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FIBER OPTIC CABLEPLACING EQUIPMENT

MANUAL

SHERMAN & REILLY, INC.P.O. Box 11267 • 400 West 33rd StreetChattanooga, TN 37401 USAPhone 423•756•5300Fax No. 423•756•2948WATS 800•251•7780Web Site www.sherman-reilly.com

March 26, 2006 I

INTRODUCTIONImportant Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1Cablejet Terms You Need To Know . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2Superjet Terms You Need To Know . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

SAFETYImportant Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1Warning Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1Operator Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2

OPERATIONSet-up of Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1Hydraulic Superjet Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2Using HRC-10 Hydraulic Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9Starting Intermediate Superjets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11End of Duct System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11Slack Coil Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12Pneumatic Superjet Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13Starting Intermediate Pneumatic Superjets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17End of Duct System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17Cascading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19DC-10 Coupler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21

SERVICEGeneral Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2Tools Required to Disassemble/Assemble Superjet and Cablejet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2Superjet Service Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3Cablejet Service Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4Lower Gear Case Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5Lower Gear Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6Chain Assembly Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7Upper Cable Feeder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8Upper Cable Feeder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9Cablejet Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10Drive Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11Drive Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12Counter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13Resetting the Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13Indicator Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14Testing the Distance Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14Resetting Distance Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14

Table of Contents

II

TROUBLESHOOTINGTroubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1

PARTSWater Separator Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2Lubricator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.411⁄4" and 2" Air Cutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.61", 11⁄4", 11⁄2", 2" Air Cutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8Base Plate and Air Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10Air Inlet and Drive Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12Upper Gear Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14Lower Gear Case and Chain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16Chain Wheel Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18Hydraulic and Pneumatic Pressure Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19Pneumatic Motor and Air Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20Air Inlet Chamber Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22Footage Counter/Speed Indicator (Version D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.24Exhaust Chamber Upper and Lower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.26Water Separator Assembly (ACM-10 Control Module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.28Lubricator Assembly (ACM-10 Control Module). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.30Air Cooler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.32Filter/Regulator/Lubricator Assembly (AC-10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.34HRC-10 Hydraulic Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.36Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.38Oil Cooler/Air Supply Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.39Hydraulic Oil Cooler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.40Hydraulic Fluid Reservoir, Power Pack 5.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.42Frame Assembly, Power Pack 5.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.43Reservoir and Frame Assembly, Power Pack 8/9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.44Engine/Pump Assembly, Power Pack 5.5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.45Engine/Pump Assembly, Power Pack 8/9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.46Cable Sealing Inserts and Cable Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.47Duct Sealing Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.48Miscellaneous Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.49Sonic Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.50Tools and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.52

1.1

SUPERJET

CABLEJET

INTRODUCTION

IMPORTANT INFORMATION

Publication of this manual and the safety precautionsin it does not in any way represent an all inclusive list.It is the operator’s responsibility to make sure themachine is operated in accordance with all state andlocal safety requirements and codes, including allapplicable OSHA (Occupational Safety and HealthAct) and ANSI (American National Standards Institute)regulations.

Should a problem or unsafe condition arise, shutthe machine down using the normal shut-downprocedure. In the event of an emergency, use theemergency stop procedure. Notify the properauthority or follow your employer’s prescribed proce-dure for an emergency situation.

Sherman & Reilly strongly recommendsthat only persons literate and under-standing the English language be con-sidered as operators or service person-nel for Cablejet/Superjet equipment.

