 1/4 in. Check Valve
79064 Label Package
53081 Owner's Manual
423538 (Transport Canada) CHECKFIRE SC-N Electric Detection 10 (4.5)

and Actuation System includes:
(All of the standard shipping assembly components
except Nitrogen Cartridge, Part No. 6979, is replaced
with Nitrogen Cartridge, Part No. 423836.)
423520 Battery Shipping Assembly (3.6 VDC) 1/4 (.1)

54919 Squib 1/4 (.1)
426461 End of Line Resistor Assembly (Package of 10) 1/4 (. 1)
Accessory Equipment
423541 ReleaseCircuitTestModule 1 (.5)
423525 Combined Bracket Shipping Assembly - 1 (.5)
For mounting control module and actuator together
423528 Control Module MountingBracket- 1 (.5)
For mounting control module separately
419772 Actuator Mounting Bracket - 1 (.5)
For mounting actuator separately
423531 Control Module Retrofit Mounting Bracket- 1 (.5)
For mounting control module to existing
CHECKFIRE SC mounting bracket
79559 RemoteHighLevelAlarm 2 (.9)
71820 Splicing Device 1/4 (. 1)
71230 356 F (180 C) Linear Detection Wire, 100 Ft. (30.4 m) 5 (2.3)
71231 356 F (180 C) Linear Detection Wire, 500 Ft. (152.4 m) 10 (4.5)
416218 270 F (132 C) Spot Detector 1/4 (.1)

416219 325 F (163 C) Spot Detector 1/4 (.1)
416220 360 F (182 C) Spot Detector 1/4 (.1)
416213 Spot Detector Connector Package 1/4 (. 1)
416221 Spot Detector Bracket 1/4 (.1)
416762 Spot Detector Cable Clamp Package (For Use 1/4 (.1)
Without Protective Tubing)
416214 Spot Detector Cable Clamp Package (For Use 1/4 (.1)
With Protective Tubing)
416215 Flex Non-Metallic Tubing 100 Ft. (30.4 m) 4 (1.8)
(For Spot Detectors)
416784 Crimp Tool (For Spot Detector) 1 (.5)
416113 Pneumatic/Linear Detector, 35 Ft. (10.7 m) 1 (.5)

(Model 808-DRV)
416216 Cable Assembly, 15 ft. (4.6 m) (For Pneumatic/ 1/4 (.1)
Linear Detector)
416378 Mounting Clips Package For Pneumatic/Linear 1/4 (.1)
Detector Sensing Element (Includes 100 Clips)
417055 Wire, 200 C, 18 AWG-2 W/Shield and Drain Wire 10 (4.5)
500 ft. (152 m)
APPENDIX
9-1-98 Page 37
COMPONENT INDEX (Continued)

Accessory Equipment (Continued)
Part Shipping Weight
No. Assembly Ib__._. (kg)
56691 NylonCableTie (Packageof 20) 1 (.5)

56692 Rubber Sleeve (Package of 20) 2 (.9)
422747 Squib Cable with Connector - 15 ft. (4.6 m) 1 (.5)
419780 PowerWiring Assembly- 15 ft. (4.6 m) 1 (.5)

(Connector on one end)
419781 Power Wiring Assembly - 15 ft. (4.6 m) 1 (.5)
(Connector on both ends)
419782 Power Wiring Assembly - 10 ft. (3.1 m) 1 (.5)
(Connector on both ends)
419783 BatteryConnection(Fused at 5 amp) 1 (.5)
423524 RS-232 PC Interface Cable Kit 1/4 (.1)
426601 Extender Cable Assembly 1/4 (.1)
426604 Battery Extender Cable Assembly 1/4 (.1)
RECHARGE EQUIPMENT
54919 Squib 1/4 (.1)
6979 LT-5-R Cartridge 2 (.9)
423520 Battery ShippingAssembly (3.6 VDC) 1/4 (.1)
423522 Installation, Maintenance, Recharge Manual 1/4 (.1)
APPENDIX
9-1-98 Page 38
DETECTION WIRE FLUID RESISTANCE CAPABILITY
Resistance Rating Key:

G = GOOD
L = LIMITED
C = CONDITIONAL (Service conditions must be outlined to
Ansul for approval of wire suitability for
applications.)
U = UNACCEPTABLE (Not to be used)
Agent Rating Agent Rating Agent Rating

Acetate
Solvents,
Crude U Diesel
Oil,Light L Naphtha C
Acetate Solvents,
Pure U Ethers U Naphthalene U
AceticAcid,Dilute(20%) U EthylAcetate U NickelChloride G
AceticAcid,Glacial U EthylAlcohol C NickelSulfate G
Acetone U EthylChloride U Nitric Acid, 10% L
Air G Ethylene Dichloride U Nitric Acid, 70% U
Alcohols C Ethylene Glycol L Nitrobenzene U
Aluminum Chloride G Oleic Acid C
Aluminum Fluoride G FerricChloride G
Aluminum Sulfate G FerricSulfate G Oleum Spirits U
AmmoniaLiquid(Anhydrous) U FerrousSalt Solutions G Perchlorethylene C
Ammonia, Chloride G Formaldehyde L PicricAcid,Molten U
Ammonium Hydroxide L Formic Acid L PicricAcid,Solution U
Ammonium Nitrate G FuelOil L Potassium Chloride G
Ammonium Phosphate G Furfural U Potassium Cyanide G
Ammonium Sulfate G Gasoline C Potassium Hydroxide C
PotassiumSulfate G
AmylAcetate U Glycerine,Glycerol L
Amyl Alcohol L Grease, Petro L Soda Ash Sodium Carbonate G
Asphalt C Sodium Bisulfate G
Heptane C Sodium Chloride G
Barium Chloride G Hexane L
Sodium Cyanide G
Barium Hydroxide G Hydraulic Fluids & Lubricating Oils,
BariumSulfide G StraightPetroleum Base L SodiumHydroxide C
Benzene,Benzol C Waterand PetroleumOil SodiumHypochorite C
SodiumNitrate G
Benzene (Petroleum Ether) C Emulsion (FR) L
Benzene(PetroleumNaphtha) C Waterand GlycolSolution L SodiumPeroxide C
Borax L StraightPhosphate-Ester (FR) L SodiumPhosphate G
Boric Acid L Silicone Oils L SodiumSilicate G
SodiumSulfate G
Bromine U Hydrobromic Acid U
ButylAcetate U Hydrochloric Acid,Cold C SodiumSulfide C
Butyl Alcohol, Butanol L Hydrochloric Acid, Hot U Sodium Thiosulfate, "Hypo" G
Calcium Bisulfite L Hydrocyanic Acid C Soybean Oil L
CalciumChloride G HydrofluoricAcid,Cold C StannicChloride G
CalciumHydroxide G HydrofluoricAcid,Hot C StearicAcid L
CalciumHypochlorite L HydrogenPeroxide(Dilute) G SulfurDioxide C
CarbolicAcid Phenol C HydrogenPeroxide(Concentrated) C SulfurTrioxide C
Carbon Dioxide G Hydrogen Sulfide C Sulfuric Acid, 10%,
10%, Hot
Cold L
SulfuricAcid, L
CarbonDisulfide U Kerosene L Sulfuric
Acid,75%,Cold L
CarbonMonoxide,Hot U
CarbonTetrachloride L LacquerSolvents U SulfuricAcid,75%,Hot L
Carbonic
Acid G LacticAcid C SulfuricAcid,95%,Cold U
Castor
Oil C LinseedOil L Sulfuric
SulfuricAcid, 9
Acid, 5%,Hot U
Fuming U
Chlorinated Solvents C Magnesium Chloride G Sulfurous Acid L
Chlorine,Dry U Magnesium Hydroxide G
Chlorine,Wet U Magnesium Sulfate G Tannic Acid G
Chloroacetic Acid U Mercuric Chloride U TartaricAcid G
Chloroform U Mercury L Toluene U
Chlorosulphonic Acid U MethylAlcohol,Methanol L Trichloroethylene U
Chromic Acid U Methyl Chloride U Turpentine L
CitricAcid L Methyl Ethyl Ketone U Varnish U
Copper Chloride G Methyl IsopropyI-Keytone U
Copper (11)
Sulfate G Mineral Oil L Xylene U
Creosote U ZincChloride L
ZincSulfate G
APPENDIX
9-1-98 Page 39
WARRANTY
The components of the Ansul CHECKFIRE SC-N Electric

Detection and Actuation System supplied by Ansul Incorporated,
("ANSUL") are warranted to you as the original purchaser for one
year from the date of delivery against defects in workmanship and
material. ANSUL will replace or repair any Ansul-supplied compo-
nent which, in its opinion, is defective and has not been tampered
with or subjected to misuse, abuse, exposed to highly corrosive
conditions or extreme high temperatures provided that written
notice of the alleged defect shall have been given to ANSUL with-
in 30 days after discovery thereof and priorto the expiration of one
year after delivery, and further provided that if ANSUL so instructs,
such article or part thereof is promptly returned to ANSUL with
shipping charges prepaid.
Disclaimer of Liability and Limitation of Damage

The above warranty is the only one given by ANSUL concerning
this system and only to Ansul CHECKFIRE SC-N Electric
Detection and Actuation System that has been installed and main-
tained in accordance with all the directions and requirements pro-
vided by ANSUL in the manual created for the Electric Detection
and Actuation System. THIS WARRANTY IS IN LIEU OF ALL
OTHER WARRANTIES WHETHER EXPRESS OR IMPLIED,
INCLUDING BUT NOT LIMITED TO FITNESS FOR PURPOSE
AND MERCHANTABILITY, AND ANSUL DOES NOT ASSUME,
OR AUTHORIZE ANY OTHER PERSON TO ASSUME FOR IT,
ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OF
ITS PRODUCTS. ANSUL SHALL NOT BE LIABLE FOR CONSE-
QUENTIAL OR SIMILAR DAMAGES.
For repairs, parts and service of the Ansul System, contact your
local Ansul representative, or Ansul Incorporated, Marinette, WI
54143-2542; 800-TO-ANSUL (800-862-6785).
SAGEFlow Monitor
Meeting Demands, Exceeding Expectations.
The SAGE Desigls Flow Monqor +s quality engineered

for the rigorous requiremeqts of aircraft de--icit_g opemtiorls.
SAGE's advanced technology anti innovative deslg+= a:+;suae
unnlatciled performance, reiiabitity and safety. Wha1_ more.
special options are available to meet sp(:cdic de-icing needs,
L_Jm___
-+ib,-- ill i,__.
Im
- +Vmnu, n _ m=
FLOW MONITOR
Sage Design Corporation

65A Mall Drive
Commack, N.Y. 11725
(631) 499 4111 Pn. (631)499 1888 Fax
Models SFM 3 and 4

SAGE FLOW MONITOR CONTENTS
._
Paragraph Pa_e
v
Introduction I-1
Section
I Installation 1-1
1.1 Connecting the Flow Monitor to a Power Supply 1-I
1.1.1 Connecting Power to a Flow Monitor that has a Power Switch 1-1
1.1.2 Connecting Power to a Flow Monitor that has No Power Switch 1-2
1.2 Connecting Flow Senders and Temperature Sensor 1-4
1.3 Mounting theFlowMeter 1-4
1.3.1 SideMountInstallation 1-5
1.3.2 PedestalMountInstallation 1-7
1.4 TestforProperInstallation 1-8
1.4.1 PowerOnCheck 1-8
1.4.2 Display Check 1-8
1.4.3 Keypadand ShiftKeyCheck 1-10
1.4.4 Printer Check 1-11
1.5 Initial
Setup 1-12
1.5.1 Passwords 1-12
1.5.2 SettingtheTimeand Date 1-13
_._ 1.5.3 ClearingJobsinMemory 1-14
1.5.4 EnterDeicer(TruckID)Number 1-15
1.5.5 SettingUnits(gallonsor liters) 1-16
1.5.6 SettingDateFormat 1-16
1.5.7 Calibrating
Senders 1-16
Section 2. Operation 2-1

2.1 General Instructions 2-1
2.2 Operating
Modes 2-2
2.2.1 Mode1StartNewJob 2-3
2.2.2 Mode2ViewFlowrates 2-4
2.2.3 Mode3Review Jobs 2-5
2.2.4 Mode4 ViewTotalVolume 2-5
2.2.5 Mode5ViewTime&Date 2-5
2.2.6 Mode6PrinterTest 2-5
2.2.7 Mode7PrintOptions 2-5
2.2.8 Mode 8 Unit Mod & S/N 2-6
TOC-1
SAGEFLOW MONITOR CONTENTS
Paragraph
v
Pa_e
2.2.9 Mode9 SetupMenu 2-6

2.2.9.1 Reset Time Menu 2-6
2.2.9.2 Reset Date Menu 2-6
2.2.9.3 Clear Job History Menu 2-7
2.2.9.4 Truck ID # Menu 2-7
2.2.9.5 Setup #2 Menu 2-7
2.2.9.5.1Units 2-7
2.2.9.5.2DateFormat 2-7
2.2.9.5.3 Calibrate Type 1 (or Type 2 or Type 4) 2-7
2.2.9.5.4Resetto Defaults 2-8
2.2.9.6PasswordSelectMenu 2-8
2.2.9.7 Return To Main Menu 2-8
2.2.10Mode0Password Select 2-8
Section3. Maintenance 3-1

3.1 Battery Replacement 3-1
3.1 Printer Supplies 3-1
,,,,.- Section 4. Specifications 4-1
APPENDIX Battery Replacement Procedure
TABLES
2-1 Operating Modes 2-2
FIGURES
1-1 Power Connection For Flow Monitor With Power Switch 1-3
1-2 Power Connection For Flow Monitor Without Power Switch 1-3
1-3 Location of Connectors at Rear of Flow Monitor 1-4
1-4 Location of Mounting Bolts and Power Cord at Side of Flow Monitor 1-5
1-5 Full Size Pattern for Side Mounting Holes 1-6
1-6 Pedestal Mounting 1-7
1-7 Power-On Troubleshooting 1-9
1-8 Sample Printer Test Printout 1-11
2-1 Display
oftheMainMenu 2-1
3-1 Printer Cover in Down Position 3-1

3-2 PrinterwithCoverRemoved 3-2
3-3 Paper Roll Being Installed in Printer 3-3
TOC-2
SAGE FLOW MONITOR INTRODUCTION
"-"_ PURPOSE
The Sage Flow Monitor measures pulses received from a flow sender installed in a pipe through
which deicing fluid is flowing. It converts those pulses into the volume of fluid dispensed. Some
models also measure voltage received from a temperature sensor, and convert the voltage to tem-
perature.
CAPABILITIES
The operator can assign a job number (or Aircraft Code) to a volume measurement and the Flow
Monitor will store information about the job for later review or printout.
Job Storage: The Flow Monitor will store in its memory the following job information.
job number deicing truck number operator number

start date enddate start time
end time volume of fluid pumped average Type 1 temperature
Job Records: If the Flow Monitor is equipped with a printer, the operator can print out
the above job information as a permanent record.
Number of Jobs: Depending on the model, the Flow Monitor can store in its memory from
1 to 100 jobs for review or printout at any time in the future.
_,._ Senders/Sensors: Depending on the model, the Flow Monitor can monitor one or two flow
senders (Type 1, Type 2, or Type 4 fluid) and an RTD temperature sensor. It can calibrate
each sender and sensor, and store a correction factor for each unit in its memory.
Password Protection: The Flow Monitor has two levels of password protection, one for an
operator and one for a supervisor. It will only accept certain information after a valid
password has been entered. The parameters that may be altered by the user depends on the
level of password protection.
OPERATOR INTERFACE
The operator enters information and commands using a keypad, receives messages on a display, and
if the Flow Monitor is equipped with a printer, receives printed copies of job histories.
Display: The display provides the user with all of the information needed to operate the
Flow Monitor, and with information about the current and past jobs.
Keyboard: The telephone-style keypad allows the the operator to send commands to the
Flow Monitor and to enter information into the Flow Monitor's memory.
Printer: The printer can print a permanent record of any job or range of jobs stored in the
Flow Monitor's memory.
MAINTENANCE
",-,." Because the Flow Monitor is a solid state device, no maintenance is required except for replacement
of the printer paper and ribbon, and the replacement of the battery every 3 to 5 years.
I-1
SAGE FLOW MONITOR INSTALLATION
1. INSTALLATION
Installation consists of connecting the Flow Monitor to a power source, connecting the senders and
sensor to the Flow Monitor, mounting the Flow Monitor, testing the unit for proper operation after
it has been installed, and performing an initial setup.
1.1 CONNECTING THE FLOW MONITOR TO A POWER SUPPLY.

