Mustang Workhorse Operator Manual

Transcription

Mustang
Hydrostatic Workhorse
OPERATOR’S INSTRUCTION MANUAL
WARNING: Serious injury may result if this product is misused. The manufacturer
provides the following instructions for use and care of this equipment and relies upon
the purchaser to see to it that these instructions are made clear
to the person who will be using the equipment.
Reciba entrenamiento y entienda el manual de instrucciones, o
haga que le lean el manual, antes de operar estta unidad.
Part Number: 160994
Revised: June 2006
2601 NIAGARA LANE, PLYMOUTH, MN 55447
Phone: (763) 553-1935
Fax (763) 553-7765
Table of Contents
Mustang Hydrostatic Workhorse ...................................................................................... 4
Specifications ............................................................................................................. 4
Safety Precautions ............................................................................................................. 5
Do Not Operate Before Reading ................................................................................ 5
Operator Preparation ......................................................................................................... 7
Roof Preparation ................................................................................................................ 7
Hoisting Machine To Roof ................................................................................................. 8
Unit Preparation ................................................................................................................. 8
Power Unit Controls ........................................................................................................... 8
Machine Operation ............................................................................................................. 9
To move the machine Forward: .................................................................................. 9
To go in Reverse: ....................................................................................................... 9
To put machine in Neutral: ......................................................................................... 9
Attachments ...................................................................................................................... 10
Machine Operation ........................................................................................................... 12
Prior to Engine Start-up ............................................................................................ 12
Engine Start-up ........................................................................................................ 12
Power Unit Operation ................................................................................................ 13
Hot Stuff Tank Operation .......................................................................................... 13
Filling the Hot Tank: ................................................................................................. 14
Asphalt Eruption/Flashing: ....................................................................................... 14
Maintenance ..................................................................................................................... 15
Lubrication ............................................................................................................... 15
Engine Fluids ........................................................................................................... 15
Engine Service ......................................................................................................... 15
Transaxle ........................................................................................................................... 16
Service and Maintenance ................................................................................................ 17
External Maintenance .............................................................................................. 17
Fluids ....................................................................................................................... 17
Fluid Volume and Level ........................................................................................... 17
Fluid Change Procedure .......................................................................................... 18
Purging Procedures ................................................................................................. 18
Transaxle Troubleshooting Checklist ....................................................................... 19
Engine and Control Assembly ......................................................................................... 20
Trans Axle Assembly ........................................................................................................ 22
Engine Assembly .............................................................................................................. 23
Safety Information Regarding Hot Stuff ......................................................................... 24
Safety Practices ................................................................................................................ 25
Safety Hazards ......................................................................................................... 25
OSHA Standards............................................................................................................... 27
1926.500 guardrails, handrails and covers............................................................... 27
Notes: ................................................................................................................................ 30
Update your instructions and decals.............................................................................. 31
4
Mustang Hydrostatic Workhorse
Thank you for purchasing this quality Garlock product. With proper use and care, the Workhorse will serve you for years with reliable service. For the safety of the operator and other
people on the job site, it is imperative that the operator read and understand these instructions
before using.
DATE OF PURCHASE____________ SERIAL NUMBER__________________________
Warning: Do not attempt any operation which is not described in this manual. Other
operations could cause serious injury or death. Read, understand and
follow the manual when operating this machine or performing
maintenance.
Specifications
Power Uni t Wei ght
Power Uni t Length
Power Uni t Wi dth
Power Uni t Hei ght
Gravel Spreader Wi dth
Gravel Spreader Wei ght
D ump Hopper Wei ght
55 Gallon Regular Tank Wei ght
55 Gallon Ins. Tank Wei ght
#30-600 D ump Hopper
410 lbs.
67"
65"
42"
36"
108 lbs.
84 lbs.
195 lbs.
236 lbs.
220 lbs.
Loaded Weights
For calculating loads, the following data may be used:
Gravel weighs approximately 108 lbs /cu. ft.
Asphalt weighs approximately 8 lbs /gal.
Check with your material sources for actual weight of material you are using.
Power Unit with Gravel Spreader
Power Unit with Dump Hopper
Power Unit with 55 Regular Tank
Power Unit with 55 Insulated Tank
Power Unit with #30-600 Hopper
518 lbs.
494 lbs
605 lbs.
646 lbs.
630 lbs.
Fully Loaded (6 cu. ft.)
Fully Loaded
Fully Loaded
Fully Loaded
Fully Loaded
1166 lbs.
1494 lbs.
1045 lbs.
1086 lbs.
1135 lbs.
5
Safety Precautions
Do Not Operate Before Reading
INTENDED USE: This machine is intended to be used as a: felt carrier, insulation carrier,
rubbish and gravel carrier, hot stuff carrier, gravel spreader and hot stuff dispenser. For
use on flat level roofs only. Any other use of this equipment voids the manufacturer's warranty and is the sole responsibility of the owner/user, should damage or injury occur.
Do not hoist the Workhorse with #30 debris hopper or hot stuff tank installed.
Do not hoist the Workhorse with gravel spreader or dump hopper loaded.
For use on flat, level roofs only.
Keep other people clear of machine during operation.
Do not operate without a perimeter warning line system.
Do not operate within ten feet of roof edge (or within six feet if operating parallel to edge).
Do not operate without spotter.
Guard all openings in the roof.
Keep the equipment in good operating condition.
Do not operate the machine if it is damaged. Repairs must be made by a qualified mechanic. Replace damaged components.
Do not modify the machine. Do not operate a machine that has been modified.
Wear proper attire: Long sleeve cotton shirt, buttoned at the cuff, long pants without cuffs,
gloves (cotton or leather) that cover your wrist and fit snug at cuff, and high top safety
shoes.
Avoid slick areas on the roof to prevent slipping.
Do not operate this machine if you are under the influence of alcohol, marijuana, or drugs
that could impair judgment and ability.
6
The owner or operator must see that all warning decals are in place and legible. Write to
Garlock Equipment Co. for replacement decals and instructions if needed.
Operator must be trained to do the specific job before operating equipment on an actual
job.