1.2

INTRODUCTION

1.2

Exhaust Chamber

Drive Roller Cover/Air Inlet Chamber

HalfFlangeUnder

Half Flange Upper

Exhaust Chamber/Footage Counter

Lubricator DripFeed Adjustment

Air Motor PressureAdjustment

WaterSeparator

Lubricator

CABLEJETTERMS YOU NEED TO KNOW

SUPERJETTERMS YOU NEED TO KNOW

1.3

INTRODUCTION

Air InletChamber

Half FlangeUnder

Pressure Tube(Hydraulic or Pneumatic)

Motors(Hydraulic orPneumatic)

Upper Gear Case

Exhaust Chamber/Footage Counter

Lower Gear Case

1.4

INTRODUCTION


It is very important to all of us at Sherman & Reillythat every machine is operated in a safe manner. Wehave taken every precaution to guard against the pos-sibility of an accident. To properly, safely operate thismachine, it is necessary and important that operatorsand service people read and understand the informa-tion in this and the engine manufacturer’s manual.ANYONE working around the machine shouldread the safety precautions in the manuals. Be awareeach warning and precaution is to help protect againstneedless injury. Taking unnecessary risks and ignoringwarnings is the primary cause of personal injury andfatal accidents in the work place. If you have any ques-tions regarding operation or safety of a procedure orsituation, contact the Sherman & Reilly CustomerService Manager at 1-800-251-7780.

This manual was prepared to help the operator useand service the machine in a safe manner. Responsi-bility for safety during operation and service rests withthe person(s) doing the work. Be alert, observe, andpractice all safety measures, including OSHA require-ments and ANSI standards, to help prevent the possi-bility of an accident.

This manual is of no value if the operator does notread and understand the instructions and precautions(before starting and trying to operate themachine). The operator must be awareof the capacities and limitations of themachine. It is the operator’sresponsibility to watch forsituations and conditionswhich could affect thenormal performance ofthe machine and safetyin the work area.

2.1

SAFETY

WARNING TERMS

Signal words in this manual call the operator’s atten-tion to safety concerns.

The word DANGER indicates the information relatesto a specific immediate hazard which, if disregarded,will result in severe personal injury or death.

The word WARNING indicates the informationrelates to a specific immediate hazard or unsafe prac-tice which, if disregarded, could result in personalinjury or death.

The word CAUTION indicates the information per-tains to a potential hazard or unsafe practice which, ifdisregarded, may result in minor personal injury orequipment damage.

The word NOTE indicates the information is impor-tant to the correct operation or maintenance of themachine.

NOTE

CAUTION

WARNING

DANGER

2.2

SAFETY

2.2

OPERATOR SAFETY PRECAUTIONS

Do not place any part of the body into a potentialpinch point. The machine must be turned off andlocked out in accordance with OSHA regulationsbefore attempting to correct a problem, working on themachine, or performing regularly scheduled service.

l Do not attempt to operate Sherman & Reillyequipment without proper instruction, includingreading and understanding the manual.

l Obey and enforce all warnings including OSHArequirements and ANSI standards.

l Always wear proper safety equip-ment as required by employer. A respirator or particle mask is also recommended.

l Never bypass safety switches or operateequipment with faulty safety devices.

l Be sure all guards and access covers are secure inplace when the machine is being operated.

l Be aware of people in the work area who may be atrisk during operation.

l Know all emergency shutdown procedures.

l Refer to the engine manufacturer’s manual for allinformation regarding the safe operation of theengine, including starting, operation and service.

l Be sure all air and hydraulic hoses and fittings aresecure.

l Safety clip or wire air fittings after connected.

l Ensure communications are working at all stationsand that start and stop signals are understood.

l Always warn downstream personnel when air is tobe sent through the system.

l Stay clear of exit end of duct when under pressure.

l Keep hands clear of hydraulic pusher while operat-ing.

l Never operate equipment while under the influ-ence of any substance which could impair operatorability or judgement. This presents a safety hazardin the work place.

l Do not operate equipment if work ability isimpaired by fatigue, illness, or other causes.

l Avoid contact with power unit engine andhydraulic fittings during operation and after use,until the unit has had time to cool.

l Do not refuel unit while the engine is running.