Some Flow Monitors come with a power switch installed on the front panel, others do not have a
power switch. Refer to the proper procedure below.
1.1.1 Flow Monitors with a power switch

1.1.2 Flow Monitors without a power switch
1.1.1 Connecting Power to a Flow Monitor that has a Power Switch (See Figure 1-1).
The Flow Monitor operates on 12 volts dc, and should be connected to the battery of the deicing
truck in which the Flow Monitor will be installed.
1. Position the Flow Monitor power switch to OFF.
NOTES
The power cable referred to in the next step is supplied with the Flow Monitor. It is
a 10 foot cable with a connector at one end. The positive wire in the cable has red
insulation; the negative wire has black insulation.
If the ignition switch is not bypassed in the following step, the Flow Monitor will
not have power when the truck's ignition is turned off.
2. Connect the red wire of the power cable to the positive side of the truck battery, at a point
before the ignition switch.
3. Connect the black wire of the power cable to the truck's ground.
CAUTION
Failure to verify the correct polarity in the next step can result in damage to the
Flow Monitor.
4. Using a multimeter, verify that 12 volts dc appears across the connector terminals at the end of
the power cable, and that the polarity is correct.
5. Attach the female connector on the end of the power cable to the male connector at the rear of
the Flow Monitor (see Figure 1-3).
1-1
1.1.2 Connecting Power to a Flow Monitor that has No Power Switch (See Figure 1-2).
The Flow Monitor operates on 12 volts dc, and should be connected to a power source in the
deicing truck in which the Flow Monitor will be installed.
NOTES
The power cable referred to in the next step is supplied with the Flow Monitor. It
has a connector at one end. The positive wire in the cable has red insulation; the
negative wire has brown insulation.
The connector on the power cable mates with a connector on a power cord that
extends from a hole in the Flow Monitor.
If the Flow Monitor is side-mounted, the power cord that extends from the Flow
Monitor needs to pass through a hole in the mounting surface in order to mate with
the power cable. It will be necessary to drill a hole in the mounting surface large
enough for the cable and connector to pass through.
1. If a mounting hole is required, see paragraph 1.3. You will have to attach the Flow Monitor to the
mounting surface before you connect it to the power source.
NOTE
In the next step, if there is no power source assigned for the Flow Monitor, then use
the truck's battery. If the truck battery is used, the Flow Monitor will be on when-
ever the truck's ignition is turned on.
2. Connect the red wire of the power cable to the positive side of the power supply.
a. If the truck battery is being used, connect the cable to a point after the ignition switch,
so that power is applied to the Flow Meter only when the truck's ignition is turned on.
3. Connect the brown wire of the power cable to the negative side of the power supply.
CAUTION
Failure to verify the correct polarity in the next step can result in damage to the
Flow Monitor.
4. Using a multimeter, verify that 12 volts dc appears across the connector terminals at the end of
the power cable, and that the polarity is correct.
5. Attach the connector on the end of the power cable to the connector at the end of the power
cord that extends from the side of the Flow Monitor. (see Figure 1-2).
a. If the Flow Monitor is side mounted, push the power cord through the hole in the mount-
ing surface before you connect the power cable to the power cord.
1-2
Ignition Switch
On
TruckBattery
1 Off
Black RedWire
Power Cable / Flow Monitor

With Connector With
(connected at rear of Flow Meter) Power Switch
Figure 1-1 Power Connection For Flow Monitor With Power Switch
Ignition Switch
or
Power Supply Switch
o./_._ On ,
AssignedPowerSupply __ __j(/
TrUCkorBattery [ _d Wire / Mounting Surface
Brow
Power Cable / / 4
With Connector Power Cord
With Connector Side-Mounted
Flow Monitor
Without
Power Switch
Figure 1- 2 Power Connection For Flow Monitor Without Power Switch
1-3
1.2. CONNECTING FLOW SENDERS AND TEMPERATURE SENSOR (SEE FIGURE 1-3).
NOTES
Depending on the Flow Monitor model, there may be more than one connector at the
rear of the Flow Monitor. The Flow Monitor may have a connector for one or two
flow senders. Some Flow Monitors have a connector for a temperature sensor.
Although Figure 1-3 shows a connector for power, not all Flow Monitors will have
this connector.
The connector shells of the flow senders and the temperature sensor are all the same.
However, each type has a different pin configuration as noted below.
1. While viewing the Flow Monitor from the rear, attach the male connector on the end of each
sender/sensor cable to the mating female connector at the rear of the Flow Monitor as follows:
a. Attach the Type 1 Fluid Flow Sender (3 pins) to the bottom left connector.
b. Attach the Type 2 or Type 4 Fluid Flow Sender (5 pins) to the bottom right connector.
c. Attach the RTD Temperature Sensor (4 pins) to the top right connector.
Note: Depend-
ing on the Flow
Monitor model,
any combina- _Pwer Connector
tionofthese
connectors may / Temperature Sensor
bepresent
Type 1 Sender Type 2 or Type 4 Sender
Figure 1-3 Location of Connectors ar Rear of Flow Monitor
1.3 MOUNTING THE FLOW MONITOR
The Flow Monitor can be permanently installed in a truck. Depending on the model ordered, the
Flow Monitor can be mounted using bolts attached to the side of the Monitor, or on a pedestal
using a pipe attached to the bottom of the Monitor. Refer to the proper procedure below.
Side Mount: Paragraph 1.3.1

Pedestal Mount: Paragraph 1.3.2
1-4
1.3.1 SIDE MOUNT INSTALLATION (SEE FIGURE 1-4)
1. The Flow Monitor has three mounting studs permanently attached to its left side.
a. Drill holes in the mounting surface for these studs in accordance with Figure 1-4. A full
size pattern is provided. See Figure 1-5
b. If a power cord extends through the side of the Flow Monitor, also drill a hole in the
mounting surface to accomodate the power cord and its connector.
2. Before attaching the Flow Monitor to the mounting surface:
a. Install the supplied grommet into the hole for the power cord.
b. Push the power cord through the hole in the mounting surface and connect it to the
Power Cable (See Figure 1-2).
c. Connect the flow senders and temperature sensor to the rear of the Flow Monitor, or make
sure they can be connected after the Flow Monitor is mounted (see Paragraph 1.2).
3. Position the Flow Monitor mounting studs into the mating holes, and secure with bolts and
"*--'_ washers suppled.
Note: Some Flow
have a wire for

external
C)_ Meterswill
location. See
() paragraph
powerin this
oq : I
o _ | 1.1.2
]
--3.1"
2.1"
...._ Figure 1-4 Location of Mounting Bolts and Power Cord at Side of Flow Monitor
1-5
i
7/8 Diameter = 2.2 cm

-- . cm
GI ._,,i _,I
_ N]
"__ 1.Toaccount forirregulari-
_. _ tiesin the printing/
Measure the dimensions

O onthispatterntoensure
_ _ b b duplicatingprocess,
theholesarelocated
::
O properly. Make any
necessary corrections.
0
o 2. Attach the marked-up

_ patternto the mounting
u _ surface and drill the four
u
_ _ holes.
tt_
..___ 2.1 inches __p,

5.3 cm
3.1 inches
7.9 cm
Bottom of Flow Monitor

Figure 1-5 Full Size Pattern for Side Mounting Holes 1-6
1.3.2 PEDESTAL MOUNT INSTALLATION
NOTES
The following steps require a pipe with an outside diameter of 2 inches.
The Flow Monitor comes provided with a flange installed at its base, for connecting
to a vertical pipe. Also provided is a two foot long pipe, two inches in diameter; and
a flange for mounting the pipe to a mounting surface.
1. Determine approximately how high from the mounting surface the Flow Monitor's Display
should be.
2 Subtract about 9 inches, and this will give the length of the pipe from the bottom of the Flow
Monitor to the mounting surface.
3. Add any additional length needed for mounting the pipe to the mounting surface; for example, if
the pipe will extend through a hole in the mounting surface, determine how far it needs to
extend.
4. Cut the pipe to the required length.
_.,, 5. Mount the pipe to it's mounting surface using the supplied flange.
6. Before attaching the Flow Monitor to the pipe, either connect the power cable and the sensors to
the rear of the Flow Monitor, or make sure the cable and sensors can be connected after the Flow
Monitor is mounted.
7. Slip the Flow Monitor flange over the pipe.
8. Rotate the Flow Monitor so it faces in the proper direction.
9. Tighten the screw in the Flow Monitor's flange.
FlowMo
-- itor
Flange with tightening screw /Pipe
Figure 1-6 Pedestal Mounting

1-7
_" 1.4 TEST FOR PROPER INSTALLATION

This paragraph verifies that when power is applied to the Flow Monitor, the Display functions,
verifies that each key on the Keypad is working, and tests the Printer operation.
1.4.1 Power-On Check

Apply power to the Flow Monitor as follows:
NOTE
When power is applied to the Flow Monitor, the display will show the time and
date.
When a Flow Monitor is being installed for the first time, the time and date will be
incorrect. The correct values will be entered after the installation tests are com-
pleted, using the Initial Setup procedure in Paragraph 1.5
1. If there is a power switch on the Flow Monitor front panel:
a. Position the Power Switch to ON and verify that the Display lights up.
b. If the Display is lit, go to 1.4.2 to check the Display.
c. If the Display is dark, perform the troubleshooting checks in Figure 1-7.
2. If there is no power switch on the Flow Monitor, then:
a. If there is a power switch for the Flow Monitor's power source, set the switch to ON, or,
if the Flow Monitor is connected to the truck battery, turn on the truck's ignition.
b. If the Display is lit, go to 1.4.2 to check the Display
c. If the Display is dark, perform the troubleshooting checks in Figure 1-7.
1.4.2 Display Check
Verify the Display can be scrolled to show all the operating modes of the Flow Monitor as follows.
1. Press the _ key and verify that the top line of the display reads Main Menu.
2. Press the _ key a number of times, and verify that each time it is pressed, the display scrolls
down, one menu item at a time, through the 10 menu items (items 1 to 9, followed by item 0).
3. Press the _ key a number of times, and verify that each time it is pressed, the display scrolls
_'_ back up, one item at a time, through the 10 menu items.
1-8
Does Flow Monitor have a power switch?
Yes [ No
Is IgnitionSwitchOn? /
No [ Yes
TurnOff
(or ignition).
Power Source _
[ Turn On Ignition. _. Note _-"
separate power
supply or the
Does Display Light? truck battery.
I
Power Cable is Does Display Light?
0
Wired to the
wrong
sideof No Yes
Ignition
Switch. [ 1
See1.1.1 _ b Power_Cable is
Turn On Power Source _ Wired to the
__ PowerSwitch.
(or ignition). _ wrong side of
See 1.1.2
Check Voltage at end of_ g//.
Power Cable Connector
Is 12 vdc present with

proper polarity?
Yes I No
Flow Monitor is Defective Power Cable is Defective
,,_ Contact Sage Design Corp Contact Sage Design Corp
Figure 1-7 Power- On Troubleshooting 1-9

1.4.3 Keypad and Shift Key Check

Verify that every key on the keypad works as follows:
1. Scroll the display so that the Start New Job Menu is shown.
2. Press _ and verify that the Display reads Enter Operator Code.
3. Press [-_[-_]_-_]_-_1[-[-_and verify that the Display reads 1234546.
4. Press _] and verify that the Display reads 0.
5. Press [-_]_1_-_1_] and verify that the Display reads 7890.
6. Press [(_]and verify that the Display requests the Aircraft Code.
7. While holding the SHIFT KEY down, press [-_[--_][-_]_-_][-_]_-_1_]_] and verify that the Display
reads ABC.
8. Press _] twice until the time and date display appears.
1-10
1.4.4. Printer Check

If the Flow Monitor is equipped with a printer, check the printer operation as follows:
NOTE
The printer comes with paper and ribbon installed. See Section 3, Maintenance, for
instructions on replacing the paper and ribbon.
1. Press the PAPER FEED button on the Flow Meter and verify that the printer motor runs while
the button is depressed.
a. If the printer motor does not run, the printer is defective.

b. If paper does not feed through the front slot, install a roll of paper (see paragraph 3-2).
2. Scroll the display, by repeatedly pressing the [-_ key, until Printer Test appears.
3. Press _] and verify the display reads Printer Ready For Print Demo.
4. Press _ and verify the display reads as follows:

Line Feed: 1
Demo Message: 2
5. Press _ and verify the printer motor runs briefly and a small amount of paper ( about 1/8 inch)
is fed through the paper slot.
6. Press _ and verify the printer produces a message similar to figure 1-8. If the paper is blank,
verify that a printer ribbon is installed (See Chapter 3).
7. Press _ to return to the time and date display.
*START OF DEMO PRINT*

Flow Monitoring System
Model #SFM-3
Serial No. 1234
Release No. 1234-5
MFG BY SAGE CORP
Current Time: 12:12:12
Current Date: 01/01/97 _,,-.-_
**END OF DEMO PRINT**
V/X
Figure 1-8 Sample Printer Test Printout

1-11
_" 1.5 Initial Setup

Before the Flow Monitor can be used, it must be initialized to show the correct time and date, to
clear factory and test data, to set the format for measurements in gallons or liters, and to calibrate
the flow senders. Before this can be accomplished, the supervisor's password must be entered.
1.5.1 Passwords.
This procedure sets the supervisors and operators passwords. These passwords are needed to
perform the initial setup functions. The passwords can be changed at any time.
Note
The Level 1 password provides access to some of the Flow Meter functions, while
the Level 2 password provides access to all of the Flow Meter functions. The proce-
dures in this section should be performed by a supervisor, who will enter both
passwords and perform the setup procedures.
Caution
Do not lose these passwords. Once a password is entered, the same password will be
required to reenter the setup function in order to change certain setup parameters.
1. Scroll the display, by repeatedly pressing the _ key, until Setup Menu appears.
2. Press _ and verify the display reads No Password Has Yet Been Selected.
Note
As you key in each number in the following step, the Display will show an *. After
all 6 numbers have been entered, the display will read Verify Level 1 Password.
3. Press _] and key in any combination of 6 numbers to be used by the operator as the Level 1
password.
Note
If the previously entered number is not reentered in the next step, the Flow Monitor
will reject the password and the only option will be to press _ to return to the
main menu.
4. Reenter the six digit number and verify that the Display reads Level 1 Password ! Verified !.
6. Scroll the display, by repeatedly pressing the [-_ key, until Setup Menu appears.
_" 7. Press _ and verify the display reads Enter 6 Digit Level 1 Password.
1-12
Note
If the correct number is not entered in the next step, the Flow Monitor will reject
the password and the only option will be to press _-_ to return to the main menu.
8. Key in the Level 1 password that was previously entered.
9. When the Display reads Setup Menu, press _] to scroll the Display until Setup Menu #2
appears.
10. Press _].
Note
As you key in each number in the following step, the Display will show an *. After
all 6 numbers have been entered, the Display will read Verify Level 2 Password.
11. When the Display reads No Password Has Yet Been Selected, press, press _ and key
in any combination of 6 numbers to be used by the supervisor as the level 2 password.
Note
If the previously entered number is not reentered in the next step, the Flow Monitor
_,,,,_ will reject the password and the only option will be to press _ to return to the
main menu.
12. Reenter the six digit number and verify the Display reads Level 2 Password ! Verified !.
1.5.2 Setting the Time and Date

This procedure sets the Flow Meter to display the correct time and date.
1. Enter the Setup Menu Mode (same as 1.5.1 steps 6, 7, 8).
2. Scroll the Display, by repeatedly pressing the _ key, until Setup Menu appears.
3. When the Display reads Setup Menu, press [-_ to reset the time.
Notes
The Flow Monitor uses 24 hour time.
In the following step, if an invalid time is entered, the Flow Monitor will not accept
the time; nothing will happen.
Press _ to clear the incorrect entry and key in the correct time.
1-13
_m_' 4. Enter the current time by pressing the correct hour, minutes, and seconds.
a. For hours from 1 am to 9 am, enter the hour as 01, 02 ..... 09.
b. For hours from 1 pm to midnight, enter the hour as 13, 14....... 24.
c. Set the minutes and seconds slightly ahead of the current time so that the resetting of the
Flow Monitor's timekkeping can by synchonized with an accurate watch.
d. When ready to reset the time, press [-_.
e. Press [-_ to accept the new time. You will be returned to the Time and Date display.
5. Enter the Setup Menu Mode (same as 1.5.1 steps 6, 7, 8).
6. When the Display reads Setup Menu, press [-_ to reset the date
Note
If an invalid date is entered, the Flow Monitor will not accept the date. The entry
will be cleared so that you can key in a valid date.
7. Enter the current date by pressing the correct month, day, and year.
a. For months and days from 1 am to 9, enter the month or day as 01, 02 ..... 09.
b. For years, enter the last two digits. Enter 1998 as 98, enter 2001 as 01.
c. Press _-_ and verify that the date on the top line of the Display is correct.
(1) If the date is not correct, key in a new date and repeat step 7.
(2) Ifthedat_ _scDzxect:,p ____[-_] to return to the date and time display.
1.5.3 Clearing Jobs In Memory.

This procedure clears all jobs in memory, including data that may have been entered at the factory.
Caution
Failure to set the Flow Monitor to the correct date and time before performing this
procedure will cause the information for the View Total Volume menu (paragaph
2.2.4) to always display the incorrect date and time.
1. Verify that the Flow Monitor displays the correct date and time. If it does not, perform procedure
1.5.2.
1-14
2. Enter the Setup Menu mode (See 1.5.1 steps 6, 7, 8).
3. Press _[] so that the Display shows the Clear Job History menu, then press [-_.
Caution
Perform the following steps even if the Flow Monitor displays a message that there are no
jobs in memory. This is necessary to ensure that the Flow Monitor recognizes the current
date and time as the last time that memory was cleared.
4. Press [-_, and then press _ to delete all jobs in memory.
1.5.4 Enter Deicer (TrucklD) Number.

2. Press _] so that the Display shows the Truck I.D. # menu, then press [_]
Note
The Truck I.D. Number is a 6 character identifier that can be any combination of
characters and numbers (alphanumeric).
Pressing a key on the Keypad causes that key's number to appear on the Display.
Keys 1 through 9 each have 2 or 3 characters printed on the keys. You can cycle
through the characters on a key by holding down the shift key and repeatedly
pressing the Keypad key. Each time the Keypad key is pressed the next character
appears on the Display.
3. Enter a 6 character Identification number as follows:
a. Enter a number or letter or a space by pressing the appropriate key.
1) if the character is a number, press the desired key.
2) If the character is a letter, hold down the shift key and press the appropriate key
until the desired letter appears.
3) If the character is a space, press the _ key
b. When the correct character is displayed, press the [-_ key to move to the next character.
c. Repeat step a. and b. until all 6 characters are entered.
1-15
4. When the display shows that the deicer number has been entered, press [-_ to return to the time
and date display.
1.5.5 Setting Units (gallons or liters)

This procedure allows the operator to designate whether the Flow Monitor will display volume
measurements in U.S. gallons or liters.
2. When the Display reads Setup Menu, scroll to Setup Menu #2 and press [-_.
3. Enter the Level 2 password.
4. When the Display reads Setup Menu #2, press [--[-[-_.
5. When the Display reads !Select Scale! select the desired scale.
6. When the Display shows which units have been entered, press _-_ to return to the time and date
display.
_m,,,_ 1.5.6 Setting Date Format

This procedure allows the operator to designate whether the Flow Monitor will display dates in
mm/dd/yy format or in dd/mm/yy format.
2. When the Display reads Setup Menu, scroll to Setup Menu #2 and press _.
3. Enter the Level 2 password.
4. When the Display reads Setup Menu #2, press [-_.
5. When the Display reads Select Date Format select the desired format.
6. When the Display shows which format has been entered, press [-_ to return to the time and date
display.
1.5.7 Calibrating Senders

This procedure calibrates the flow senders. Refer to Operating Modes, paragraph 2.2.9.5.3, for the
procedure.
1-16
SAGE FLOW MONITOR OPERATION
2. OPERATION
Operation of the Flow Monitor consists of using the Keypad to enter data and commands for the
Flow Monitor, viewing information on the Display, and, if a Printer is present, printing reports.
2.1 GENERAL INSTRUCTIONS

All of the operator's instructions to the Flow Monitor are made using the Keypad. The Display
provides information to the operator so that the Flow Monitor can be used with little or no need to
refer to printed procedures.
When power is applied to the Flow Monitor, the Display shows the current date and time and gives
the operator the option to proceed to the main menu by pressing the _] key. Figure 2-1 shows the
Main Menu display.
_, Figure 2-1 Display of the Main Menu

2.1.1. Interpreting The Display
a. The top line of the Display tells the operator that this is the main menu, The second line
tells the operator which keys to press to scroll the display up or down, and the third and
fourth lines show the names and numbers of two Flow Monitor modes.
b. In figure 2-1, the following keys cause the following actions:
causes the display to scroll down one line. Mode 1 will disappear from the display
and the last two lines will show the names and numbers of modes 2 and 3.
[-_ causes the display to scroll up one line. When the Main Menu is at the top of the list
of modes, the _] key will have no effect until the display is scrolled down.
[-_ causes the Flow Monitor to display the Instructions for Mode 1, Start New Job.
[-_ causes the Flow Monitor to display the current flow rates that are being measured
o by the sensors, under Mode 2, View Flow Rates.
c. If a key is pressed that is not shown on the Display (for example, an attempt to view
mode 3 by pressing the _] key), the Flow Monitor will not accept the entry. The Display
will momentarily show the words Unassigned Key Depressed, and will return to
thecurrentdisplay. 2-1
2. OPERATING MODES
To access a mode, first scroll the Display until the mode name and number appears,
then press the mode number on the Keypad. The mode number must show on the
Display before it is entered on the Keypad, otherwise the Display will momentarily
read UnassignedKeyDepressed.
Table 2-1 Operating Modes

|
NO MODE NAME DESCRIPTION

I I I I
1 Start New Job Operator enters operator number and aircraft code.
I Display shows job number, event number, gallons dispensed
i See Para. 2.2.1 and flow rates; waits for operator to end job.
I I I I
2 View Flow rates Displays the current flow rates, in gallons or liters per
See Para. 2.2.2 minute for each flow sender connected to the Flow Monitor.
I I I I
3 Review Jobs Shows how many events were recorded. Operator can
See Para. 2.2.3 select any one event and review the data for that event.
l 1 I I
4 View Total Volume Shows the total amount of fluid dispensed for each sender,
See Para. 2.2.4 since the last date the Flow Monitor memory was cleared.
I fl I I
I
5 ! View Time & Date Shows the current date and time.
[ See Para. 2.2.5
I !1 I I
6 i Printer Test Allows the operator tO test the printer's line feed function
=
I
!l
SeePara. 2.2.6
i
and to print out a DemoMessage. i
i
7 Print Options Allows the operator to print out any job, or range of jobs in
!
See Para. 2.2.7 I
the Flow Monitor's memory. !
8 Unit Mod & S/N Displays Flow Monitor's model, serial, and release numbers.
See Para. 2.2.8
9 Setup Menu Requires Level 1 or Level 2 password. Allows operator to set

the time, date, clear the job history, enter the truck ID num-
ber. Allows the Supervisor to set the Flow Monitor to mea-
sure in gallons or liters, set the date format to mm/dd/yy or
dd/mm/yy, to calibrate the flow senders, and to enter or
See Para. 2.2.9 change the Level 2 password.
Password Select Allows the operator to enter or change the Level lpassword.
: See Para. 2.2.10
2-2
NOTE
If a Flow Monitor can store only one job, it stores that job in a memory location that
will be written over by the next job. Therefore it only stores the last job entered.
If a Flow Monitor can store more than one job (n jobs) it will store the first n jobs
permanently. When permanent memory is filled up, the job history can be reviewed,
and printed out if necessary, and then memory can be cleared. If a new job is started
when memory is full, the stored jobs will not be affected, but the next job will be
stored in a memory location that will not be protected. Every time a new job is
entered it will overwrite the previous job.
2.2.1 Mode 1 Start New Job

