Académique Documents
Professionnel Documents
Culture Documents
Maple Crete
Part 1 of 2
Record the Model and Serial Number of equipment for parts ordering information
www.vikingcives.com
CAB CONTROLS 11
CAB CONSOLE AUX LIGHTING 9 SWITCH 12
PEDESTAL ASSEMBLY 9 SWITCH BOX MOUNTING 17
ELECTRICAL 89
ELECTRICAL LAYOUT 91
BETTS SEALED JUNCTION BOX 93
HARNESS KIT CAB POWER FEED 94
HYDRAULICS 97
HYDRAULICS LAYOUT 99
HYDRAULIC OIL TANK WELDMENT 350SCL 100
PUMP KIT METARIS SINGLE (MHP20A) 101
RETURN MANIFOLD BLOCK 104
STAINLESS HOSE HANGER KIT 120 LG 105
1" HIGH PRESSURE FILTER KIT 108
NOTES 271
VIKING-CIVES LTD. (Canada) warrants products of its manufacture against defects in workmanship and material for a
period of one year from date of shipment to customer; and in consequence of this warranty, any component part or parts of such
products proving defective within the above specified time will be repaired or replaced F.O.B. factory, providing such parts are
returned, transportation prepaid, to the factory and found defective by VIKING-CIVES LTD. (Canada). This warranty will
not apply to any product, which have been repaired or altered outside of the VIKING-CIVES LTD. (Canada) factory in any
way so as, in VIKING-CIVES LTD. (Canada) sole judgment, to affect its stability or reliability, nor which has been subjected
iii
to misuse, negligence or accident.
The obligations of VIKING-CIVES LTD. (Canada) under this limited warranty are limited to the replacement of defective
parts as set forth above; such obligations are exclusive and in lieu of all other remedies, warranties, guarantees or liabilities,
express or implied, with respect to each product delivered hereunder, arising by law or otherwise (including without limitation
any obligation or liability of VIKING-CIVES LTD. (Canada), arising from negligence or with respect to fitness for a
particular purpose, merchantability, loss or use, revenue, or profit, or any incidental, indirect, special or consequential damages
or injuries, even if VIKING-CIVES LTD. (Canada) has been advised of the possibility of such damages or injuries; and all
other remedies, warranties, guarantees, or liabilities are hereby expressly excluded and disclaimed. This limited warranty shall
not be extended, altered, or varied except by a written instrument signed by VIKING-CIVES LTD. (Canada).
VIKING-CIVES LTD. (Canada) assumes no responsibility for engines, electrical equipment, or any other
equipment and accessories not manufactured by VIKING-CIVES LTD. (Canada).
Identification of Equipment
Each specific unit is identified by a unique E-Job Number (E00XXXX). To ensure accurate service, your
Viking-Cives representative will need this E-Job Number whenever parts and/or service is required.
All units assembled at Viking-Cives Ltd., Mt Forest, ON will have a National Safety Mark label inside the driv-
er’s door. The E-Job Number will be printed on this label, as shown below:
E-JOB Number
MARCH2016 E08456
NOTICE: The E-Job Number is the most important identifier for any specific plow. It allows the Viking-Cives
parts and service team to access complete information for the specific project. For the fastest possible
service, always have the E-Job Number ready when making inquiries.
In order to provide more accurate service, you may also be asked to provide your individual equipment Model
and Serial No. The information required to identify the equipment may be found on the serial number tag
secured to the equipment.
500HD
XXXXXXX
M00000
When placing orders, be sure to include the following information, printed/typed clearly:
For the fastest service, place orders with your nearest dealer.
Dealer
Address
Phone
Toll Free
Fax
3/24/2016
1. Contact your Viking-Cives Ltd. Customer Service Department to obtain approval to proceed, and the
necessary paperwork.
2. Mail, email, or fax the completed form to Viking-Cives Ltd., attention: Customer Service Department.
3. Once the work order has been reviewed, warranty authorization will be granted or denied. Any part(s)
involved will follow the Parts Warranty Consideration procedures.
NOTE: Viking-Cives Ltd. E-Job Number must be provided in order to proceed, the E-Job number must be
on all paperwork sent to Viking-Cives.com
M00000
All illustrations contained within this manual are accurate at the time of printing, however, due to changes and
improvements in our design and manufacturing processes, the actual equipment may vary slightly in detail.
Viking-Cives reserves the right to redesign or make changes to existing products without notification to the end
user.
Safety
DANGER: It is the responsibility of the OWNER & ALL OPERATORS to ensure that all per-
sons operating, or performing maintenance on this equipment have read and fully under-
stand the contents of this manual. Failure to follow the instructions outlined in this manual
may result in serious injury or death.
Remember at all times that as the operator YOU are responsible for the safe operation of this equipment and
responsible for the safety of others. Good safety practices not only protect you, but also protect the people
around you.
Whenever there is doubt in regards to operator/bystander safety, always look to:
• Your employer’s safety programs and • The safety procedures outlined in this manual.
regulations. • The safety decals placed on the equipment.
• Local, state/provincial, and federal laws, rules • Your own good judgement.
and regulations.
3/24/2016
Whenever you see the safety alert symbol, BE ALERT, PAY ATTENTION! Always read and unserstand the
accompanying text and images. Wherever you see the safety alert symbol, YOUR safety is involved.
CAUTION: Indicates a potentially hazardous situation that, if not avoided, MAY result in minor
or moderate injury.
WARNING: Indicates an imminently hazardous situation that, if not avoided, COULD result in
serious injury or death.
DANGER: Indicates an imminently hazardous situation that, if not avoided, WILL result in
serious injury or death.
NOTICE: Identifies tips, helpful hints, and maintenance information the owner/operator should
know. May be used to alert against unsafe practices that may result in non-personal injury or
damage.
M00000
Lockout Procedure
Before leaving the operator’s position or beginning any type of work on this product:
1. Lower all attachments to the ground.
2. Apply the prime mover’s parking brake, stop the engine and remove the starter key.
3. Wait for all moving parts to stop.
4. With the engine off, relieve all pressure in the hydraulic system by moving hydraulic levers in both
directions.
WARNING: After following the lockout procedures, pneumatic pressure may still be present in
the system. Residual pressure can be relieved by pumping the brakes after the vehicle is shut
off or by opening the release valve located on the prime mover’s air tank. As air pressure is
relieved, component motion may occur. Exercise extreme caution when servicing pneumatic
systems.
DANGER: Springs may be present throughout the equipment, including the brake chambers
used in the design of the Pro-Line tailgate locks. Springs under pre-load pressure may not
be secured by following Lockout Procedures. Viking-Cives Ltd does not recommend or
encourage tampering with and/or servicing spring loaded mechanisms without compre-
hensive training. Mishandling WILL result in severe injury.
3/24/2016
The following checklist should be performed before and after each plowing shift to ensure operational
readiness.
NOTE: For more specific information and maintenance instructions, refer to the individual equipment sections
in this manual.
Check the fluid level in the hydraulic oil reservoir. If the sight gauge indicates low oil level, add the
appropriate amount of the specified hydraulic fluid.
Grease all required components:
• All plow harness sheave nipples.
• All hydraulic pump drive shaft nipples.
• Front and rear tower sheaves and swivel blocks.
• Wing extension arm nipples.
• Front and rear tower guide tracks.
• All front harness pivot points.
Check all components for loose and/or missing fasteners. Tighten and/or replace as necessary.
Visually inspect all hydraulic connections and hoses for cracks and/or leaks.
Check all cables, chains and sheaves for excessive wear or damage.
Visually inspect all caution and warning decals. All decals should be complete and legible. If cleaning the
decals does not make them legible, install new decals.
Visually inspect plow and wing units. Check cutting edges and shoes for signs of excessive wear and
replace as necessary. Some cutting edges may be rotated or “flipped over” to use the opposite side edge.
NOTE: Do not allow cutting edge to wear down to mounting angle. Any wear to the mounting angle may affect the
operation and safety of the equipment.
M00000
3/24/2016
01901288-M 1/8/2014
8 6 10
10 6 8
Page 5 of 273
11 6 6 8
REFERENCE ONLY
12
Rev.3
01903259: MOUNTING KIT FOR 275 OIL TANK WELDMENT - NO WING
ITEM ID ITEM NO DESCRIPTION QTY REQ
1 01001300 REAR MAST LOWER MTG ANGLE 1
2 01901613 MOUNTING BRKT PS BOC OIL TANK WELDT 1
3 01903260 MOUNTING BRKT DS BOC OIL TANK 275 WELDT 1
4 HW14D-08 FLATWASHER HARDENED 1/2 ZINC 6
5 HW14D-10 FLATWASHER HARDENED 5/8 ZINC 14
6 HW36D-08 NUT HEX ELASTIC 1/2 UNC ZINC 3
7 HW36D-10 NUT HEX ELASTIC 5/8 UNC ZINC 7
8 HW40A-0820 BOLT HEX 1/2 X 2 1/2 UNC ZINC 3
9 HW40A-1020 BOLT HEX 5/8 X 2 1/2 UNC ZINC 7
6 4 4 8
2
1
9 5 5 7
Page 7 of 273
BOSCH 266545 BRACKET
01901288-M 1/8/2014
2 3
| |
IGNITION 12 VOLTS
1 - PIN 6 - SOCKET
2 - PIN 8 - SOCKET 5 4
NOTE: SEE WIRING HARNESS FOR CONNECTOR WIRE GUIDE
THIS OWNER'S MANUAL FILE IS CONTAINED WITHIN 0660257.idw, REV 3
E08626-M & E08791-M Page 12 of 273
BOX 1120, NORPARK DRIVE, MOUNT FOREST, ONT. N0G 2L0 (519)323-4433 PH (519)323-4608 FX
Page 13 of 273
This Owner's Manual File is Contained Within 0660257.idw
EQUIPMENT MAY NOT BE EXACTLY AS SHOWN. SOME COMPONENTS MAY BE OPTIONAL
TO MAINTAIN OUR ON-GOING PRODUCT AND DEVELOPMENT IMPROVEMENT PROGRAM, VIKING-CIVES LTD. RESERVES THE RIGHT TO CHANGE EQUIPMENT & SPECIFICATION WITHOUT NOTICE.
BOX 1120, NORPARK DRIVE, MOUNT FOREST, ONT. N0G 2L0 (519)323-4433 PH (519)323-4608 FX
SWITCH BOX
E08626-M & E08791-M Page 14 of 273 This Owner's Manual File is Contained Within 0660257.idw
BOX 1120, NORPARK DRIVE, MOUNT FOREST, ONT. N0G 2L0 (519)323-4433 PH (519)323-4608 FX
SCHEMATIC
E08626-M & E08791-M Page 15 of 273 This Owner's Manual File is Contained Within 0660257.idw
THIS PAGE LEFT BLANK
01901288-M 1/8/2014
00202152-M 4/8/2014
9 8 7
Page 19 of 273
5
4
00202152-M 4/8/2014
WARNING! When the hydraulics or the anti-icing liquid are under pressure – STAND CLEAR!
WARNING! The driver of the truck must understand the behaviour of towing liquid tanks. The water
moving around in the tank may cause truck stability and braking issues. The behaviour of the truck will
change as the level of liquid in the tank changes.
Note : this attachment may only be loaded or unloaded at a maximum of half the capacity of the tank; otherwise, the tank will fracture
causing equipment damage. There is a decal located at the pull hook as a reminder of this.
Note : there is a rear bumper mounted rubber flap that should be mounted prior to use of the DLA Attachment. Its intended function is
to protect the truck from spray of anti-icing/de-icing solutions, and also to reduce the effect of the wind on the spray stream/pattern.
The following steps and considerations must be taken prior to loading, operation, and unloading.
Prior to Loading
Prior to Operation
Prior to Unloading
03706201-M 5/31/2016
Store the hoses and quick disconnect couplings in the tipping frame storage plate so that they are not resting on the ground and are out
of the way to prevent damage.
Be sure to cap all hose ends to prevent damage to the quick disconnect hose ends and prevent the introduction of foreign materials into
the hydraulic system.
Note : if equipped with a Force America 6100 CANBUS control system there will be an electrical connection at the pintle plate of the
chassis. Be sure to disconnect this cable prior to unloading.
1. All lights on the DLA Attachment are in working condition and meet regulatory standards.
2. The manual, electric and air ball valves all turn on and off.
3. The hydraulic pump and plumbing system operate as expected. While testing, check that the spray nozzles are aimed for the
desired spray pattern by running the spreader control in manual unload. Be sure to unload in an environmentally safe manner.
4. You must have liquid in the tank and follow operating instructions listed under the DLA ATTACHMENT OPERATING
INSTRUCTIONS in this manual. If the pump does not sound right, it may be drawing air. See the AIR BLEEDING
PROCEDURE in this section.
When all conditions of installation and setup have been met, the DLA Attachment is ready to operate. The switches for controlling the
DLA Attachment pump functions are located in the cab of the prime mover.
WARNING! When the hydraulics or the anti-icing liquid are under pressure – STAND CLEAR!
03706201-M 5/31/2016
Refer to the liquid plumbing schematic at the end of this instructional section for assistance with the following instructions.
1. Check that the electric ball valves - Valve F, Valve G, and Valve H are closed. There are indicators on top of the ball valve
manifold. They can be turned to the OFF position using the controls in the cab of the prime mover.
2. Ensure that Valve A, Valve D, and if equipped, Valve I, Valve J, Valve K are turned off.
3. Turn Valve B and Valve C to the RUN position.
4. Open Valve A, and visually check for any leaks. The unit can now be controlled from the cab of the prime mover.
5. Once in the cab, select your rates on the spreader control. Refer to your spreader control manual for more information.
6. Open the safety shut off, Valve E, with the air switch in the cab of the prime mover.
7. Select the booms that you are going to initially spray with. This will open a combination of Valve F, Valve G and Valve H
based on your selection.
8. Engage the spreader control.
9. You can now begin spraying on the roadway. Note : the unit may not start spraying until it reaches a predetermined ground
speed based on your spreader control settings.
10. You may turn booms on and off as you drive, but depending on the spreader control system on your prime mover, you may or
may not have to adjust your spreading rates.
11. Each boom is controlled by its own electric ball valve.
03706201-M 5/31/2016
1. Turn off all boom electric ball valves - Valve F, Valve G and Valve H in the cab of the prime mover.
2. Close the safety shut off air (pneumatic) ball valve - Valve E in the cab of the prime mover
3. Ensure Valve B and Valve C are in the RUN position.
4. Ensure that Valve I, Valve J, and Valve K are closed.
5. Ensure that electrical ball valves -Valve F, Valve G and Valve H are physically closed. The dials on the top of the electric
ball valve indicate their position.
6. Visually check for leaks.
CAUTION! Be aware of conditions where the liquid in the attachment may freeze. This can cause
damage to the plumbing components. If freezing conditions are expected, take the appropriate
precautions to avoid freezing or drain the system completely.
FILL PROCEDURE
1. With Valve C in the PURGE position ,Valve A in ON position, and Valve B in the RUN position, remove the camlock plug
at Valve B and connect a hose with a 2" camlock male connector from your fill station.
2. With the filling hose securely connected, turn Valve B to the FILL position.
3. Begin pumping liquid from the fill station at a maximum rate of 225 GPM. Visually inspect for leaks. Note: The tank vent
has a maximum rate of 450 GPM for intermittent flow only.
4. Continue filling until the desired level has been reached in tank. Note: The tank has volume marked in gallons to assist with
filling.