Do not exceed weight carrying capacity of the deck. Check with owner or architect for deck
capacity.
Never tip dispenser when filling, transporting or dispensing hot stuff.
Never stand downwind of draincock when filling or draining hot tank. Fumes and hot stuff
will blow on windy days.
Stand clear of the path of discharging hot material.
Keep external ignition sources away from hot stuff.
Check material temperature with an accurate thermometer.
The following information is quoted from OSHA:
Safety and Health Standards Digest, OSHA 2202 revised September 1983.
It is usually a good idea for the employer to keep a record of all safety and health training.
Records can provide evidence of the employer’s good faith and compliance with OSHA
standards. Documentation can also supply an answer to one of the first questions an
accident investigator will ask: “Was the injured party trained to do the job?”
Training in the proper performance of a job is time and money well spent and the employer
might regard it as an investment rather than an expense. An effective program of safety
and health training for workers can result in fewer accidents and illnesses, better morale
and lower insurance premiums and other benefits.
Readers with questions concerning worker safety and health training should contact their
regional OSHA office.
7
Operator Preparation
Read Instruction Manual
Reading the instructions completely is the first step to safe operation. An uninformed
operator can subject himself and others to death or serious injury.
Wear Proper Attire
Safety glasses are recommended and must be worn if any roof cutting or scraping is being
done in the vicinity. Safety glasses and/or face shield are also necessary when working
with hot stuff. Wear properly fitting clothes. Tight clothing can restrict movement and slow
down reaction time in a dangerous situation. Loose fitting clothing can be dangerous and
cause serious injury if it gets caught in moving mechanical parts. Wear a long-sleeved
shirt, buttoned at the cuffs, safety shoes, and pants without cuffs. Operator must wear hard
hat when work is being done at a higher level
Roof Preparation
Inspect Roof Deck
Before allowing equipment and personnel access to roof, make certain roof is strong
enough to support the weight. Check load limits of deck with owner, builder or architect.
Clear the work area of all potentially dangerous obstacles that could cause personal injury
to the operator or others. Keep unauthorized people away from construction area. Check to
see that all roof openings are guarded to protect against falls.
Warning Line System
Operation of Workhorse must be in compliance with Federal OSHA standards governing
safety perimeters with respect to the use of power equipment. When operating parallel to
roof edge, warning line system must be at least six feet from edge. When operating perpendicular to edge, warning line must be ten feet from roof edge. For specific information
on warning lines, the use of guard rails and motion-stopping –safety systems, refer to
section on OSHA Law.
8
Hoisting Machine To Roof
Make certain hoist is in safe operating condition; it should be secure and properly counterbalanced. Hoist should only be operated by trained personnel. The hoist should be clear of
ground objects and overhead obstacles, such as power lines. Hoist should be inspected for
frayed cables, bent frame members or faulty mechanical parts. Make sure everyone on
the ground is completely clear of the lifting area. Don’t exceed the weight and size capacity of your hoist.
Hoisting machine to roof is accomplished by connecting hoist hook to lifting eye located on
cross rail in the center of machine. This single lifting point can be used to hoist power unit
separately or with gravel spreader attachment or standard dump tray attached.
Warning: Do not hoist power unit to roof with #30 debris hopper or hot stuff tank
attached. These units were not designed to be hoisted in this manner and
must be hoisted to roof separately.
Unit Preparation
Check to see that engine is serviced properly. Read the Honda operating instructions and
safety warnings. Also see “Servicing Your Honda Engine”. Check oil level and fuel level.
Check to see that spark plug is tight.
Recommended tire pressure; two 8.5x8 front tires should be at 22 psi and the rear tires are
solid rubber.
Make certain Chain Guards and Engine Guard are in place and fastened securely. Check
guards for cracked or broken welds or any other damage. Repair or replace if damaged.
Warning: Operation without chain guards or engine cover could cause serious
personal injury. Do not operate with damaged or missing guards or covers.
Power Unit Controls
Fig 1
Fig 2
9
Fig 3
Machine Operation
To move the machine Forward:
Make sure Engine Throttle lever is at or near the “FAST” position. Running engine at the
“CHOKE” position will eventually foul the spark plug. Squeeze the right side lever on the
Speed Bar (Fig 1). Squeeze a little to go slow, squeeze more to increase speed.
Letting go of the Speed Bar will stop the machine.
To go in Reverse:
Slip your hand through the safety ring and squeeze the left side lever on the Speed Bar (Fig 2).
For safety, the machine will go approximately ½ speed in reverse.
To put machine in Neutral:
Reach under the machine to the axle. Slide the drive collar (long tube) away from you until
butted against the far locking collar. You will feel the drive collar click into place. With locking
collar in this position, the Mustang is in neutral. To return to engaged position, line up the key
on the shaft and the keyway in the collar by rolling the workhorse foward or backwards. Once
lined up, pull the drive collar towards your self until you feel the collar click into place.
Run the machine under power whenever possible.
The Gravel Dispenser Lever is located on the right side of the Power Unit Handle. Pulling back
on the handle opens the discharge door of gravel dispenser. Pushing forward will close door.
For detailed Gravel Spreader installation instructions, see “Gravel Spreader Attachment”
section in this manual.
The Dump Hopper (or Felt Carrier) release lever is located just to the right of the engine
cover. Pull back to release the hopper lock. Be sure hopper is locked in down (load)
position before leaving dump site. For detailed Dump Hopper installation instructions, see
“Dump Hopper Attachment” section in this manual.
The #30 Debris Hopper Dump Lever is located beneath the rear and on both sides of the
Debris Hopper. The Debris Hopper lock is disengaged when the dump lever is lifted. The lock
is automatically engaged when the Debris Hopper is set back down. For detailed Debris
Hopper installation instructions, see “#30 Debris Hopper Attachment” section in this
manual.
10
Attachments
Warning: On wide span decks, check load limits with builder, owner, or architect
before setting up unit.
Gravel Spreader Attachment
Hammer and pliers are required for installation. Install gravel spreader as shown. Shaft ends of
spreader drop into mount brackets of frame. Two swivel locks are located on frame of Workhorse. Use a hammer to lock in top of gravel spreader. To install handle and linkage, first
attach linkage to dispenser and then connect other end to handle and secure with clevis pins
and cotter pins provided. An adjustment screw is located on the upper right corner of dispenser. Clockwise adjustment of screw will make dispenser door open less; counterclockwise
makes door open more. Yoke assembly on back of dispenser is preset to proper door tension.
If more tension is needed for door closure, remove clevis pin on yoke and tighten as needed.
Dump Hopper Attachment
Install Dump Hopper as shown. Shaft ends drop into mount brackets on sides of power unit.
Be sure Hopper is “Locked” in down (Load) position before leaving dump site.
11
#30 Debris Hopper Attachment
To install #30 debris hopper, lift hopper with one person on each end. Insert “u” shaped guides
on bottom front of hopper frame into stake pockets on power unit frame, let back of debris
hopper set down on top of dump latch. Let go of hopper and pull back on latch handle to allow
back of debris hopper to settle down into place.
55 Gallon Hot Tank Attachment
Install channel irons, tank, and rods as shown. If tank was built before 1985, the tank must be
mounted so that draincock is higher than rear of tank. Refer to the “Hot Stuff Tank Operation”
section in this manual.
12
Machine Operation
Prior to Engine Start-up
After reading through all of the instructions, the Mustang Hydrostatic Workhorse should be
ready for operation. When operating the machine for the first time, position the machine on the
ground or in an open level area away from obstructions and roof edges. Start engine and allow
to warm up for five minutes. With no load on the Workhorse, practice maneuvering the machine by operating controls as described in the “Power Unit Controls” section of this manual.
Check brake operation. When the Speed Bar is released the Workhorse should stop instantly.
If not, do not operate machine until repairs or adjustments are completed.
Engine Start-up
Fuel Shut Off
Shown in Open position
Fig 4
See illustration for lever locations.