This mode records the information about a deicing job. It requires the operator to enter his identifi-
cation number (operator code), and the aircraft identification number (aircraft code). The job starts
as soon as the operator enters the aircraft code. While the job is in progress, the Flow Monitor
records the gallons of fluid dispensed for each fluid sender. The operator must end the job before
before any other job can be started.
NOTES
While the job is in progress, the operator can view the flow rates for each fluid
sender.
Depending on the Flow Monitor model, it can store in its memory from 1 to 100
separate jobs. The Flow Monitor automatically assigns each job an internal, sequen-
tial number (event number).
As soon as an aircraft code is entered, the Flow Monitor will start recording the job.
No other jobs may be started until the current job is ended. There is no way to get
back to the main menu until the operator terminates the current job.
If the Flow Monitor loses power when a job is in progress, a message similar to the
following will be displayed when power is restored, and the job will be automati-
cally terminated.
!!Warning!!
Power Lost during deicing event# 4
Job # AA 12
1. Operator Code. The operator must enter a code that is used to identify the operator who is
running the job.
NOTE
The code is not the same as a password. It is any number, from 1 to 6 digits long.
_,_ The default value is 0, if no number is entered and the _] key is pressed, the Flow
Monitor will use 0 as the operator code for this job.
2-3
a. Enter the desired number (from 1 to 6 digits), and press the _ key.
NOTE
After you enter the operator code, you will be asked to enter the aircraft code. If you
wish to cancel the new job, you can do so before you enter the aircraft code. If you
enter the aircraft code, the job will start automatically.
b. If you wish to cancel the new job, Press the [-_ key until you return to the time and date
display, otherwise continue with the following step.
2. Aircraft Code/Job Number. The aircraft code is an alpha-numeric code that identifies the
aircraft that is being deiced. The Flow Monitor asks the operator to enter an aircraft code when
starting a new job. When the job is reviewed or printed, the Flow Monitor refers to the aircraft
code as the job number.
a. The code is an alphanumeric code that must be 6 characters long. Enter it as follows:
1) Enter a number or letter or a space by pressing the appropriate key.
If the character is a number, press the desired key.
If the character is a letter, hold down the shift key and press the appropriate key
until the desired letter appears.
If the character is a space, press the [-_ key.
2) When the correct character is displayed, press the _ key.
3) Repeat step 1) and 2) until all 6 characters are entered.
b. When the six character code is entered, press the _ key and the Flow Monitor will
accept it. Once an aircraft code is accepted the Flow Monitor will start the job record. No
other jobs may be started until the current job is ended.
3. End Job. Selecting this display gives the option to end the current job, but it does not actually
end the job, it brings up a submenu that gives the option to end the job or cancel the submenu.
Any fluid being pumped while the submenu is displayed will be recorded as part of the job.
2.2.2 Mode 2 View Flow rates

As long as power is applied to the Flow Monitor, it records the volume and rate of fluid being
pumped. If a job is in progress, the operator can view the the fluid flow rates while in the Start
New Job mode.
2-4
If the operator has not started a job, but wishes to monitor fluid being pumped for some other
purpose, this mode allows the operator to view the flow rates of the fluid currently being pumped.
2.2.3 Mode 3 Review Jobs

This mode allows the operator to review any of the jobs in memory. The Display selects the latest
event stored in memory and shows the Flow Monitor's event number and the job number. The
operator can scroll through the events/jobs to find the one he wishes to review.
2.2.4 Mode 4 View Total Volume

This mode allows the operator to review the total volume of fluid pumped for each sensor since the
Flow Monitor's memory was last cleared. This value includes all fluid pumped while power was
applied to the Flow Monitor, even if there was no job in progress.
NOTE
The View Total Volume menu shows the total amount of fluid dispensed, for each
sender, since a certain date and time. That date and time is what the Flow Monitor
was set to when memory was last cleared. Therefore, if the Flow Monitor was show-
ing an incorrect date or time the last time that jobs in memory were cleared, the
Flow Monitor will report the incorrect date or time when it displays total volume
dispensed, even if you later change the date or time to the correct values using the
Reset Time menu and the Reset Date menu.
2.2.5 Mode 5 View Time & Date

This mode shows the current date and time. It is the default mode when the Flow Monitor is
turned on.
2.2.6 Mode 6 Printer Test

This mode provides two tests of the printer. It prints a demo message (see figure 1-8), and it per-
forms a line feed, which feeds the paper about 1/8 inch.
2.2.7 Mode 7 Print Options

This mode allows the operator to determine which jobs should be printed.
NOTES
The printer's buffer can only handle a certain amount of data, so the Flow Monitor
will break a large print job up into 25 jobs at a time.
You need to be sure that there is enough printer paper to print the jobs. Allow about
1.75 inches per job.
If all of the jobs are printed, the printout will also show the total volume pumped
for each sender for all of the jobs, and also the total volume.
2-5
2.2.8 Mode 8 Unit Mod & S/N

This mode displays the Flow Monitor's Model Number, Serial Number, and Release Number. If the
Flow Monitor has a printer, this same information is printed as part of the Demo Message in Mode
6, Printer Test.
2.2.9 Mode 9 Setup Menu

This mode cannot be entered without a password.
There are seven submodes associated with this mode.

Submode Paragraph
Reset Time Menu 2.2.9.1
Reset Date Menu 2.2.9.2
Clear Job History Menu 2.2.9.3
Truck ID # Menu 2.2.9.4
Setup #2 Menu 2.2.9.5 Requires the Level 2 password
Password Select Menu 2.2.9.6
Return to Main Menu 2.2.9.7
NOTES
Although the display asks for the Level 1 password, either the Level 1 or Level 2
passwords can be used. The Level 1 or Level 2 password can access all the submodes
except for Setup #2 Menu, which requires the Level 2 password.
When you select a submode and either complete the procedure or quit the procedure
you are automatically returned to the Date and Time display to prevent leaving the
Flow Monitor in a password protected mode.
2.2.9.1 Reset Time Menu

The clock reads in 24 hour time.
a. For hours from 1 am to 9 am, enter the hour as 01, 02 ..... 09, and for hours from 1 pm to
midnight, enter the hour as 13, 14....... 24.
b. Set the minutes and seconds slightly ahead of the current time so that the resetting of the
Flow Monitor's timekeeping can by synchonized with an accurate watch.
c. When ready to reset the time, press _].
2.2.9.2 Reset Date Menu

a. For months and days from 1 am to 9, enter the month or day as 01, 02 ..... 09.
b. For years, enter the last two digits. Enter 1998 as 98, enter 2001 as 01.
2-6
2.2.9.3. Clear Job History Menu

This procedure clears all jobs in memory, including data that may have been entered at the factory.
Before you perform this procedure, you should verify that all jobs currently in memory are no
longer needed. Refer to paragraph 1.5.3 for detailed instructions on performing this procedure.
If the Flow Monitor has a printer, you can print out a record of all jobs in history, or any jobs that
you wish to save as a permanent record.
NOTES
When you clear the job memory with this procedure, the Flow Monitor will save the
date and time that the Flow Monitor is currently set to, and will display that date
and time whenever the View Total Volume menu shows the total volume dis-
pensed.
The View Total Volume menu will always show the date and time that existed
when the job history memory was cleared, even if the time and date are later reset
using the Reset Time menu and the Reset Date menu.
2.2.9.4 Truck ID # Menu

The Flow Monitor is normally installed in a truck. This procedure asks for a Deicer number. The
Truck ID number that you enter will be printed out as the Deicer number on the first line of every
job printout. If several jobs are printed at once, the deicer number will be printed once, followed
by all of the jobs.
2.2.9.5 Setup #2 Menu

This Menu requires the Level 2 password. If you do not know the Level 2 password consult an
authorized person, usually the supervisor, who can use the Level 2 password to enter this menu
and perform the desired procedures.
If your organization has lost the Level 2 password, have an authorized person contact Sage Design
Corporation for assistance.
2.2.9.5.1 Units.
This menu provitl_s the option to display all flow measurements in U.S. gallons or in liters.
2.2.9.5.2 Date Format.

This menu provit_es the option to display the date in mm/yy/dd format or in dd/mm/yy format.
2.2.9.5.3 Calibrate Type I(or Type 2 or Type 4).

This procedure:allows the operator to calibrate a flow sender by either entering a measured vol-
ume, a known_ev rate, or a correction factor.
If the deicer can_ump a known volume of fluid (for example by filling a container with a known
capacity) then fie=operator can enter the known volume into the Flow Monitor's memory. The Flow
2-7
_ Monitor will receive a volume measurement from the sender, will compare it to the value entered
by the operator, and will compute, and store in its memory, a correction factor, called the K-Factor.
This K-Factor should be recorded in case it needs to be reentered.
Similarly, if the deicer can pump fluid at a known flow rate, the operator can enter that flow rate
and the Flow Monitor will compare the measured flow rate with the value entered by the operator
and will compte the K-Factor.
If the operator knows the K-Factor for the sender, because it has been recorded from a previous
calibration based on known volume or known flow rate, then the operator only needs to enter the
K-Factor to complete the calibration. This would be useful if, for example, the Flow Monitor used
for the deicer needs to be repaired, and is replaced by another Flow Monitor. Since the calibration
is for the sender and not the Flow Monitor, the operator need only enter the K-factor into the new
Flow Monitor's memory.
2.2.9.5.4 Reset to Defaults.

This menu resets the Flow Monitor to factory defaults: units are set to U.S. gallons, date format set
to mm/dd/yy, and sender K-Factors may be reset. If this happens, the correct K-Factors, if known
from a previous calibration, may be entered using the Calibrate Mode.
2.2.9.6 Password Select Menu

This procedure allows the person who knows the Level 2 password (usually the supervisor) to
change the Level 2 password. If the password has been lost, have the supervisor contact SAGE
Design Corp for assistance.
2.2.2.9.7 Return to Main Menu

This menu will return you to the main menu.
2.2.10 Mode 0 Password Select

This procedure allows the person who knows the Level 1 password (usually the operator) to change
the Level 1 password. If the password has been lost, have the supervisor contact SAGE Design
Corp for assistance.
2-8
SAGE FLOW MONITOR MAINTENANCE
3. MAINTENANCE
The only mainenance required is to replace consumable printer supplies and to replace the memory
backup battery.
3. I BATTERY REPLACEMENT
The battery should be replaced every three to five years. If the battery fails, then all of the data
stored in memory will be lost. Therefore, it is recommended that the battery be replaced after
approximately three years after it has been installed in the Flow Monitor (or three years after the
Flow Monitor is received from the factory).
The battery must not be replaced except when authorized by the supervisor. See the supervisor for
the battery replacement procedure.
3.2 PRINTER SUPPLIES

The printer paper and printer ribbon must be replaced as they are used up. To gain access to these
supplies, you must remove the printer cover. The following step explains how to remove and
replace the printer cover.
1. Remove the printer cover as follows (See Figure 3-1)
_ a. Place the thumb of each hand on the front surface of the printer cover, and the
remaining fingers of each hand on each side of the cover.
b. Press the fingers firmly against the sides of the cover, and pull straight down. The
cover should slide down about 0.5 inch.
Figure 3-1 Printer Cover in Down Position
3-1
c. Lift the cover straight out from the Flow Monitor, towards you.
d. To replace the cover:
1) Press the Paper Feed button until at least 1.5 inches of paper protrudes past the
ribbon.
2) Slip the paper through the slot in the cover, underneath the paper cutter.
3) While holding the cover as before, push it straight in with the top about 1.5"
below the top of the opening for the printer.
4) Wiggle the cover until it drops flush against the mounting surface, then push it
straight up until it clicks into place.
2. Replace the Ribbon as follows (See Figre 3-2):
Ribbon
Holder
Figure 3-2 Printer with cover removed

a. Press on the Ribbon Holder at the point shown in Figure 3-2. It will pop out.
NOTE
If you are going to replace the paper at this time, go to step 3 and return here after a
new roll of paper has been installed.
b. Hold the new Ribbon Holder horizontally so that it can be slipped into position,
with the paper between the ribbon and the top of the plastic Ribbon Holder.
3-2
_ c. Position the new Ribbon Holder in its cavity and snap it into place.
d. Replace the printer cover.
3. Replace The Paper as Follows (See Figure 3-3).
The printer accepts standard printer paper (2.25 inches wide), however the diameter
of the paper rolls normally available is too large to fit in the printer. SAGE provides
rolls that are about 1.5 inches in diameter.
Paper feeds up through slot J
'.
Spindle inserted in paper roll

with "T" on the left side
Figure 3-3 Paper Roll being installed in Printer
a. Remove the Ribbon Holder (see step 2a.).
b. Place your right thumb on the spindle on the left side of the paper roll and the
remaining fingers on the right side of the Flow Montitor.
c. Press with the thumb and pull out. The Paper Roll should pivot outward.
d. Remove the Paper Roll, and remove the spindle.
e. Insert the spindle into the core of a fresh roll of paper, so that the "T" of the spindle
is on the left and the paper unwinds from the back of the roll.
3-3
Note
With the Ribbon Holder removed, you will see a black plastic piece mounted to a
metal piece. The paper slot is between these two pieces and the paper feeds up from
the bottom.
f. Hold the paper roll and spindle with one hand, and locate the slot that the paper
feeds through.
g. Push the paper into the slot, and then press the paper feed key. If enough paper is in
the slot, it will catch and the paper feed will pull it through the slot and out the top.
h. Place the right side of the spindle into its slot at the right side of the printer hous-
ing. You can locate the slot by noting the two projections that bracket a tab-shaped
object. The slot for the spindle is behind the tab.
i. Push the other side of the spindle into its slot.
j. Replace the Ribbon Holder (step 2b).
_,j k. Replace the Printer Cover (step 1.d.)
3-4
FLOW MONITOR SPECIFICATIONS
4. SPECIFICATIONS
The Flow Monitor has several options, an inspection of the Model Number will indicate which
options are provided
FLOW SENDERS TEMPERATURE SENSOR PRINTER NUMBER OF

1 = Type 1Fluid only X = None X = None RECORDED
2 = Type 2 Fluid only R = Type RTD P = Printer/EVENTS
3 = Type 1 & Type 2
4 = Type 1 & Type 4\

/
/ /
/ TYPE OF MOUNT
\ / / /x one
BASIC MODEL NUMBE__ - //_ Pedestals
P == SideSPECIAL
-
SFM-3XP10SX FE'r l S
X = None
Temperature: Flow Meter operates down to -40C/-40F.

Printer operates down to 0C/32F (freezing point of the ink in the ribbon).
Power: Main power: 12 volts dc
Memory Backup: Lithium battery 3 volts dc; life 3-5 years.
Memory: Stores in permanent memory, until reset, the number of events shown on the
model number. When memory is full, any additional events are stored in a
temporary memory location, which is always overwritten by the next event.
Replacement Parts: Contact SAGE for ribbons, paper, and replacement battery.
4-1
SAGE FLOW MONITOR
MODEL SFM-3
BATTERY REPLACEMENT
PROCEDURE
SAGE FLOW MONITOR BATTERY REPLACEMENT
Caution
This procedure should be stored in a safe place, otherwise it can be used to circum-
vent password protection
When the battery is removed, all information stored in memory will be lost, includ-
ing the passwords. Passwords will have to be entered after a new battery is installed.
1. Turn off power to the Flow Monitor.
2. Remove all connectors from the rear of the Flow Monitor.
3. At the rear of the Flow Monitor, remove 6 small screws at the outer periphery.
4. Carefully pull the Flow Monitor's back out, being careful not to damage the wiring, and lay the
back on a solid supporting surface.
Note
Refer to the illustrations on the next page for the following steps.
5. Locate the battery, in its holder, under a black retaining clip at the bottom center of the circuit
board. A wire soldered to the battery leads to a battery connector next to the battery.
6. Carefully slide the battery connector out from under its tie-down.
Note
Disconnecting the battery plug from its connector may take some force. A very
strong pull may be needed to separate the plug and the connector.
7. Disconnect the battery plug from the battery connector.
8. Pry up the battery clip by inserting a small scredriver between the clip and the outside of the
battery compartment.
9. Remove the clip and battery.
10. Install a new battery, by reversing the above procedure.
11. Carefully reposition the Flow Monitor's back and push the wires into the cabinet.
12. Replace the six screws.
13. Reconnect the cables to the connectors at the back of the Flow Monitor.
14. Refer to the Flow Monitor Manual and perform the Test for Proper Intallation (Section 1.4) and
the Initial Setup (Section 1.5).
Battery- 1
SAGE FLOW MONITOR BATTERY REPLACEMENT
Battery Connector tie-down
Battery Connector
Battery Plug
Battery under black

plasticretaining
clip
Battery with
__ soldered-on
battery
removed.
Circuit Board with _i

-lugl
Battery Connector
Battery Compartment
Battery Retaining Clip
Retaining Clip.
(Fits over outside
ofbattery _
compartmen_
Batteryf _------"
Battery Compartment /
End view of battery in its compartment
Battery - 2
+GF+ SIGNET 8550-3 Flow Transmitter Instructions ENGLISH
Hlllllm,ll.,o.ogo.lWlllJlllltlt
,lllJ!t
noSlJlJ
IIJ
J,
lJJlllt,
sh
IJJJ
Iml!!ll_
CAUTION! Contents
input and output connections. 2. Specifications

Remove
Follow instructions
power to unit
carefully
beforewiring
to avoid 1. Installation
3. Electrical Connections
personal injury. 4. Menu Functions
1. Installation
The transmitter is available in three versions: a panel mount version, an integral (pipe mount) version, and a universal assembly for
installation near the sensor. _e" panel
The
installPanel Mounting kits
instrumentation arepanels
into supplied
and with the hardware
maintain a NEMA to
4X __'" ""'""". _ mounting
bracket
,,,--,,ns,a,,a,,on
seal.
1. Punch out panel and de-burr edges. Recommended
2.
3.
clearance on all sides between instruments is 1 inch.
Place gasket on instrument, and install in panel.
Slide mounting bracket over back of instrument until
quick-clips snap into latches on side of instrument.
*- quick-clip
4. Connect wires to terminals, transmitter

5. To remove, secure instrument temporarily with tape from
front or grip from rear of instrument. DO NOT RELEASE.
Press quick-clips outward and remove.
1. Punch out conduit ports if necessary.