5. Turn off the filling station and turn Valve B to the RUN position.
6. Disconnect the filling hose and replace the camlock plug into the female camlock connector. Note: Be aware that some liquid
may initially leak from the filling hose and the trailer plumbing when disconnecting the fill hose.
UNLOAD PROCEDURE
The Viking-Cives DLA Attachment has been designed and built to provide more function during the off season. The DLA Unit can be
equipped with three versatile powered unload options.
Note : the rear electric ball valves must be closed during the operation of any of the powered unload options. The manual option
override switch will need to be used to operate any of the rear options.
Note: It is the owner's/operator's responsibility to ensure that the liquid is unloaded in an environmentally safe manner.
03706201-M 5/31/2016
8. With the spreader control and pump disengaged, leave Valve I open to allow gravity to clear the remaining liquid in the lines.
9. Once fully unloaded, close Valve I. Replace the camlock cap and plug.
10. Close the air safety ball Valve E using the switch in the cab of the prime mover.
CAUTION! After fully draining the system, you will need to bleed the air in the plumbing prior to
operating the DLA Attachment when it is refilled with liquid. See the AIR BLEEDING PROCEDURE.
Note: It is the owner's/operator's responsibility to ensure that the liquid is unloaded in an environmentally safe manner.
CAUTION! Once the pump draws air, turn off the spreader control immediately to turn off the pump.
The pump can be damaged if it continues to pump air.
8. With the spreader control and pump disengaged, leave Valve J open to allow gravity to clear the remaining liquid in the lines.
9. Once fully unloaded, close Valve J and move Valve "C" to the PURGE position. Replace the camlock cap.
10. Close the air safety ball Valve E using the switch in the cab of the prime mover.
CAUTION! After fully draining the system, you will need to bleed the air in the plumbing prior to
operating the DLA Attachment when it is refilled with liquid. See the AIR BLEEDING PROCEDURE.
1. Ensure that the flush tank is full of the flushing liquid that is suitable for winter weather conditions (i.e. a glycol based
windshield washer fluid).
2. Move Valve B to the RUN position and Valve C to the FLUSH position.
3. Open Valve D located on the flush tank.
4. Have one person in the cab of the prime mover and another at the attachment.
5. In the cab, select manual unload on the spreader control and set it to the lowest rate. Refer to the spreader control manual for
more information.
6. Turn on all three booms in the cab (Valve F, Valve G and Valve H) and open the air safety ball valve, Valve E, using the
switch in the cab.
7. Engage the spreader control to begin flushing.
03706201-M 5/31/2016
CAUTION! It is important not to allow the pump to draw air. Never let the flush tank go completely
empty. The size of the flush tank has been designed to completely flush the plumbing without emptying.
If you do draw air into the pump, shut off the pump immediately from the spreader control and follow the AIR BLEEDING
PROCEDURE.
1. With liquid in the main tank, move Valve B and Valve C to the RUN position.
2. Ensure that safety shut off valve E is closed. If not, close using the switch in the cab of the prime mover.
3. Open the main tank shut off valve - Valve A.
4. Place a container or bucket under the bleed line. Open Valve L, the bleed valve. Note: It is the owner's/operator's
responsibility to ensure that the liquid is unloaded in an environmentally safe manner.
5. Let the attachment sit for a few minutes or until liquid begins to flow out of the bleed valve. Note : there may be some
residual liquid in the bleed valve line, in which case there will be a small amount of liquid that will bleed out before the air is
bled out of the plumbing system.
6. Close the bleed valve.
7. Close Valve A, the main tank shut off valve.
8. The system is now primed.
03706201-M 5/31/2016
1. Check the fluid level in the hydraulic oil reservoir. If the sight gauge indicates low oil level, add the appropriate amount of
the specified hydraulic fluid.
2. Check the level of liquid in the DLA main tank.
3. Check that all connections are correctly connected and are in working order.
4. Visually inspect the working operation of all lights, including the flashing warning lights.
5. Grease all required components (i.e. front guide rollers on the attachment).
6. Check all components for loose and/or missing fasteners. Tighten and/or replace as necessary.
7. Visually inspect all hydraulic connections and hoses for cracks and/or leaks.
8. Visually inspect all anti-icing/de-icing plumbing connections, hoses and fittings for cracks and/or leaks.
9. Check all cables for excessive wear or damage.
10. Visually inspect all caution and warning decals, including the anti-icing/de-icing sign. All decals should be complete and
legible. If cleaning the decals does not make them legible, install new decals.
03706201-M 5/31/2016
1. Mark targets on the ground with the dimensions given in the Spray Pattern Set-up diagram. This is the recommended pattern,
but can be changed to suit specific applications.
2. The group of four nozzles on the left will cover the left side lane. The group of four nozzles on the right will cover the right
side lane. Lastly, the two groups of two nozzles are to be directed to opposite sides of the centre lane for proper coverage.
3. Adjust each nozzle to their appropriate directions by loosening the nut, rotating the nozzle and ball assembly, and then
securing in position by tightening the nut. Hand tightening is all that is required to secure in place.
4. Using water as the liquid for aiming and set ground speed at 80km/hr and enter 80 litres per lane kilometre. Use these values
to aide in aiming the nozzles or enter the most frequently used speed and rate values. When the system is operational, use the
adjusting nut to position the nozzles to the correct spread pattern as water is being sprayed. Take precautions to avoid the
stream itself. Wind may affect the spread pattern; adjust the aiming of the nozzles to compensate.
5. The spread pattern may need to be adjusted if there is a wide range of rates to address.
6. Drain the water once the spray pattern has been set and fill the tank with your anti-icing/de-icing liquid.
1. The spray pattern for this set-up can only be fine tuned and not altered like that of the variable orifice nozzle set-up.
2. The group of nozzles along the centre stainless spray bar cover the centre lane, while the group of nozzles on both the left
side and right side stainless spray bars cover the left and right lanes respectively.
3. The centre lane nozzles are set a fixed distance apart from one another, but can be aimed slightly by loosening the nut and
rotating the nozzle and ball assembly to the needed position. Once the position has been located, tighten the nut to secure.
Hand tightening is all that is required. The left and right groups of nozzles are stacked vertically and must be positioned
independently of each other for proper lane coverage.
4. Using water as the liquid for aiming, set ground speed to 80km/hr and enter 80 litres per lane kilometre. Use these values to
aide in aiming the nozzles or enter the most frequently used speed and rate values. Wind may affect the spread pattern, adjust
the nozzles to compensate.
5. The spread pattern may need to be adjusted if there is a wide range of rates to address. The nozzle tips can also be changed to
provide more backpressure depending on the rates required.
6. Drain the water once the spray pattern has been set and fill the tank with your anti-icing/de-icing liquid.
03706201-M 5/31/2016
19
11
14
2
1 B
Page 33 of 273
A C
18
2
17
34 28 28 30
37 26 26 31
7
10
36
29 35 28 28 30 36 29 29 31
39 25 25 33
29
Rev.4
BOX 1120, NORPARK DRIVE, MOUNT FOREST, ONT. N0G 2L0 (519)323-4433 PH (519)323-4608 FX
20
22
16
Page 34 of 273
D 5
G
4
12
33 39
33 25 25 39 13 15
40 23 25 33
24
DETAIL E DETAIL F 21 16 15
SCALE 3 : 16 SCALE 3 : 16
DETAIL D
SCALE 3 : 8
Rev.4
01903224
DLA FRAME MOUNTED ELECTRICAL
KIT
16
DETAIL M
REF: 01902726 SCALE 3 : 8
REF: 01902717
DETAIL L
SCALE 3 : 16
10 9
Page 37 of 273
7
N
9
6
7
L
11
M
7
7 3
18
6
Rev.4
0660011 - 6 WIRE HARNESS BOX 1120, NORPARK DRIVE, MOUNT FOREST, ONT. N0G 2L0 (519)323-4433 PH (519)323-4608 FX
WIRE ASSIGNMENTS #1
Page 38 of 273
WIRE ASSIGNMENTS
BLUE REVERSE
ST/T/T
GREEN SIGNAL
Rev.4
01903282
DLA PNEUMATIC & HYDRAULIC KIT
FRAME MOUNT
9
2
7 6 DETAIL C
DETAIL A SCALE 3 : 8
SCALE 3 : 16
Page 41 of 273
3/8 GROMMET FOR AIR LINE
10 C
14 12 12 13 11
B
DETAIL B 8
REFERENCE EXTERIOR HYD HOSES
Rev.1
01903177: DLA FRAME MOUNTED INSTALL
ITEM ID ITEM NO DESCRIPTION QTY REQ
1 00403650 LINK 0.813B 3.000 0.813B 0.250 A 4
2 01904064 BODY HOLD DOWN WELD'T 12
3 01904150 BODY HOLD DOWN MTG SPACER PLT (SSTL) 6
4 0720609 URETHANE DIE SPRING 8
5 HW14D-10 FLATWASHER HARDENED 5/8 ZINC 80
6 HW14D-12 FLATWASHER HARDENED 3/4 ZINC 16
7 HW36D-10 NUT HEX ELASTIC 5/8 UNC ZINC 40
8 HW36D-12 NUT HEX ELASTIC 3/4 UNC ZINC 8
9 HW40A-1016 BOLT HEX 5/8 X 2 UNC ZINC 18
10 HW40A-1024 BOLT HEX 5/8 X 3 UNC ZINC 4
11 HW40A-1048 BOLT HEX 5/8 X 6 UNC ZINC 18
12 HW40A-1252 BOLT HEX 3/4 X 6 1/2 UNC ZINC 8
2 11
5
10
7
5
5 12
7 6
4
9
1
5
6
5
8
7
21 4 54 46 46 50
45 53 24 10 22
10
22
21
B
30
C 37
A 36
23
25
10
G
8 22
43
Page 46 of 273
15
45 DETAIL B
41 11
SCALE 1 : 4
53
16
13
34
12
36
9
10
30
22
10
22
19 6 39 10
22
DETAIL G
SCALE 1 : 4
Rev.4
BOX 1120, NORPARK DRIVE, MOUNT FOREST, ONT. N0G 2L0 (519)323-4433 PH (519)323-4608 FX
2
49 44 44 52
48
47
20
F
E
26
35
DETAIL E
SCALE 1 : 8 18 14
Page 47 of 273
D
8
14
29
28
32
28 29
29 28
38
41 17
33
27
41
5
Rev.4
BOX 1120, NORPARK DRIVE, MOUNT FOREST, ONT. N0G 2L0 (519)323-4433 PH (519)323-4608 FX
46
Page 48 of 273
50
31
3
41
40
Rev.4
4 3 2 1
D D
PURGE TANK
MAIN TANK
VALVE D VALVE L
VALVE A PURGE TANK BLEED VALVE
TANK SHUT OFF SHUT OFF
PRESSURE RELIEF VALVE
C C
TANK FILL
FILTER
VALVE B
FILL/RUN VALVE CHECK VALVE
CENTRIFUGAL PUMP
VALVE C
PURGE/RUN VALVE FLOWMETER
Page 49 of 273
ELECTRIC BALL VALVE MANIFOLD
B B
CHECK VALVE
VALVE E
PNEUMATIC BALL VALVE
VALVE K VALVE F
FRONT EXIT AUXILIARY KIT LEFT LANE SPRAY BOOM
(IF EQUIPPED)
VALVE H VALVE G
RIGHT LANE SPRAY BOOM CENTRE LANE SPRAY BOOM
A VALVE J VALVE I A
HOSE REEL KIT REAR EXIT AUXILIARY KIT
(IF EQUIPPED) (IF EQUIPPED)
4 3 2 1
4 3 2 1
VALVE E
PNEUMATIC BALL VALVE
D D
DETAIL M
C SCALE 1 : 8 C
VALVE D
PURGE TANK SHUT OFF VALVE A - MAIN TANK SHUT OFF
Page 50 of 273
B B
DETAIL N
SCALE 3 : 16
VALVE C - PURGE/RUN
A FILL PORT A
VALVE B - FILL/RUN
DETAIL L
SCALE 3 : 16
4 3 2 1
03706202
DLA LIQUID PLUMBING KIT BALL
VALVE ASSEMBLY
7 3 2 9 6 2 3 6 9 2 3 4 1
LIQUID FILL
COUPLER
Page 53 of 273
FROM FLUSH TANK
8
TO LIQUID PUMP
Rev.2
This Page Left Blank
FROM 03706202
10
4 3 8 4 3 5
FROM PRESSURE
SPIKE VALVE
9
ARROW MUST POINT DETAIL A
DOWN TOWARDS TEE SCALE 1 : 1 A
E08626-M & E08791-M Page 57 of 273 This Owner's Manual File is Contained Within 03706203.idw Rev. 2
This Page Left Blank
10 3 2 7 3 2 2
DETAIL B
SCALE 3 : 4
TO FLOW METER
Page 61 of 273
3
9 4 1 11 4 1 8
TO 03706203
Rev.3
0811474
PUMP ANTI ICE HYPRO 9303C-HM1C-U
Nozzle Positioning:
Adjust each nozzle to their appropriate directions by loosening
7
1
8
16
13
DETAIL AF
SCALE 1 : 4
12
AD DETAIL AD
10
SCALE 1 : 4
2
Page 65 of 273
AF
5 17
4 14
AE
14
15
AG
DETAIL AG
SCALE 1 : 4
DETAIL AE
SCALE 3 : 16
Rev.7
03706190: DLA SPRAY BAR CENTRE BOOM ASSEMBLY
ITEM ID ITEM NO DESCRIPTION QTY REQ
1 0620069 200 SERIES WORM SCREW CLAMP 4
2 0640627 FITTING PIPE 1 1/2 NPT FEM TEE 304 SS 1
3 0640628 FITTING PIPE 1 1/2 NPT CAP 304 SS 2
4 0640630 FITTING PIPE 1 1/2 NPT X 36 LG 304 SS 2
5 0810931 FITTING POLY 2 FLANGE X 1 1/2 M-THREAD 3
6 0810935 EPDM GASKET 150 SERIES FULL PORT 1-1/2 4
7 0811223 FITTING POLY 2 FLANGE X 1 1/2 HOSE BARB 1
8 0811224 FITTING POLY 2 FLANGE X 1 1/2 90 DEG HOSE 1
9 0811382 VALVE CHECK POLY SPRING 1 1/2 FNPT 5PSI 1
10 0811386 NOZZLE ASSY TJET CLIP-EYELET 1 1/2 12
11 0811465 VALVE BALL POLY 3 WAY 2 STD PORT FLANGE 1
5 9 5 7 6 1
1
3-WAY BALL VALVE
USED FOR CATCH TEST
6
8
5
6
3
11
10
1
2
6
4
10
0810856 - NOZZLE
SHOWN AS REFERENCE
7 1
3
6
9 5
4 3 8 5 5 6
1
2
6 5 5 7
6 5 5 7
5 14
2
32
21
26
3
G
32
DETAIL F 21 18
9 DETAIL G
SCALE 1 : 4
26 F SCALE 1 : 8
H
4
Page 71 of 273
18
31
23
23 28 31
25 19 23
28
6 27 30 23
19
20 20 22 25
29
6
24 7 7
20
20
20 20
7
24
24 24
20
24
29 7 20 24
1
1
REAR PASSENGER SIDE FRONT PASSENGER SIDE 15
Rev.1
01903279: FRAME MNT ALUMINUM FENDER KIT 54 SPREAD
10
13
13 13
DRIVER
8
FRONT
MARKER
12
10 8
10
11 PASSENGER
FRONT
MARKER
8 8
3
8
12
3
34 NOTE: DO NOT OVERTIGHTEN
BOLTS ON SIGNBOARD OR SIGNBOARD
MAY CRACK! 12
34
2
2
32 19 19 26
29 21 21 24
4
30
22
1
Page 75 of 273
25
32 19 19 26
4 15 11
16
17 31 22 6 22 25
17
NOTE: RUBBER WASHER BETWEEN
BRACE AND BACKSIDE OF SIGN
16 PANEL 27 20 18
23 18 18 28
Rev.7
BOX 1120, NORPARK DRIVE, MOUNT FOREST, ONT. N0G 2L0 (519)323-4433 PH (519)323-4608 FX
Rev.
