Elastec AmericanMarine D9 Installation and operating instructions

ELRSTE[; (I
OPERATION & SERVICE MANUAL
AmericanMarine ~
www.elastec.com
D9 HYDRAULIC POWERPAK
0-043 Rev 005

ELRSTE[;
TABLE OF CONTENTS
AmericanMarine ~
www.elastec.com
Introduction...................................................................................................................1
Contact Information......................................................................................................1
Getting Started ..............................................................................................................2
Engine Speed Control ...................................................................................................3
Maintenance..................................................................................................................4
Parts List .......................................................................................................................5
Warranty ........................................................................................................................7
Items Not Covered ................................................................... .. ...................................8
0-043 Rev 005

ELR5TE~
INTRODUCTION
AmericanMarine ~
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This manual contains information on 09 Hydraulic PowerPak manufactured by
Elastec I American Marine. All data in this publication is based on the latest product
information.
Elastec I American Marine reserves the right to make changes at any time without
notice and without incurring any obligations.
If a problem is encountered, or if you
have questions about your Elastec I American Marine equipment, please call one of
our consultants at [phone].
Elastec I American Marine products are designed to provide safe and dependable
service when operated according to instructions. Read and understand this manual
before operating this system. Failure to do so may result in personal injury or
equipment damage.
Your Serial Number is __ y ---=- ft ---L..>- D oL.. O=---9 --l<----L. l ----"'. t ---' O .......L.- :1 --4-- 91.--- ____ _
+SERIAL NUMBER MUST BE INCLUDED WHEN ORDERING PARTS.
CONTACT INFORMATION
Elastec/American Marine
1309 West Main Street
Carmi,
IL 62821
USA
Telephone: [phone]
Fax:
[phone]
E-mail: [email protected]
Website: www.elastec.com
D-043 Rev 005

ElRSTEC .
GETTING STARTED
AmericanMarine ~
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Component List:
1. Diesel engine
2. Hydraulic pump
3. Hydraulic reservoir
4. Hydraulic hoses and fittings
Before Starting your PowerPak
1.
Fill oil reservoir with hydraulic oil. (Tank capacity: 8 gallons / 30.28 liters)
• Hydraulic oil with anti-wear additives should
be used. In arctic environments during
times of extremely low temperatures,
automotive transmission fluid may be used.
• Suggested oil types include hydraulic oil
commonly available for agricultural
equipments, forklifts, etc. in your country.
BRAND
Pennzoil
Texaco
Shell
Mobil
Chevron
TYPE
AW46 Hydraulic Oil
Rando HOAZ
Tellas Hydraulic Oil
O.T.E 20 Series
EP Hydraulic Oil
2. Check the engine oil. The engine oil selected
Ex x on J-58 Hydraulic Oil
should be chosen based on the optimum oil viscosity for the climate (temperature
range)
in which the PowerPak will be used. An oil selection guide in the
manufacturer's operation manual will assist the operator
in choosing the correct
oil.
3. Connect battery cables. Your D9 PowerPak is shipped with the battery cables
disconnected.
4. Fill the engine's fuel tank with diesel fuel.
5. Connect hydraulic hoses.
• WARNING: Always connect hydraulic hoses to power unit before starting.
• All hydraulic hoses in this system are color-coded. Return lines are colored
with green markings that match the green markings on the fittings on the
boom reel. Pressure lines are marked with yellow.
• Hydraulic hoses are tested at the factory and contain oil. If the ambient
temperature at the final location
is higher than when tested, hoses may be
under pressure and difficult to connect. To connect the hoses, this pressure
will have to be released by depressing the pin on the male end of the hose.
This pin can
be depressed by tapping with a hammer or pressing against a
solid object.
2
0-043 Rev 005

ELRSTEC
ENGINE SPEED CONTROL
AmericanMarine ll
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Several types of engine speed control are used in this series of engines. The following procedures are
for three typical applications. See engine manufacturer's service manual for more information.
(2 )
• Slide engine speed •
control lever (A-1 ) to the
RUN position (A-2). •
•
Turn engine speed control knob (8-1 ) •
to the left (8-2).
Slide engine speed control knob to
the START position (8-3
Turn engine speed control know to
the right (8-
4) to tighten it.
Slide engine speed con-
trollever (C-1) to the
RUN position (C - 2) .
CAUTION: Never use an engine starting aid such as ether. Engine damage will result.
START THE ENGINE
1. Insert key into key switch (#2).
2. Turn key clockwise to the START POSITION
(#4). Release the key as soon as engine starts.
It will return to ON position (#3). CAUTION:
Never hold key in START position for longer
than 15 seconds to avoid overheating of
starter motor.
3. If engine fails to start:
a. Wait until engine comes to a complete stop
before you attempt to start again. Engaging
the starter while the engine
is still rotating will
result in damage to the starter motor and fly-
wheel.
(1) (2) (3)
o ,~
·U (')
o
b. Wait at least 30 seconds before you attempt to start the engine again. This pause will
allow the battery voltage to recover and prevent damage to the starter motor due to low
battery Voltage.
NOTE: The Battery Indicator Lamp (#1) comes
on if there is a problem in the charging system.
3 0-043
Re v 005