1.2 2. Connect
Integral sensor(3-8051)
Assembly to integral adapter. Push and twist-lock cable _a
_ t
integral adapter to conduit base and secure with locking .........
ring and screw.
3. Mount unit in pipe. Route cable through cable gland and
connect to transmitter.
4. Closeunitandsecure.Sealcableentry.
1. Install transmitter base

1.3 Universal Assembly (3-8050) II__- wires
3. Close unit and secure with push and twist lock. IM'_ (_aJ.. I
2. Seal cablewires
Connect entry.to transmitter. I _'''1"_""lJ
XJI _! !
2. Specifications
General Electrical
Compatibility:+GF+ SIGNET FlowSensors(w/freqout) SensorInputs:
Accuracy: +_0.5Hz Range: 0.5 to 1500 Hz
Enclosure: Sensorpower: 2-wire: 1.5 mA@ 5 VDC + 1%
Rating: NEMA 4X/IP65 front 3 or 4 wire: 20 mA @ 5 VDC + 1%
Case: PBT Optically isolated from current loop
Window: Polyurethane coated polycarbonate Short circuit protected
Keypad: Sealed 4-key silicone rubber Current output:
Weight: Approx. 325g (12 oz.) 4 to 20 mA, isolated, fully adjustable and reversible
Display: Power: 12 to 24 VDC +10%, regulated
Alphanumeric 2 x 16 LCD Max loop impedance: 50 _ max. @ 12 V, 325 _ max. @ 18
Update rate: 1 second V, 600 Q max. @ 24V
Contrast: User selected, 5 levels Update rate: 100 ms
Accuracy: +0.03 mA
Environmental Open-collector outputs:Hi, Lo, Frequency, Pulse Programmable
Operatingtemperature: -10 to 70C (14 to 158F) " Open-collector,opticallyisolated,50 mA max.sink,30 VDC
Storage temperature: -15 to 80C (5 to 176F) max. pull-up voltage. "" Tn_er_alo-pen-'c_Hector""
i
Relativehumidity:0 to 95%, non-condensing output circuit , Outputs
Standards and Approvals: CSA, CE, UL listed

Manufactured under ISO9001 I
Isolation
................... J
-
+
+GF+
SIGNET
8550-3
Flow
Transmitter page
1of8
Dimensions
Panel
Mount Field
Mount
96mm (3.8 in.)"--'1 I*-- 96 mm (3.8 in.) '1
(3.8 _ [] Optional
Rear Cover mm.
98 I_J- (+ 0.8,- 0 mm)_ I 23 ,n )
I I 3.6x3.Tin. I
[ _
-- /56mm m I' 102mm
(4.0 in.) ,I
1mm,_--(2.2 in.)--_
,(1.6 in.) o7,_
(3.8in.)
3. Electrical Connections
/_ permanently damage
Caution: Failure instrument.
to fully open terminal jaws before removing wire may
Wiring Procedure
1. Remove 0.5 - 0.625 in. (13-16 mm) of insulation from wire end.
2. Press the orange terminal lever downward with a small screwdriver to open
terminal jaws.
3. Insert exposed (non-insulated) wire end in terminal hole until it bottoms out. I
4. Release orange terminal lever to secure wire in place. Gently pull on each wire
to ensure a good connection.
Wiring Removal Procedure

1. Press the orange terminal lever downward with a small screwdriver to open
terminal jaws.
2. When fully open, remove wire from terminal.
Terminals Description
1. AUX1+ 12-24VDC
2. AUX 2-
System Power/Loop
3. System Power/Loop 1+ 12-24 VDC +5%, system power and current loop connections.
4. System Power/Loop 1- Max. loop impedence: 50 D max @12 V, 600 D max. @ 24 V.
5. Loop 2+
6. Loop 2-
Open Collector Output

7. Output 1+ Open-collector transistor output programmable as:
8. Output 1 - High/Low alarm with adjustable hysteresis
9. Output 2+ Proportional pulse output
10. Output 2- Disable (Off) selection
12, Red (Sensr I IN)

Preamplifier/Sensor Input
13. Silver (Sensr I Gnd) _!
,Loo
6
4
Loo.-
,.
1111OI10
ILIIOI9
LOOp2"
system Pwr Output2+2-
Output lUlOI14
,,'"'"(.0)
(=,cK)S"s'2v+
_21_2116 Snsr2end
t(sHIELD)
15. Red (Sensr2 IN) L_i21

16. Silver (Sensr 2 Gnd) 2 AUXpower. 12 SnsrI(RED)
IN
14. Black(Sensr2V+) _! 1
3 AUX
Power+ lUlO I 7
SystemPWrLoop+_10_ Out.at1+ lU10111
_2113 SnsrIV+
snsrlGnd(sHIELD)
Wiring Tips:
Do not route sensor cable in conduit containing AC power wiring - electrical
noise may interfere with sensor signal.
Routing sensor cabling in grounded metal conduit may prevent moisture
damage, electrical noise, and mechanical damage.
Seal cable entry points to prevent moisture damage.
When placing two wire ends into a single terminal, solder or crimp ends
together.
page 2 of 8 +GF+ SIGNET 8550-3 FlowTransmitter

3.1 System Power/Loop Connections
Stand-alone application, no current loop used Connection to a PLC with built-in power supply
Terminals PowerSupply Terminals I Terminals

Loop2- NC DC 12 " 24 V Loop2- 6 Power Supply
Ground
Loop2+ NO Loop2+ 5 _" Power

Transmittei I Transmitter i .[_II+iPLC
Sys. Pwr. 4 Supply
Power Sys.Pwr.
4 " 4-20
._,n
Channel
2
Sys. Pwr. Power Sys. Pwr. Channel 2

Loop + 3 Supply Loop
+ 3 4-20 mA in
l
AUX AUX Channel 1
AUX
Power- 2 AUX
Power- 2 I Channel
4-20 main1
Power + 1
,
Power + 1 I
I
I
Internal PLC =
4-20 mA in
Connection
Connectionto a PLC/Recorder,separatesupply Example: Two transmittersconnectedto PLC/Recorder

_
with separate powersupply
Transmitter DC 12 - 24 V Loop2- 6J
Loop2+
Power _ 5
Terminals Supply _ Sys. Pwr. 4

"1" Power "_ Loop- DC 12 - 24 V
Loop2- SuPplV _ Sys. Pwr.
3
i._ Loop +
AUX Power
Loop2+ PLC or Recorder Power- '2 Power
AUX
Channel 2 Power + 1
Sys. Pwr.
Loop - 4 4-20 mA in
Channel 2
Loop + 3 4-20 mA in
I _ PLC or Recorder
AUX Channel 1 ,,-- Loop2+ I
Power - 2 4-20 mA in + Channel 4
Sys. Pwr.
Power + 1 4-20 mA in
Loop2-
Loop -
I 6_H
_ +
Channel
Channel
4
3
I _
_" Sys.
Loop Pwr.
+ I 0,,',=4 -+ Channel
Channel 22
AUX Channel 1 ._ Sys. Pwr.
Power-
AUX
Power + i i_i
I
4j_l) i _11
w "+
[
-
I
Channel3
Channel 1
3.2 Sensor Input Connections Terminals 515 2000

WiringTip: 525
21O0 2507
2530
Do not routesensor cable in any conduit 2517 2535
containingAC powerwiring- electrical 2536
noisemay interferewith thesignal. 3-8510-XX
3-8512-XX
2540
Vortex
3.3 Open Collector Functions

Low: Output triggerswhen process variableis lessthan Off: Disablesoutputpulse.
setpoint.
Pulse: Outputsa pulsewhenevera specifiedamountof
High: Output triggerswhen processvariableis higherthan volumehas been totalized.
setpoint.
Frequency: Outputsa pulsewheneverthe dividednumberof
Example: In Low Alarm Mode Operation,the outputbecomes pulsesare input.
active when the process drops below the setpoint, and
becomesinactivewhen the processrisesabove the setpoint
plushysteresis.The oppositeis true for High Alarm Mode.
OutputActive
Output Inactive
Temperature
Hysteresis i ........ []
Setpoint -
> Time
+GF+SIGNET8550-3FlowTransmitter page3 of 8
4. Menu Functions
VIEW Menu: is displayedduringstandardoperation. OPTIONS Menu: containssetupand displayfeaturesfor minor

Press UP or DOWN buttons to view process parameters, display or output adjustments. To access OPTIONS menu:
Press UP and DOWN buttons at the same time, to exit any Press ENTER button for 5 seconds to display: I oPtioNs
..... ]
other display and return to VIEW menu. Press UP, UP, UP, DOWN buttons in sequence Ent_ KeyCode
Display will return to VIEW menu in 10 minutes unless a key to display: I OPTIONSEnter
Key
.....Code ]
is pressed.
Menu Tips
CALIBRATE Menu: containsdisplaysetup and output Right buttonscrolls to right,from top to bottomrow,and allows
parameters. A securitycode feature prevents unauthorized editingwhen ">" symbolis shown.
tampering. To access CALIBRATE menu: Ic_LIB........ I In CALIBRATE or OPTIONS menus, the transmitter will
Press ENTER button for 2 seconds to display: E,ter Keycode continue to measure and control outputs. When > is pressed,
Press UP, UP, UP, DOWN buttons in sequence ic............ I the input value is held at the last measured process value.
to display: EnterKeyCode " When sensor is not connected, unit will display CHECK
SENSOR and any output controlled by sensor will be at 3.6 mA
Example orOFF.
To change date, first enter CALIBRATE menu (Press ENTER button for 2 seconds; Press UP, UP, UP, DOWN buttons in sequence)
Once in CALIBRATE menu, press UP button 1 time.
1. Display shows right 2. Press RIGHT button 3. Press buttons to scroll 4. Press ENTER button 5. Display now reads
arrow to display "01" blinking through numbers, to save new date
Menu Functions
GHM
0.0000 to 60.00
99999
j '_?_i:_ i_!,_ ...... _ a-z,A-Z,/,0-9 Gallons

I Total1 Reset Lock: ON oooooooo eight digit
_ field
__ _ 0.0000
99999 to 60.00
_'_'_i'] ,_:
00000000 -
99999999 Plow 1 View
1
Flow 2
OOOOOOO(J- OF
999999994_2U
mA _i_ u.euo099999to O tO 10U
PlOW 1 PlOW 2
Plow 2
4-20
mA DF
U.uOOUto U to lUO
_i _ oo-oo-oo
to g9999
_;_ !_i_;:
i 39-39-99
;_ii .............. _:;!" _ Plow 1 Plow 1 (OUtput1)
FIOWo
F2 Flow2(Output2)
Ott Low (Output1)
- Low High(Output2)
............... Freq
U.0OOUto 99999 19 (Output1)

Settings repeat fol Output2 90 (Output2)
ili_
_ O.O000 to 99999 gpm
Pulse ,_elected
U.UUUUto 99999 100
Oft
seconds
1 to 264 1
UU-UU-00 to 01-01-99
39-39-99
page4 of8 +GF+SIGNET8550-3FlowTransmitter

Troubleshooting
Display Problem Solution
Displaytimebasetoo large Changeflow timebase

(S=seconds,M=minutes,H=hours,D=days) in CALIBRATE
menu to a smaller value (e.g. GPD to GPM
Check settings Pulse width value too large for frequency Reduce output Plswidthsetting or increaseOutputVolume
for Output inputor pulse volume too small setting.
SETUP READ ERROR Memory fault occurred. Press any key to reload presets, then reprogram setpoints.
Press Any Key
+GF+SIGNET8550-3FlowTransmitter page5 of8

I
+GF+ SIGNET i
Signet Scientific Company, 3401 Aerojet Avenue, El Monte, CA 91731-2882 U.S.A. Tel. (626) 571-2770 Fax (626) 573-2057 _ !
For Worldwide Sales and Service, visit our website: gfsignet.com Or call (in the U.S.): (800) 854-4090 _]_
GEORGE FISCHER +GF+ Piping Systems

3-8550.090-3/(A-9/99) English ScientificCompany1999 Printedin U.S.A. on RecycledPaper
page 8 of 8 +GF+ SIGNET 8550-3 Flow Transmitter
Option Menu Changes:
1. Contrast does not change and stays at setting of 3.
2. Scroll down to 'Flowl Decimal'.

Change default from XXXX.X to XXXXX..
3. Scroll down to 'Totall Decimal'. Keep default of XXXXXXXX..
4. Scroll down to 'Flow2 Decimal'. Change default from XXXX.X to XXXXX..
5. Scroll down to 'Total2 Decimal'. Keep default of XXXXXXXX..
6. Remaining menu's NOT USED.
Calibrate Menu Changes:
1. 'Flowl Units' default is set to GPM. Change to LPM for Euro units.
2. 'Flowl K-Factor' is set to 10.0.

Tempest : Change to 27.0 for Liters and XX.X for Gallons.
LMD: Change to xx.x for Liters and xx.x for Gallons.
3. 'Totall Units' default is set to Gallons. Change to Deicing.
4. 'Totall K-Factor' MUST BE SET THE SAME as Flowl K-Factor.
5. 'Flow2 Units' default is set to GPM. Change to LPM for Euro units.
6. 'Flow2 K-Factor' is set to 10.0.

Tempest : Change to 25.0 for Liters and XX.X for Gallons.
LMD: Change to xx.x for Liters and xx.x for Gallons.
7. 'Total2 Units' default is set to Gallons. Change to Anti/Ice.
8. 'Total2 K-Factor' MUST BE SET THE SAME as Flow2 K-Factor.
9. Next 4 screens for 'LOOPI' and 'LOOP2' are NOT USED.
10. 'Outputl Source' is set to Flowl, no change.
11. 'Outputl Mode' is set to Low. Change to Pulse.
12. 'Outputl Volume' is set to 100.00. Change to 1.0000.
13. 'Outputl Plswdth' is set to 0.1 Seconds, no change.
14. 'Outputl Freq' is NOT USED.
15. 'Output2 Source' is set to Flow2, no change.
16. 'Output2 Mode' is set to High. Change to Pulse.
17. 'Output2 Volume' is set to 100.00. Change to 1.0000.
18. 'Output2 Plswdth' is set to 0.1 Seconds, no change.
19. 'Outputl Freq' is NOT USED.
20. 'Last Cal' needs to be set to current date.

Setup for Signet Counter for North America and Euro
General Information:
The Signet counter is calibrated from the Front Panel. The method for making changes to the display and K-Factors is
through the 'Calibrate' and 'Options" menu.
The Front Panel consists of four buttons as shown below.
[ 1
\ J
Arrow Up will scroll up to the next screen and if in 'Calibrate' or 'Option' mode, will change the characters or numbers on
the screen.
Arrow Down will scroll down to the next screen and if in 'Calibrate' or 'Option' mode, will change the characters or
numbers on the screen.
Arrow Right when displayed on the screen will put you in edit mode for that screen.
Enter if pressed for 2 seconds will place operator in 'Calibrate' mode and if held an additional 3 seconds, 'Option' mode.
When editing a screen, pressing 'Enter' will perform a 'Save' of the parameters changed.
A password sequence is required to enter 'Calibrate' or 'Option' mode and it is a sequence of pressing Arrow Up, Arrow Up,
Arrow Up and Arrow Down.
Operator Menu:
Initial powering up unit will display the Flow Rate when spraying from Deicing or Anti-Icing tanks. Pressing the 'UP' or
'DOWN' arrows will scroll through user screens. If the Printer Option has been added, it is not likely that operates will look
at the counter due to the batch counts are seem on the Printer.
The counter does maintain a Totalizer counter that is not resetable.
Screen 1: Flow Rates as seen when spraying.
Screen 2: Delta Flow NOT USED.
Screen 3: Totl and Tot2, which are the batch counters, are resetable. Press 'RIGHT' arrow once to view Flow 1 which is
Deicing fluid, press 'Enter' to reset. Flow 2 will appear which is Anti-Icing fluid, press 'Enter' to reset.
Screen 4: Perml which is on going totals of Deicing Fluid, not resetable.
Screen 5:Perm2 which is on going totals of Anti-Icing Fluid, not resetable.
Screen 6: Loopl Output NOT USED.
Screen 7:Loop2 Output NOT USED.
Screen 8: Last Calibration date.