TO MAINTAIN OUR ON-GOING PRODUCT DEVELOPMENT AND IMPROVEMENT PROGRAM, VIKING-CIVES LTD. RESERVES THE RIGHT TO CHANGE EQUIPMENT & SPECIFICATION WITHOUT NOTICE.
BOX 1120, NORPARK DRIVE, MOUNT FOREST, ONT. N0G 2L0 (519)323-4433 PH (519)323-4608 FX
Rev.
TO MAINTAIN OUR ON-GOING PRODUCT DEVELOPMENT AND IMPROVEMENT PROGRAM, VIKING-CIVES LTD. RESERVES THE RIGHT TO CHANGE EQUIPMENT & SPECIFICATION WITHOUT NOTICE.
BOX 1120, NORPARK DRIVE, MOUNT FOREST, ONT. N0G 2L0 (519)323-4433 PH (519)323-4608 FX
Rev.
TO MAINTAIN OUR ON-GOING PRODUCT DEVELOPMENT AND IMPROVEMENT PROGRAM, VIKING-CIVES LTD. RESERVES THE RIGHT TO CHANGE EQUIPMENT & SPECIFICATION WITHOUT NOTICE.
BOX 1120, NORPARK DRIVE, MOUNT FOREST, ONT. N0G 2L0 (519)323-4433 PH (519)323-4608 FX
Rev.
TO MAINTAIN OUR ON-GOING PRODUCT DEVELOPMENT AND IMPROVEMENT PROGRAM, VIKING-CIVES LTD. RESERVES THE RIGHT TO CHANGE EQUIPMENT & SPECIFICATION WITHOUT NOTICE.
01902726: MTO CONSPICUITY SIGN AIR FOIL ASSEMBLY (SSTL)
Page 81 of 273
5
1 11
14 12 12 16
8 6 17 13 13 15 7 9 10
8
6
7
Page 83 of 273
4 11 9 10 3
SQUARE CORNERS
A
END VIEW
1
2 6
7
3 5
4
SECTION A-A
SCALE 1 : 1
A
Page 84 of 273
6-WAY SHROUD 20A (MOLD-O6P) YELLOW TPU (MOLDED)
14 AWG/6, -40°C, 300V
12010975 QTY:1
W-PACK CONNECTOR TRAILER CONNECTOR
12124582 QTY:6
PIN DESCRIPTION 15324983 QTY:6 SOCKET DESCRIPTION
A/WT GROUND 1/WT GROUND
B/RD 12VDC 2/BK STOP
C/BN I-NETWORK 3/YL LH TURN
D/GN RH TURN 4/RD 12VDC
E/YL LH TURN 5/GN RH TURN
F/BK STOP 6/BN I-NETWORK
7/BU SPARE
Rev.1
BOX 1120, NORPARK DRIVE, MOUNT FOREST, ONT. N0G 2L0 (519)323-4433 PH (519)323-4608 FX
Page 85 of 273
6-WIRE MALE
WEATHER PACK
WEATHERPACK VCL HARNESS WIRE FUNCTION LOCATION (WHERE WIRE IS TO BE CONNECTED) MINIBAR WIRES
REF:
NI-50710
A WHITE GROUND ANY TRUCK GROUND BLACK
B RED POSITIVE AMBER 15A SWITCH OR RELAY 12V IGN POWER RED
WHITE
RED
BROWN
GREEN
YELLOW
BLACK
C BROWN i-NETWORK ONLY CONNECTS WITH MTO TRAILER RECEPTACLE WHITE
Rev.1
BOX 1120, NORPARK DRIVE, MOUNT FOREST, ONT. N0G 2L0 (519)323-4433 PH (519)323-4608 FX
Page 86 of 273
RECEPTACLE OUTER FACE
4 RED 12V POWER AMBER 15A SWITCH OR RELAY 12V IGN POWER
Rev.1
0820140
MTO CONSPICUITY SIGN PANEL -
ANTI-ICING
Note: An alpha designation on the Item ID column indicates a sub-component of a parent item. When placing parts orders
reference the parent item to receive a complete assembly. Individual items can be ordered separately, if required, by
ordering the alpha designated item number.
3
6
6 1
6
2B
2A
TABLE 4 5
RELAY PIN DESCRIPTION COLOUR GAUGE
30 +12V BATTERY FEED RED 8
87 +12V SWITCHED BLACK 8 8
85 IGNITION PURPLE 16
86 GROUND WHITE 14
-12V BATTERY GND WHITE 8
60
13 17 10 9 17
3
7
Page 95 of 273
4 21
120
3 120
180
13 6 1 2
15 15 16 16 14 12 11 14 16
Rev.2
THIS PAGE LEFT BLANK
01901288-M 1/8/2014
01901288-M 1/8/2014
4 7
5 3
6 2
01900090-M 5/13/2014
01901852-M 4/8/2014
5 6 7 8
4 5
01901288-M 1/8/2014
Pumps are available in single section units or several sections can be combined into one unit. A wide
selection of mounting flanges and drive shafts are available to fit most applications. Pipe thread, "O" ring,
or split flange are available in both metric and SAE standards.
Metaris pumps and motors are manufactured under strict quality control systems which are monitored by
ISO 9001-2000 standards.
Multiple Pump Units; Several pump sections or piggyback units can be combined on a single drive, to
eliminate multiple power take-off drives.
Precision Matched Gears; All gear sets are designed, and machined from high alloy bar, surfaces are
precision finished and each gear set is matched for maximum efficiency. The 10 tooth construction gives
maximum output per centimeter width per revolution.
Bearings; Quality roller bearings are utilized on journals to reduce the wear caused from contamination
within the hydraulic system.
Bushing Pumps; Bushings are constructed from quality materials and Teflon coated for maximum wear life.
INTERCHANGEABILITY
Metaris hydraulic units are directly interchangeable with most other manufactures.
ALL MANUFACTURERS NAME SYMBOLS AND DESCRIPTIONS IN THIS DOCUMENT ARE FOR
REFERENCE PURPOSES ONLY. IT IS NOT IMPLIED THAT ANY PART LISTED IS THE PRODUCT
OF THESE MANUFACTURERS.
1 MOTOR M 1 PUMP P
2 SERIES 50 2 SERIES 75
3 MODEL A 3 MODEL B
4 SHAFT END COVER 842 4 SHAFT END COVER 178
5 PORT END COVER BE 5 PORT END COVER BI
6 GEAR HOUSING OL15 6 GEAR HOUSING OK15
7 DRIVE SHAFT 43 7 DRIVE SHAFT 7
8 BEARING CARRIER C
9 GEAR HOUSING OK12
SHAFT END COVER LOOK AT THE SHAFT END AND COMPARE IT TO THE VIEWS BELOW, SELECT THE SHAFT
TYPE OF YOUR UNIT.
GEAR HOUSING
SERIES MH31 / MH51 / MH76 - THE ONLY WAY TO DETERMINE THIS SERIES IS TO DISASSEMBLE THE UNIT AND LOOK FOR DOWEL PINS
MH 20,25,30,31,50,51
HOUSING WIDTH 1.25 1.5 1.75 2 2.25 2.5 2.75 3
GEAR WIDTH 0.5 0.75 1 1.25 1.5 1.75 2 2.25
MH 37X,75,76
HOUSING WIDTH 1.5 1.75 2 2.25 2.5 2.75 3 4
GEAR WIDTH 0.5 0.75 1 1.25 1.5 1.75 2 3
MH 315
HOUSING WIDTH 0.9 1.15 1.4 1.65 1.9 2.15 2.4 N/A
GEAR WIDTH 0.5 0.75 1 1.25 1.5 1.75 2 N/A
MH 330
HOUSING WIDTH 1 1.5 1.75 2 2.25 2.5 N/A N/A
GEAR WIDTH 0.5 1 1.25 1.5 1.75 2 N/A N/A
MH 350
HOUSING WIDTH 1 1.5 1.75 2 2.25 2.5 2.75 3
GEAR WIDTH 0.5 1 1.25 1.5 1.75 2 2.25 2.5
MH 365
HOUSING WIDTH 1.5 1.75 2 2.25 2.5 2.75 3 N/A
GEAR WIDTH 1 1.25 1.5 1.75 2 2.25 2.5 N/A
Model Unit weight 1/2" 3/4" 1" 1 1/4" 1 1/2" 1 3/4" 2" 2 1/4" 2 1/2" 2 3/4" 3"
MH15 Pounds 24 25 26 27.5 29 30.5 32.5 * * * *
MH20 Pounds 24 25 26 27.5 29 30.5 32.5 * * * *
MH25 Pounds 36 39 42 43.5 45 46.5 48 50 52 * *
MH30 / 31 Pounds 30 31 32 33 34 35 36 * 38.5 * *
MH37 Pounds 52 54 56 58 60 62 65 68 71 * 78
MH50 / 51 Pounds 37 40 43 44.5 46 47.5 49 51 53.5 * *
MH75 / 76 Pounds 67 70 72 74 76 79 82 85 88 * 92
MH 315 Pounds 16 17 18 19 20 21 22 * * * *
MH 330 Pounds * 34.8 36 37.3 38.5 39.8 41 42.3 43.5 * *
MH 350 Pounds * 49.5 51 52.5 54 55.5 57 58.5 60 * *
MH 365 Pounds * * 56 58.5 61 63.5 66 68.5 71 73.5 76
MHC 101 Pounds * * * * * * 67 * 69 * *
MHC 102 Pounds * * * * * * 68 * 70 * *
MHG 101 Pounds * 31 * * 35 * 38 * * * *
MHG 102 Pounds * 31 * * 35 * 38 * * * *
For the total weight of a multiple unit add the weight from the column of the single unit and the multiple unit column.
( e.g. MH15 single unit 3/4” gear width is 25 pounds plus MH15 multiple unit 3/4” gear width is 22 pounds total weight is 47 pounds)
For total weight in kilograms divide total weight in pounds by 2.2 = weight in kilograms
(e.g. 47 pounds ÷ 2.2 = 21.36 kilograms)
PL Factor
Each section of a multiple unit should be regarded as a single unit with corresponding delivery and power input requirements. Since the entire input
horsepower is fed through a common drive shaft, the power delivered to or from the unit is limited by the physical strength of the shaft. This limit is
defined as a “PL” factor, “P” being the operating pressure and “L” being the summation of the total gear widths.
In multiple units the “PL” must be calculated for the first connecting shaft as well as the drive shaft.
Each style or type of shaft has a unique “PL” factor as noted in the table with the performance data.
Performance data shown are the average results based on series of tests of production units and not necessarily representative of any
one unit. Tests were run with oil viscosity 150 SUS at 100°F
MH101
RETURN
1.00 [25.40]
INLET
0.25 [6.35]
-20 2.75 [69.85]
2.38 -25 3.25 [82.55]
2 UNIT
A SINGLE UNIT
B TANDEM UNITS
C SINGLE OR TANDEM WITH A CONTINENTAL SHAFT
NOTE
* N.P.T. PORTING IS NOT RECOMMENDED FOR PRESSURES ABOVE 1500 P.S.I.
* Ports marked with a “X” are recommended porting, for all other porting please consult the factory
* SHADED CELLS ARE GOOD FOR MOTOR UNITS
* ORIENTATION IS VIEWED FROM THE SHAFT END
1" 3/4" KX XK
LIMITATIONS ON WARRANTY
This Warranty is expressly in lieu of any other warranties expressed or implied. Buyers sole and
exclusive remedy under this Warranty shall be limited to the repair, replacement or exchange of
warranted products at our option, F.O.B. our factory, or designated service center.
No special, incidental, consequential or other damage shall be recoverable. Metaris shall not be
liable for consequential damages or contingent liabilities including, but not limited to, loss of life,
personal injury, loss of crops, loss due to water or fire damage, loss of business income, down
time costs and trade or other commercial loss arising out of failure of the product. Metaris will in
no event be liable for any sum in excess of the price received by it for the product for which
liability is claimed or asserted.
No products shall be returned without prior authorization from Metaris. Buyers and their Agents
shall prepay all transportation charges for the return of such products to a Metaris location or
designated service center. There will be no acceptance of any charges for labor and/or parts
incidental to the removal or remounting of products repaired or replaced under Warranty.
The above Warranty does not cover conditions over which Metaris has no control, including,
without limitation, contamination, pressure in excess of recommended maximum, products
damaged or subject to accident abuse or misuse after shipment from our factory, products
altered or repaired by anyone other than Metaris personnel, authorized Metaris factory personnel
or persons so designated in writing by Metaris prior to commencement of said work.
A return goods authorization number must be obtained from Metaris or a Metaris authorized
service center, or a Metaris authorized agent prior to any products being returned for Warranty.
Form L-1547
Rev. B
Pentair
375 5th Ave., New Brighton, MN 55112
Phone: (651)766-6300 -OR- 800-424-9776 Fax: 800-323-6496
www.hypropumps.com
EU Authorized Representative: EC QNET BV Hommerterweg 286
REP
-2-
Vor dem Ablesen des Handbuches versuchen Sie NICHT, Ihre Pumpe zu installieren. Originale des Handbuches fur
Hypro-Pumpen werden auf englisch zur Verfugung gestellt. Zu eine Kopie in Ihrer Muttersprache finden, zu
www.hypropumps.com zu gehen (German)
N’essayez pas d’installer votre pompe avant de lire le manuel. Des exemplaires originaux du manuel pour des pompes
de Hypro sont fournis en anglais. Pour trouver une copie dans votre langue maternelle pour aller a
www.hypropumps.com (French)
NON tentare di installare la vostra pompa prima di leggere il manuale. Esemplare originale del manuale per Hypro
pompe sono in inglese. Per trovare una copia nella vostra lingua andare a www.hypropumps.com (Italian)
Не пытайтесь установить ваш насос до чтения руководства. Оригинальные копии этого руководства для насосы
Hypro на английском языке. Найти копию на ваш родной язык перейти к www.hypropumps.com (Russian)
NO intente instalar su bomba antes de leer el manual. Copias originales del manual para Hypro se provee de bombas
en ingles. Para encontrar una copia en tu idioma nativo ir a www.hypropumps.com (Spanish)
NIE probować instalować pompy przed jej odczytaniem instrukcji. Oryginalne kopie instrukcji obsługi pomp Hypro są
dostarczane w języku angielskim. Aby uzyskać kopię w twoim ojczystym języku przejdź do www.hypropumps.com
(Polish)
Takmaya calışmayın okumadan once pompanın manuel. Orijinal kopyalarını Hypro pompaları icin Ingilizce olarak
sunulmuştur. Bir kopyasını bulmak icin yerel dil git www.hypropumps.com (Turkish)
Nao tente instalar a bomba antes de ler o manual. As copias originais dos manuais para Hypro bombas sao
fornecidos em Ingles. Para encontrar uma copia em sua lingua nativa ir para www.hypropumps.com (Portuguese)
VERGEET NIET uw pomp voor het lezen van het handboek. Exemplaren van de handleiding voor Hypro pompen zijn
beschikbaar in het Engels. Op zoek naar een exemplaar in uw eigen taal ga naar www.hypropumps.com (Dutch)
-3-
Intended Uses
Hypro centrifugal pumps are intended for creating or boosting dynamic pressure in approved fluids. Hypro centrifugal
pumps should never be used to pump liquids above 140°F (60°C), or below 34°F (1°C). For pumps equipped with
hydraulic motors, the pump should not be run if the hydraulic oil temperature exceeds 135°F (57°C). Any uses outside
of those specified in this manual are considered misuses and are prohibited. Contact Hypro technical service with any
questions regarding specific acceptable uses.