Move fuel shut off valve to the ON or open position (Fig 4).
If engine is cold, move throttle lever to Choke position. If engine is warm, move throttle
lever to Fast position.
For easier start-up when cold, push Belt Tension Lever (found beneath left side of
Engine (Fig 5)) forward until it engages in hook - when ready to move machine lift hook
and lever will slide back to engage belt.
Pull the starter grip lightly until you feel resistance, then pull briskly. Return the starter
grip gently.
To shut off engine, move throttle to STOP position.
Fig 5
13
Power Unit Operation
The Mustang Hydrostatic Workhorse is designed for use inside a perimeter warning system.
Do not operate within 10 feet of roof edge (or 6 feet if operating parallel to roof edge). If the
machine is operated near a roof edge material handling area, operator must comply with
OSHA regulations in regards to the use of an MSS system. See OSHA Law section IX. Engage speed bar with left hand only. Keep hands and feet away from chain drive area. Keep
well clear of other people on the roof while operating.
Turn machine off when not in use by a qualified operator.
Hot Stuff Tank Operation
Warning: Eruption of overheated asphalt is possible. Read and understand
instructions.
Note: Garlock hot tanks should be used only with Garlock carriers. Only Garlock
carriers should be used with Garlock hot tanks.
Before Operating:

Make sure tank is dry and there is no foreign matter in the tank. Even small amounts
of moisture will react violently with hot material.

Inspect tank lining for any coke buildup or condensation. Clean if necessary.

Always wear proper clothing (cotton is best) as recommended by the roofing association when on a roof: Hardhat with face shield. Long sleeve work shirt buttoned at the
wrist and collar. Long work pants with no cuff. Safety high top shoes. Work gloves with
knit wrists to prevent hot material from spilling into glove.

Be sure that hot line is secure and cannot move or splash operator during the filling of
hot tanks.

Check tank thermometer for accuracy before each use against a thermometer you
know to be accurate. Replace if necessary.

Be sure carrier is secure and brake is set (neutral lock must be released).

Use tank only on a flat level roof and within a perimeter warning system. Never operate
within 6 feet of a roof edge. Refer to OSHA Standards in Federal Register Vol. 45 No.
222 dated November 4 1980 or as amended.

Check temperature of material in kettle or tanker and do not accept hot material
unless it is within the manufactures recommended temperature range.

Keep an approved fire extinguisher available in case of fire. Never use water.

Make sure lid and draincock are closed.

Inspect tank for any exterior damage and do not use if any interior damage is suspected.

Check that roof deck is rated to handle weight of the lugger, carrier and asphalt (8
lbs/gallon) before using. Refer to “loaded Weights” table in this manual.