LANYARD AND SHOCK
ABSORBER INSTRUCTION
AND WARNING INFORMATION
FOR ALL MILLER MODELS
WARNING
A fall could result in serious injury or death. Do not use unless properly
trained. Read, understand and follow all instructions. Failure to do so
may result in serious injury or death.
QUESTIONS? CALL 1-800-873-5242

All workers utilizing fall protection must read and understand all
information contained in this brochure. It is the employer's
responsibility to ensure that all users are trained in the proper use,
inspection, and maintenance of fall protection equipment. Fall
protection training should be an integral part of a comprehensive
safety program.
FILIN DE SI_CURITI_ ET
AMORTISSEUR DE CHUTE
INSTRUCTIONS ET
INFORMATION
D'AVERTISSEMENT POUR
TOUS LES MODELES MILLER _
AVERTISSEMENT
Une chute peut provoquer de graves blessures ou m_me la mort. Ne
pas utiliser ce produit sans avoir rec;u la formation appropriee. Veiller
lire, comprendre et respecter toutes les instructions. Le non-respect de
ces instructions peut _tre la cause de graves blessures, voire d'un
accident mortel.
POUR TOUTE QUESTION, TI_LI_PHONER AM

1-800-873-5242.
INSTRUCCIONES DE USO DE
LA CUERDA DE SEGURIDAD Y
AMORTIGUADOR Y
ADVERTENCIAS PARA TODOS
LOS MODELOS MILLER
ADVERTENCIA
Una caida puede producir una lesion grave o mortal. No utilice este equipo a
menos que haya recibido entrenamiento adecuado. Lea, comprenda y siga
todas las instrucciones. En caso contrario se pueden producir lesiones graves
o mortales.
_,CONSULTAS? LLAMAR AL 1-800-873-5242

Proper use of fall arrest systems can save lives and reduce the potential of serious injuries from a fall. The The user shall have a rescue plan and the means at hand to implement it when using this equipment.
user must be aware that forces experienced during the arrest of a fall or prolonged suspension may cause
bodily injury. Consult a physician if there is any question about the user's ability to use this product. This product is designed for personal fall protection. Never use fall protection equipment for purposes other
Pregnant women and minors must not use this product, than those for which it was designed. Fall protection equipment should never be used for towing or hoisting.
Always check for obstructions below the work area to make sure potential fall path is clear.
GENERAL REQUIREMENTS All synthetic material must be protected from slag, hot sparks, open flames, or other heat sources. The use
All warnings and instructions shall be provided to users. Warnings and instructions must be read and of heat resistant materials are recommended in these applications.
understood prior to using the equipment.
Environmental hazards should be considered when selecting fall protection equipment. Equipment must not
Equipment must be used by trained personnel only. be exposed to chemicals which may produce a harmful effect. Polyester should be used in certain chemical
All users must reference the ANSI Z359.1 standard and applicable regulations governing occupational safety, or acidic environments. Consult the manufacturer in cases of doubt.
To minimize the potential for accidental disengagement, a competent person must ensure system compatibility. Maximum working load is 310 Ibs., unless labeled otherwise.
All equipment must be visually inspected before each use. SYSTEM COMPATABILITY
All equipment should be inspected by a qualified person on a regular basis. Miller full body harnesses are designed for use with Miller approved components. Substitution or replacement
with non-approved component combinations or subsystems or both may affect or interfere with the safe
Equipment must not be altered in any way. Repairs must be performed only by the equipment manufacturer, function of each other and endanger the compatibility within the system. This incompatibility may affect the
or persons or entities authorized in writing by the manufacturer, reliability and safety of the total system.
Any product exhibiting deformities, unusual wear, or deterioration must be immediately discarded.
Any equipment subject to a fall must be removed from service.
,C.haquet.r.availleuru.tilisant un d.isp.ositif,de prqteq.ti.on con.tre les chutes dqit I!re et compre.n,,d,

re .toute Tout produit manifestant deformation, usure inhabituelle ou deterioration dolt _tre immediatement retire du
i'in.Torm,auon pre.semee aans c.etle oroc.nure..u'est..ai'empioyeur qu'incomoe Haresponsa.?,idmae service,
v.eiiler a..cequ.e.cnaque uu.lisateur,regolv.ei.atormau.o,n appropr!ee e.nc.equ.icgncer.ne i'utiiisadon,..
i',nspecuon et !'en.treuen.ae i'eq.m._em.em ae protecuon comre ies.cn.ums..La,Tormadonconcernam la Tout equipement qui a fait robjet d'une chute doJt_tre retire du service.
protection conTreles crimes aolt etre incorporee au programme ae securlte a'ensemole.
L'ut.ilisateurdolt c.o,nn.ailre un pla.n de sauvetage et avoir & sa disposition les moyens necessaires & son
La bonne utilisation des syst_mes d'arr_t de chutes peut sauver.des vies et reduire le risque de blessures execuuon Iorsqu'H utl_se cet equ_pemenc
serieuses b la suite d'une chute. L'utilisateur doit 6tre avisd .queies torces exercdes mrs ae i'arr_t d'une
chute ou d'une suspension prolongdepeuvent causer aes blessures..Consulter un medecin si vous avez Ce pro.d, uitest coqu pour la protectionindiyiduelle contre les c,hutes.N,ejarr),ais.,
util!serun equipement de
aes questions concernant.la capac,t_ de I'utilisateur a'ud,iser ce proauit. Les remmes enceintes et les protecuon comre _es cnutes aans une ap.p_c, at on autre,que ce e pour aque !e est conu _,_e],ama s
entants ne aoivent pas utiliser ce produit, uddser un equipement de protectioncontre les cnutes oans une appiication ae remorquage ou ae levage.
EXIGENOES GI_NI_RALES V,eil!er toujours' & ins.pecter I_esl#,ace.au-.dessous
de la zone de travail pour verifier que la trajectoire d'une
cnute evemueile est exempte d'ODStrucdon.
Tousles avertissements et instructions doivent _tre fournis a rutilisateur. Celui-ci dolt les lire et les
comprendre avant d'utiliser I'equipement. Tout ma_riau synthet[.que.,dolt _tre protege contre scqri.es,,etincelles, flammes, nues et autres sources de
cna_eur, your ces appiicat=ons,on recommanoe _'empJoM ae materiaux resistant & Hacnaleur.
L'equipement dolt etre utilise uniquement par un personnel qui a reu la formation appropriee. Les eangers provenant de renvironnement do vent 6tre pris en consideration Iors du choix d'un equipement
Tousles utilisateurs doivent se referer & la norme ANSI Z359.1 et aux r_glements se rapportant & la securite de p,rotect,ion contre les chutes,.Ce,t equ pement, ne .dot pas _tre expos.e auxpro,du tsch m ques p.ouvant
au travail, proauire a.es e.nectsnuis,ib!es.,L'udiisation au polyester est recommanae.'e aans ie,s e,nv!ronnements
renzermant certains proauits cnimiques ou aciaes. L;onsulter le raoricam en cas ae ooute.
Pour m!ni.,m..i.ser les risques de s,epara.ti.on accidentelle, une personne competente dolt veiller & la
compatioiHteaes composants au systeme. Sauf indication differente sur une etiquette, la charge de service maximum est de 310 livres.
Chaque equipement dolt faire I'objet d'une inspection visuelle avant chaque utilisation. COMPATIBILITI_ DU SYSTIEME
Chaque equipement doit etre inspecte par une personne qualifiee a intervalles reguliers. Les baudriers complets Miller sont con(2uspour _tre utilises avec les composants approuves par Miller. Le
.L',_quipe.meqtne .dolt sub.mraucun,e modification. Les re."
.pctrationsd,oivent _.tre.e.ffectqee.sunique,ment,par le
taDncant ae i'equipement, ou par ies personnes ou emites posseaam i'autonsation ecrite au TaDncant.
Todos los trabajadores que utilicen equipo de proteccibn contra caidas deben leer y comprender Todos los equipos deben ser inspeccionados visualmente antes de cada uso.
bien toda la informacion contenida en este folleto. El empleador debe asegurarse de que todos los
Todos los equipos deben ser inspeccionados regularmente por una persona calificada.
usuarios hayan sido entrenados en el uso, inspecci_n y mantenimiento apropiado del equipo
No se debe alterar el equipo bajo ningQn concepto. La,s reparaciones sSIo debe ser rea zadas por el
contra cafdas. El entrenamiento sobre proteccibn contra caidas debe ser parte integral de un fabricante del equipo o personas o entidaaes autorizaaas por escrito por dicho fabricante.
programa de seguridad completo.
Cualquier producto que presente deformidades, desgaste poco comL_n o deterioro debe de ser
El uso correcto de los sistemas de protecciUn contra caidas puede salvar muchas vidas y reducir el inmediatamente descartado.
potencial de lesionamiento grave como consecuencia de una caida. El usuario debe estar consciente de Cualquier equipo que ha estado involucrado en una caida debe ser puesto fuera de servicio.
que las fuerzas experimentadas durante la supresiUn de una caida o la suspension prolongada pueden El usuario contara con un plan de rescate y los medios disponibles para implementarlo cuando haga uso de
causar lesionamiento corporal. Consulte a un medico si existe cualquier pregunta sobre la capacidad del este equipo.
usuario en utilizar este producto. Las mujeres embarazadas y los menores no deben hacer uso de este Este producto esta dise5ado para proteccion personal contra caidas. Nunca use e equipo de proteccion
producto, contra caidas para propositos q.ueno sean aquellos para os cua esha sido diseSado. El equipo de
REQUERIMIENTOS GENERALES proteccien contra caidas no debe nunca ser usado para remo_caro levantar cargas.
Siempre verifique si hay obstrucciones debajo del Area de trabajo para asegurarse de que en caso de una
Todas las advertencias e instrucciones sera_nproporcionadas al usuario. Se debe dar lectura a cak_a el lugar este despejaoo.
advertencias e instrucciones, y entenderlas, antes de hacer uso al equipo. Todo el material sintetico debe ser protegido contra escorias, chis.pas calientes, llamas descubiertas u otras
El equipo debe ser usado solamente por el personal que ha sido entrenado, fuentes de calor. En estas aplicaciones se recomienda usar materiales termorresistentes.
Todos los usuarios deben hacer referencia al esta.ndar ANSI Z359.1 y los reglamentos aplicables sobre la Se deben tomar en cuenta los peligros ambientales cuando se rea za a se ecciSn de equipo p.ara la
seguridad en el trabajo, protecciSncontra caidas. El equipo no debe quedar expuesto a productos quimicos capaces de produc r un
efecto daSoso. Se debe hacer uso del poliester en ciertos entornos qufmicos o acidicos. Si existe cualquier
A fin de reducir a un minimo la posibilidad de desenganche accidental, una persona competente debe duda, consulte con el fabricante.
2 asegurar la compatibilidad del sistema. La carga de trabajo maxima es 310 libras, a menos que se indique Io contrario en la etiqueta. 3
A LOOK AT DALLOZ FALL PROTECTION PRODUCT GROUPS cross-arm straps and eyebolts are sometimes necessary to make compatible connections between the
connect ng device and the anchor point.
A comprehensive fall protection program must be viewed as a "total system" beginning with hazard
Individually, none of these components will provide protection from a fall.
identification and ending with ongoing management review. Dalloz Fall Protection views its products Used properly with each other, they form the."Miller System" and become a
as a "system
properly usedwithin a system."
to provide Threeworker
maximum key components
protection. of the "Miller System" need to be in place and critically important part of the '"octalfall protection system." FALL ARREST
THREE SYSTEM COMPONENTS FOUR FUNCTIONAL PRODUCT CATEGORIES

Body Wear Fall Arrest,
Fall protection products Suspension,
Positioning, may be broken down into four functional categories:
Retrieval. _
The first component is the personal protective gear worn by workers while performing the job. Dalloz Fall
Protection manufactures a variety of body belts, positioning belts, and full body harnesses used in various
work environments. Because harnesses are the most appropriate equipment to be worn in the event of a free
FALL ARREST
A fall arrest system is required if any risk exists that a worker may fall from
an elevated position.
1
fall, more and more workers are using this type of device. Dalloz Fall Protection offers the broadest selection As a general rule, Dalloz Fall Protection recommends that a fall arrest
of harnesses in the industry and will design custom harnesses if necessary, system be used any time a working height of six feet or more is reached. 2__._>,
The second system component is the connecting device. This device is most commonly a shock-absorbing A fall arrest system is designed to be passive, and will only come into service
Connecting
lanyard or retractable
Devices lifeline because of their ability to dramatically reduce fall arresting forces, but may also , toWrkinga
shouldgradeheightor
a fall occur.
IoweriS
definedievei,
The following
as the aistance
are the proaucts
from the recommenaed
walking/workingbysurface
Dalloz I
I
be a conventionalrope or webbing lanyard. FallProtectionas part of a fall arrestsystem.
Anchor Point/Anchorage connector 1. Personal Protective Gear: Full Body Harness
The final component of the system is the anchor or tie-off point. This point must be capable of supporting 2. Connecting Device: Shock-Absorbing Lanyard
5,000 pounds per worker, such as an I-beam or other support structure. Anchorage connectors, such as 3. Anchor Point/Anchorage Connector: Cross Arm Strap/Support Beam
remplacement de ces composants par une combinaison de composants ou un sous-systeme non approuves, Dispositifs de connexion
ou les deux, pourrait modifier ou entraver leur fonctionnement securitaire mutuel et compromettre la
compatibilite interne du systeme. Une telle incompatibilite pourrait affecter la fiabilit_ etla securit6 du systeme Le second composant du systeme est le dispositif de connexion. Ce dispositif est tr_s frequemment un filin
dans son ensemble, amortisseur de choc, ou un filin de securite retractable, car ces dispositifs sont capables de reduire
considerablement les forces mises en jeu Iors d'un arr(_tde chute; cela peut aussi _tre un cordage
BRi=VE PRI_SENTATION DES GROUPES DE PRODUITS DALLOZ FALL conventionnel ou une sangle de securit&
PROTECTION DE PROTECTION CONTRE LES CHUTES I_l_ment de support/connecteur d'ancrage
Un programme global de protection contre les chutes dolt _tre considere comme un <<syst(_me complet>,
couvrant tousles aspects, depuis I'identification des risques jusqu'& I'examen critique permanent par la Le dernier composant du syst(_meest I'el(-_mentde support au point d'utilisation. Cet el(._mentde support dolt
direction. Dalloz Fall Protection consid_re que ses produits constituent un ,,syst_me au sein d'un systeme>,. 6tre capable de r_sister & une charge de 5 000 livres par travailleur protege; il s'agit par exemple d'une poutre
Pour que les travailleurs beneficient de la protection maximale, il faut que trois composants essentiels du de charpente ou d'un autre element de structure similaire. II est parfois necessaire d'utiliser un connecteur
,,systeme Miller>>soient en place et convenablement utilises, d'ancrage, comme un dispositif & sangles croisees ou & mousqueton, pour realiser un raccordement
LES TROIS COMPOSANTS DU SYSTf=ME compatible entre le dispositif de connexion et I'el_ment de support.
Harnais Individuellement,aucun de ces composants ne fournit une protectioncontre une chute. Lorsqu'ilssont utilises
convenablernent ensemble, ilsforment le <<syst_meMiller,, et sont alors les elements d'importance critique
Le premier composant est le harnais de protectionou autre accessoire porte par le travailleurqui execute une d'un <<syst_mecomplet de protectionoontreles chutes,,.
t&che. Dalloz Fall Protection fabrique une vari_t_ de ceintures de retenue, ceintures de positionnement et
harnais complets utilises dans divers environnements de travail. Comme le harnais est 1'equipement le plus QUATRE CATI_GORIES FONCTIONNELLES DE PRODUITS
appropfi_ & porter en cas de chute libre, de plus en plus de travailleurs utilisent ce type de dispositif. Dalloz
Fall Protection propose le plus grand choix de harnais dans I'industrie, et assure la conception de harnais On peut repartir les produits de protection contre les chutes en quatre categories fonctionnelles : arret de
personnalises Iorsque c'est necessaire, chute, positionnement, suspension, recuperation.
COMPATIBILIDAD DEL SISTEMA Dispositivos Conectores

Los ameses de cuerpo completo Miller est__n disefiados para el uso con componentes aprobados por Miller. La El segundo componente del sistema es el dispositivo conector. Com_nmente consiste en una cuerda
sustitucien o el reemplazo con combinaciones de componentes, subsistemas o ambos que no son aprobados amortiguadora o una cuerda salvavidas retractil debido a su habilidad para reducir dramAticamente las fuerzas
puede afectar o interferir con el funcionamiento seguro de cada uno y poner en peligro la compatibilidad de detenci6n de caida, pero tambien puede ser una cuerda tradicional o una cincha.
dentro del sistema. Esta incompatibilidad puede afectar la confiabilidad y la seguridad del sistema en total.
Punto de Anclaje/Conector de Anclaje
UNA MIRADA A LOS GRUPOS DE PRODUCTOS DE PROTECCION CONTRA
CAIDAS DE DALLOZ FALL PROTECTION El componente final del sistema es el punto de anclaje o de amarre. Este punto debe ser capaz de soportar
5000 libras por trabajador, tal como una viga I u otra estructura de apoyo. Algunas veces es necesario usar
Un programa de proteccien contra cafdas completo debe ser considerado como un "sistema total" conectores de anclaje, tales como correas en traviesas y pernos de argolla para hacer conexiones
comenzando con la identificacion de los riesgos y finalizando con una revision periedica por parle de la compatibles entre el dispositivo de conexion y el punto de anclaje.
administracion. Dalloz Fall Protection considera a sus productos como un "sistema dentro de un sistema."
Para proveer maxima protecci6n al trabajador, es necesario que se implementen y se utilicen adecuadamente Individualmente, ninguno de estos componentes proporcionara protecci6n contra una cafda. Sin embargo,
usados como un conjunto y de manera adecuada, ellos forman el "Sistema Miller_" y constituyen una parle
tres componentes claves del "Sistema Miller." esencialmente importante del "sistema total de proteccien contra caidas."
LOS TRES COMPONENTES DEL SISTEMA CUATRO CATEGORIAS FUNCIONALES DE PRODUCTOS
Equipo Corporal Los productos de proteccion contra cafdas pueden ser divididos en cuatro categorfas funcionales: Detenci6n
El primer componente es el equipo protector personal usado por los trabajadores cuando estan realizando el de la Cafda, Posicionamiento, Suspensi6n e Izamiento.
trabajo. Dalloz Fall Protection fabrica una variedad de cinturones para el cuerpo, cinturones de DETENCION DE CA[DAS
posicionamiento y arneses para todo el cuerpo usados en diversos ambientes de trabajo. Debido a que los
arneses son el equipo mas apropiado para usar en el caso de una cafda libre, su uso se esta haciendo cada Un sistema de detencion de cafdas es necesario si existe cualquier riesgo de que un trabajador pueda caerse
vez mas popular entre los trabajadores. Dalloz Fall Protection ofrece lamAs amplia seleccion de arneses de desde una posicion elevada.
4 la industria y tambien disefia arneses de acuerdo a especificaciones si es necesario. Como regla general, Dalloz Fall Protection recomienda que se utilice un sistema de detenci6n de cafdas 5
A full body harness distributes the forces throughout the body should a fall occur, thus reducing the chances By using this combination system, the fall arrest components will be activated should the worker suffer a fall while
of internal injuries. The shock-absorbing lanyard dramatically decreases the total fall arresting forces and is working or changing work positions.
designed to soften the impact of the arresting force onthe worker. SUSPENSION
The third component of the system is the anchor point/anchorage connector, POSITIONING The third category that can be supplied by Dalloz Fall Protection is the SUSPENSION
which must be capable of supporting 5,000 Ibs. per worker. This type of fall personal suspension system. These systems are used widely in the window
POSITIONING
arrest system must be used whenever there is a danger of falling, worker
washingwhileallowing a hands-free
and painting industries, workenvironment.
and Thecomponents
are designed to lower and support o
af a 3_3__ _ /
The second category is the personal positioning system, which holds a suspension system typically are: /%_
worker in place while allowing a hands-free work environment. Whenever a 1. Personal Protective Gear: Bos'n Chair
worker leans back, the system is activated, making this an "active" system.
The following is an example of a widely used positioning system: _ 2. Connecting Device: Workline/Lifeline 2
1. Personal Protective Gear: Full Body Harness 3. Anchor Point: Anchor Bolt/Carabiner
2. Connecting Device: Rebar Chain Assembly " Because the suspension system components are not designed to arrest a
3. Anchor Point:Vertical Rods 1 free fall, a back-up fall arrest system should be used in conjunctionwith the
, personal suspension system. This fall arrest system will only activate should
Note that a fall arrest system is used in conjunct/bnwith the personal positioning the worker experience a free fall.
system. DallozFall Protection urges the use of such a combination system
because a personal positioning system is not designedfor fall arrest purposes.
ARRF:T DE CHUTE de blessures internes. Le filin amortisseur de choc reduit considerablement la force maximale gener_e Iors
Un systeme d'arr_t de chute est necessaire s'il existe un risque quelconque d'un arr_t de chute; il est con(_upour amortir I'impact de I'arrt de chute sur
qu'un travailleurpuissetomber depuis une position6levee. le travailleur. '
ARRI_T DE CHUTE POSlTIONNEMENT
En regle generale, Dalloz Fall Protection recommande qu'un dispositif Le troisieme composant du systeme est le connecteur d'ancrage arrime sur
hauteur de travail de six pieds ou plus. On d6finit la hauteur de travail livres par travailleur. II convient d'utiliser ce type de dispositif d'arr_t de chute
d'arr_t de chute soit utilise chaque lois qu'un travailleur doit evoluer & une _lj_ _ un support d'ancrage; il doit _tre capable de supportel" une charge de 5 000
comme la distance entre la surface de marche/travail et le sol ou un niveau .7 chaque lois qu'il existe un risque de chute.
inf_rieur. I , ___3_3 POSITIONNEMENT
Un systeme d'arr_t de chute est congucomme un systeme passif; il n'entre La seconde cat_gorie regroupe les syst_mes de positionnement indMduels
en service qu'& I'occasiond'une chute. Dalloz Fall Protectionrecommande destines & maintenir un travailleur& une position appropriee tout en lui
remploi des produitssuivants dans le cadre d'un systeme d'arrCt de chute. 2_____>_ permettant de travailler a mains libres dans son environnementde travail. Le
1. Dispositif de protectionindMduel harnais complet systeme est active chaque lois que le travailleur se redresse, ce qui en fait
un syst_me actif. On decrit ci-dessous I'exemple d'un systeme de
2. Dispositif de connexion filin absorbeur de thee _ positionnement frequemment utilis& 1
3. I_l_ment de support/connecteur d'ancrage sangles crois_es sur 1 Dispositif de protection individuel - harnais complet
poutrelle de support
Un harnais couvrant I'ensemble du corps repartit & travers le corps toutes 2. Dispositif de connexion ' chaine 2
les forces mises en oeuvre & roccasion d'une chute; ceci r_duit les risques 3. I_l_ment de support/connecteur d'ancrage barres verticales
siempre que se trabaje a una altura de seis pies o mAs. La altura de trabajo se define como la distancia sistema de detencion de caidas debe ser usado siempre que exista peligro de sufrir una cafda.
desde la superficie de trabajo/marcha hasta el suelo o un nivel inferior.
POSlClONAMIENTO
Un sistema de detenci6n de caidas es diseSado para ser pasivo y solamente DETENCION DE La segunda categoria es el sistema de posicionamiento personal que
CAIDAS POSlCIONAMIENT(:
entra en servicio si es que se produce una cafda. A continuaci6n se indican mantiene al trabajador en el lugar permitiendole libre uso de las manos para
los productos recomendados por Dalloz Fall Protection como parte del efectuar el trabajo. Siempre que un trabajador se recuesta hacia arras, el
sistema de detenci6n de cafdas. _ _ sistema se activa, transformandoloen un sistema "activo." A continuacionse
2. Dispositivo Conector: Cuerda Amortiguadora 1. Equipo Protector Personal: Ames para Todo el Cuerpo
1. Equipo Protector Personal: Arn_s para Todo el Cuerpo I _ proporciona un ejemplo de un sistema de posicionamiento muy usado.
3. Punto de Anclaje/Conector de Anclaje: Correa para Traviesa/Viga de 2. Dispositivo Conector: Conjunto de Cadena Rebar
Soporte 21 _ I 3. Punto de Anclaje: Varillas Verticales