Purpose of Manual
This manual provides instructions and requirements that must be met when installing, using and maintaining the
product(s) identified on the cover.
If the product is sold, the seller must pass this manual onto the new owner.
The following special attention notices are used to notify and advise the user of this product of procedures that may be
dangerous to the user or result in damage to the product.
ATTENTION
Attention is used to notify of installation, operation, or maintenance information that is important but not safety related.
This symbol is used to denote the presence of an electrical hazard that will result in personal injury, death or property
damage.
This symbol is used to denote the presence of a hazard that will result in personal injury, death or property damage.
California Proposition 65 Warning -- This product and related accessories contain chemicals known to the
State of California to cause cancer, birth defects or other reproductive harm.
Misuses
Hypro centrifugal pumps are designed to operate effectively within the specified speed, pressure and environmental
ranges. Going outside of these ranges will void the warranty and could cause damage to property, serious injury, or death.
• DO NOT run the pump faster than the maximum specified speed.
• DO NOT run the pump higher than the maximum specified pressure.
• DO NOT run pumps when the liquid has exceeded the maximum or minimum temperature limit (see Intended Uses).
• DO NOT pump non-approved liquids.
• DO NOT pump water or other liquids for human consumption.
• DO NOT operate any Hypro pump under the influence of drugs or alcohol.
• DO NOT run the pump dry.
• DO NOT run the pump with a higher than recommended voltage.
• DO NOT run the pump hydraulic motor higher than the specified RPM, pressure or flow.
-4-
Pump Dimensions
Dim. Inch mm
A 8.43 214.1
B 8.19 208.0
HM1,2,3,4,5 C 4.60 116.8
D 3.81 96.8
E 3.06 77.7
HM1C-U F 11.86 301.2
HM2C-U F 11.98 304.3
HM3C-U F 12.36 313.9
HM4C-U F 11.98 304.3
HM5C-U F 12.29 312.2
G 5.42 137.7
HM1,2,3,4,5 H 5.25 133.4
I 2.63 66.8
-5-
-6-
-8-
-9-
- 10 -
Tools
The Hypro centrifugal pumps and mounting assemblies are designed with Imperial (inch) bolts, however, there are many
metric (mm) sizes which will work with these mounts. In most cases, an adjustable spanner wrench can also be used.
- 12 -
Transport
• All Hypro pumps are capable of being transported by air, sea, rail or motor vehicle. When the pump is shipped, ensure
that the pump is moved in accordance with local and national laws and is properly secured to prevent unwanted
movement which could cause damage to person or property. Prior to shipping, all fluids should be removed from the
pump.
Storage
• New pumps in their boxes can be stored several years as long as the port plugs are not removed. Once the plugs
have been removed, if the pump is not to be used for an extended period of time (i.e. more than 30 days), the pump
must be winterized as described in the Cleaning section of this manual.
Installation
Before attempting to install your Hypro centrifugal pump it is imperative to read and understand the following:
• Installation of a Hypro pump should only be performed by a technician having the knowledge and skills necessary
to install the pump without the risk of property damage or injury.
• When handling Hypro pumps, one should wear steel-toed shoes and protective gloves in order to protect the feet
in the event the pump is dropped and protect the hands from any sharp surfaces on the pump or chemicals.
• Pumping systems must be installed in accordance with Hypro installation instructions. Failure to do so will void
your warranty and could cause damage to property, serious personal injury, or death
• It is the installer’s responsibility to conduct electrical tests in accordance with EN60204-1:2006/A1:2009, or its
superseding standard, on finished pump assemblies.
• All connections to electrical components must be number, symbol, or color-coded generally as recommended by
EN60204-1:2006/A1:2009, or its superseding standard.
• Installers must provide hydraulic components that are capable of withstanding maximum source pressure.
• The working pressure must be controlled by a pressure relief valve that is adjusted to operate at a maximum
pressure of the hydraulic motor.
• If a rigid plumbing system is to be used on a Hypro centrifugal pump, the system must be properly aligned with the
inlet and outlet ports.
- 13 -
Standard Mounting
• In order to prevent injury or damage to property, all Hypro pumps should be properly mounted to a solid base where
there is no danger of the pump falling or breaking loose. All Hypro pumps come with mounting holes which allow
bolts to be put into the pump so it can be secured to a sturdy base. When mounting your Hypro centrifugal pump, be
sure to use bolts and nuts which are compatible with any chemicals that may come into contact with them as well as
choosing the correct grade of bolt based on the pump weight and any expected loads. Pumps should be mounted
as close to the liquid source as possible. Non self-priming pumps must be mounted below the liquid level to function
properly.
Pump Plumbing
• To achieve maximum pump performance, the outlet port on the pump should be pointing straight up, and pump
inlet and outlet lines should be at least the same size as their respective port. Pump plumbing must be capable of
withstanding the maximum suction, and pressure, generated by the pump and should have as few restrictions as
possible.
• For best priming results, the upper most vent plug can be removed and a vent line can be installed. This line prevents
air lock and allows the pump to prime itself by bleeding off trapped air.
Ref.
No. Description
1 Tank Lid
2 Vent Line
3 Jet Agitator
4 Shut-off Ball Valves
5 Centrifugal Pump
6 Spray Control Console
7 Centrifugal Pump Control
8 Manifold Boom Valve
9 Flowmeter
10 Jet Turret Nozzle Body
- 14 -
Hooking up the motor in the wrong direction will damage the hydraulic seal.
• Correct orifice size is determined by system performance. Start by installing the smallest orifice in the adapter con-
nected to the pressure port. Once the orifice is installed, test system performance and if system performance is low,
install the next largest orifice. Continue this process until pump performance reaches the desired level, or no orifices
are installed in the adapter.
Control Systems
• All pump systems with electric or hydraulic power sources are required to have a control system which meets all local
and national standards.
• For more detail on a typical system installation, see preceding subsections of the “Assembly and Installation” section
of this manual.
- 15 -
Information
• When running Hypro centrifugal pumps, it is essential that operators use hearing protection as the sound levels
can reach levels of 80 decibels.
• When handling Hypro pumps, one should wear steel-toed shoes and protective gloves in order to protect the feet
in the event the pump is dropped and protect the hands from any sharp surfaces on the pump or chemicals.
• Only authorized operators having the knowledge and skill necessary to safely use a Hypro pump, or any
equipment the pump is connected to, may run the pump.
• When spraying manually, it is recommended that chemical-resistant face masks and clothing be worn to prevent
any chemicals from coming into contact with the skin or being inhaled.
• When spraying manually, always spray upwind of yourself as long as the sprayed chemical will not drift into the
vicinity of other people.
• When installing, adjusting or removing a Hypro centrifugal pump, ensure that there are no objects which can fall
on the installer and make certain that all machinery to which the pump is to be attached is turned off.
• Hypro centrifugal pumps should only be used on tractors or tow-behind spray platforms which have electrically
conductive tires in order to reduce the risk of electrocution.
• Never operate a Hypro centrifugal pump outside while there is a chance of getting struck by lightning.
• Never leave electrical wires or plumbing components where they can be a tripping hazard or become entangled
in a moving component. Ideally, electrical cables, hoses, pipes and fittings should be routed overhead. In the event
electrical wiring must be routed over the ground, operators are required to use rubber ramps if they cross a gangway.
• Hypro centrifugal pumps should not be used if the ambient light is below 200lux.
Only use approved chemicals in your pump. For a complete list of approved chemicals, see the “Fluid
Pumping Applications” section. Failure to follow this warning will void your warranty and could lead to property
damage, serious injury or death.
- 16 -
- 17 -
Disposal
When disposing of a Hypro pump, be sure to remove all fluids from the pump before scrapping. These fluids should be
disposed of in a manner which complies with local and national regulations. Never dump fluids onto the ground. Once the
pump is free of all fluids, it may be scrapped in accordance with local and national laws.
Cleaning
Your pump will last longer and give best performance when properly taken care of. Proper pump care depends on the
liquid being pumped and when the pump will be used again. After each use, flush pump with a neutralizing solution for the
liquid just pumped. Follow with a clean water rinse. This is especially important for corrosive chemicals. It is good practice
to clean the pump after each use to prevent deposits from forming and damaging the pump. For infrequent use and before
long periods of storage, drain pump thoroughly. Open any drain plugs, remove suction hose from liquid, and blow pump
dry with air. An antifreeze/rust inhibitor should be injected into the pump before both ports are plugged and the pump is
stored. Plug all ports to keep out air until pump is used again.
• Each system’s maintenance cycle will be exclusive. If system performance decreases, check immediately.
• Duty cycle, temperature, quality, type of fluid being pumped, and inlet feed conditions all affect the life of spray boom
assemblies and service cycle.
- 18 -
- 19 -
- 20 -
1 4 2210-0087 Hex Head Cap Screw 31 1 1610-0031 Roll Pin (HM1C / HM5C)
2 2 2210-0016 Hex Head Cap Screw (Base Only) 31 1 1610-0055 Roll Pin (HM3C)
3 6 2270-0041 Washer 32 1 0150-2500C Motor Body (includes needle bearing)
4 4 2406-0020 Pipe Plug 33 4 2210-0021 Hex Head Cap Screw
5 1 0700-9000P Pump Casing 34 2 1720-0110 O-ring
6 1 2250-0052 Impeller Nut 35 1 1600-0045 Dowel Pin (HM2C / HM4C)
7 1 2250-0051 Jam Nut 35 1 1600-0044 Dowel Pin (HM1C/HM5C)
8 1 1700-0097 Gasket (Viton) 35 1 1600-0052 Dowel Pin (HM3C)
9 1 2270-0057 Washer 36 1 1600-0068 Dowel Pin (HM3C)
10 1 0402-9100P Impeller 36 1 1600-0042 Dowel Pin (HM2C/ HM4C)
11 1 1700-0100 Rubber Gasket 36 1 1600-0037 Dowel Pin (HM1C/HM5C)
12 1 2120-0009 Mechanical Seal (Viton/Ceramic) (Std 9303P) 37 1 3900-0022 Gerotor (HM1C)
12 1 3430-0593 Mechanical Seal (Silicon Carbide) (Optional) 37 1 3900-0023 Gerotor (HM2C)
13 1 1721-0083 O-ring 37 1 3900-0024 Gerotor (HM3C)
14 1 0750-9300P Cover 37 1 3900-0025 Gerotor (HM4C)
15 1 2210-0088 Screw 37 1 3900-0048 Gerotor (HM5C)
16 1 0750-9006C Intermediate Flange 38 1 0701-2500C1 Gerotor Housing (HM2C Models) 1/4” wide
17 1 1510-0063 Base Plate 38 1 0700-2500C1 Gerotor Housing (HM1C Models) 1/2” wide
18 2 2250-0008 Hex Nut 38 1 0703-2500C1 Gerotor Housing (HM4C Models) 5/16” wide
19 1 1410-0056 Slinger Ring 38 1 0702-2500C1 Gerotor Housing (HM3C Models) 1” wide
20 1 1810-0014 Snap Ring 38 1 0704-2500C1 Gerotor Housing (HM5C Models) 5/8” wide
21 1 1820-0013 Retaining Ring 39 1 0254-2500C2 Motor End Plate (includes needle bearing)
22 1 2000-0010 Ball Bearing 40 4 2270-0039 Washer
23 1 1410-0131 Cartridge, Front 41 4 2220-0032 Cap Screw (HM5C Models)
24 2 1720-0268 O-ring 41 4 2220-0045 Cap Screw (HM2C / HM4C Models)
25 1 2104-0010 Lip Seal 41 4 2220-0021 Cap Screw (HM1C Models)
26 1 1410-0130 Seal Spacer 41 4 2220-0044 Cap Screw (HM3C Models)
27 1 2029-0014 Thrust Bearing Assembly 42 1 1720-0108 O-ring
28 1 1610-0042 Woodruff Key (9303P all except HM3C) 43 1 3360-0021A Pressure Port Adapter (includes o-ring)
28A 1 1610-0053 Square Key (9303P-HM3C Only) 44 1 3320-0051A Tank Port Adapter (includes o-ring)
29 1 3430-0850 Shaft (HM2C/HM4C) 45 1 1720-0262 O-ring
29 1 3430-0852 Shaft (HM1C/HM5C) 46 1 3220-0029 Bypass Adjusting Screw
29 1 3430-0855 Shaft (HM3C) 47 1 1700-0047 Gasket
30 1 1810-0026 Snap Ring 48 1 2270-0027 Washer
31 1 1610-0032 Roll Pin (HM2C / HM4C) 49 1 2250-0038 Lock Nut
- 21 -
- 22 -
Declare that the partially complete machinery described below conforms to applicable health and safety requirements of
Parts 1 of Annex I of Machinery Directive 2006/42/EC. This partly completed machinery must not be put into service until
the equipment into which it is to be incorporated has been declared in conformity with the provisions of this directive.
Confidential technical documentation has been compiled as described in Annex VII Part B of Machinery Directive 2006/42/
EC and is available to European national authorities on written request. If a request is received, documentation will be
transmitted either electronically or by post. Clauses 1.1.4, 1.1.7, 1.1.8 Section 1.2, Clauses 1.3.5, 1.3.6, 1.3.7, 1.3.8.1, 1.3.8.2,
1.3.9, 1.4.1, 1.4.2.1, 1.4.2.2, 1.4.2.3, 1.4.3, 1.5.2, 1.5.7, 1.5.12, 1.5.14, 1.5.16, 1.6.2, 1.7.1.1, 1.7.1.2, 1.7.2, and 1.7.4.2 are clauses of
Machinery Directive 2006/42/EC that have not been met, but could be applicable and must be addressed during installation by
a third party.
The following standards have either been referred to or been complied with in part or in full as relevant:
ENISO 12100 Machinery Safety General principles for design - Risk assessment and risk reduction
EN809-1998 + A1 2009 Machinery Safety Pumps and pump units for liquids - Common safety requirements
EN ISO 13732-1 Machinery Safety Ergonomics of the thermal environment
EN ISO 3744:2010 Acoustics Determination of sound power levels and sound energy levels of noise sources using
sound pressure
EN ISO 11202/A1 1997 Machinery Safety Noise emitted by machinery and equipment
EN 12162:2001+A1:2009 Machinery Safety Liquid pumps - Safety requirements - Procedure for hydrostatic testing
EN ISO 4254-6:2009 Machinery Safety Sprayers and liquid fertilizer distributors
97-68-EC + 2010/26/EU Gas Emission Non-road gas emissions
Place of Signing……………………………………………………………………………………………………….........
QNET BV
EC REP Hommerterweg 286
6436 AM Amstenrade
The Netherlands
- 23 -
Hypro/Shurflo (hereafter, “Hypro”) agricultural products are warranted to be free of defects in material and workmanship under
normal use for the time periods listed below, with proof of purchase.
- Pumps: one (1) year from the date of manufacture, or one (1) year of use. This limited warranty will not
exceed two (2) years, in any event.
- Accessories: ninety (90) days of use.