l Cable Route Construction• Use quality pre-lubricated duct with a duct to

cable ratio of 2:1 if possible.l • Do not kink or overstress duct during installa-

tion.l • Use only air tight couplers such as S&R DC-10

couplers at duct splice points.l • Plug ends of duct to keep water, mud and other

debris out.l • Remove plugs immediately prior to installation.

l Equipment Settings for Maximum Efficiencyl • Air compressor sized to fit installation parameters

(185 CFM minimum, 750 CFM maximum) 375CFM average requirement for 11⁄4" ID duct.

l • Air pressure at compressor (110 to 175 PSI).l • Air pressure at Superjet (100 to 175 PSI).

l Keep all body parts, head, and limbs away from allmoving parts.

l Know location and function of all controls, gauges,instruments, and protective devices.

l Never use controls or hoses for hand holds.

l Do not exceed unit specifications andlimitations for weight.

l Know where to get help in the event of an emergency or injury.

DANGER

3.1

OPERATIONSET-UP OF INSERTS

3.2

OPERATIONHYDRAULIC SUPERJET SET-UP

l Measure the duct. Select proper size duct clampand secure with screw. Use a duct clamp that isequal to or smaller than the duct to insure a goodmechanical connection.

Do not tape around duct in the duct clamp area.

l Select proper duct sealing insert. Make sure thelower one has the groove for the small rubber gas-ket and secure with proper screw in lower half of airinlet chamber. If duct diameter is in between ductsealing inserts, use the next larger size and applytape just to the end of the duct for a snug fit. Installthe large round rubber gasket and trim with sharpknife.

Duct Clamp should be smaller than the outsidediameter of the duct.

Duct Sealing Insert should be larger than the out-side diameter of the duct.

NOTE

DUCT SEALING INSERTSMetric Inch

25 0.9832 1.2634 1.34

37 1.46

40 1.5742 1.6548 1.8950 1.9560 2.3663 2.48

COMPRESSOR SIZESDuct Size (I.D.) Compressor.625" to 1.00" 185 CFM1.00" to 1.25" 250 CFM1.25" to 1.50" 375 CFM1.50" to 2.00" 450 CFM

2.00" 600 to 700 CFM

NOTE

DUCT CLAMPSMetric Inch

25 0.9832 1.2634 1.3437 1.4640 1.5742 1.6548 1.8950 1.9560 2.3663 2.48

CAUTION

DuctClamp

Screw

DuctSealing

Insert

LargeRoundRubberGasket

3.3

OPERATION

l Measure the diameter of the cable. Install correctsize threaded cable end cap by screwing it on theend of the cable. Sometimes it is necessary to trima little of the cover at the end of the cable.

l Select proper size cable sealing insert and securewith screw in lower half of air inlet chamber. Use acable sealing insert that is just larger than the cableto insure the cable slides free.

l Install two correct size half round seals. Careshould be taken that the open “V” should be facingthe direction of air flow open to the duct side. Usea cable seal that is just larger than the cable toinsure the cable slides free.

l Place small round rubber gasket in the groove inthe cable sealing insert and along the sides of thebottom section of the air inlet chamber and intothe duct sealing insert.

Cable Sealing Inserts should be larger than the outsidediameter of the cable. It may be necessary to go to thenext larger size seal or insert in cases of borderlinecable or insert diameters

Cable Seals should be larger than the outside diameterof the cable (usually within 1mm). It may be necessaryto go to the next larger size seal or insert in cases of bor-derline cable or insert diameters.