Do not allow any external ignition source (match, cigarettes) near heated asphalt or
your hot tank.
14
Filling the Hot Tank:
Never stand down wind of hot source when filling as fumes and/or hot material may cause
injury.
Do not fill hot tank more than ¾ full to avoid the splashing of material.
Warning: Never fill hot tank with overheated material. Overheated asphalt may erupt.
Flash points vary and proper temperature must be obtained from the
asphalt manufacturer.
Asphalt Eruption/Flashing:
An eruption requires these three components to happen.
Fuel: Flammable gasses from overheated or poorly refined hot material.
Air: Can come from tipping, sloshing or discharging asphalt with lid open.
Ignition: Overheated material or material in tank with lower flash point (coked
material on tank walls, trash, cigarettes or matches).
Obtain information from your supplier of hot material for specific instructions on ways to
avoid eruption or flashing of their particular product.
Transporting and Draining Hot Tank:
Transport hot tank very smoothly and slowly so splashing can’t occur. Check path
for obstacles and bumps and approach with caution. Do not make sudden stops or
turns. Avoid transporting hot stuff on ramps. Keep lid closed during transporting and draining. Never tip hot tank while transporting, filling, or draining. Tip only when tank is empty
and cool. Be sure brake is set (neutral lock released) before discharging Hot material.
Never stand downwind from draincock while discharging as wind may blow fumes or hot
material. Stand clear of the path of discharging hot material.
Warning: Do not attempt any operation which is not described in this manual. Other
operations could cause serious injury or death. Read, understand and
follow the manual when operating this machine or performing
maintenance.
15
Maintenance
Note: Disconnect spark plug wire before working on the machine.
Lubrication
Lubrication recommendations are as follows: Grease roller bearings on wheels weekly or
as needed. Zerks for 8.5x8 wheels are located on the hub between the tire and chain drive
sprocket. Also grease swivel caster and speed bar. Zerks are provided for both. Bearings on
transaxle assembly are sealed and do not require grease. Dispenser handles should be
greased at rotation points (zerks provided). Also oil pivot points of linkages. Roller chain
should be lubricated with spray chain lube such as PJI Blue Label or a quality bar oil. Clean
monthly with a wire brush.
Engine Fluids
Read Honda Maintenance instructions. Use unleaded fuel for longer valve life. To prolong the life
of your engine, change oil after five hours of initial
use, then every eight hours thereafter. Use the
chart to determine the proper oil viscosity to run for
the current temperature range.
Ambient Temperature
Engine Service
If service or repair of engine is needed, contact an authorized Honda Service Center. Garlock
Equipment Co. warranty does not cover the engine. Engine is covered under separate warranty from Honda Motor Co.
16
Fill Port
Neutral Arm
Fig 6
Brake Disk
Transaxle
WARNING
Do not attempt any servicing or adjustments with the engine running.
Use extreme caution while inspecting the
drive belt, and all vehicle linkages.
Follow all safety procedures outlined in
the vehicle owner's manual.
Most often, problems with the drive system are
not related to a defective transaxle, but are
caused by slipping drive belts, partially
engaged bypass valves(neutral rod), and loose
or damaged control linkages. Be sure to perform
all operational checks and adjustments outlined
the Service and Maintenance section before
assuming the unit is malfunctioning.
A troubleshooting check list is provided herein
to help determine the cause of operational problems.
17
Service and Maintenance
NOTE:
Any servicing dealer attempting warranty
repair must have prior approval before
conducting maintenance of the Transaxle
unless the servicing dealer is a
current Authorized Service Center
recognized by the Transaxle manufacturer.
EXTERNAL MAINTENANCE
Regular external maintenance of the Transaxle
should include the following:
7. Inspect the bypass (neutral) mechanism on
the transaxle and vehicle linkage to insure it
actuates and releases fully.
FLUIDS
The fluids used in Transaxle have been
carefully selected, and only equivalent, or
better products should be substituted.
1. Check page 4 of this manual for
the recommended load ratings. Insure
the current application does not exceed
load rating.
Typically, an engine oil with a minimum rating
of 55 SUS at 212 degrees F (100 degree C) and
an API classification of SL is recommended.
20W-50 engine oil has been selected for use
by the factory and is recommended for normal
operating temperatures.
2. Check oil level through Fill port in (Fig 6)-Oil
Level should be to top of Fill Port
FLUID VOLUME AND LEVEL
3. Inspect vehicle drive belt, idler pulley,
and idler spring. Insure that no belt
slippage can occur. Slippage can cause low
input speed to the transmission.
Certain situations may require additional fluid to
be added or even replaced. Refer to (Fig 6)
for the proper fill port location.
DO NOT POUR FLUID IN THE EXPANSION TANK!
4. Inspect the transmission cooling fan for
broken or distorted blades and remove any
obstructions.
5. Inspect the axle brake and vehicle
linkage to insure proper actuation and
adjustment of brake.
6. Inspect the vehicle control linkage to the
directional control arm on transaxle. Also,
insure the control arm is securely fastened
to the trunnion arm of the transaxle.
Fill Transaxle to the top of the oil fill port with
20w-50 engine oil. Maximum capacity 79 fl oz.
Recheck the fluid level once the unit has been
operated for approximately 1 minute.
Purging may be required. Refer to the purging
procedures listed in this section.
External Maintenance
Fluids
Fluid Volume and Level
18
Fluid Change Procedure
Purging Procedures
FLUID CHANGE PROCEDURE
This transaxle is factory filled, sealed and does
not require oil maintenance. However, in the
event of oil contamination or degradation, oil
addition or change may alleviate certain performance problems.
1. Remove the transaxle from the vehicle.
2. Clean the expansion tank and oil port
areas of any debris.
3. Remove the oil fill port fitting.
6. Remove the tank and drain the oil from the
tank. DO NOT remove the vent cap from the
tank. DO NOT remove the tank hose or
o-ring unless a replacement is needed.
7. Install the tank by first inserting the hose
into the opening in the expansion tank.
Push the tank opening over the o-ring to ensure a proper seal.
8. Install the tank support bracket and self tapping bolt making sure not to cross thread
the bolt. Torque the bolt to 42-65 LB-IN