This limited warranty will not apply to products that were improperly installed, misapplied, damaged, altered, or incompatible with
fluids or components not manufactured by Hypro. All warranty considerations are governed by Hypro’s written return policy.
Hypro’s obligation under this limited warranty policy is limited to the repair or replacement of the product. All returns will be tested
per Hypro’s factory criteria. Products found not defective (under the terms of this limited warranty) are subject to charges paid by the return-
ee for the testing and packaging of “tested good” non-warranty returns.
No credit or labor allowances will be given for products returned as defective. Warranty replacement will be shipped on a freight allowed
basis. Hypro reserves the right to choose the method of transportation.
This limited warranty is in lieu of all other warranties, expressed or implied, and no other person is authorized to give any other
warranty or assume obligation or liability on Hypro’s behalf. Hypro shall not be liable for any labor, damage or other expense, nor
shall Hypro be liable for any indirect, incidental or consequential damages of any kind incurred by the reason of the use or sale of
any defective product. This limited warranty covers agricultural products distributed within the United States of America. Other world market
areas should consult with the actual distributor for any deviation from this document.
Return Procedures
All products must be flushed of any chemical (ref. OSHA section 1910.1200 (d) (e) (f) (g) (h)) and hazardous chemicals must be labeled/
tagged before being shipped* to Hypro for service or warranty consideration. Hypro reserves the right to request a Material Safety Data
Sheet from the returnee for any pump/product it deems necessary. Hypro reserves the right to “disposition as scrap” products returned
which contain unknown fluids. Hypro reserves the right to charge the returnee for any and all costs incurred for chemical testing, and proper
disposal of components containing unknown fluids. Hypro requests this in order to protect the environment and personnel from the hazards
of handling unknown fluids.
Be prepared to give Hypro full details of the problem, including the model number, date of purchase, and from whom you purchased your
product. Hypro may request additional information, and may require a sketch to illustrate the problem.
Contact Hypro Service Department at 800-468-3428 to receive a Return Merchandise Authorization number (RMA#).
Returns are to be shipped with the RMA number clearly marked on the outside of the package. Hypro shall not be liable for freight damage
incurred during shipping. Please package all returns carefully. All products returned for warranty work should be sent shipping charges
prepaid to:
HYPRO / PENTAIR
Attention: Service Department
375 Fifth Avenue NW
New Brighton, MN 55112
For technical or application assistance, call the Hypro Technical/Application number: 800-445-8360, or send an email to: technical@
hypropumps.com. To obtain service or warranty assistance, call the Hypro Service and Warranty number: 800-468-3428; or send a fax
to the Hypro Service and Warranty FAX: 651-766-6618.
*Carriers, including U.S.P.S., airlines, UPS, ground freight, etc., require specific identification of any hazardous material being shipped. Failure to do so may
result in a substantial fine and/or prison term. Check with your shipping company for specific instructions.
Hypro (10/15)
Printed in USA
Table of
of Contents
Contents
1 Panel Controls 3
2 Program Screen Layout 4
3 Screen Controls 5
3.1 Pause 5
3.2 Blast 5
3.3 Reverse 5
3.4 Change Solid Material 6
3.5 Change Prewet Material 6
3.6 Manual Gate Adjustment 6
3.7 Error Messages 7
4 Symbol Actions 7
4.1 Error Log/Diagnostic – Gear Symbol 7
4.2 Unloading – UNLOAD Symbol 8
4.3 Data Retrieval/Clear Trip Summary – USB Symbol 9
4.4 Brightness/Volume Adjustment – Backlight Symbol 9
4.5 Manual Hydraulic Gate Adjustment – Cylinder Symbol 10
4.6 Programming Mode – Lock Symbol 10
5 Joystick Control 11
5.1 Button Status 11
5.2 Joystick Status 11
5.3 Joystick Screen 11
6 Anti-
Anti-ice Mode 12
7 Pattern Mode 13
8 Air Gate Mode 13
9 Liquid+ Mode 14
10 Cross Conveyor Mode 14
11 Spinner Reverse Mode 15
12 Error Codes 15
13 Warning 18
Bosch Rexroth Canada Corp. reserves the right to revise this information at any time and for
any reason and reserves the right to make changes at any time, without notice or obligation,
to any of the information contained in this piece of literature.
Please check for updates at: www.boschrexroth.ca/compu-spread
1 Panel Controls
Turn knobs clockwise to increase.
3 Screen Controls
3.1 Pause
Press the Pause button to pause, and press again to resume spreading.
3.2 Blast
Press the Blast button to increase the spreading output, and press again to resume
regular rate.
3.3 Reverse
Press and hold the Reverse button to change the direction of the Auger (an optional
feature to dislodge obstructions). Release the button to resume spreading.
Press the Gate Position Number to select the gate adjustment mode.
4 Symbol Actions
All symbols on the right of the screen require a press and hold for >1 seconds.
A program key is required to clear the error log; hold the button for >5 seconds.
When a vehicle is moving press the ‘Gear’ symbol to display the real-time status of
spreading.
4.2 UNLOAD
UNLOADING
ADING
and to exit unload mode. Moving the vehicle will suspend the unload process. It will
automatically resume when the truck is stopped again.
Note: ‘PROGRAMMING KEY’ is for programming and data log. ‘DATA LOG KEY’ is for
log data only.
To adjust volume, the “Vol Adj” needs to be checked on setup user screen.
Press the ‘Lock’ symbol to enter into programming mode. (Note: A valid
‘PROGRAMMING KEY’ must be inserted into the USB port.)
5 Joystick Control
For systems equipped with Joystick Option ONLY.
Screen flips when the Deadman Trigger is pressed. When the trigger is released, the
screen reverts back to the spreader layout.
Note: The joystick will only operate while the Deadman Trigger is pulled.
The default spreader or joystick screen is selectable on USER setup screen.
6 Anti-ice Mode
6.1 3 Boom
Boom Selection
Press the oval buttons to select the desired boom. Pause and Blast operate the
same as a Granular Spreader.
Rate Selection
Use the dial on the right to select the desired liquid flow rate. The reverse button is
de-activated.
7 Pattern Mode
Use the controls on the top right of the screen to control the Chute.
Select left or right with the circular buttons.
Note: To calibrate the centre position you would need to click on the symmetry
reading while a program key is inserted.
9 Liquid + Mode
This screen is only available when the LIQUID+ mode is selected in the programming
mode. (See Calibration Manual for details.)
Boom Selection
Press the red dial buttons to select the desired Boom. Pause and Blast operate the
same as a Granular Spreader.
Rate Selection
Use the upper right arrows to select the desired liquid flow rate.
Select left or right with the circular buttons. Use the up and down arrows to adjust
the speed.
12 Error Codes
ERROR DEICE BLST TOO LONG 2 Turn off blast, reset timer
WRONG SPINNER CONTROL MODE 42 Auto null not allowed for MANUAL mode
PREWET PULSES/GAL TOO LOW 49 Check prewet sensor, and calibrate again
PREWET PULSES/GAL TOO HIGH 50 Check prewet sensor, and calibrate again
ANTI-ICING PULSES/GAL TOO LOW 51 Check anti-icing sensor, and calibrate again
SPNR WIDTH AT 0 RPM TOO LOW 53 Check spinner sensor, and recalibrate
SPNR WIDTH PER RPM TOO LOW 54 Check max width, and recalibrate
GATE MOVEMENT TOO LOW 55 Range too small (Low -> High)
GATE AT CALIBRATION TOO LOW 57 Calibrated gate needs tob a non-zero value
SPINNER SENSOR PULSES TOO LOW 58 Spinner sensor pulses 0 or too low
CONV SENSOR PULSES TOO LOW 59 Conv sensor pulses 0 or too low
SPINNER OUTPUT RANGE TOO LOW 60 Range between spn Min and Max too small
CONV OUTPUT RANGE TOO LOW 61 Range between Conv Min and Max too small
CROS CONV1 OUTPUT RANGE LOW 62 Range between Cros1 Min and Max too small
CROS CONV2 OUTPUT RANGE LOW 63 Range between Cros1 Min and Max too small
PREWET OUTPUT RANGE LOW 64 Range between prewet Min and Max too small
ANTI-ICING OUTPUT RANGE LOW 65 Range for anti-icing Min to Max too small
JOY1 OUTPUT RANGE TOO LOW 66 Range between Joy1 Min and Max too small
JOY2 OUTPUT RANGE TOO LOW 67 Range between Joy2 Min and Max too small
REQUIRED CONV RPM TOO HIGH 68 Setpoints too high, incorrect wt/rev
REQUIRED PREWET FLOW TOO HIGH 69 Setpoints too high, incorrect pulses/gallon
13 Warning
This glass LCD touch screen display has been extensively tested and validated
against its intended use. This glass could crack and break if the display is dropped
on to a hard surface or receives a substantial impact. If the glass chips or cracks,
discontinue use and contact Bosch Rexroth Canada to have it replaced - do not
touch or attempt to remove the broken glass. Any misuse/abuse causing damage,
whether intended or not, will become the sole responsibility of the owner/buyer
which will render the warranty of this product, void.
Notes:
Table of
of Contents
Contents
1 Programming Mode 3
2 Program Screen Layout 4
3 Changing Fields – Data Entry 5
4 Initial Set-
Set-up 6
5 Ground Speed Calibration 7
6 Valve Nulling – Conveyor/Spinner/Prewet/Norm 8
6.1 Auto Nulling 8
6.2 Manual Nulling 8
7 Gate Calibration 9
8 Material Calibration 10
9 Material Catch Test 12
10 Load Parameters 13
11 Advanced Features 14
12 WiFi and GPS tracking 15
13 Optional Modes and Operation 17
13.1 Pattern/Chute Mode 17
13.2 Air Gate Mode 17
13.3 Liquid+ Mode 18
13.4 Cross Conveyor 19
13.5 Spinner Reverse Mode 21
13.6 Solid reduction for Prewet 21
13.7 Dedicated 3 Boom Anti-ice 22
14 Optional Modes and Operation - 550 Lite 23
14.1 Liquid – 1 Boom Anti-icing 23
13.2 Liquid – dedicated 3 Boom Anti-icing 24
15 Error Codes 25
16 Joystick Calibration 30
16.2 Joystick Solenoid Nulling 30
16.2 Joystick Emergency (Panic Button) – If Equipped 30
17 Advanced Joystick Set
Set-
et-up 31
17.1 Power Float 31
17.2 Function Labels 31
18 Warning 31
Bosch Rexroth Canada Corp. reserves the right to revise this information at any time and for
any reason and reserves the right to make changes at any time, without notice or obligation,
to any of the information contained in this piece of literature.
Please check for updates at: www.boschrexroth.ca/compu-spread
1 Programming Mode
All symbols on the right of the screen require a tap and hold for >1 second.
3 Changing Fields
Note: Due to the compact nature of these screens, the use of a selection tool like a
pen or stylus is recommended.
4 Initial Set-up
1. Set the units to imperial (LBS/Mile) or metric (Kg/Km).
2. Set the TRUCK ID.
3. Set the REGION NAME.
4. Set the DRIVER ID (optional), 4 driver IDs allowed.
5. Set the type of Temperature Sensor (optional).
6. Set the Options – see Advanced Features on page 13 (optional).
7. Set the items that the user has access to(optional).
8. Set Blast Timer, 0-timer disabled (optional).
9. Set Temp Compensation % based on 3 degree change (optional).
10. Set the vehicle speed alarm (optional).
11. Select AVL or GPS tracking (optional).
12. Set WIFI/TIME/STYLUS (if required).
The default error configuration values will work well for most applications, no
changes required.
5. Once calibration is complete, verify the speed by driving the vehicle through its
speed range and verify if the controller matches the speedometer.
7 Gate Calibration
1. Select the Gate tab.
2. Select the appropriate mode of gate operation :
Manual - Enter max height, and no further calibration required.
Read back - Press High value field to enter into edit mode
- Move the gate to its max opening
- Press High value field to end mode and save the value
- Repeat the same procedure for Low value
Note: A Gate Position Sensor required for Read back.
Auto - Press High value field to enter into edit mode
- Press Up/Down buttons to move the gate to max opening
- Press High value field to end mode and save the value
- Repeat the same procedure for Low value
Note: A gate cylinder with a position Sensor required.
8 Material Calibration
1. Tap on the “valve” symbol and CONV tab to enter into solid calibration.
2. Place an adequate catch container under the spreader discharge chute.
3. Make sure that sufficient material in the hopper and the system is safe to run.
4. Set gate position:
Manual - Change CAL Gate to match actual gate position
Readback - Adjust actual gate position on the truck
Auto - Set to a desired gate position for calibration
5. Press “CALIBRATION” button to proceed.
6. Turn CONV Knob and/or SPN Knob to run.
7. Stop when desired amount is reached.
8. Weigh the material and enter the value.
9. Press “CALIBRATION” Button to complete.
Note: Press “STOP” button to stop the process anytime during calibration.
Note: The material names can be changed by tapping on the text “SALT - -” and
using the keypad to edit.
10 Load Parameters
The operation requires an USB PROGRAM key. It allows end users to load
parameters from an existing file on the USB stick.
11 Advanced Features
Tap on symbol to enter into the user calibration screen. This series of
drop-down menus allow the adjustment of special features of the 550 system.
System Reset – Press and hold the preset button for 5 seconds.
WARNING: All parameters will be reset to factory defaults.
Temperature Sensor
Sensors
s – Roadwatch, Surface Patrol
System Options – Normal, Pattern, Air Gate, Liquid+, Cross Conv
User Options – MATERIAL and or GATE (operators allowed to adjust
without a programming key).
Blast Timer – Blast turns off automatically when time out
Speed alarm – alarm will sound when the set speed is exceeded.
Temp Comp – Temp compensation, per three degree change
Network Setting:
Setting: A static IP Address needs to be assigned for the 550 PC WiFi
software to communication with a CS5550/150 unit.
GPS Tracking:
Tracking: For 550 controllers it is easy to enable the GPS tracking option by
simply connecting a GPS receiver to the display unit. Here are the part numbers for
the cable and the GPS receiver puck:
R987376776, 550 Serial cable for GPS and Temp sensor
R987380745, GPS receiver
1. Select the Pattern mode under “Options” menu from USER screen.
2. Click ‘L’ and ‘R’ buttons on operator screen to move chute to the Middle position
3. Click on the value of ‘Chute-%’ to record the position with an USB PROGRAM key
inserted into USB port.
position changes the 550 controller also automatically set the gate position to the
correct calibrated gate position for the material.
1. Select the Air Gate mode under “Options” menu from USER screen.
2. Click buttons on operator screen to turn on/off Air Gate.
1. Select the Crs Conv under “Options” menu from the USER screen.
2. Click on Valve icon and then click on C CNV tab.
3. Set the min and max values as defined in the valve nulling procedure (page 8).
4. Select left/right cross conveyor, click up/down buttons to adjust speed.
1. Select the Spn Rvs under “Options” menu from the USER screen.
2. System assume the same Min&Max for Spinner reverse output
3. Click ‘R’ button to select spinner forward or reverse operation
1. Select Norm under the “Options” menu from the USER screen.
2. Click on Valve icon and then click on NORM icon, and select “3 BOOM”.
1. Select the Liquid mode under “Options” menu from USER screen.
2. Click on Valve icon and then click on NORM icon, and select “3 BOOM”.
14 Error Codes
The following error messages are user configurable, both timeouts and controller
actions.
The following Errors are warning messages, and not user configurable.