Un arnes para todo el cuerpo distribuye las fuerzas a traves del cuerpo si es Cabe destacar de que un sistema de detencion de caidas se usa conjuntamente
que se produce una cafda reduciendo de tal modo las posibilidades de sufrir con el sistema de posicionamiento personal. Dalloz Fall Protection encarece el 1
lesionestotales
fuerzas internas. La cuerda de
de detencion amortiguadora disminuye dramaticamente
la caida y esta.destinada a suavizar el las _ uso de un sistema combinado de tal tipo porque un sistema deposicionamiento
impacto de la fuerza de detencion en el trabajador, personal no esta disehadopara propositos de detencionde cafdas. Usando
este sistema combinado los componentes de/sistema de detencidn de cafdas
El tercer componente del sistema es el punto de anclaje/conector de anclaje, serbn activados si el trabajadorsufriera una cafda cuando est# trabajando o 2
el cual debe ser capaz de soportar 5,000 libras por trabajador. Este tipo de cambiando de posicidn.
6 7
F
RETRIEVAL WARNINGS
The fourth category of the system is mostly used in confined space, and is BODY WEAR
known as a personal retrieval system. This system is primarily used where
workers must be lowered into tanks, manholes, etc., and may require Visually check all buckles to assure proper and secure connections before each use. All straps
retrieval from above should an emergency occur. The following shows a RETRIEVAL must be connected and adjusted to provide a snug fit.
typical personal retrieval system: Fall protection connecting devices should be attached to the back d-ring of a full body harness.
1. Personal Protective Gear: Full Body Harness 3 Unless compatible, never attach non-locking snaps to a d-ring.
2. Connecting Device: Retractable Lifeline/Rescue Unit 2 Side, front, and chest d-rings should be used for positioning only.
3. Anchor Point: Tripod _ Shoulder d-rings should be used for retrieval only.
CONNECTING DEVICES
Do not use lanyards equipped with non-locking snap hooks or carabiners.
Always visually check that each snap hook and carabiner freely engages d-ring or anchor point,
and that its keeper is completely closed and locked.
Tie-off in a manner that limits free fall to the shortest possible distance. (Six feet maximum)
Shock absorbers can elongate up to 3-1/2 feet. This elongation distance must be considered when
choosing a tie-off point.
Noter qu'un syst#me d'arr#t de chute est utilis# en conjonctionavec le systeme de positionnementindividuel. Dalloz Comme les composants du systeme de suspension ne sont pas conus pour I'arr_t d'une chute libre, on dolt
Fall Protection recommandeinstamment I'emploi d'une telle combinaison, parce utiliser un systeme d'arr_t de chute en conjonction avec le syst_me de
qu'un systeme de positionnement individuel n'est pas con?u pour les fonctions suspension individuel. Le systeme d'arret de chute ne s'activera que si le
Ri_CUPI_RATION
d'arrdt de chute. Lors de I'emploi d'un systeme combin#,les composants d'arr#t travailleur subit une chute.
de chute entrent en oeuvresi le travailleur tombeen se d6plaantou en RI_CUPI_RATION
changeant de position de travail. La quatrieme cat_gorie regroupe les syst_mes utilises essentiellement dans 3
SUSPENSION un espace confine, pour la recuperation ou la descente d'une personne. Un 2
La troisieme cat6gorie d'equipements que Dalloz Fall Protection peut fournir tel systeme est utilis_ essentiellement Iorsqu'un travailleur dolt descendre
est celle des syst_mes de suspension individuels. Ces systemes sont dans un reservoir, regard, etc., pour qu'on puisse le remonter & I'air libre en
frequemment utilises dans les activites de lavage de fen_tres et peinture; ils cas d'urgence. Un systeme de recuperation individuel comprend
sont con_us pour permettre rabaissement et le support d'un travailleur, qui typiquement les composants suivants "
peut alors travailler & mains libres dans son environnement de travail. Un 1. Dispositif de protection individuel "harnais complet
systeme de suspension est typiquement constitue des composants
suivants ' 2. Dispositif de connexion filin de s_curit_ r_tractable/syst_me de secours
1. Dispositif de protection individuel siege suspendu 3. l_lement de support/connecteur d'ancrage " trdpied
2. Dispositif de connexion filin de s_curit_
3. 1_16mentde support/connecteur d'ancrage : boulon d'ancrage/mousqueton
SUSPENSION sistema es primordialmente usado donde los trabajadores deben ser bajados hacia depositos, pozos de
La tercera categorfa que puede ser suministrada por Dalloz Fall Protection es el sistema de suspension _ inspeccion, etc. y pueden requerir ser trafdos a la superficie desde arriba en
personal. Estos sistemas son usados ampliamente en las industrias de caso de una emergencia. A continuaci6n se indica el sistema de izamiento
limpieza de ventanas y pintura y estan diseSados para bajar y apoyar a un personal tipico: IZAMIENTO
trabajador a la vez que le deja las manos libres para trabajar. Los
componentes de un sistema de suspension tipica son: , 1. Equipo Protector Personal: Arnes para Todo el Cuerpo
1. Equipo Protector Personal: Silleta 2. Dispositivo Conector: Cuerda Salvavidas Rectrdctil/Unidad de Rescate
2. Dispositivo Conector: Cuerda de Trabajo/Cuerda Salvavidas 3. Punto de Anclaje: THpode _ _
3. Punto de Anclaje: Perno de Anclaje/Mosquetbn ADVERTENCIAS /; _///

Debido a que los componentes del sistema de suspensi6n no est_m EQUIPO CORPORAL / _ '_B__/
detencion de cafda conjuntamente con el sistema de suspensi6n personal, comprobar de que las conexiones sean correctas y seguras antes ' ,_ ._,, _,
dise_ados para detener una cafda libre, se debe usar un sistema auxiliar de Antes de cada uso revise visualmente todas las hebillas para _ "" _'
Este sistema de detenci6n de caida solamente se activara,si el trabajador de cada uso. Todas las correas deben ser conectadas y ajustadas I_ _,_
sufre una cafda libre, de manera que provean un ajuste sin holgura. ,_tI _ #
La cuarta categorfa del sistema es mayormente usada en espacios