NOTE

CABLE SEALSMetric Inch Insert

#10 .36 to .39 9 to 11#12 .40 to .47 11 to 12.5#14 .48 to .55 12.5 to 14#15 .56 to .59 14 to 15.5#16 .60 to .62 15.5 to 18#18 .63 to .70 17.5 to 22#19 .71 to .74 15.5 to 18#20 .75 to .76 17.5 to 22#22 .79 to .86 17.5 to 22

#23 .87 to .90 22 to 24#25 .91 to .98 24 to 28

#28 .99 to 1.10 24 to 28

#30 1.11 to 1.18 28 to 32#32 1.19 to 1.25 28 to 32#35 1.26 to 1.37 32 to 36#38 1.38 to 1.49 32 to 36

NOTE

CABLE SEALING INSERTSMetric Inch6 to 9 .24 to .359 to 11 .35 to .43

11 to 12.5 .43 to .4912.5 to 14 .49 to .5514 to 15.5 .55 to .6115.5 to 18 .61 to .7117.5 to 22 .69 to .8722 to 24 .87 to .9424 to 28 .94 to 1.10

28 to 32 1.10 to 1.2532 to 36 1.25 to 1.41

CABLE END CAPSReorder Number

CEC-41CEC-49CEC-54CEC-60CEC-67CEC-74CEC-88CEC-92CEC-101

ThreadedCableEnd Cap

HalfRound

Seal

CableSealingInsert

Groove

RoundRubberGasket

Air InletChamber

3.4

OPERATION

l Repeat seal installation procedure for the upperportion of the air inlet chamber. The upper ductsealing and cable sealing inserts do not have thesmall rubber gasket grooves.

l Insert lower guide for the counter in the lower por-tion of the exhaust chamber. Secure in place withlocking screws.

l Lubricate the duct. Pour Cablejet Lube in the endof the duct (see chart for quantities), then insertJetCoat Spreader “foam plug” (see chart for sizes).

l Secure the duct in the duct clamp with the end ofthe duct firmly seated in the duct sealing insert.Insert the white or green dummy cable plug incable groove.

Reorder Duct I.D.Number to Fit

JCS-10-100 .75" to 1.125"JCS-10-125 1.25" to 1.50"JCS-10-150 1.50" to 2.00"

Duct Qty. perI.D. 1000 ft.

1 inch 3 fl. oz.1.25 inch 4 fl. oz.1.5 inch 5 fl. oz.2 inch 6 fl. oz.

LowerGuide

3.5

OPERATION

The wire grip “catch” must be installed over the exitof the duct before pressurizing the system.

l Place top half of duct clamp and secure with bolts.Place top half of air inlet chamber and secure withbolts. Connect compressor air hose being sure toinsert both safety pins.

l Make sure air inlet valve is in closed position (hor-izontal). Start compressor. Open compressor airvalve. Wait for pressure to build to 100 psi mini-mum at the Superjet. Then open air inlet valve.This will advance foam plug at approximately 100feet per second in the duct. Be sure foam plug isout of duct before proceeding.

l After advancing the plug to the end of the ductrun, be sure to turn off the air valve on the com-pressor as well as the Superjet. In some instances itmay be necessary to shut the compressor off as well.Now, slowly open the valve at the Superjet to“bleed off” the air in the line, then return the valveat the Superjet to the “off position” before recharg-ing the line. The air valve handle on the compres-sor should be perpendicular to the valve in order toshut the valve off.

l Take top off of air inlet chamber. Remove dummycable plug. Insert cable guides in grooves of air inletchamber. Insert cable. Advance cable by hand intoduct 5 feet. Replace top of air inlet chamber.

WARNING

3.6

OPERATION

l Be sure cable is resting in caterpillar tracks and thatit is centered in the cable guide opening. If not,adjust air inlet chamber by loosening the three nutsand center the air inlet chamber.

Pneumatic Superjet operators skip to page 3.13 forfinal set-up and operating instructions.

See page 4.3 for Superjet service requirements.

l Place the top of the cable pusher and tighten all theway until handle will not tighten anymore.

l Install the counter distance/speed indicator andtighten the four bolts. Reset the counter. Hold inplace until it shows zero.

l Connect the remote kill switch (when applicable)to the hydraulic power pack. Connect hydraulichoses from Superjet to hydraulic source usingquick disconnect couplings.