4. Position the transaxle so the oil will drain
completely out of the housing.
5. After all the oil is drained from the transaxle,
remove the expansion tank by removing the
self tapping bolt (10-32x1/2) that holds the
tank support bracket.
9. Fill the transaxle at the oil fill port shown in
(Fig 6). Oil level should be to the top of the
Fill Port
10. Install the oil fill port fitting.
PURGING PROCEDURES
Due to the effects air has on efficiency in
hydrostatic drive applications, it is critical that it
be purged from the system.
The following procedures should be performed
with the vehicle drive wheels off the ground,
then repeated under normal operating conditions.
These purge procedures should be implemented
any time a hydrostatic system has been opened
to facilitate maintenance or any additional oil has
been added to the system.
1.W ith the bypass valve open and the engine
running, slowly move the directional control
in both forward and reverse directions
(5 to 6 times), as air is purged from the unit,
the oil level will drop.
Air creates inefficiency because it's compression
and expansion rate is higher than that of the oil
approved for use in hydrostatic drive systems.
The resulting symptoms in hydrostatic systems
may be:
1. Noisy operation or lack of power or drive
after short term operation.
2. High operation temperature and excessive
expansion of oil.
Before starting, make sure the transaxle is filled
with oil to the proper level. If it is not,
fill to the specification described above in
"Fluid Volume And Level" and (Fig 6)
2. W ith the bypass valve closed and the engine
running, slowly move the directional control in
both forward and reverse directions
(5 to 6 times). Check oil level, and add oil as
required after stopping engine.
3. It may be necessary to repeat Steps 1 and 2
until all the air is completely purged from the
system. W hen the transaxle moves forward
and reverse at normal speed purging is
complete.
Transaxle Troubleshooting Checklist
19
Transaxle Troubleshooting Checklist
Possible Cause
Corrective Action
UNIT OPERATES IN ONE DIRECTION ONLY
Control linkage bent or out of adjustment
Repair or replace linkage
Drive belt slipping or pulley damaged
Repair or replace drive belt or pulley
VEHICLE DOES NOT DRIVE/TRACK STRAIGHT
Vehicle tires improperly inflated
Refer to vehicle manufacturer guidelines
Control linkage bent, loose or out of adjustment
Repair, adjust or replace vehicle linkage
Bypass (neutral lever) partially engaged
Adjust bypass (neutral ) linkage
UNIT IS NOISY
Oil level is low or contaminated oil
Fill to proper level or change oil
Excessive loading
Reduce vehicle loading
Brake setting incorrect
Adjust brake to proper setting, call Vehicle Dealer
Loose parts
Repair or replace loose parts
Bypass (neutral lever) assembly sticking
Repair or replace valve or linkage
Air trapped in hydraulic system
Purge hydraulic system
UNIT HAS NO/LOW POWER
Engine speed low
Set Throttle to "FAST" position
Control linkage bent or out of adjustment
Repair or replace linkage
Drive belt slipping or pulley damaged
Repair or replace drive belt or pulley
Oil level low or contaminated oil
Excessive loading
Bypass (neutral lever) assembly sticking
Repair or replace valve or linkage
UNIT OPERATING HOT
Debris buildup around transaxle
Clean off debris
Cooling fan damaged
Repair or replace cooling fan
Oil level low or contaminated oil
Excessive loading
TRANSAXLE LEAKS OIL
Damaged seals, housing, or gaskets
Replace damaged component
20
Engine and Control Assembly
39 40 9
3
15
33
2
34
10
5
19
35
12
11
7
41
36
18
17
38
37
32
32
4
6
20
27
21
25
30
28
26
25
1
22
24
21
23
31
8
13
14
21
ITE M # Q TY .
1
1
2
1
3
1
4
1
5
1
6
1
7
2
8
2
9
1
10
1
11
1
12
2
13
2
14
8
15
1
16
2
17
1
18
1
19
1
20
2
21
4
22
2
P A R T#
404782
404784
404785
404786
404787
404788
404789
404790
404791
421343
100655
100902
140005
100135
130139
140511
421353
421363
421365
110500
110501
111243
D E SC R IP TIO N
FRA M E W ELD M EN T
H A N D LE W ELD M EN T
H A N D LE B A R W D M T .
REA R A XLE A SSEM B LY
EN G I N E A SSEM B LY
T RA N SA XLE A SSEM B LY
C A ST ER W ELD M EN T
FRO N T H U B W D M T .
F/R LEV ER
EN G I N E C O V ER
H H C S 1 X 5-1/2
H H C S 5/8 X 9
W H EEL 18/8.50
LU G - .50-20 X .75
T H RO T T LE A SSEM B LY
W H EEL 12x3x3/4
SH A FT C O LLA R
A XLE SH A FT
C U P H O LD ER
B EA RI N G 3/4 I D
SP H ERE B RN G FLN G
SP KT . C P LG . 1" ( 16t )
ITE M # Q TY . P A R T# D E SC R IP TIO N
23
2
111241 50E15 I D LER SP RO C KET
24
2
100035 H H C S 1/2 X 2-1/4
25
4
100196 1/2 X2.5 O D W A SH ER
26
2
100095 1/2 LO C K W A SH ER
27
6
100457 1/2 FLA T W A SH ER
28
2
100170 1/2-13 N U T
29
1
421349 C H A I N G U A RD -LEFT
30
1
421350 C H A I N G U A RD -RH
31
4
110091 K EY , 3/16 X 1 1/2
32
3
100593 1.0 I N SERT N U T
33
1
111245 RO D EN D .25 M A LE
34
1
152012 C A B LE C LA M P N O .6
35
2
130090 P U SH O N C A B LE
36
4
421364 SP A C ER
37
2
419013 H O LD D O W N
38
2
100081 5/8 JA M N U T
39
1
150013 G REA SE ZERK 3/16
40
1
100022 G REA SE B O LT -.38
41
1
150013 G REA SE ZERK
*42
1
111244 B ELT
*43
2
111247 D RI V E C H A I N
* I N D EC A T ES I T EM N O T SH O W N
22
Trans Axle Assembly
11
5
1
4
9
10
6
3
12
7
2
8
ITEM# QTY.
1
1
2
1
3
1
4
1
5
1
6
1
7
1
8
1
9
1
10
3
11
5
12
2
13
1
PART#
111238
110112
130155
421358
421359
421360
421375
421376
421355
110764
100207
100577
100107
DESCRIPTION
TRANSAXLE
3/8 SET COLLAR
CLEVIS KIT-.25-28 X .25
LINK
THREADED ROD LONG
THREADED ROD SHORT
NEUTRAL PLATE
NEUTRAL ROD
SPACER TUBE
ROD END .25 MALE
.25 NUT
HHCS 1/4 X 1/2
CLEVIS PIN .25 X 3/4
23
Engine Assembly
NOTE ORIENTATION
OF RECOIL MUST BE
IN THIS POSITION
9
8
11
1
7
3
2
17
15
17
6
14
4
16
13
18
16 14 10
5
ITEM# QTY. PART# DESCRIPTION
1
1 404795 ENGINE M NT. W DM T.
2
1 404796 IDLER ARM WDM T
3
1 421338 NEUTRAL HOOK
4
1 200470 PULLEY BUSHING Ø1.0
5
1 200469 PULLEY BK50H
6
1 110125 IDLER PULLEY
7
1 110394 EXTENSION SPRING
8
1 111239 5.5 hp HONDA
9
1 111255 WOODRUF 5/32 X 5/8
10
2 100010 HHCS 5/16 X 2
11
1 100035 HHCS 1/2 X 2-1/4
12
2 100068 HEX NUT 5/16
13
4 100092 LOCK WASHER 5/16
14
4 100125 5/16 FLAT W ASHER
15
1 100169 5/16-18 PLASTIC LOCK NUT
16
2 100170 1/2-13 PLASTIC LOCK NUT
17
2 100457 1/2 FLAT WASHER
18
2 100366 HHCS 5/16 X 1 FINE THREAD
24
Safety Information Regarding Hot Stuff
Hot Stuff Burns
Hot stuff burns are the most common types of injury that Roofers have. Using good work practices can help
prevent or minimize their occurrence. Always wear your protective clothing. Do not overfill containers. Keep
the level of hot stuff where it will not splash out. Keep clear from opening of hot luggers. Use the shut off on
the pump and keep back as far as possible when checking the level of hot stuff in luggers. Avoid spilling and