Error 20 - Output Non-Zero. This is a safety function to prevent the controller from
accidentally sending an unexpected output when the controller is turned on, or
when the user leaves programming mode and enters normal operation mode. The
outputs will be kept at zero until the error condition is removed. To recover, set the
application rates to zero or exit Blast mode.
Error 21 - Unload Not Allowed. An attempt was made to enter Unload mode while
the truck was moving, which is not allowed. The Unload command will be ignored in
this case.
Error 22 - BB3 System Error. This is an unrecoverable error in the RC controller. Try
rebooting the controller to see if it goes away, otherwise report the failure to Bosch
Rexroth. This error can also occur if an attempt is made to run a joystick without
having an RCE controller present.
Error 23 - This is a communication failure between the RC controller and the display.
It will show up in the logging history in the RC controller after the display is re-
connected.
Error 25 - Joystick 1 communication failure. This will shut down the joystick outputs,
and will show up as a 40 in the live DIG display item.
Error 26 - Joystick 2 communication failure. This will shut down the joystick outputs,
and will show up as a 80 in the live DIG display item.
Error 27 - No Gate Sensor. Gate sensor failure, most likely caused by cable break.
This will force the gate control into Manual.
Error 28 - Gate Position is Zero. This will occur only if the gate position is zero while
in gate read-back mode. The conveyor will not be allowed to move until this is fixed.
Error 30 - Under-Application: Spinner. The spinner cannot meet the desired RPM
setpoint. This should not happen in manual mode, but could happen if the spinner is
in PPS mode and the ground speed is high.
Error 31 - Under-Application: Conveyor. The conveyor cannot meet the desired RPM
setpoint. Caused by too high application rate or too high ground speed or incorrect
calibration..
Error 32 - Under-Application: Pre-Wet. The pre-wet pump cannot meet the desired
flow setpoint. Caused by too high application rate or too high ground speed or
incorrect calibration.
Error 33 - Under-Application: Anti-Ice. The anti-ice pump cannot meet the desired
flow setpoint. Caused by too high application rate or too high ground speed or
incorrect calibration.
Error 38 - Spinner Maximum RPM Too Low. During auto nulling, the calculated
maximum RPM was too low, most likely caused by no sensor feedback.
Error 39 - Conveyor Maximum RPM Too Low. During auto nulling, the calculated
maximum RPM was too low, most likely caused by no sensor feedback.
Error 40 - Pre-Wet Maximum Hz Too Low. During auto nulling, the calculated
maximum Hz was too low, most likely caused by no sensor feedback.
Error 41 - Anti-Ice Maximum Hz Too Low. During auto nulling, the calculated
maximum Hz was too low, most likely caused by no sensor feedback.
Error 42 - Wrong Spinner Control Mode. An attempt was made to perform auto
nulling of a spinner while it was in manual.
Error 44 - Wrong Pre-Wet Control Mode. An attempt was made to perform auto
nulling, or volume calibration, of a pre-wet pump while it was in manual.
Error 45 - Wrong Anti-Ice Control Mode. An attempt was made to perform auto
nulling, or volume calibration, of an anti-ice pump while it was in manual. This error
could also be caused by an I/O conflict between a cross conveyor mode and the
anti-ice pump output, in which case the anti-ice pump will be disabled.
Error 47 - Wt. per Revolution Too Low. During conveyor weight calibration, the
calculated weight per revolution was too low, most likely caused by typing in zero
for the weight.
Error 48 - Wt. per Revolution Too High. During conveyor weight calibration, the
calculated weight per revolution was too high, most likely caused by no conveyor
sensor feedback.
Error 49 - Pre-Wet Pulses per Gallon Too Low. During calibration of pre-wet volume
output, the pulses/gal was too low, most likely caused by no flow sensor feedback.
Error 50 - Pre-Wet Pulses per Gallon Too Hi. During calibration of pre-wet volume
output, the pulses/gal was too high, most likely caused by typing in zero for the
volume.
Error 51 - Anti-Ice Pulses per Gallon Too Low. During calibration of anti-ice volume
output, the pulses/gal was too low, most likely caused by no flow sensor feedback.
Error 52 - Anti-Ice Pulses per Gallon Too Hi. During calibration of anti-ice volume
output, the pulses/gal was too high, most likely caused by typing in zero for the
volume.
Error 53 - Spinner mm at zero RPM too Low. During calibration of the relationship
between spinner RPM and spinner spread width, a value of 0 mm at zero RPM was
used.
Error 54 - Spinner mm per RPM too Low. During calibration of the relationship
between spinner RPM and spinner spread width, a value of maximum spread width
was used that was less than the mm at zero RPM.
Error 55 - Gate Movement Too Low. During calibration of gate maximum and
minimum position, the difference between minimum and maximum height was less
than 1 inch.
Error 56 - Gate Zero in Manual. While in manual gate control mode, the operating
gate position was specified to be zero.
Error 57 - Gate at Calibration Too Low. While calibrating the weight per revolution
for a specific material, the gate position at calibration was specified to be zero.
Error 58 - Spinner PPR Too Low. A value of zero was used for spinner pulses per
revolution.
Error 59 - Conveyor PPR Too Low. A value of zero was used for conveyor pulses per
revolution.
Error 60 - Spinner Output Range Too Low. The difference between maximum and
minimum spinner nulling values was less than 5%.
Error 61 - Conveyor Output Range Too Low. The difference between maximum and
minimum conveyor nulling values was less than 5%.
Error 62 - Cross Conveyor 1 Output Range Too Low. The difference between
maximum and minimum cross conveyor nulling values was less than 5%.
Error 63 - Cross Conveyor 2 Output Range Too Low. The difference between
maximum and minimum cross conveyor nulling values was less than 5%.
Error 64 - Pre-Wet Output Range Too Low. The difference between maximum and
minimum pre-wet nulling values was less than 5%.
Error 65 - Anti-Ice Output Range Too Low. The difference between maximum and
minimum anti-ice nulling values was less than 5%.
Error 66 - Joystick 1 Output Range Too Low. The difference between maximum and
minimum joystick nulling values for one of the six outputs was less than 5%.
Error 67 - Joystick 2 Output Range Too Low. The difference between maximum and
minimum joystick nulling values for one of the six outputs was less than 5%.
Error 68 - Theoretical Maximum Conveyor RPM Too High. Based on the specified
application rate setpoints, and the maximum ground speed, the maximum
theoretical conveyor RPM required has been calculated to be more than twice the
actual conveyor capacity, which will lead to serious under-application problems. The
actual controller RPM setpoint will be clamped at this value to prevent the
controller from becoming unstable, and the conveyor should be re-calibrated to
determine the source of the problem.
15 Joystick Calibration
15.1 Solenoid Nulling
1. Start vehicle and achieve full pump flow.
2. Tap on Joystick symbol.
Any mode or direction can be assigned to Panic Button. In operation mode when the
Panic button is pushed in conjunction with the Deadman trigger, the selected
function(s) will activate simultaneously.
All the mode names and special functions will be configured by the factory. Only
solenoid nulling may be required.
Resetting
Re-engages float when the joystick is returned to neutral.
Non-
Non-resetting
The button must be pushed to re-enable the float after the stick is deflected.
Note: Editing the names of the functions does not re-allocate the outputs on the
valve cable. They are fixed and defined in the valve layout for the specific system.
17 Warning
This glass LCD touch screen display has been extensively tested and validated
against its intended use. This glass could crack and break if the display is dropped
on to a hard surface or receives substantial impact. If the glass chips or cracks,
discontinue use and contact Bosch Rexroth Canada to have it replaced - do not
touch or attempt to remove the broken glass. Any misuse/abuse causing damage,
whether intended or not, will become the sole responsibility of the owner/buyer
which will render the warranty of this product, void.
Notes:
Table of Contents
1 Software Installation 5
2 Menu System 8
2.1 File Menu 8
2.1.1 Synchronize 8
2.1.2 Save Truck 8
2.1.3 Display Truck 8
2.1.4 Email Truck 9
2.1.5 Log Data 9
2.1.6 GPS Data 9
2.1.7 Exit 9
2.2 Options Menu 9
2.2.1 Choose Database 9
2.2.2 English/French 10
2.2.3 Import CS-550 Log 10
2.2.4 Import CS-440 Data 10
2.2.5 Sync at Start 10
2.3 Records Menu 10
2.3.1 Add Truck 10
2.3.2 Delete Truck 11
2.3.3 Reset Truck to Default 11
2.3.4 Reset Trip Summary 11
2.4 Select Truck Menu 11
2.5 Help Menu 11
2.5.1 CS-550 Help 12
2.5.2 About Truck 12
2.5.3 About Us 12
3 Truck Parameter Configuration 13
3.1 System Tab 13
3.1.1 System Units 13
3.1.2 Driver ID/Solid Name/Pre-wet Name/Anti-ice Name 13
3.1.3 Operator Access 13
3.1.4 Cross Conveyor Mode 14
3.1.5 Spinner Control Mode 15
3.1.6 Conveyor Control Mode 16
3.1.7 Pre-wet Control Mode 16
3.1.8 Anti-ice Control Mode 17
3.1.9 Gate Control Mode 18
3.1.10 Password Select 18
Bosch Rexroth Canada Corp. reserves the right to revise this information at any time and for
any reason and reserves the right to make changes at any time, without notice or obligation,
to any of the information contained in this piece of literature.
1 Software Installation
On the CD, if the software installation does not start automatically, double-click on
the CS-550Desktop.msi file. If you cannot see what the file type is, allow the mouse
to hover over the filename, and you should see a tooltip message that says
“Windows Installer Package”.
On the screen that says “Welcome to the CS-550Desktop Set-up Wizard”, click
‘Next’.
On the screen that says “Select Installation Folder”, click ‘Next’. This should look as
shown below.
If you wish to view truck parameter reports in a printable form, or if you wish to
view logging reports, then you will need to install support for Crystal Reports. On
the CD, double-click on the file CRRedist2005_x86.msi and follow the on-screen
instructions to do this. If this installation is not performed, and if you try to access
truck parameters using the menu item ‘File->Display Truck’, then you may get the
warning message shown below.
If you are using the GPS/WiFi option, and if you want to view the GPS route, then
you will need to install Google Earth 5. On the CD, double-click on the file
GoogleEarthWin.exe and follow the on-screen instructions. On Windows 7, it is
recommended that you perform a right-mouse-button click on the file and select the
option ‘Run as Administrator’ if it is available. If this installation is not performed
and if you try to access GPS data using the menu item ‘File->GPS Data->Drive GPS
Route’ then you will receive the warning message shown below.
Finally, the first time you run the CS-550 Desktop program, you will probably get the
warning shown below.
This is because the program automatically checks for the presence of a USB stick
every time it starts running. The USB stick is used to transfer data to and from the
CS-550 display. To avoid this message, you can insert a USB stick before starting
the program, or you can disable the automatic check. To disable the automatic
check, click on the menu item ‘Options->Sync at Start’. If you disable the automatic
check, you can manually check for a USB stick at any time by using the menu item
‘File->Synchronize’.
If you need to confirm the version number of the software, you can do so by clicking
on the menu item ‘Help->About Us’. This will produce a message in the format
shown below.
2 Menu System
2.1 File Menu
2.1.1 Synchronize
This will check to see if a USB stick is present. If so, then truck parameter files will
be copied in both directions so that the computer’s hard disk and the USB drive are
exact duplicates of each other. No truck data files will ever be deleted by this
procedure. If two versions of the same truck are found, then the newest one will be
kept. Log data files will be moved from the USB stick to the computer and will be
read into a Microsoft Access database. The original log file will be deleted on the
USB stick, but kept on the computer.
The ‘Synchronize’ item is also accessible using the icon shortcut (shown to the left)
at the top middle of the menu bar.
2.1.7 Exit
This will stop the program. If you have edited the truck data, you will be prompted
to save the data.
Please note that all future Synchronizations of data will be performed at the new
location, so the old parameter database at the old location will be abandoned and a
new parameter database will be started at the new location. The parameter data is
stored separately from the logging data, in a subdirectory called 550Data.
2.2.2 English/French
This allows you to switch to a new language. The switch will take place only after
you close and restart the program.
When selecting a truck you will first specify the region and then select a truck from
within that region. The main menu shows a list of available regions for which truck
parameter data is available. When you hover over a region, then the sub-menu
shows a list of available trucks in that region. Clicking on this truck name will load a
new set of truck data and you will be prompted to save the previous truck, if any
changes were made.
Firmware Version
This can be 400 for an RC4-4 platform, or 200 for an RC2-2 platform, with an
optional (tow) in either case, if the device is a tow plow. The firmware version could
also be in the series 1xx for an imported CS-440 MC-08 or 2xx for an imported CS-
440 RC6-9. In this case, both the RC build No. and the Display build No. would be
zero.
RC Build No.
This is the version number of the firmware in the RC controller. This will be zero if
the truck configuration data has never been downloaded into the RC controller.
File
This is the file name of the truck parameter data. It can be found in the subdirectory
550Data and it should follow the format regionname_truckname_Parm.bin.
2.5.3 About Us
This shows the current desktop software version number, and the location of the
logging database, which is also the location of the 550Data directory that contains
the truck parameter data.
None
This option will prevent the operator from making any changes to the gate setting
or the material selected.
Material
This option will allow the operator to make changes to the material selection.
Gate
This option will allow the operator to make changes to the manual gate setting.
Normal
This will be the most typical configuration, which supports spinner/conveyor/pre-
wet/anti-ice and closed loop gate control. It also supports two additional outputs:
reverse, and a GS12V digital output signal which is turned on by a ground-speed
input. The four outputs: Pre-wet, Anti-ice, GS12V and Reverse can be redefined to
be used for 3 boom anti-icing, in which case they become: Boom left, Anti-ice
output, Boom centre, and Boom right.
Pattern
This supports closed loop gate control, pre-wet, and two momentary-contact digital
outputs to adjust the position of a chute for pattern spreading. It also supports the
option of simulated anti-ice output on the pre-wet channel.
Air Gate
This supports pre-wet output, reverse output, and a special digital output to move
the gate to a fixed location.
Liquid Plus
This supports pre-wet, plus 3 boom anti-icing, and reverse.
Cross Conveyor CA
This supports closed loop gate control, Pre-wet, and an analog output and two
digital outputs for controlling a cross conveyor.
Cross Conveyor US
This supports pre-wet, GS12V output, reverse, and two analog signals for controlling
cross conveyors.
Spinner Reverse
This supports re-direction of the spinner output to either a forward or reverse motor
using a live switch. In this mode anti-icing is disabled, and the normal pre-wet
output signal will be sent to the spinner connector on the cable. The spinner
forward signal is sent to the pre-wet connection and the spinner reverse signal is
sent to the anti-ice connection.
For the RC2-2 platform the modes are defined differently. In this case the modes
refer to the use that is made of the digital output labeled ‘S7 Reverse’:
2-2 Anti-ice
Supports anti-icing output, in addition to the normal pre-wet.
2-2 Reverse
Supports conveyor reverse signal.
2-2 GS12V
Supports GS12V digital output signal, which is turned on by ground-speed input.
Closed Loop
The controller receives a signal from a feedback sensor that measures the spinner
RPM. Spinner speed can be controlled to give a previously calibrated spread width.
PPS Mode
"Precision Placement System". In this mode the spinner speed is proportional to
ground speed, using a previously calibrated relationship.
Manual
The spinner does not have any feedback from either the ground speed sensor or the
spinner speed sensor, instead the speed is specified by means of a preset
percentage of output.