IZAMIENTO instalados
Los en el anillo
dispositivos en Dendelaproteccion
conectores parte trasera de un
contra arn_s deben
caidas para todo
ser _ "_-_,_
confinados y se conoce como un sistema de izamiento personal. Este el cuerpo.
8 9
Tie-off in a manner which ensures a lower level will not be struck should a fall occur. Always work directly under the anchor point to avoid a swing-fall injury.
Never disable or restrict locking keeper or alter connecting device in any way. Never wrap lanyards around sharp or rough anchor points. Use a cross arm strap or other
Do not attach multiple lanyards together, or attach a lanyard back onto itself, unless specifically compatible anchorage connector to connect lanyard snap hook.
MAKING
designed for such a connection. Ensure that the anchor point is at a height that limits free-fall
CONNECTIONS
Do not allow rope or webbing to come in contact with high temperature surfaces, welding, heat distance to six feet or less.
sources,electrical hazards, or moving machinery. Anchor point must be compatiblewith snap hook or carabinerand (_
Do not tie knots in lanyards. Do not wrap lanyards around sharp, rough edges, or small diameter must not be capable of causing a load to be applied to the keeper.
structural members. Use a cross-arm strap or other compatible anchorage connector to attach Ensure that the anchor point is at a height that will not allow a lower
lanyard snap hook. level to be struck should a fall occur.
The use of shock absorbers, like the Miller Manyard or SofStop, is highly recommended to reduce
fall arresting forces. When selecting an anchorage point, always remember that shock "r
Never use a steel cable lanyard for fall arrest unless used in conjunction with a shock absorber. "
absorbers may elongate up to 3-1/2 feet.
Never use an anchor point which will not allow snap hook or
L
Never use natural materials (manila, cotton, etc.) as part of a fall protection system, carabiner keeper to close. _
Do not tie-off into an object which is not compatible with lanyard snap hooks or carabiners.
Make sure snap hook is positioned so that its keeper is never load bearing. ._
ANCHOR POINTS
Anchor points must be capable of supporting 5,000 pounds per worker.
AVERTISSEMENTS Effectuer I'arrimage d'une manibre qui limitera au maximum la distance de chute (six pieds
ACCESSOIRES INDIVIDUELS maximum).
Avant chaque utilisation, inspecter visuellement tous les anneaux et boucles pour v_rifier leur bon L'amortisseur de choc peut subir une _longation de 3,5 pieds. On dolt tenir compte de cette
6tat et leur fixation. Connecter et ajuster chaque sangle pour obtenir un bon ajustement, distance d'_longation Iors du choix d'un point d'ancrage.
L'organe de connexion du dispositif de protection contre les chutes devrait _tre fix_ b la boucle en Effectuer I'arrimage d'une mani_re telle que le travailleur ne rentrera pas en contact avec un
D, dans le dos du harnais complet, niveau inf_rieur b I'occasion d'une chute.
Sauf Iorsque la compatibilit_ est v(_rifi_e,ne jamais fixer un mousqueton non verrouillable taune Ne jamais ddsactiver ou entraver le dispositif de verrouillage, ou modifier d'une manibre
boucle en D. quelconque le dispositif de connexion.
Ne pas attacher ensemble plusieurs filins de si=curiti: ou accrocher un filin de s/:curit# sur lui-mime,
Utiliser les boucles en D des c6t_s, de I'avant et de la poitrine uniquement pour le positionnement. $ moins qu'il ne soit spi:ciflquement conAu pour une telle connexion.
Utiliser les boucles en D des epaules uniquement dans une situation de r6cup(_ration. Ne pas laisser le filin ou la sangle venir en contact avec surface _ temperature 6levee, materiel de
DISPOSITIFS DE CONNEXION soudage, sources de chaleur, conducteurs _lectriques ou machine en mouvement.
Utiliser uniquement un filin de s6curit_ dot_ de mousquetons verrouillables ou d'anneaux _ _crou Ne pas faire des nceuds dans les filins. Ne pas enrouler un filin autour d'un _l_ment de structure
de verrouillage, de petit diambtre ou comportant des arr_tes acdrdes. Utiliser un connecteur d'ancrage _ sangles
Effectuer toujours une inspection visuelle pour v6rifier que chaque mousqueton ou anneau a crois_es ou autre connecteur compatible pour arrimer le mousqueton du filin.
6crou de verrouillage est correctement plac6 sur la boucle ou I'organe d'ancrage et que son On recommande fortement I'emploi d'un amortisseur de choc, comme un dispositif Manyard ou
dispositif de verrouillage est parfaitement ferm_ et verrouill6. Sofstop de Miller, pour r_duire la force d6ployde Iors d'un arr6t de chute.
A menos que sean compatibles, nunca instale mosquetones sin cierres en un anillo en D. No permita que la cuerda o la cuerda entre en contacto con superficies a altas temperaturas, con
, soldaduras, fuentes de calor, riesgos el_ctricos o maquinaria mbvil.
Los anillos en D laterales, frontales y del pecho deben ser usados solamente para
posicionamiento. No haga nudos en las cuerdas. No enrolle las cuerdas alrededor de bordes afilados o asperos o
Los anillos en D de los hombros deben ser usados para propdsitos de izamiento solamente. miembros estructurales de diametro peque6o. Use una correa de traviesa u otro conector de
anclaje compatible para instalar el mosquet6n de la cuerda.
DISPOSITIVOS
CONECTORES
El uso de amortiguadores, tales como el Manyard o Sofstop de Miller, es altamente recomendado
Use solamente cuerdas de seguridad con ganchos de resorte o mosquetones de seguridad, para reducir el impacto de las fuerzas de detenci6n de caidas.
Siempre verifique visualmente que el gancho de seguridad y el mosquetbn enganchen libremente Nunca utilice una cincha de cable de acero para detener una caida a menos que conjuntamente
el anillo en D o el punto de anclaje y que su fijador este completamente cerrado y bloqueado, con ella utilice un amortiguador.
Instale de manera que limite la caida libre a la distancia m_s corta posible. (Seis pies mdximo). Nunca use materiales naturales (manila, algodbn, etc.) como parte de un sistema de proteccion
Los amortiguadores pueden alargarse hasta 3 1/2 pies. Esta distancia de elongacibn debe ser contra caidas.
considerada cuando se esta eligiendo el punto de amarre. No enganchar en ningt_n objeto que no sea compatible con las cuerdas de seguridad con ganchos
Instale firmemente de manera que en caso de una caida no exista ningt_n riesgo de golpear un de resorte o mosquetones.
nivel inferior. Asegdrese de que el mosquetbn estd colocado de manera que su dispositivo de cierre nunca estd
Nunca desconecte o restrinja los dispositivos de cierre ni altere el dispositivo de conexibn de soportando carga.
ninguna
manera. PUNTOS
DEANCLAJE
No conecte cuerdas m.ltiples juntas, ni instale una cuerda sobre si misma a menos que haya sido Los puntos de anclaje deben poder soportar 5,000 libras por trabajador.
10 especificamente diseOada parasemejante conexiUn. 11
r
A. Connecting to the body support
...,NO
CO.NEC.,ONS
For general fall protection, connect the lanyard to the back D-ring on the full body harness. The energy
absorber portion of the lanyard (if equipped) should be connected to the body support (back d-ring).
B. Connecting to the Anchorage
Single leg lanyards: Connect the other end of the lanyard to anchorage or anchorage connector. Make
sure connections are compatible in regards to size, strength, and shape.
Dougle leg lanyards: Connect one of the free ends of the lanyard to anchorage or anchorage connector.
to retain a 100% tie off, make sure at least one of the legs is connected at all times to an anchorage or LANYARD INSPECTION obstructed (Fig. 1). The keeper spring should
anchorage connector of compatible size, strength and shape. When inspecting lanyards, begin at one end and exert sufficient force to firmly close the keeper.
NOTE: CONNECT THE SPARE LEG OF THE LANYARD ONLY TO THE LANYARD RING OR CLIP. work to the opposite end. Slowly rotate the lanyard Keeper locks must prevent the keeper from
DO NOT CONNECT SPARE LEG OF LANYARD TO PERMANENTLY FIXED COMPONENTS OF THE so that the entire circumference is checked. Spliced opening when the keeper closes.
HARNESS (i.e., Chest strap, side D-rings) ends require particular attention. Hardware should b. Thimbles: The thimble must be firmly seated in
be examined under procedures also detailed below, the eye of the splice, and the splice should have
INSPECTION AND MAINTENANCE i.e., snaps, d-ring and thimbles, no loose or cut strands. The edges of the thimble
Miller lanyards are designed for today's rugged work environments. To maintain their service life and high 1. HARDWARE must be free of sharp edges, distortion, or cracks
performance, lanyards should be inspected frequently. Visual inspection before each use is just common ," a. Snaps: Inspect closely for hook and eye (Fig. 2).
sense. Regular inspection by a competent person for wear, damage or corrosion should be a part of your distortions, cracks, corrosion, or pitted surfaces. 2. STEEL LANYARD
safety program. Inspect your equipment daily and replace it if any of the defective conditions explained in this The keeper (latch) should seat into the nose While rotating the steel lanyard, watch for cuts,
manualarefound, withoutbindingandshouldnotbedistorted or
Ne jamais utiliser un filin en acier comme dispositif pour arr_ter une chute, except_ en conjonction II Tautque I'organe d'ancrage soit compatible avec le mousqueton ou I'anneau ta_crou de
avec dispositif amortisseur de choc. verrouillage; il ne Taut pas qu'il puisse provoquer I'application d'une
Ne jamais utiliser des matdriaux naturels (manille, coton, etc.) dans un systbme d'arr_t de chute, charge sur I'orange de verrouillage.
Ne jamais effectuer I'accrochage sur un objet qui serait incompatible avec les mousquetons ou Choisir un element de support situd a une hauteur appropride pour que
anneaux & dcrou de verrouillage du filin de s_curit& le travailleur prot_g_ ne puisse entrer en contact avec un niveau
infdrieur & I'occasion d'une chute.
Veiller _ ce que chaque mousqueton soit positionn_ de telle mani_re que son dispositif de
verrouillage ne soit jamais soumis & une charge. Lors de la sdlection de I'_ldment de support, ne pas oublier qu'un
amortisseur de choc peut subir une elongation de 3,5 pieds.
ELEMENTS DE SUPPORT/ANCRAGE
Ne jamais utiliser pour I'ancrage un organe ou composant qui ne
Chaque _l_ment de support dolt _tre capable de soutenir un charge de 5 000 livres par travailleur, permettrait pas la fermeture parfaite du mousqueton ou anneau ta 1
Travailler directement dans I'alignement du point d'ancrage pour 6viter les risques de chute
pendulaire,
dcrou de verrouillage.
RI_ALISATION
DIESCONNEXlONS
t
rugueuses.
Ne jamais enrouler
Utiliser un
unefilin de s_curit_
sangle croisde autour d'un _l_ment
ou un autre de structure
connecteur d'ancrageaux arr_tes acCrUes
compatible ou le
pour fixer A. Connexion au harnais I
mousqueton du filin de s_curit& Pour une protection g_n_rale contre les chutes, connecter le filin & la /&
Veiller b utiliser un _l_ment de support situd b une altitude qui limitera la descente en chute libre b boucle en D situee dans le dos du harnais complet. La section /r_
six pieds ou moins, d'absorption d'energie du filin (s'il y en a une) dolt _tre connect6e au
harnais (par la boucle en D du dos).
Siempre trabaje directamente bajo el punto de anclaje para evitar una caida pendular que puede Para protecci6n general contra caidas, conecte la cuerda al anillo en D de la espalda en el arnes de todo el
causar una lesion, cuerpo. La parte de la cuerda que absorbe la energ/a (si la tiene) debe conectarse al arnes (anillo en D de
Nunca pase las cuerdas sobre puntos de anclaje afilados o dsperos. Use una correa de traviesa u _ la espalda).
otro conector de anclaje compatible para instalar el mosquetbn de B. Conexibn al Anclaje
la cuerda. Lanzaderas de pata sencilla: Conecte el extremo opuesto de la lanzadera al anclaje o al conectador de
Aseg_rese de que el punto de anclaje estd a una altura que limite la anclaje. AsegOrese de que las conexiones sean compatibles en Io que respecta al tamaSo, fuerza y forma.
distancia de caida libre a seis pies o menos.
El punto de anclaje debe ser compatible con el gancho de resorte o B__ _lJ_ Lanzaderas de pata doble: Conecte uno de los extremos libres de la lanzadera al anclaje o al conectador
fijador, conectada en todo momento a un anclaje o conectador de anclaje compatible en tamaSo, fuerza y forma.
mosquet6n y no debe permitir que se pueda aplicar una carga al _ de anclaje. Para retener un amarre a1100%, asegLirese de que al menos una de las patas se encuentre
Asegdrese de que el punto de anclaje estd a una altura que no AVISO: CONECTE LA PATA ADICIONAL DE LA LANZADERA AL ANILLO O PRESlLLA DE LA
permitird que el nivel inferior sea golpeado si ocurriera una caida. LANZADERA SOLAMENTE. NO CONECTE LA PATA ADICIONAL DE LA LANZADERA A LOS
Cuando seleccione un punto de anclaje, siempre recuerde que las COMPONENTES DE FIJACION PERMANENTE DEL ARNES (p.ej., correa de pecho, anillos laterales
cuerdas elasticas amortiguadoras se pueden alargar hasta 3 1/2. en "D")
o
Nunca use del
el fijador un punto de anclaje
mosquetbn quecerrarse.
puedan impida que el gancho de resorte INSPECClON f MANTENIMIENTO
HACIENDO LAS CONEXIONES Los arneses Miller estan diseSados para las condiciones de trabajo rudas de hoy en dfa. Para mantener su
vida de servicio y alto rendimiento, los arneses deben ser inspeccionados con frecuencia. La inspecci6n
A. Conexi6n al arnds visual antes de cada uso es una buena practica. La inspecci6n regular por una persona competente para
12 13
frayed areas, or unusual wearing patterns on the observe each side of the webbed lanyard (Fig. 4). end-to-end will bring to light any fuzzy, worn, broken for burn holes and tears (Fig. 6). Stitching on areas
wire (Fig. 3). Broken strands will separate from the This will reveal any cuts, snags, or breaks. Swelling, or cut fibers (Fig. 5). Weakened areas from extreme where the pack is sewn to d-rings, belts, or lanyards
body of the lanyard, discoloration, cracks, charring are obvious signs of loads will appear as a noticeable change in original should be examined for loose strands, rips, and
chemical or heat damage. Observe closely for any t diameter. The rope diameter should be uniform deterforation.
3. WEB LANYARD/MANYARD breaks in the stitching. Inspect manyard warning throughout, following a short break-in period.
While bending webbing over a pipe or mandrel, flag for signs of activation, l 5. MILLER SOFSTOPS/STRETCHSTOPS Nylon & Cordura
4. ROPE LANYARD The outer portion of the pack should be examined
Rotation of the rope lanyard while inspecting from
B. Comment se relier au point d'attache
d'attache ou au connecteur d'ancrage. S'assurer que les connexions soient compatibles en matiere de
grosseur, force et forme. ' '
Pour les cordes d'amarrage a jambe double: Relier I'une des extremites libres de la corde d'amarrage
au point d'attache ou au connecteur d'ancrage. Pour retenir une corde de fixation & 100 %, s'assurer
qu'au moins
Pour les une des
cordes jambes soit
d'amarrage reliee simple:
_ jambs en tout temps
Relier &I'autre
un point d'attachede ou
extremite & un connecteur
la corde d'amarrage d'ancrage
au point _ _
de grosseur, de force et de forme compatibles.
REMARQUE: RELIER LA JAMBE LIBRE DE LA CORDE D'AMARRAGE UNIQUEMENT ,&.L'ANNEAU INSPECTION DES FILINS Ioquet dolt prendre appui sans blocage contre le
nez du crochet, et il ne dolt pas tre deform6 ou ne
OU LA BRIDE DE FIXATION. NE PAS RELIER LA JAMBE LIBRE DE LA CORDE D'AMARRAGE Lors d'une inspection d'un filin, commencer & une pouvoir manoeuvrer (fig. 1). Le ressort du Ioquet
AUX COMPOSANTS DU HARNAIS FIXI_S DE FA(_ON PERMANENTE (les courroies pectorales, les extremite, et progresser vers I'autre extremit& Faire dolt exercer une force suffisante pour fermer
poigndes-_triers, par exemple), pivoter lentement le filin pour pouvoirI'inspectersur fermement le mousqueton. Le dispositifde
toute sa circonference. Accorder une attention verrouillage doit emp_cher I'ouverturedu Ioquet
INSPECTION ET ENTRETIEN particuli_re aux epissures des extremites. Examiner apr_s la mise en place.
Les filins de securite Miller sont congus pour les environnements de travail agressifs d'aujourd'hui. Pour les accessoires (mousquetons, boucles en D et oeillets
pouvoir maximiser leur Iongevite et leur performance, il convient d'inspecter frequemment les filins. II coule de conformement aux m_thodes d_crites ci-dessous, b. _illets : L'eeillet de garnissage dolt 6tre
fermement embofte darts la boucle de I'epissure,
source qu'il convient d'effectuer une inspection visuelle avant chaque utilisation. Le programme de securite 1. ACCESSOIRES et I'epissure ne dolt comporter aucun brin coupe
devrait comprendre des inspections regulieres par une personne competente, pour la recherche des indices a. Mousquetons : Inspecter de pros pour identifier les ou detach& Les bords de I'oeillet de garnissage
d'usure, de deterioration ou de corrosion. Inspecter I'equipement chaque jour, et remplacer celui-ci Iors de la indices de distorsion du crochet ou de la boucle, doivent _.treexempts de bavures, distorsion ou
decouverte de toute defectuosite decrite dans ce manuel, fissuration, corrosion ou attaque superficielle. Le fissures.
2. FILIN D'ACIER
coupure, brins ef rme ou r pus, ou
_ le la rtatin du filin _'a_ier' I_chercther les
verificar desgaste, da_o o corrosi6n debe formar toda la circunferencia. Los extremos empalmados debe calzar contra la nariz del gancho sin atascarse y 2. CUERDA DE ACERO
parte de su programa de seguridad. Inspeccione su requieren atencion especial. Se debe examinar la no debe estar deformado u obstruido (Fig. 1). El Gire la cuerda de acero para verificar si tiene cortes,
equipo diariamente y reempla.celo si encuentra ferreter(a siguiendo los procedimientos indicados a resorte del cierre debe ejercer suficiente fuerza para Areas raidas o configuraciones de desgaste poco
alguna de las condiciones defectuosas indicadas en continuaci6n, es decir, cierres, anil}os en D y cerrar firmemente el cierre. Los seguros del cierre comunes en el alambre (Fig. 3). Los torones rotos se
este manual, guardacabos, debenimpedirque este se abracuandoestacerrado, separarandel cuerpode la cuerda.
INSPECCION DE LA CUERDA DE SEGURIDAD 1. FERRETERiA b. Guardacabos: El guardacabo debe estar 3. CINCH.& TEJIIB.&/M.&NY.&RI_
Cuando inspeccione las cuerdas, comience en un a. Mosquetones: Inspeccione detenidamente para firmemente asentado en el ojo del empalme y el Doble la cincha sobre una tuberia o husillo y observe
extremo y continL_ehasta Ilegar al otro extremo. Gire verificar distorsi6n del gancho y del ojo, grietas, empalme no debe tener hebras sueltas o cortadas, ambos lados de la cincha (Fig. 4). Esto revelarA
lentamente la cuerda de modo que se pueda revisar corrosion o superficies picadas. El cierre (pestillo) Los bordes de los guardacabos no deben ser cualquier corte, desbaste o roturas. El hinchamiento,
afilados, presentar distorsion o grietas (Fig. 2).
14 descoloracion, grietas, carbonizaci6n son seSales 15
Basic care of all Dalloz Fall Protection equipment will prolong the durable life of
the unit and will contribute toward the performance of its vital safety function.
becomes brittle and has Change in color usually Webbing strands fuse Paint which penetrates Proper storage and maintenance after use are as important as cleansing the
a shriveled brownish appearing as a brownish together. Hard shiny and dries restricts equipment of dirt, corrosives, or contaminants. Storage areas should be clean,
CLEANING !
appearance. Fibers will smear or smudge, spots. Hard and brittle movement of fibers, dry and free of exposure to fumes or corrosive elements.
break when flexed. Transverse cracks when feel. Will not support Drying agents and
Should not be used belt is bent over a combustion, solvents in some paints Wipe off all surface dirt with a sponge dampened in plain water. Squeeze the
above 200 F. mandrel. Loss of will appear as chemical sponge dry. Dip the sponge in a mild solution of water and commercial soap or
elasticity in belt. damage, detergent. Work up a thick lather, with a vigorous back and forth motion. Then
wipe dry with a clean cloth. Hang freely to dry, but away from excessive heat,
steam, or tong periods of sunlight.
Polyester (Dacron*)
........ .... , ..... r--
do not use above 180 F. Same as nylon. Same as nylon, except Same as nylon.
Inexcessiveheat,nylon willsupportcombustion.
Note. Contact Dalloz Fall Protectionat 1-800-873-5242if you have any questions regardingthe above chart.
*DuPonttrademark.
zones d'usure inhabituelle du c&ble (fig. 3). Les sangle (fig. 4). Ceci permet d'identifier les coupures et extremit_ & I'autre permet d'identifier les brins de SOFSTOPS/STRETCHSTOPS
brins brises se s_pareront du corps du filin, les brins rompus ou d_form_s. Les gonflements, fibre coup_s, brises, uses ou d6t_rior_s (fig.5). Examiner la partie externe du dispositif pour
3. SANGLE changements de couleur, fissures et traces de Toute zone affaiblie par une charge extreme sera rechercher les perforations ou dechirures (fig. 6).
combustion sont des indices evidents de deterioration caracterisee par une modification notable du Examiner les coutures au voisinage des points de
En cintrant une sangle sur un tuyau ou autre par la chaleur ou les produits chimiques. Rechercher diametre initial. Le diametre du filin devrait 6tre fixation sur boucle en D, ceinture ou filin pour
accessoire cylindrique, observer chaque face de la les indices de declenchement du dispositif d'activation, uniforme d'une extremite & rautre awes une breve rechercher les brins d_tach_s, d_chirures et
4. FILIN DE CORDAGE periode de rodage, d6teriorations.
La rotation du filin Iors d'une inspection d'une 5. DISPOSITIFS D'ARRF:T DE CHUTE MILLER Nylon et Cordura
(Fig. 6). Las costuras en los lugares en que el dispositivo es cosido a los anillos en D, correas o cuerdas
deben ser examinadas para verificar si hay hilos sueltos, razgaduras y deterioro.
obvias de da_o quimico o por calor. Observe Las Areas mas debilitadas debido a cargas extremas
detenidamente para verificar si las costuras estan se caracterizaran por una reducci0n notable del
deshilachadas. Inspeccione la bandera de diametro original. El di,_metro de la cuerda debe ser
advertencia del Manyard para comprobar si tiene uniforme en todo el largo, despu_s de un breve
seSasde activaci6n, periodode rodaje.
4. CUERDA DE FIBRA 5. DISPOSlTIVOS DE PARADA DE CAiDAS
Haga girar la cuerda a la vez que la inspecciona de SOFSTOP/STRETCHSTOP
un extremo al otro para verificar si las fibras se han Se debe inspeccionar la parte externa del dispositivo
apelusado, estan gastadas, rotas o cortadas (Fig. 5) para descubrir si tiene perforaciones o desgarres
16 17
DATE: LENGTH: MODEL: MATERIAL: NYLON CAPACITY: 310 LBS.
ARRESTING FORCE: 900 LBS ANSI A10.14. OSHA 1925.502 MADE IN THE U.S.A. LMANYARD& LANYARD LABEL
I
WARNING:
* RIG LANYARD TO ALLOW A MAXIMUM FREE FALL DISTANCEOF NOT MORE THAN SIX FEET (6'). l lll FI -_ |_it_;_
"DO NOT ALLOW LANYARD
TEMPERATURES TO DEGREES.
ABOVE 180 CONTACT SHARP OR ABRASIVE SURFACES, SPARKS OR Ill I I_];_ 1!_ It_.,_l,;.,
10_]_, _
SNAP HOOKS WITH GATE OPENINGS LARGER THAN ONE INCH (1 ") MUST NOT BE CONNECTED - ____ li _iii } _
TO D-RINGS ON HARNESSES AND BELTS. |, , , ,=,, ,i_l,_.,_l , _ .u=

REMOVE FROM SERVlCE BFANY DAMAGE IS DETECTED. /IIIH_ _|_ : _ _
WARNING _ill ,-_ "_":.
, _.=_ _;_
MANUFACTURER'S
MUST
CONTACT BE FOLLOWED:INSTRUCTIONS
DALLOZ FALLFAILURE SUPPLIED
TO DO
PROTECTION SO WITHRESULT
COULD THIS PRODUCT
IF INSTRUCTION
ATTHETIME
IN SERIOUS
MANUAL INJURY OROF
IS NEEDED.
SHIPMENT
DEATH. -fl'
_ltl
_1 I I I1 1"1_
t _
"' !il _""'
_ f -_'
__ ""_';_ __ii
A'I-I'ACH THIS END TO HARNESS. CAUTION: INSPECT BEFORE EACH USE. PUNCH GRID ON _ } I I I I_1 __ _ _ _ .u_.<_'_=--
DATEOFFIRSTUSE _11111t . _ i _ .o._"
_.
INDICES VISUELS DE DI_TI_RIORATION DES SANGLES E1 FILINS NETTOYAGE

YPE DE MATERIAU CHALEUR COMPOSE CHIMIQUE FLAMME OU MI_TALFONDU PEINTURE ET SOLVANT_ Un entretien ordinaire de tout _quipement de securite Dalloz Fall Protection
maximisera sa Iongevite et lui permettra de remplir ses fonctions de securite au
chaleur excessive, le couleur se manifeste Fusion et agglomeration La peinture qui penetre et niveau de performance maximum. Le remisage et rentretien convenables apres
En presence d'une nylon se fragilise et se generalement par une des brins. Zones dures et seche entre les fibres I'utilisation sont des facteurs tout aussi importants que le nettoyage de
contracte en prenant une teinte brun&tre. Fissures brillantes. Sensation de entrave leur mouvement. I'_quipement pour relimination de souillures, contaminants ou produits corrosifs.
teinte marron. Les fibres transversales Iors de la durete et fragilitY. Le Les agents dessiccants Les lieux de remisage doivent _tre propres, secs et exempts de gaz et
se brisent Iors d'une flexion de la ceinture ou produit n'entretient pas la et solvants de certaines d'_lements corrosifs.
flexion. Ne pas utiliser & sangle sur un support combustion, peintures produisent les
une temperature cylindrique. Perte m_mes dommages que I_liminer les souillures superficielles par essuyage avec une _ponge humidifiee
superieure a 2000 F. d'elasticite de la ceinture, les produits chimiques, d'eau propre. Serrer I'_ponge pour I'essorer. Plonger I'eponge dans une
solution & faible concentration d'eau et de detergent ou de savon commercial.
Unchangementde Frottervigoureusement dansun mouvementde va-et-vientpourproduireune
mousse epaisse. Secher ensuite avec un linge propre. Suspendre I'equipement
pour le faire secher, mais & distance de toute source de chaleur ou vapeur;
Polyester (Dacron*) Comme pour le nylon; ne Comme pour le nylon. Comme pour le nylon; Comme pour le nylon, eviter egalement une exposition prolongee au rayonnement solaire.
pasutiliser&une maisce materiau
temperature superieure a entretient la combustion.
180F.
Note: Contacter Dalloz Fall Protectionau 1-800-873-5242pur toute questions concemant le tableau ci-dessus. *Marquecommercialede D__ont.
INDICACIONES VISUALES DE DAI_IO A LAS CUERDAS Y CINCHAS

LIMPIEZA
IPO DE MATERIAL CALOR PRODUCTOS QUiMICOS METAL FUNDIDO O LLAI_ PINTURA Y SOLVENTES
El cuidado b&sico del equipo de seguridad de Dalloz Fall Protection prolongara
su duracion y contribuira al buen desempeSo de su funcion vital de seguridad.
Nilon y Cordura Con calor excesivo, el El cambio de color por Io Las hebras de la cuerda La pintura que penetra y El almacenamiento y el mantenimiento adecuado despues del uso son tan
nilSn puede general aparece como se fusionan. Puntos duros se seca restringe el importantes como la limpieza del equipo para extraer la suciedad, corrosivos o
quebrajarse y tomar una mancha cafe. brillantes. SensaciSn de movimiento de las contaminantes. Las areas de almacenamiento deben estar limpias, secas y no
una apariencia reseca Grietas transversales dureza y fragilidad. No fibras. Los agentes de estar expuestas a emanaciones o elementos corrosivos.
de color cafe. Las cuando el cinturon es soportara la combustiSn, secado y los solventes
fibras se quiebran curvado sobre un tubo. en algunas pinturas Limpie toda la suciedad de la superficie con una esponja humedecida en agua
cuando se doblan. No Perdida de elasticidad apareceran como daSo pura. Estruje bien la esponja. Introduzca la esponja en una solucion de agua y
debe usarse con del cinturon, qu_mico, jabon comercialo detergentesuave. Forme una espuma abundantecon un
temperaturas movimiento vigorosohaciaadelantey haciaatras.Luegosequeconun paso
superioresa 200F. limpio.Cuelgueloparasecarloperoalejadodelcalorexcesivo,vaporo
pefiodos prolongados de luz solar.
Poli_ster (DacrSn*) Igual al nilSn, excepto Igual que el nilSn. Igual que el nilSn, excepto que nilon.
no usar atemperaturas no soportarala
superiores a 180-F. combustion. Igualque el
Nota: *Marca Registrada de Du Pont. Pongase en contactocon Dalloz Fall Protectional 1-800-873-5242si tiene
18 alguna pregunta respecto a la tabla anterior. 19

DATE: LENGTH: MODEL: MATERIAL: NYLON CAPACITY: 310
ARRESTING FORCE: 900 LBS ANSI: Z359.1, A1014, OSHA 1925.502 MADE IN THE U.S.A. _ v l_J _ IMANYARD & LANYARD LABEL_
WARNING
RIG MANYARD TO ALLOW A MAXIMUM FREE FALL DISTANCE OF NOT MORE THAN SIXFEET (6'). 9_:_'_] , II>_ll_ii :_|_ _,,',, Eal,,{
-
USER MUST ALLOW FOR 3'-6" EXTENSION DISTANCE BEYOND THE STATED LENGTH OF THE z _i_ : ,- ._ ,' -_
MANYARD.
* CONNECTORS AND ANCHORAGE POINTS MUST BE COMPATIBLE AND ABLE TO SUPPORT 5,00OLBS. /i _ I _ t_|_o i
=_' ' it,
' ''i'_ o=._
TEMPERATURES ABOVE 180DEGREES. ,: _ _ _ I _ . _