ELRSTEC .
MAINTENANCE
AmericanMarine ~
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Engine:
Maintain your engine as directed in the manufacturer's instructions provided with your
PowerPak.
PowerPak:
1. Hydraulic oil and filter should be changed every three hundred (300) hours of
operation.
2. Clean hydraulic filter suction strainer every six hundred (600) hours of operation.
The strainer is located in the hydraulic tank. Access the strainer by removing the
adapter.
3. Hydraulic pumps are not serviceable items. If pump malfunctions, it must be
replaced.
Relief Valve:
1. Relief valves are pre-set and do not require service.
Hydraulic Hoses and Couplers:
1. Couplers used on the PowerPak will have a long service life if kept clean. The
quick disconnect couplers can be cleaned with kerosene or solvent using a brush
or compressed air.
2. Damage to hoses comes primarily from kinking and chafing. This should be
avoided at all times.
If the hoses begin to leak, they should be replaced.
4
D- 043 R ev 005

ELRSTEC
PARTS LIST
AmericanMarine ~
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Item# Part # Description
1 4FRAMPOO09C Frame PowerPak 09
2 4CAP-F1010 Cap Filler Hydraulic Tank
3 4TANKHY008P Tank Hydraulic 8 Gallon
4 4GAUGOI012 Gauge Oil Level
5 6222361212 Adapter Hydraulic 90 JICM/MPT Steel 3/4" x 3/4"
6 4HOSEC0080 Hose Connector Hydraulic
09 Reservoir/Pump
7a 4HOUSFI012 Housing Filter 3/4" 0-20 gpm
7b 4FILTHY010 Filter Hydraulic Oil
8 4BATTEN320 Battery Engine 320 amp 12V
9 4BAR-BA010P Bar Battery Holding
10 4BUMPRU024 Bumper Rubber 1/4" x 3/4" x
1-1 /2"
11 4ENGIYA010 Engine Yanmar L100V6
12* 4COUPJA008 Coupler Jaw Keyed L095 Cast 1/2"
13 * 4COUPJA016 Coupler Jaw Keyed L095 Cast 1"
14* 4SPACSP010 Spacer Spider L95
*Not Shown
5
D- 043 Re v 005

ELRSTE[; •
PARTS LIST
AmericanMarine ll
www.elastec.com
Item# Part # Description
1a 6240471212 Coupler Hyd Universal Sis 3/4" x 3/4"
1b 6269240012 PIl!9 Dust Rubber 3/4"
2 4GAUGPR030 Gauge Pressure Basemount 3000
3 4VALVRE110 Valve Relief Hyd Body, SAE #6, Boss x 1/4" FPT
4a 6222760608 Adapter Hyd 90 Boss/Mpt Steel 3/8" x 1/2"
4b 6223670808 Adapter Hyd Quick Ss 1/2"x1/2"
5 6269460012 Plug Mpt Steel 3/4"
6 6271561212 Tee Threaded Steel 3/4"x 3/4"
7 6220261212 Adapter Hyd Reg Mpt/Mpt Steel 3/4"x3/4"
NOTE: The following changes apply to units equipped with AeroQuip fittings:
Item# Part # Description
1 6241061212 CouQler Hyd AeroQuip Steel 3/4" x 3/4"
4 6223460808 Adapter Hyd AeroQuip Steel 1/2" x 5/8"
6 D-043 Rev 005

ELR5TEC.
WARRANTY
AmericanMarine ~
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ELASTEC / AMERICAN MARINE warrants and guarantees that articles supplied are
free from defects in materials and workmanship, but seller's liability hereunder is lim-
ited to making good by replacement or repair without charge to the buyer any such
defects as arise within the period of one year from dispatch of the articles (with the
exceptions listed below), provided always that such defects are notified
in writing to
the seller within fourteen days of their discovery and that the defective parts, where
reasonable, are promptly sent carriage paid to the seller's premises. Such liability
shall not extend to such faults as are caused by ordinary wear and tear, incorrect
handling of the articles or their defective maintenance or storage.
Unless otherwise noted, products are warranted against defects
in material and work-
manship under normal use and service for a period of 1 year.
SmartAsh incinerators have a warranty period of 6 months.
ELASTEC obligation under this warranty is limited solely to repairing or replacing
parts, which
in their judgment are defective in material and/or workmanship. Elastec
will be responsible for shipping of replacement parts to customer.
Li mitations:
ELASTEC is not liable for expenses incurred in repairs or alterations made outside
their factory or licensed dealer locations
wi thout prior authorization, nor shall they be
responsible for the performance of this product to which any revisions or alterations
have been made by others.
7 D-043 Rev 005

ELRSTEC
ITEMS NOT COVERED
AmericanMarine lf
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1. Products that have been subjected to alteration, modification, neglect, or repairs.
2. Products no longer owned by the original purchasers.
3. Products suffering shipping or freight damage, normal wear, accident, improper
maintenance or improper protection
in storage.
4. Rental costs, return transportation cost of product to Elastec's place of business
or phone communications.
5. Any repeat or shop comeback repairs resulting form poor service work, improper
diagnosis or testing. Replacement of parts as a trial and error method of
diagnosis will not be considered for warranty.
6. Replacement parts other than those sold or supplied by Elastec / American
Marine Inc.
7. Any normal replacement and/or service of wiper blades.
8. Natural calamity such as fire, flood, etc.
9. Any damage caused by failure to immediately correct a known or suspected
problem with skimmer products.
In the case of components or accessories that have been supplied to the buyer's
design, the seller shall by under
no liability to replace or repair defects arising there
from.
The guarantee contained
in the clause above shall constitute the seller's sole liability
for latent and other defects and
is in full exclusion of any warranty or liability
whatsoever implied of common law, statute or otherwise as to the quality of the
goods, their fitness for any particular purpose, their merchantability or otherwise, and
the seller shall not be liable for the consequential loss, injury or damage of any
nature whatsoever arising out of or
in connection with the supply of the articles.
8 0-043 Rev 005