Half Lane
The spinner speed and spread width will increment in units of half a lane as the
spinner knob position is increased. The conveyor output will be proportional to the
spinner output, so that the amount spread per lane remains constant. The pre-wet
output will also be proportional to the spinner output, so that the pre-wet
application rate in liter/tonne remains constant. The spinner control mode will be
manual, and the conveyor and pre-wet control modes should be either open loop or
closed loop.
Full Lane
Same as ‘Half Lane’ mode, except that the spinner speed and spread width will
increment in units of a full lane as the spinner knob position is increased, and the
conveyor and pre-wet will increase proportionately.
Closed Loop
This is a closed loop controller which uses a feedback signal from both the ground
speed sensor and the conveyor speed sensor to apply the desired application rate in
units of weight per distance travelled.
Open Loop
This uses feedback from the ground speed sensor to apply the desired application
rate as above. The conveyor speed sensor is not used, but the conveyor speed is
calculated based on valve position.
On/Off
This is a manual mode of operation in which the conveyor is interlocked with a
ground speed sensor, so the conveyor shuts down if the ground speed is zero.
Manual
In this mode, the controller does not have any feedback from either the ground
speed sensor or the conveyor speed sensor, the application rate is determined by
means of a preset percentage of conveyor output.
gm/sq.m.
This is a closed loop control mode in which both solid and liquid application rates
are specified in terms of weight per area (square meters) rather than weight per
distance. The width of the spread area is calculated based on the spinner RPM.
KOMBI
This is a closed loop control mode similar to gm/sq.m. in which the total application
rate is specified in terms of weight per area. The liquid application rate is specified
as a percent of the total, rather than as weight per area.
Off
This deactives the pre-wet controller.
Fixed Pre-wet
Select the fixed pre-wet mode if the pre-wet system consists of a limited flow pump
driven by the conveyor motor exhaust oil.
Closed Loop
In this mode the liquid system has an inline flow meter which measures flow rate
using a pulse rate. The controller will control the liquid flow to be a constant
fraction of the conveyor solid flow. The fraction is specified as liters/tonne or
gallon/ton.
Manual
The application rate is determined by means of a preset percentage of liquid output.
On/Off
This is a manual mode of operation in which the pre-wet is interlocked with a
ground speed sensor, so the pre-wet shuts down if the ground speed is zero.
Off
This deactives the anti-ice controller.
1 Boom
This is a closed loop controller which uses a feedback signal from both the ground
speed sensor and the anti-ice flow meter to apply the desired application rate in
units of volume per distance travelled.
3 Boom
This is a closed loop controller which uses a feedback signal from both the ground
speed sensor and the anti-ice flow meter to apply the desired application rate in
units of volume per distance travelled per boom activated. The volume of output is
proportional to the number of booms that are on, and there are digital outputs to
activate each boom.
Manual
The application rate is determined by means of a preset percentage of anti-ice
output.
Manual
Gate position is fixed, and the value of the gate height must be specified by the
operator at startup, or during calibration.
Read Back
A read-back device is attached to the gate. The controller will read and use the
actual gate position. Gate height must be manually adjusted.
Closed Loop
A read-back device is used and the gate is under hydraulic control as well. The gate
will be controlled to close at zero ground speed, and to minimize variations in
conveyor RPM when running. The gate operating position can be manipulated
directly from the controller for calibration purposes.
Disabled
No password is used, and only the USB key is needed to enter programming mode.
Enabled
A password will be generated and will be needed each time the programming mode
is entered.
If the password is enabled, a text box will allow you to enter a password. This
should be 3 characters long, and consist only of numbers, in the range 0 - 999.
Always On
If this is selected the spinner will always be turning whenever a spinner rate is
selected by the operator.
Pause Only
The spinner will stop whenever the system is in the Pause mode.
Max Output
This is a manual control mode in which the conveyor runs at maximum output when
Blast is activated. The conveyor will stop if the ground speed is zero. The maximum
output value can be adjusted during calibration.
Stationary Max
This is a manual control mode in which the conveyor runs at maximum output when
Blast is activated. The conveyor will continue to run even if the ground speed is
zero.
Closed Loop
This is a closed loop blast control mode in which the conveyor will deliver a fixed
amount of weight per distance. The blast rate can be adjusted during calibration.
Off
This deactivates the Blast function.
The number of pulses per revolution will vary depending on the make of the sensor,
and should be obtained from the manufacturer.
In the case of a liquid flowmeter, there is no physical shaft whose RPM can be
measured, therefore, the ‘pulses per rev.’ is not used. Instead a direct relationship
is measured between accumulated tachometer pulses and accumulated liquid
volume of output.
Maximum RPM
This is the RPM at the maximum valve output. For a closed loop controller, it will be
calculated automatically during the auto-nulling event. For an open loop controller,
it could be obtained from a manufacturer’s spec sheet or by comparison with
similar closed loop results. For a liquid pump, the measured value will be a pulse
rate in Hz (pulses/sec) instead of RPM.
This spread width is used only if the conveyor is in “gm/sq.m.” or “KOMBI” mode.
These gate settings are used only if you are in ‘Gate Read-Back’ mode or ‘Closed
Loop Gate’ mode.
If the calibration is checked using a timed catch test, and if it is found that the
calibration is off, then this number can be manually adjusted to bring the calibration
into line with the catch test.
If the calibration is checked using a timed catch test, and if it is found that the
calibration is off, then this number can be manually adjusted to bring the calibration
into line with the catch test.
If the calibration is checked using a timed catch test, and if it is found that the
calibration is off, then this number can be manually adjusted to bring the calibration
into line with the catch test.
There are a total of 16 possible outputs. These are arranged in groups of two. In
each group, ‘A’ is normally the ‘down’ direction and ‘B’ is normally ‘up’. Twelve of
these outputs are analog signals, so the range of output is from 0 to 100%. The
remaining four are digital outputs which are either on or off. The Emg. setting for
these four outputs is either 1 or 0, to enable or disable the emergency output.
Function Type
Each joystick axis can operate in four possible modes. These modes are: disabled,
proportional output, on/off at 5%, on/off at 10%. The on/off modes are modes in
which the normal proportional output of the joystick has been converted in the
software to an on/off signal with a different threshold of movement to trigger the
switch, either 5% or 10% of the full stroke.
Float Enable
The power float output can be disabled by moving a specific joystick axis in the ‘B’
direction. This checkbox indicates which axis will be used. Only one axis, and only
one mode, can be chosen for this task. If two Power Floats are configured then two
joystick axes need to be chosen.
None
Disabled
Mode 1 - Mode 4
One of four modes which are mutually exclusive; defined in the ‘Joystick
Configuration’ section. These mode switching buttons are interlocked so that only
one mode can be active. All double-pushes of more than one button will be ignored.
Latched output.
Emergency
Activates the emergency outputs configured in the ‘Output (%)’ section. Momentary
contact.
Pause
Puts the controller into ‘Pause’ mode. Latched output.
Blast
Puts the controller into ‘Blast’ mode. Latched output.
Power Float
One of the input signals required to activate power float output. Latched output.
Spin Reverse
Activates a spinner reverse digital output signal. Latched output.
Aux A
Activates a digital output signal. Momentary contact.
Aux B
Activates a digital output signal. If both ‘Aux A’ and ‘Aux B’ are used, then the
outputs will be interlocked so that only one output is active. All double-pushes of
both buttons will be ignored. Momentary contact.
Dump Limit
One of the input signals required to activate dump limit. Momentary contact.
Power Float 2
One of the input signals required to activate the second power float. Latched
output.
PTO
One of the input signals that can be used to re-activate the PTO output. Momentary
contact.
0
Disabled.
1
Reset option. This is the same as the Non-Reset option except that, when the Power
Float output has been interrupted by sending a joystick output, then it is necessary
to put the joystick into neutral and also release the joystick button before the Power
Float can be reactivated.
2
Non-Reset option. This is the default. When both the joystick button and the
proximity switch are active, then the Power Float output will be activated. Activating
the appropriate joystick output will shut off the Power Float. It can be reactivated
by moving the joystick to neutral.
The left-hand-side text box specifies some additional Power Float options:
0
Proximity switch required, one Power Float.
2
Proximity switch required, two Power Floats.
0
Disabled.
1
Dump limit enabled. This will disable a specific joystick ‘B’ output if a limit switch is
encountered. The output disable can be overridden with a joystick button.
2
Tow plow deploy enabled. This will disable a specific joystick ‘B’ output unless the
joystick mode button is pushed. The mode button serves two purposes here: It acts
as a latched output to switch into tow plow deploy mode, and it also acts as a
momentary contact to momentarily enable output to this axis.
0
Disabled.
X
Time in seconds for the Auto-raise feature. This will activate a specific joystick axis
‘B’ output for X seconds if a digital input signal is received, typically from a ground-
speed sensor. This axis will be activated regardless of what mode the joystick is in.
The Auto-raise will be activated only once, when the digital input signal is initially
turned on. It will turn off after X seconds regardless of the status of the digital
signal. The Auto-raise can be restarted by turning off the digital signal and then
turning it back on.
The three options: ‘Dump Limit’, ‘Tow Plow Deploy’, and ‘Auto-raise’ are mutually
exclusive, meaning that either the left text box or the right text box should be zero.
Error 2 De-ice Blast Too Long The time limit for the Anti-ice Blast function has been
exceeded.
Error 3 Over-Speed The vehicle has exceeded the maximum allowable speed.
Error 4 Spinner Valve Output An open circuit has been detected in the conveyor output.
Failure This could also be caused by setting a maximum nulling
output value too large.
Error 5 Conveyor Valve An open circuit has been detected in the conveyor output.
Output Failure This could also be caused by setting a maximum nulling
output value too large.
Error 6 Cross conveyor 1 An open circuit has been detected in the cross conveyor
Output Failure output. This could also be caused by setting a maximum
nulling output value too large.
Error 7 Cross conveyor 2 An open circuit has been detected in the cross conveyor
Output Failure output. This could also be caused by setting a maximum
nulling output value too large.
Error 8 No Material Detected The material detect sensor has detected an empty
hopper.
Error 11 No Conveyor Sensor This is caused by a long term, persistent, loss of conveyor
speed signal, most likely a cable break or sensor
misalignment.
Error 12 No Pre-wet Flow This is caused by a long term, persistent loss of pre-wet
Sensor flow signal, most likely a cable break or sensor
misalignment.
Error 13 No Anti-ice Flow This is caused by a long term, persistent, loss of anti-ice
Sensor flow signal, most likely a cable break or sensor.
Error 21 Unload Not Allowed An attempt was made to enter Unload mode while the
truck was moving, which is not allowed. The Unload
command will be ignored in this case.
Error 22 BB3 System Error This is an unrecoverable error in the RC controller. Try
rebooting the controller to see if it goes away, otherwise
report the failure to Bosch Rexroth. This error can also
occur if an attempt is made to run a joystick without
having an RCE controller present.
Error 25 Joystick 1 This will shut down the joystick outputs, and will show up
Communication as a 40 in the live DIG display item.
Failure
Error 26 Joystick 2 This will shut down the joystick outputs, and will show up
Communication as a 80 in the live DIG display item.
Failure
Error 27 No Gate Sensor Gate sensor failure, most likely caused by cable break.
This will force the gate control into Manual.
Error 28 Gate Position is Zero This will occur only if the gate position is zero while in
gate read-back mode. The conveyor will not be allowed to
move until this is fixed.
Error 30 Under-Application: The spinner cannot meet the desired RPM setpoint. This
Spinner should not happen in manual mode, but could happen if
the spinner is in PPS mode and the ground speed is high.
Error 31 Under-Application: The conveyor cannot meet the desired RPM setpoint.
Conveyor Caused by too high application rate or too high ground
speed or incorrect calibration.
Error 32 Under-Application: The pre-wet pump cannot meet the desired flow setpoint.
Pre-wet Caused by too high application rate or too high ground
speed or incorrect calibration.
Error 33 Under-Application: The anti-ice pump cannot meet the desired flow setpoint.
Anti-ice Caused by too high application rate or too high ground
speed or incorrect calibration.
Error 34 Over-Application: The solid application rate is above setpoint. Most likely
Conveyor caused by a minimum null value for conveyor output that
is too high, so the conveyor never stops.
Error 35 Over-Application: The pre-wet application rate is above setpoint. Most likely
Pre-wet caused by a minimum null value for the pre-wet pump
output that is too high, so the pump never stops.
Error 37 Calibration: Ground- Calculated pulses per km is too low during calibration.
Speed Pulses Too Possibly caused by no sensor feedback, or try
Low recalibrating the ground speed sensor.
Error 38 Spinner Maximum During auto-nulling, the calculated maximum RPM was too
RPM Too Low low, most likely caused by no sensor feedback.
Error 39 Conveyor Maximum During auto-nulling, the calculated maximum RPM was too
RPM Too Low low, most likely caused by no sensor feedback.
Error 40 Pre-wet Maximum Hz During auto-nulling, the calculated maximum Hz was too
Too Low low, most likely caused by no sensor feedback.
Error 41 Anti-ice Maximum Hz During auto-nulling, the calculated maximum Hz was too
Too Low low, most likely caused by no sensor feedback.
Error 46 Wrong Cross An attempt was made to go into Reverse while this output
conveyor Mode was being used by a cross conveyor mode. The Reverse
command will be ignored in this case. Could also be
caused by attempting to use gm/sq.m. mode while there
was an I/O conflict with a Cross conveyor CA mode, in
this case gm/sq.m. mode will not be allowed. Could also
be caused by attempting to use closed loop gate control
while in Cross conveyor US mode or Liquid-Plus mode, in
which case the gate control will be forced into gate read
back mode.
Error 47 Wt. Per Revolution During conveyor weight calibration, the calculated weight
Too Low per revolution was too low, most likely caused by typing in
zero for the weight.
Error 48 Wt. Per Revolution During conveyor weight calibration, the calculated weight
Too High per revolution was too high, most likely caused by no
conveyor sensor feedback.
Error 50 Pre-wet Pulses Per During calibration of pre-wet volume output, the
Gallon Too High pulses/gal was too high, most likely caused by typing in
zero for the volume.
Error 51 Anti-ice Pulses Per During calibration of anti-ice volume output, the
Gallon Too Low pulses/gal was too low, most likely caused by no flow
sensor feedback.
Error 52 Anti-ice Pulses Per During calibration of anti-ice volume output, the
Gallon Too High pulses/gal was too high, most likely caused by typing in
zero for the volume.
Error 54 Spinner mm Per RPM During calibration of the relationship between spinner
Too Low RPM and spinner spread width, a value of maximum
spread width was used that was less than the mm at zero
RPM.
Error 55 Gate Movement Too During calibration of gate maximum and minimum
Low position, the difference between minimum and maximum
height was less than 1 inch.
Error 56 Gate Zero in Manual While in manual gate control mode, the operating gate
position was specified to be zero.
Error 57 Gate at Calibration While calibrating the weight per revolution for a specific
Too Low material, the gate position at calibration was specified to
be zero.
Error 58 Spinner PPR Too Low A value of zero was used for spinner pulses per revolution.
Error 59 Conveyor PPR Too A value of zero was used for conveyor pulses per
Low revolution.
Error 60 Spinner Output The difference between maximum and minimum spinner
Range Too Low nulling values was less than 5%.
Error 61 Conveyor Output The difference between maximum and minimum conveyor
Range Too Low nulling values was less than 5%.
Error 62 Cross Conveyor 1 The difference between maximum and minimum cross
Output Range Too conveyor nulling values was less than 5%.
Low
Error 64 Pre-wet Outrange The difference between maximum and minimum pre-wet
Range Too Low nulling values was less than 5%.