walking in hot stuff; It is slippery and may cause falls resulting in burns. Keep an adequate supply of water on
the job site while working with hot stuff. If you are burned, cool the area with water. Do not apply ointment or
salve to second or third degree burns. Cool the burned area only until the bitumen has hardened. Do not
remove bitumen or clothing from burned area. Seek medical attention for serious burns.
Important For Users Of Hot Bitumen
Asphalt is the major bituminous material used in the roofing industry while coal tar pitch is minor, being used
in less than 10% of applications. Asphalt is the high boiling residual remaining after the exhaustive distillation
of crude oil. Coal tar pitch is the high boiling point fraction of the distillate obtained during the production of
coke from bituminous coal. While pitch and asphalt look alike, their chemical composition and physical
properties are quite different with unique application, behavior, and air pollution potential.
Asphalt is primarily a mixture of paraffinic, alicyclic, and aromatic hydrocarbons with a very small amount of
polymeric oxygenated derivatives, which are produced during the blowing process from the labile unsaturated
hydrocarbons. The small amount of oxygenated material most likely provides a bonding medium for the
aliphatic hydrocarbon polymeric chains, similar to sulfur as a bonding agent for vulcanized rubber. This
bonding or cross-linking is necessary to enhance the elasticity and durability of the hydrocarbon polymer. A
number of properties of roofing asphalt are listed in Table I. These are significant in considering certain
aspects relative to air pollution control.
Table I
(i)
Density
Slightly greater than water at all temperatures (1.01-1.05). The rule of thumb is 8 pounds per gallon.
(ii)
Softening Point (Fusion Temperature)
The softening point roughly corresponds to the temperature at which the melt commences in a
melting point determination. Because the composition of the material is so complex, the melting point may be
over 200°F, i.e. Softening point°F + 200°F = Temperature°F at which all of the material has melted. Asphalt is
frequently characterized by this parameter according to the following ASTM specifications:
“Dead Level” Type I
SP=135-150pen@77=18/60
“Standard” Type II
SP=160-175pen@77=18/40
“Steep” Type III
SP=180-200pen@77=15/35
“Special Steep” Type IV SP=205-225pen@77=12/25
(The majority of usage is with Types I and III)
(iii)
Specific Heat (and Latent Heat of Fusion)
Heat required to raise the heat of one pound of material one degree F. The rule of thumb for all
temperatures is 0.5 BTU/pound/°F
Example: Heat required to bring 1# of solid asphalt from ambient temperature (75°F) to 475°F.
0.5 BTU/# x 1# x (475-75) = 200 BTU
Asphalt may show a slight plateau, but in general will show a slow steady increase in temperature
with time even when there is considerable solid in the melt. This is in contrast to water, which has a high heat
fusion enabling the ready maintenance of 32°F at the triple point. For this reason in rough heat balance the
latent heat of fusion is not taken into consideration.
(iv)
Cracking Temperature (Paralysis or Destructive Distillation)
This is the temperature at which thermal degradation occurs, primarily of the paraffinic components of
asphalt producing a wide array of low molecular weight saturated and unsaturated hydrocarbons. For all
asphaltic material, cracking commences at 200°F. It slowly increases but is generally not significant at
temperatures up to 550°F.
25
(v)
Flash Point
The temperature at which sufficient hydrocarbons are emitted in gas phase from liquid melt to exceed
concentration of lower explosive limit (LEL). Material of low flash point = 400-550°F. Material of high flash
point = 550-650°F. (Majority of materials being used correspond to the latter).
(vi)
Auto Ignition Temperature
Provided overhead gasses have exceeded the concentration of the LEL, this is the temperature
necessary for ignition. Auto ignition temperature for the majority of materials being used = 650°F.
(Note: It is not necessary to have an arc, spark, or flame for ignition. A heated surface of sufficient
temperature may cause ignition).
(vii)
Explosive limits of gaseous emissions from heating asphalt.
Lower explosive limit = 2% by volume.
Upper explosive limit = 6% by volume.
(viii)
Viscosity
Operating viscosity = 2000 centistoke or less.
CAUTION: Avoid Overheating
Flash point of coal tar is generally lower than that of asphalt. Most manufacturers recommend an application
temperature of from 345° to 375°F, and a kettle temperature of 425°F. Kettle operator and pipeline operator
must monitor temperature of asphalt to avoid overheating. Maintaining proper temperature is important not
only for a good application job. It could also help avoid sever personal injury.
WARNING: Due to the possibility of flashing and fire, never heat material higher than
material manufacturer’s recommendation. Check material temperature with an accurate
thermometer.
Be familiar with the danger signs of overheating material:
Change of smoke color from kettle or tanker.
Leakage at unions.
Worsening of odor from hot stuff
Fire or flame at kettle, tanker or rooftop.
Safety Practices
Safety Hazards
Safety hazards are not always obvious to workers. Unlike exposure to health hazards, where illness and
injury develop slowly, safety hazards result in immediate injury or death. Broken bones, cuts, bruises, sprains
and burns, as well as loss of limbs, eyesight, and hearing may be caused by safety hazards. The rate of
injuries in the roofing industry ranks among the top ten of all major occupational groups.
Falls
Falls are the number one cause of serious injury and death to Roofers. An estimated 10% of all roofing
accidents are a result of falls from roof edges, through roof openings, or from ladders. Unprotected and
unguarded roof edges and roof openings create extremely hazardous conditions. More than half of the
nonfatal accidents result in serious injury.
Ladders should be inspected and maintained regularly. Ladders with any of the following conditions should be
discarded or repaired:
Cracked, loose, or missing steps.
Broken, loose, or missing locks.
Coated with grease oils or hardened bitumen.
Ladders should be long enough to extend three feet above the rooftop.
26
Improperly balanced or unstable hoists may overturn and often carry the worker(s) along with it. Rolls of roofing
felt should not be used as counterweight. Workers should know the load capacity; it should be posted on hoist.
Burns
Skin contact with hot asphalt and hot coal tar pitch usually results in second or third degree burns. They
usually involve deeper portions of the skin and are easily infected. An estimated 16% of all roofing accidents