SNAP HOOKS WITH GATE OPENINGS LARGER THAN ONE INCH (1") MUST NOT BE CONNECTED c> _._ __ _,_
REMOVE FROM SERVICE IF ANY DAMAGE IS DETECTED. [_;:_

l}_ 5_ _ ._[ _ _ .=
MANUFACTURER'S INSTRUCTIONS SUPPLIED WlTH THIS PRODUCT AT THE TIME OF SHIPMENT W_ i_ _-" _ .1_ _ ;_ _ I_ ; _.:_
MUST BE FOLLOWED: FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH. . _ _ _ _ " '==
CONTACT DALLOZ FALL PROTECTION IF INSTRUCTION MANUAL IS NEEDED. _ [i I _'I _ _ _ _ _ _
ATTACH THIS END TO HARNESS. CAUTION: INSPECT BEFORE EACH USE. PUNCH GRID ON
DATE OF FIRST USE.
MILLER EQUIPMENT LANYARD LABEL (FIG. A) CE PRODUIT LORS DE SA LIVRAISON. LE NON-RESPECT DE CES INSTRUCTIONS PEUT
DATE : MOD#LE : LONGUEUR : CAPACITI_: 310 LB. LONGUEUR : ENTRAINER DE GRAVES BLESSURES, VOIRE UN ACCIDENT MORTEL.
MATI_RIAU: NYLON FORCE D'ARR_T DE CHUTE : 900 LB. FIXER CEI-FE EXTREMITE AU HARNAIS
FABRIQU AUX F:TATS-UNIS ANSI A10,14 OSHA 1926.502 MISE EN GARDE : INSPECTER AVANT CHAQUE UTILISATION
AVERTISSEMENT : POIN(_ONNER CETTE CARTE A LA DATE DE LA PREMIX:RE UTILISATION
. LE CONNECTEUR ET L'ELI_MENT DE SUPPORT/D'ANCRAGE DOIVENT _:TRE COMPATIBLES ET
CAPABLES DE SUPPORTER UNE CHARGE DE 5 000 LIVRES. MILLER MANYARD _ LABEL (FIG. B)
. ARRIMEZ LE FILIN DE SI_CURITE. VEILLER ,_,CE QUE LA DISTANCE MAXIMUM DE CHUTE LIBRE DATE : MOD_:LE: LONGUEUR : CAPACIT# : 310 LB. LONGUEUR :
NE PUISSE DEPASSER SIX PIEDS (6 PI). MATI_RIAU: NYLON FORCE D'ARRET DE CHUTE : 900 LB.
NE PAS LAISSER LE FILIN DE SI_CURITE ENTRER EN CONTACT AVEC DES ARR_:TES ACERI_ES, FABRIQU_= AUX ETATS-UNIS ANSI Z359.1 ANSI AI0.14 OSHA 1926.502
UNE SURFACE ABRASIVE OU DES I_TINCELLES, OU ATTEINDRE UNE TEMPI_RATURE AVERTISSEMENT :
SUPERIEURE A 180 DEGRES F. LE CONNECTEUR ET L'I_LI_MENT DE SUPPORT/D'ANCRAGE DOIVENT _:TRE COMPATIBLES ET
NE PAS CONNECTER SUR UNE BOUCLE EN D DU HARNAIS OU DE LA CEINTURE UN CAPABLES DE SUPPORTER UNE CHARGE DE 5 000 UVRES.
MOUSQUETON DONT LA DIMENSION D'OUVERTURE EST SUPERIEURE ._ UN POUCE (1 PO). ARRIMEZ LE DISPOSITIF MANYARD. VEILLER A CE QUE LA DISTANCE MAXIMUM DE CHUTE
RETIRER CE PRODUIT DU SERVICE LORS DE LA DETECTION DE TOUTE DET#RIORATION. LIBRE NE PUISSE DEPASSER SIX PIEDS (6 PI).
L'UTILISATEUR DOff PREVOIR UNE DISTANCE D'I_TIRAGE DE 3 PI ,_.6 PI AU-DELA DE LA
AVERTISSEMENT : LONGUEUR INDIQUEE DU DISPOSITIF MANYARD.
IL EST INDISPENSABLE DE RESPECTER LES INSTRUCTIONS DU FABRICANT FOURNIES AVEC
ETIQUETAS DEL MANYARD Y CUERDA DE SEGURIDAD (FIG. A) GRAVES O MORTALES. PONGASE EN CONTACTO CON DALLOZ FALL PROTECTION SI
LARGO: MODELO: MATERIAL: NILON CAPACIDAD:310 LIBRAS I NECESITA UN MANUAL DE INSTRUCCIONES.
FUERZADE PARADA DE CAIDA: 900 LIBRAS ANSI AI0.14, OSHA 1926.502 HECHO EN EE.UU. INSTALL ESTE EXTREMO EN EL ARNES
ADVERTENClA: ATENCION: INSPECCIONAR ANTES DE CADA USO.
LOS CONECTORES Y PUNTOS DE ANCLAJE DEBEN SER COMPATIBLES Y CAPACES DE PERFORE EL DIAGRAMA EN LA FECHA DEL PRIMER USO
SOPORTAR 5000 LIBRAS. MILLER MANYARD M" CUERDA AMORTIGUADORA (FIG. B)
INSTALL LA CUERDA DE MODO QUE QUEDE UNA DISTANCIA MAXIMA DE CAIDA LIBRE NO FECHA: LARGO: MODELO: MATERIAL: NILON CAPACIDAD:310 LIBRAS
MAYORDE6 PIES(6'). FUERZA DEPARADA DECAIDA:900LIBRAS ANSIA10.14, OSHA1926.502 HECHO ENEE.UU.
NO PERMITA QUE LA CUERDA TENGA CONTACTO CON SUPERFICIES AFILADAS O ABRASIVAS, ADVERTENClA"
CHISPAS O TEMPERATURAS SUPERIORES A 180 GRADOS. LOS CONECTORES Y PUNTOS DE ANCLAJE DEBEN SER COMPATIBLES Y CAPACES DE
LOS GANCHOS DE RESORTE CON ABERTURAS DE MAS DE UNA PULGADA (1") NO DEBEN SOPORTAR 5000 LIBRAS.
CONECTARSE A LOS ANILLOS EN D DE LOSARNESES Y CORREAS. INSTALEEL MANYARDDE MODO QUE QUEDE UNA DISTANCIA MAXIMADE CAIDA LIBRE NO
RETIRAR ESTE PRODUCTO DEL SERVICIO SI SE DETECTA CUALQUIER DANO. MAYOR DE 6 PIES (6").
EL USUARIO DEBE PREVER UNA DISTANCIA DE EXTENSION DE 3" A 6" MAS ALLA DEL LARGO
ADVERTENClA: INDICADO DEL MANYARD.
SE DEBEN SEGUIR LAS INSTRUCCIONES DEL FABRICANTE SUMINISTRADAS CON EL EQUIPO
AL MOMENTO DE SER DESPACHADO. DE LO CONTRARIO SE PUEDEN PRODUCIR LESIONES NO PERMITA QUE LA CUERDA TENGA CONTACTO CON SUPERFICIES AFILADAS O
20 ABRASIVAS, CHISPAS O TEMPERATURAS SUPERIORES A 180 GRADOS. 2 1
]
MILLER SOFSTOP TM I.D. LABEL (FIG. D) FIG. C _ /
MODEL: MATERIAL: NYLON LENGTH: OSHA 1925.502 ANSI Z359.1, A10.14
MADE IN THE U.S.A.
WARNING (FIG. C)
INSPECT BEFOREEACH USE
CONNECTORS AND ANCHORAGE POINTS MUST BE COMPATIBLE AND ABLE TO SUPPORT

SOFSTOP, STRETCHSTOP AND
BACKB TEN LABEL !
5,000 LBS. FIG. D
RIG FALL PROTECTION SYSTEM TO REGULATORY REQUIREMENTS. .oo. 9_3_ o,]__,_9 L_.G,.6 ..........Z_'.:_.:'.."
DO NOT ALLOW PRODUCT TO CONTACT SHARP OR ABRASIVE SURFACES. cAp,
c,7,_,o
L, ,A_
,_ _,,_,,_oF
=,u,,,,
OSHA1_5 _,_ ml Br[molfz -r I}Io_ ;'tiT}6t_-I_H
MANUFACTURER'S INSTRUCTIONS SUPPLIED WITH THIS PRODUCT AT THE TIME OF

SHIPMENT MUST BE FOLLOWED: FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR
..................................
,,o},,0_, SE,_AL
0000002 ItlLLBIt"
DEATH. IllIIIIIIIIIIIIIIIIIIIIIIIIIIII $ OF$ TOP
MARl[IN6PEC]IONGRIDONDAT[ OFFIRS] US[ .,.._
._r_:,Z&,'_t
"___ ,--
_ _7,,__
-- :_'.:_=%.'_::
OD
0_!1
03 .........
LB378
NE PAS LAISSER LE DISPOSITIF MANYARD ENTRER EN CONTACT AVEC DES ARRETES AVERT|SSEMENT (FIG. C)
ACEREES, UNE SURFACE ABRASIVE OU DES I_TINCELLES, OU ATTEINDRE UNE LES CONNECTEURS ET LES ELEMENTS DE SUPPORT D'ANCRAGE DOIVENT ETRE
TEMPI_RATURE SUPI_RIEURE A 180 DEGRI_S F. COMPATIBLES ET CAPABLES DE SUPPORTER UNE CHARGE DE 5000 LIVRES.
NE PAS CONNECTER SUN UNE BOUCLE EN D DU HARNAIS OU DE LA CEINTURE UN INSTALLER LE SYSTf:ME D'ARRET DE CHUTE EN CONFORMITE AUX EXlGENCES DE
MOUSQUETON DONT LA DIMENSION D'OUVERTURE EST SUPERIEURE A UN POUCE (1 PO). RI_GLEMENTATION.
RETIRER CE PRODUIT DU SERVICE LORS DE LA DETECTION DE TOUTE DETERIORATION. NE PAS LAISSER LE PRODUIT ENTRER EN CONTACT AVEC DES ARRETES ACI_RI_ES OU UNE
SURFACE ABRASIVE.
AVERTISSEMENT : IL EST INDISPENSABLE DE RESPECTER LES INSTRUCTIONS DU FABRICANT FOURNIES AVEC
IL EST INDISPENSABLE DE RESPECTER LES INSTRUCTIONS DU FABRICANT FOURNIES AVEC CE PRODUIT LORS DE SA LIVRAISON. LE NON-RESPECT DE CES INSTRUCTIONS PEUT
CE PRODUIT LORS DE SA LIVRAISON. LE NON-RESPECT DE CES INSTRUCTIONS PEUT ENTRAINER DE GRAVES BLESSURES, VOIRE UN ACCIDENT MORTEL.
ENTRAINER DE GRAVES BLESSURES, VOIRE UN ACCIDENT MORTEL.
FIXER CETTE EXTRI_MITE AU HARNAIS AVERTISSEMENT :

MISE EN GARDE : INSPECTER AVANT CHAQUE UTILISATION IL EST INDISPENSABLE DE RESPECTER LES INSTRUCTIONS DU FABRICANT FOURNIES AVEC
POIN(_ONNER CETTE CARTE A LA DATE DE LA PREMIERE UTILISATION CE PRODUIT LORS DE SA LIVRAISON. LE NON-RESPECT DE CES INSTRUCTIONS PEUT
MILLER SOFTSTOP TM I.D. LABEL (FIG,D) ENTRA/NER DE GRAVES BLESSURES, VOIRE UN ACCIDENT MORTEL.
MODELE: MATI_RIAU: NYLON LONGUEUR: OSHA 1925.602, ANSI Z359,1, A10.14 INSPECTER AVANT CHAQUE UTILISATION
FABRIQUI_ AUXETATS-UNIS INSPECTER AVANT CHAQUE UTILISATION
LOS GANCHOS DE RESORTE CON ABERTURAS DE MAS DE UNA PULGADA (1") NO DEBEN ADVER'rENClA (FIG. C)
CONECTARSEA LOS ANILLOS EN D DE LOS ARNESES Y CORNEAS. LOS CONECTORES Y PUNTOS DE ANCLAJE DEBEN SEN COMPATIBLES Y CAPACES DE
RETIRAR ESTE PRODUCTO DEL SERVICIO SI SE DETECTA CUALQUIER DAI_IO. SOPORTAR 5000 LIBRAS.
AJUSTE EL SISTEMA DE PARADA DE CAJDA SEGUN LOS REQUISITOS REGLAMENTARIOS.
ADVERTENCIA:
NO PERMITA QUE EL PRODUCTO TENGA CONTACTO CON SUPERFICIES AFILADAS O
SE DEBEN SEGUIR LAS INSTRUCCIONES DEL FABRICANTE SUMINISTRADAS CON EL EQUlPO ABRASIVAS.
AL MOMENTO DE SEN DESPACHADO. DE LO CONTRARIO SE PUEDEN PRODUCIR LESIONES
GRAVES O MORTALES. PONGASE EN CONTACTO CON DALLOZ FALL PROTECTION SI SE DEBEN SEGUIR LAS INSTRUCCIONES DEL FABRICANTE SUMINISTRADAS CON EL EQUIPO
NECESITA UN MANUAL DE INSTRUCCIONES. AL MOMENTO DE SEN DESPACHADO. DE LO CONTRARIO SE PUEDEN PRODUCIR LESIONES
GRAVES OR MORTALES.
INSTALL ESTE EXTREMO EN EL ARNES
ATENCION: INSPECCIONAR ANTES DE CADA USO.
PERFORE EL DIAGRAMA EN LA FECHA DEL PRIMER USO ADVERTENCIA:
1-800-873-5242 PAT. 4.253.544 SE DEBEN SEGUIR LAS INSTRUCCIONES DEL FABRICANTE SUMINISTRADASCON EL EQUIPO
AL MOMENTO DE SEN DESPACHADO. DE LO CONTRARIO SE PUEDEN PRODUCIR LESIONES
ETIQUETA DEL SOFSTOP Y STRETCHSTOP/MILLER SOFSTOPTM I.D. LABEL (FIG. D) GRAVES O MORTALES.
MODELO: MATERIAL: NYLON LARGO: OSHA 1925.502, ANSI Z359.1, A10.14
HECHO EN EE.UU. INSPECCIONAR ANTES DE CADA USO INSPECCIONAR ANTES DE CADA USO LB303
22 23
I128
Rev. C
MILLER BACKBITER LABEL
AVERTISSEMENT! ADVERTENCIA!
MILLQ
Franklin, PA U.S.A.
Trenton, Ont. Canad_
800-873-5242
FAX 800-892-4078
www.cdalloz.com
"_'"_' _'" _"'"'" '"".'__1_
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TABLE OF CONTENTS

CHAPTER 5. MANUFACTURERS APPENDICES

Section 2. Power Module

CUMMINS ENGINE QSB 4.5 T3 - OPERATION AND MAINTENANCE MANUAL WITH

CUMMINS ENGINE QSB 6.7 T3 - OPERATION AND MAINTENANCE MANUAL WITH

GEAR PRODUCTS, INCORPORATE

GEAR BOX PARTS LIST

STEERABLE AXLES FRONT AXLE (625-9152) FRONT AXLE SERVICE MANUAL

MERITOR HEAVY VEHICLE SYSTEMS, LLC

Q-PLUS LX500 MX500 CAM BRAKES, MAINTENANCE MANUAL

ALLIED SIGNAL CORPORATION - BENDIX HEAVY VEHICLE SYSTEM GROUP

BRAKES SERVICE DATA

MANUFACTURERS APPENDICES 5-Contents

GRESEN MANUFACTURER DANA CORPORATION

MGG2 HYDRAULIC MOTORS SERVICE MANUAL

MGG2 HYDRAULIC MOTORS PARTS CATALOG

GULF CONTROLS CORPORATION

MONARCH 24VDC ELECTRIC PUMP M326-0214 (EMERGENCY PUMP) MANUAL

PARKER-HANNIFIN HYDRAULIC VALVE PUMP MANUAL

D1VW SERIES DIRECTIONAL VALVES MANUAL

D3W SERIES DIRECTIONAL VALVES MANUAL

SUN HYDRAULICS CORPORATION - (SOLENOID CARTRIDGE VALVES)

CARTRIDGE SERVICE BULLETIN

420 MOBILE PISTON PUMP MODEL CODES (E-PUPI-TH001-E)

420 PUMP SERIES INSTALLATION INFORMATION (E-PUPI-TI006-E)

420 MOBILE PISTON PUMP CATALOG MANUAL (E-PUPI-TM002-E)

420 MOBILE PISTON PUMP SERVICE PARTS MANUAL (E-PUPI-TP002-E)

TRW, ROSS GEAR DIVISION

HYDRAULIC MOTOR MG, MF, MB, ME SERIES SERVICE PROCEDURE

PISTON PUMP SERVICE MANUAL

HYDRAULIC MOTOR SERVICE MANUAL

TASKFORCE TIPS INCORPORATE

5-Contents MANUFACTURERS APPENDICES

COLD AND HOT FLUID PUMPS DISASSEMBLY INSTRUCTIONS AND LUBRICANT

F.E. MYERS COMPANY

TWO STAGE CENTRIFUGAL PUMP INSTALLATION, SERVICING AND PARTS MANUAL

MISCO VIP INLINE

PROCESS REFRACTOMETER, INSTRUCTIONAL MANUAL

HEATER SOOT REMOVAL INSTRUCTIONS

DAVID CLARK COMPANY INCORPORATE

SERIES 3800 INTERCOM SYSTEM INSTALLATION/OPERATION INSTRUCTIONS

MODELS H3332, H3392 PARTS LIST

ANSUL FIRE PROTECT

INSTALLATION, RECHARGE, INSPECTION AND MAINTENANCE

TROUBLESHOOTING, AND PROGRAMMING

SAGE FLOW MONITOR

INSTALLATION, OPERATION, AND BATTERY REPLACEMENT PROCEDURES

SIGNET FLOW TRANSMITTER

TRANSMITTER INSTRUCTIONS, AND ELECTRICAL INSTRUCTIONS

LANYARD AND SHOCK ABSORBER INSTRUCTIONS

GENERAL OPERATING INSTRUCTIONS AND PARTS SALES

MANUFACTURERS APPENDICES 5-Contents

AIR FIRST SUPERCHARGER, OPERATION AND MAINTENANCE

AIRTRONIC/ESPAR HEATER SYSTEMS

TECHNICAL DESCRIPTION, INSTALLATION, OPERATING AND MAINTENANCE

INSTRUCTIONS, TROUBLESHOOTING AND REPAIR, HEATER PARTS

TECHNICAL DOCUMENTATION AND OPERATING INSTRUCTIONS

5-Contents MANUFACTURERS APPENDICES

Information is included only for components that are considered repairable.

CUMMINS ENGINE QSB 4.5 T3 - OPERATION AND MAINTENANCE MANUAL WITH

CUMMINS ENGINE QSB 6.7 T3 - OPERATION AND MAINTENANCE MANUAL WITH

MANUFACTURERS APPENDICES 5-2

GEAR PRODUCTS, INCORPORATE

GEAR BOX PARTS LIST