Error 65 Anti-ice Output Range The difference between maximum and minimum anti-ice
Too Low nulling values was less than 5%.
Error 66 Joystick 1 Output The difference between maximum and minimum joystick
Range Too Low nulling values for one of the six outputs was less than 5%.
Error 67 Joystick 2 Output The difference between maximum and minimum joystick
Range Too Low nulling values for one of the six outputs was less than 5%.
Error 68 Theoretical Maximum Based on the specified application rate setpoints, and the
Conveyor RPM Too maximum ground speed, the maximum theoretical
High conveyor RPM required has been calculated to be more
than twice the actual conveyor capacity, which will lead to
serious under-application problems. The actual controller
RPM setpoint will be clamped at this value to prevent the
controller from becoming unstable, and the conveyor
should be re-calibrated to determine the source of the
problem.
Error 69 Theoretical Maximum Based on the specified application rate setpoints, and the
Pre-wet Hz Too High maximum ground speed, the maximum theoretical pre-wet
pump flow required has been calculated to be more than
twice the actual pump capacity, which will lead to serious
under-application problems. The actual pump flow
setpoint will be clamped at this value to prevent the
controller from becoming unstable, and the pre-wet pump
should be re-calibrated to determine the source of the
problem.
Error 70 Theoretical Maximum Based on the specified application rate setpoints, and the
Anti-ice Hz Too High maximum ground speed, the maximum theoretical anti-ice
pump flow required has been calculated to be more than
twice the actual pump capacity, which will lead to serious
under-application problems. The actual pump flow
setpoint will be clamped at this value to prevent the
controller from becoming unstable, and the anti-ice pump
should be re-calibrated to determine the source of the
problem.
4 Logging Reports
Clicking on the icon to the left will bring up the Logging Report dialog shown below.
This allows for selection of logging data involving multiple trucks. The logging
reports can be either Crystal Reports, or Excel reports, or a graphical pie chart
report; the default is Crystal Reports. Clicking on ‘View Report’ will produce a
Crystal Report in a multi-page format that is suitable for either printing or exporting
to a file, similar to the Truck Parameter Report. Clicking on ‘Email Report’ will email
the same report as an attachment, and the person who receives it will need to
rename the attachment from ‘untitled.txt’ to ‘something.rtf’ in order to view it as a
Rich Text Format file.
When selecting data, if nothing is selected in a specific category (such as ‘Truck’, for
example), then all the items in that category will be used. Any selection can be
toggled on or off by holding down the Ctrl key while clicking on an item. The
number of records currently selected will be displayed at the top in the title of the
dialog box. Due to space limitations, the liquid data will be displayed in one of three
formats: pre-wet only (letter size), anti-ice only (letter size), or both (legal size).
Clicking on the option ‘Only Spreading Events’ will produce a report in which
calibration events, unload events and zero application rate have been removed. The
reports can be grouped by date and by driver, if desired.
If desired, logging data can be selectively deleted using this dialog screen. Due to
the fact that different printers may use different alignment at the edges, there is an
option to adjust the margins, in case a letter is missing at the left or right edge.
This allows for selection of GPS data, similar to the logging data selection
procedure. The GPS data will be displayed using Google Earth. Click on ‘Drive GPS
Route’ to display the entire route as a blue/green line (blue for non-spreading
events, green for spreading events). The waypoints on the route will be displayed as
balloons. The balloon style can be chosen to represent either the solids’ application
rate or the status of the digital inputs. If ‘Rate’ is chosen, then for a spreading event
the balloon will be green with either a ‘B’ for Blast or a number from ‘1’ to ‘9’
indicating the application rate. For a non-spreading event the balloon will be blue
with either a ‘P’ for Pause or a ‘0’ for zero application rate. If ‘Digital’ is chosen,
then the balloon will represent the status of six possible digital inputs. Clicking on a
balloon will bring up a snapshot of the truck status at that point. The fields to
display in this status report can be chosen by clicking on ‘Choose GPS Fields’. When
choosing fields, use the Ctrl key to allow a specific field to be selected or de-
selected without affecting any of the other fields.
Not all of the data points will be displayed as balloons when the map first loads. The
number of balloons that are displayed is controlled by the Google slider at the top
left.
Only the points that are between the Start time marker and the End time marker
will be displayed. These markers can be dragged to focus on a specific time. You
can dynamically drive the entire route by dragging the end time marker from start to
finish. You can also automatically drive the route by clicking on the ‘Drive’ button.
There are various types of additional information that can be overlaid onto the map.
In particular, the option to display road names is useful; this can be selected as
shown below.
When using Google Earth, the data is stored in an intermediate file called
‘google.kml’ in the same directory as this program. This file can be double-clicked at
any time to view it in Google Earth independently of this program, or it can be
emailed to others. An alternative view of the data, outside of Google Earth, is
obtained by clicking on ‘Scroll through GPS Data’. This will show a numerical table
of the data. This table can be copied and pasted into Excel by selecting some rows
and using Ctrl-C and Ctrl-V. If desired, GPS data can be selectively deleted using
this dialog screen.
The title should say ‘GSPI86861’. The tab called ‘Wireless Information’ should
contain a connection called ‘CS-WDTS’ and the status should say ‘Connected’.
The next piece of information that is needed is the display’s IP address. You will
need this later when setting up the WiFi data transfer program. This is shown in the
‘IP Information’ tab. You will need this later when setting up the WiFi data transfer
program.
On the computer, you can confirm the WiFi connection by double-clicking on the
WiFi network icon on the taskbar to produce the display shown below.
This should also show that the connection CS-WDTS is present and that the status
is ‘connected’. If you are not able to locate the WiFi connection icon on the taskbar,
then it may be that the adapter is not running. In this case, an independent check of
the WiFi status can be obtained by clicking on the ‘Network’ icon in the CS-550WiFi
program, described below.
This will run the DOS command ‘ipconfig/all’. If the WiFi adapter is running, then
you should get a response like what is shown below.
This will also give you the IP address of the computer, which you normally will not
need. If the WiFi adapter is not running, you may see a response that looks like what
is shown below.
Finally, if all of the above tests are passed, and if you are still not able to
communicate using the CS-550WiFi program described below, you can
independently confirm that the connection is present using the DOS command
‘ping’. The presence of the computer’s wireless adapter can be confirmed using the
same IP address shown above, and the response in DOS should look like this:
The presence of the CS-550 display can also be confirmed using the IP address from
the display, and the response should look like this:
If either of these tests fails, then you will get a response like this:
CS-550WiFi.exe. This program does not need to be installed separately, it just needs
to be copied from the CD to the same directory as the program CS-550Desktop.exe.
This will normally be the directory C:\Program Files\CS-550Desktop\. After copying
it, you may wish to create a shortcut on the desktop by performing a right mouse
button click on it, and selecting the option ‘Send To->Desktop (create shortcut)’.
This shortcut should will look like the icon to the left.
The first time you run the program you will get the message shown below.
In the case of a successful connection, the Region Name, and Truck ID, and
Parameter Date will show the last successful transfer of parameter data for this
truck, and the Log Date field will show the date of the last successful transfer of log
data.
The program will now run continuously in the background, checking to see if new
trucks have arrived. If you wish to stop it completely, perform a right mouse button
click on the icon on the taskbar, and select ‘Exit’. In the same menu that shows
‘Exit’, you can also choose ‘Configure’, which will return you to the above dialog,
which allows you to either configure the IP addresses or check the status of the
communication.
During the ‘Configure’ step, you can add and delete IP addresses, and enable or
disable the monitoring of these addresses. First click ‘Stop’ to stop the monitoring
process. To delete an address, click on the appropriate row, so that the cursor in
the left column moves to that row. Then click the ‘Delete’ button. You will get a
warning message asking you to confirm this deletion. If you select ‘Yes’ then this
truck will disappear. Note that this does not delete any of the data that had
previously been received from this truck. It simply means that this truck will no
longer be monitored in the future. You may need to do this, for example, if a truck’s
IP address changed because the CS-550 display was changed. To add a new truck
to the list, click on ‘Add’ and create a new IP address as done above. When finished,
then click on ‘Run’ to start monitoring. If you want this IP address to be used
immediately, then click on ‘Use’ before clicking on ‘Run’. If a syntax error was made
in typing the IP address, for example not enough ‘.’, or some illegal characters, then
the IP address may be cleared, in which case you will need to stop the monitor,
click on that row, and delete the address, which will be blank at this point. Note
that only two fields can be changed by the user, namely the IP address field when
you are adding a new address, and the ‘Use’ field which enables monitoring. All the
other fields contain data that will be read from the truck and cannot be modified.
It is not necessary that all the trucks be monitored all the time. If you have trucks
that are temporarily not in use, you can temporarily avoid monitoring them by
clicking on ‘Stop’, then uncheck the ‘Use’ column, and then click on ‘Run’. Only
those trucks that have a check mark in the ‘Use’ column will be monitored for
activity. Most of the fields in this table represent historical data, meaning that they
show information only on the last successful connection. The one field that shows
‘live’ data is the ‘Connected’ field. This field will automatically show a check mark
when a new truck arrives, and the check mark will automatically disappear when the
truck leaves or is turned off. The actual data transfer from the truck occurs only
when the connection is first established. No further data transfer from this truck will
be attempted until the truck first leaves and then reappears.
Once the configuration of IP addresses is complete, if you do not wish the dialog
box to be present, you can click on ‘Done’. The program will continue monitoring,
until you close it by clicking on the taskbar and selecting ‘Exit’. When you restart the
program it will automatically go into monitoring mode, as though you had pressed
the ‘Run’ button. The title bar of the ‘Configure’ dialog box will indicate whether the
program is ‘Running’ or ‘Stopped’.
There are three other icons in the dialog box, entitled ‘Help’, ‘IP Config’, and ‘Log
file’. The ‘Help’ button shows the software version number and the initial startup
message. The ‘IP Config’ button shows information on the wireless adapter card, for
diagnostic purposes. The ‘Log file’ button displays a text file called CS-550WiFi.log.
This is a history of recent IP addresses which have been used, and it indicates how
much data was read from each truck. It also reports any error messages that
occurred, which may be useful for diagnostic purposes. The size of this file has been
limited to 25K, which will be roughly 500 messages.
Notes:
Table of Contents
1 System Components 3
2 Spreader System Layout 4
3 Joystick System Layout 5
4 Mounting 7
4.1 Microcontroller 7
4.2 Display and Joystick 8
5 Dimensions 9
5.1 Display 9
5.2 Joystick 9
6 Connector Details 10
6.1 Microcontroller Connection 10
6.2 Solenoid Connection 10
7 Cable Connections 11
7.1 Cable Connections 11
7.2 Main Harness Connections 12
8 Cable Function Chart 13
9 Installation Notes 15
9.1 Step 1 15
9.2 Step 2 15
10 Installation Test Checklist 17
11 Warning
Warnin g 18
12 Appendix – Detailed CS550/150 System Layout
Bosch Rexroth Canada Corp. reserves the right to revise this information at any time and for
any reason and reserves the right to make changes at any time, without notice or obligation,
to any of the information contained in this piece of literature.
Please check for updates at: www.boschrexroth.ca/compu-spread
1 System Components
The following is a detailed navigation chart for the system layout. See Appendix for
the detailed CS550/150 system layout including all the components and part
numbers.
550 SPREADER
150 ARMREST
SPECIAL FUNCTIONS
TOW PLOW
4 Mounting
4.1 Microcontroller
1. The microcontrollers(s) can be mounted horizontal or with the connectors
oriented to the bottom. The controller cannot be mounted with the connectors
facing upwards.
2. The mounting surface must be flat and all four bracket holes used.
3. Sufficient space must be allowed for the mating and un-mating of the
connectors.
4. If the controller is mounted in the cab, valve extension cables are required to be
routed into the valve enclosure.
5. If the controller is mounted in the valve enclosure, the main harness leads will
terminate directly to the valve solenoid.
6. The mount hole spacing is 188mm (7.4”) by 59mm (2.32”).
7. See the “Installation Notes” for additional recommendations (page 15).
5 Dimensions
5.1 Display
5.2 Joystick
6 Connector Details
6.1 Microcontroller Connection
1. Extend sliding tabs.
2. Partially insert connector into socket and ensure the 4 coding posts align into
housing.
3. Push sliding tabs in and the connector will fully insert and lock itself.
4. To remove, pull the tabs out and the connector will un-mate.
Note: The RC4-4 “Spreader” controller uses only the larger connector, while the
RCE “Joystick” controller uses both.
7 Cable Connections
7.1 Cable Connections
Connect the CANBUS EXTENSION from CAN1 to the CANBUS lead on the main
harness or to the FEMALE CONNECTOR on the armrest (if equipped).
If switches are present: Connect the power harness to the ignition, disconnect then
to the 2 PIN CONNECTOR.
Note: Valve extensions are required if the microcontroller is mounted in the cab (see
page 7, note 4, 5).
S12 ANTI-ICE Anti-ice Feed, Boom Left Cross CONV(Cross Cnv, Metric)
9 Installation Notes
9.1 Step 1
Unpack all the supplied parts and check the packing list for completeness.
9.2 Step 2
Untie and layout all the cables supplied, to ensure proper lengths.
Note: Electromagnetic devices such as relays, magnetic switches and solenoids, can
generate large negative voltage spikes. These large spikes are conducted into the
vehicle’s electrical system and may adversely affect all electronic devices including
engine computers. It is strongly recommended that these electromagnetic devices
be electrically suppressed. See warnings and instructions in Body Builder manuals.
1. Connect the Controller 12V power supply and the ground wire using a
dedicated circuit only. (Connect to the ignition disconnect, if available.
Otherwise, connect directly to the battery.)
2. Ensure wiring for transmission devices such as radios, etc. are not attached to
the controller or bundled with the controller wiring.
3. A sufficiently large distance to radio systems must be maintained.
4. Make sure all mounting posts are properly grounded; a direct ground wire to the
negative battery post is recommended. Floor mats and undercoating will
interfere with proper grounding.
5. Disconnect the battery terminals before welding on a vehicle with electronic
equipment.
6. Disconnect the negative battery terminal when wiring electronic devices.
7. Mount the consoles so that they do not interfere with vehicle controls or
obstruct visibility.
8. Mount microcontrollers so that oil and salt spray do not contact the housing.
9. Route cables so that they will not be abused, damaged or immersed in oil.
10. When routing cables through metal opening, always use grommets to prevent
cable damage.
11. When running wires around a dump box pivot point, ensure no connectors can
be separated when the hoist is activated.
12. Tie cables clear of all moving parts like drive-axles or conveyor chains.
13. Observe the cable labeling (under the clear cover) for the proper termination of
inputs and outputs.
14. Use dielectric grease on all external cable connections and pins to ensure
proper corrosion protection.
15. Thoroughly clean all power and ground terminals before connecting power
harness.
16. Stand clear of any hydraulic functions when first powering up the system
Press the “speed” field and hold the “up arrow” for 5 seconds – Release
(Turning on simulated ground speed)
Press the up arrow again to increase speed to 20
11 Warning
This glass LCD touch screen display has been extensively tested and validated
against its intended use. This glass could crack and break if the display is dropped
on to a hard surface or receives a substantial impact. If the glass chips or cracks,
discontinue use and contact Bosch Rexroth Canada to have it replaced - do not
touch or attempt to remove the broken glass. Any misuse/abuse causing damage,
whether intended or not, will become the sole responsibility of the owner/buyer
which will render the warranty of this product, void.
Notes
Maple Crete
Part 2 of 2
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