are a result of burns from hot stuff. The major causes are from:
Kettle flashes.
Kettle splashes from dropping pieces of coal pitch or asphalt into the kettle.
Slips and trips while carrying hot bitumen in open containers.
Splashes involving transfer operations from the hot pipe outlet to a hot lugger, from a hot lugger to a mop cart or
pail, or from the kettle to a pail.
Heavy Lifting
Sprains and strains, majorities of which involve the back, are a common roofing injury. Almost 30% of these
injuries result in ten or more days away from work.
Fire/Explosion
Two conditions must be met in order for fires or explosions to occur. First, there must be an ignition source; a
welding arc, spark, cigarette, flame, or simply a hot spot as in a kettle or tanker. Second, there must be the
right mixture of vapors (from asphalt, pitch, or solvents), and oxygen. For kettles and tankers, fire/explosion
conditions arise when:
Oversized burners are used to fire the kettle, causing localized overheating of the heating tubes creating a hot
spot.
The temperature of the bitumen is brought up to the desired operating temperature to quickly.
The level of bitumen is allowed to drop to the level of the firing tubes allowing excessively high surface temperature.
The bitumen is heated to its flash point (525-540°F for asphalt, 450-475°F for pitch).
The bitumen is heated to its auto-ignition level.
The vent pipe is clogged or plugged so that flammable vapor is allowed to build up to explosive levels.
Many solvents evaporate quickly at room temperatures. Explosive mixtures of vapor can be readily formed
within confined spaces like high parapet walls, in atrium or in any space where little or no ventilation exists.
Any kind of spark or flame may ignite the vapors.
Electrocution
Low voltage electricity can cause shock, muscle contraction, breathing difficulty, irregular heartbeat, severe
burns, and death. The route the current takes through the body effects the degree of injury. Current flowing
from one finger to another would not pass vital organs while from one hand to the other would pass through
the heart and lungs.
Electrical tools should be properly grounded. The electrical cord should end in a three prong grounding
contact, or the wires should be enclosed in a metal case with a special grounding attachment.
Employers are required to provide ground fault circuit interrupters for all outlets on construction sites that are
not part of the permanent wiring of the building. This is actually a fast acting circuit breaker, which can shut
off electricity in a fraction of a second.
Aluminum or other metal ladders pose a serious electrical hazard around electrical equipment and energized
lines.
Falling Objects
Tools, bricks, materials, buckets, boxes, pallets or almost anything dropped from a sufficient height can cause
severe damage. Head injuries, one of the highest compensated injuries to workers, often include brain
damage. Workers need protective headgear when working beneath people, tools and equipment.
Flying Objects
27
Objects can be projected by machines, from welding or grinding operations and can be wind blown. Tears off
operations, where power cutters, power brooms and power spudders are generally used, are the major
source of flying substances. The eyes are the part of the body most often injured by flying objects.
Upgraded Machinery
Exposed blades and chains on powered machinery like hoists and roof cutters can severely lacerate and
crush parts of the body. Guards should always be fitted over moving parts to protect workers.
OSHA Standards
1926.500 guardrails, handrails and covers.
(g) Guarding a low-pitched roof perimeter during the performance of built up roofing work.
(1)
(i)
(ii)
(iii)
(2)
(3)
(i)
(ii)
General provisions. During the performance of built up roofing work on low pitched roofs with a ground
to eave height greater than 6 feet (1.8 meters), employees engaged in such work shall be protected
from falling from all unprotected sides and edges of the roof as follows.
By use of a motion stopping safety system (MSS); or
By the use of a warning line system erected and maintained as provided in paragraph (g) (3) of this
section and supplemented for employees working between the warning line and the roof edge by the
use of either an MSS; or
By the use of a safety monitoring system on roofs 50 feet (15.25 meters) or less in width (see appendix
A), where mechanical equipment is not being used or stored.
Exception. The provisions of paragraph (g) (1) of this section do not apply at points of access such as
stairways, ladders, and ramps, or when employees are on the roof only to inspect, investigate, or
estimate roof level conditions. Roof edge materials handling areas and material storage areas shall be
guarded as provided in paragraph (g) (5) of this section.
Warning lines
Warning lines shall be erected around all sides of the work area..
(a)
When mechanical equipment is not being used, the warning line shall be erected not less than
6 feet (1.8 meters) from the roof edge;
(b)
When mechanical equipment is being used, the warning line shall be erected not less than 6
feet (1.8 meters) from the roof edge which is parallel to the direction of mechanical equipment operation
and not less than 10 feet (3.1 meters) from the roof edge which is perpendicular to the direction of
mechanical equipment operation.
The warning line shall consist of either rope, wire, or chain and supporting stanchions erected as follows:
(a)
The rope, wire, or chain shall be flagged at an interval of not more than 6 feet (1.8 meters) with
high visibility material;
(b)
The rope, wire, or chain shall be rigged and supported in such a way that its lowest point
(including sag) is no less than 34 inches (.86 meters) from the roof surface and its highest point is no
greater than 39 inches (1 meter) from the roof surface;
(c)
After being erected, with the rope, wire, or chain attached stanchions shall be capable of resisting, without tipping over, a force of at least 16 pounds (71 Newtons) applied horizontally against the
stanchion, 30 inches (0.76 meters) above the roof surface, perpendicular to the warning line, and in the
direction of the roof edge;
(d)
The rope, wire, or chain shall have a minimum tensile strength of 500 pounds (227 Kilograms),
and after being attached to the stanchions, shall be capable of supporting, without breaking, the loads
applied to the stanchions prescribed in paragraph (g) (3) (ii) (c) of this section; and
(e)
The line shall be attached at each stanchion in such a way that pulling on one section of the line
between stanchions will not result in slack being taken up in adjacent sections before the stanchion tips
over.
28
(iii)
Access paths shall be erected as follows:
(a)
Points of access, materials handling areas and material storage areas shall be connected to the
work area by a clear access path formed by 2 warning lines;
(b)
When a path to a point of access is not in use, a rope, wire, or chain equal in strength and height
to the warning line shall be placed across the path at the point where the path intersects the warning line
erected around the work area.
(4)
Mechanical Equipment. Mechanical equipment may be used or stored only in areas where employees
are being protected by either a warning line or an MSS. Mechanical Equipment may not be used or
stored between the warning line and the roof edge unless the employees are being protected by a MSS.
Mechanical equipment may not be used or stored where the only protection provided is by a safety
monitoring system.
(5)
Roof Edge Materials Handling Areas and Materials Storage. Employees working in a roof edge materials handling or materials storage area located on a low pitch roof with a ground to eave height of greater
than 6 feet (1.8 meters) shall be protected from falling by the use of an MSS along all unprotected roof
sides and edges of the area.
(i)
When guardrails are used at hoisting areas, a minimum of four feet of guardrail shall be erected on each
side of the access point through which materials are hoisted.
(ii) A chain or gate shall be placed across the opening between the guardrail sections when hoisting operations are not taking place.
(iii) When guardrails are used at bitumen pipe outlets, a minimum of four feet of guardrail shall be erected on
each side of the pipe.
(iv) When safety belt systems are used, they shall not be attached to the hoist.
(v) When safety belt systems are used they shall be rigged to allow the movement of employees only as far
as the roof edge.
(vi) Materials may not be stored within 6 feet (1.8 meters) of the roof edge unless guardrails are erected at
the roof edge.
(vii) Materials that are piled, grouped, or stacked shall be stable and self supporting.
(6)
Training
(i)
The employer shall provide a training program for all employees engaged in build up roofing work so that
they are able to recognize and deal with the hazards of falling associated with working near a roof
perimeter. The employees shall also be trained in the safety procedures to be followed in order to
prevent such falls.
(ii) The employer shall assure that employees engaged in build up roofing work have been trained and
instructed in the following areas:
(a)
The nature of fall hazards in the work area near a roof edge;
(b)
The function, use, and operation of the MSS, warning line, and safety monitoring systems to be
used.
(c)
The correct procedures for erecting, maintaining, and disassembling the systems to be used;
(d)
The role of each employee in the safety monitoring system when it is in use.
(e)
The limitations on the use of mechanical equipment; and
(f)
The correct procedures for the handling and storage of equipment and materials.
(iii) Training shall be provided for each newly hired employee and for all other employees as necessary to
assure that employees maintain proficiency in the areas listed in paragraph (g) (6) (ii) of this section.
Section 1926.502 of 29 CFR Part 1926 Is Amended By Adding a New Paragraph (p) to Read as
Follows:
(p) For the purpose of paragraph (g) of 1936.500, the following definitions shall apply:
(1)
(2)
“Built-up-roofing” – a weatherproof cover, applied over roof decks, consisting of either liquid applied
system, on single-ply system or a multiple-ply system. Liquid apply systems generally consist of silicon
rubber, plastics, or similar material applied by spray or roller equipment. Single-ply systems generally
consist of a single layer of synthetic rubber, plastic, or similar material, and a layer of adhesive. Multipleply systems generally consist of a layer of felt and bitumen, and may be covered by a layer of mineral
aggregate.
“Built-up-roofing work” – the hoisting, storage, application, and removal of built-up-roofing materials and
equipment, including related insulation, sheet metal, and vapor barrier work but not including the construction of the roof deck.
29
(3)
(4)
(5)
(6)
(7)
(8)
(9)
“Low pitched roof” – a roof having a slope less than or equal to four in twelve.
“Mechanical equipment” – all motor or human propelled wheeled equipment except wheel borrows and
mop carts.
“MSS” (motion stopping safety system) – fall protection using the following equipment singly or in combination; standard railings (guardrails) as described in 1926.500(f); scaffolds or platforms with guardrails
as described in section 1926.451; safety nets as described in 1926.105; and safety belt systems as
described in 1926.104.
“Roof” – the exterior surface on the top of the building. This does not include floors, which because the
building has not been completely built, temporarily becomes the top surface of the building.
“Safety monitoring system” – a safety system in which a competent person monitors the safety of all
employees in a roofing crew, and warns them when it appears to the monitor that they are unaware of
the hazard or are acting in unsafe manner. The competent person must be on the same roof and within
visual sighting distance of the employees, and must be close enough to verbally communicate with the
employees.
“Unprotected side or edge” – any side or edge of a roof perimeter where there is no wall 3 feet (.9
meters) or more in height.
“Work area” – that portion of a roof where built-up roofing work is being performed.
30
Notes:
31
CUT ALLONG DOTTED LINES AND MAIL TO GARLOCK EQUIPMENT CO., 2601 NIAGARA LN., MINNEAPOLIS, MN 55447
32
33
Notes:
34
Notes:
35
Update your instructions and decals.
In the interest of your safety we feel it is important that all GARLOCK products in use, no matter how old, have up to date instructions and decals. The
instructions as well as decals should stay with the product. Indicate below
any GARLOCK product you have that does not have readable operation
instructions and decals.
The following items are available free of charge for each unit:
1)
Clamp-on instruction tube with tabs. You clamp it on to the appropriate
place on the machine.
2)
3)
Operation instructions.
Set of current decals.
WE CARE ABOUT SAFETY
Cut along line and return.
Name of Product
De
ca
ls
In
st
ru
ct
io
Tu
ns
be
s
I care about safety too.
Please send me instruction tubes, current instruction manuals,
or decals as indicated for the following Garlock quality products.
Indicate quantity of
each item required.
Mail to:
Company
Street
2601 NIAGARA LANE
PLYMOUTH, MN 55447
City, State, Zip
Your Name
2601 NIAGARA LANE, PLYMOUTH, MN 55447
Phone: (763) 553-1935
Fax (763) 553-7765