NOTE

NOTE

3.7

OPERATION

Do not exceed 800 PSI hydraulic pressure when jet-ting small dielectric cables under .60 inches O.D.There are some applications for cables under .50inches, do not exceed 500 PSI or use a Cablejet. Usea maximum of 1200 PSI when jetting larger, morerigid armored cables.

l Close hydraulic flow control handle (vertical posi-tion). “Back off” hydraulic pressure control (fullcounter clockwise position).

l Start engine. Engine should run at maximumRPM. Adjust the throttle control if necessary.Advance hydraulic pressure to pre-determined set-ting by rotating pressure control in the clockwisedirection. 800 PSI is recommended for dielectriccables under .6" diameter. Maximum of 1200 PSIfor larger and more rigid cables.

l Without air pressure, slowly advance the hydraulicflow control counter clockwise toward the horizon-tal position. At this point air compressor should berunning with the indicated pressure at the SUPER-JET at least 100 psi.

WARNING

3.8

OPERATION

l Watching the distance indicator, at 150 feet startair flow by rotating the air inlet valve at theSuperjet to the vertical position.

l At intermediate position, all of the above steps areto be accomplished as outlined. The only differencewill be that the exhaust manifold will be fitted withthe proper size duct clamp in both bottom and top(See page 3.19 for cascading units).

l Duct sealing insert is secured in place in both thelower and upper sections. It is not necessary toplace the round rubber gasket in the exhaust man-ifold. Place the duct in the clamp and properly seatit in the duct sealing insert. Tighten the bolts onthe duct clamp.

l Place the exhaust module and tighten the bolts.The top of the pusher is left off until after the cablearrives.

DuctSealing

Insert

ExhaustModule

3.9

OPERATION

l Connect hydraulic hoses from hydraulic powersource to the power source connections on theremote control. Connect hydraulic hoses from theSuperjet to the Superjet connections on the remotecontrol.

l Close hydraulic flow control handle (back to the“off” position). “Back off” hydraulic pressure con-trol (full counter clockwise position).

Do not exceed 800 PSI hydraulic pressure when jet-ting small dielectric cables under .60 inches O.D.There are some applications for cables under .50inches, do not exceed 500 PSI or use a Cablejet. Usea maximum of 1200 PSI when jetting larger, morerigid armored cables.

l Start hydraulic power source. Advance hydraulicpressure to pre-determined setting by rotating pres-sure control in the clockwise direction. 800 PSI isrecommended for dielectric cables under .6" diam-eter. Maximum of 1200 PSI is recommended forlarger and more rigid cables.

l Without air pressure, slowly advance the hydraulicflow control (pushing forward toward the “fast”position) until the cable moves freely. After 150 feetof cable has been installed, start the air flow on theSuperjet. Follow standard installation procedures.

WARNING

USING HRC-10 HYDRAULIC REMOTE CONTROL

3.10

OPERATION

l Cable should be allowed to advance approximately100 feet before calling for a stop by the lead unit.

l The top is then placed on the pusher and tightenedall the way down to a stop. Then restart will beaccomplished at the instruction given by the oper-ator of the lead unit. The air compressor should beon with reading at the Superjet at 100 PSI mini-mum and the hydraulic power ready with the pres-sure set at the pre-determined setting. Informupstream Superjets you are “ready to go.”

See page 3.11 for starting intermediate Superjets.

l After use and as units are disassembled, it is veryimportant that all components are carefully cleanedwith the air gun provided. Depending on theamount of dirt or mud or other foreign matter thatmight be present, it might be necessary to thor-oughly wash at a service center with high pressurewater. Make sure the chain and sprockets are ade-quately lubricated after each wash. Use white lithi-um grease for lubrication.

See page 4.3 for Superjet service requirements.

l Caterpillar chain tension is pre-set at the factory.Tensioning nuts should be finger tight, thensecured with the outer lock nut.

Do not overtighten the chain.

CAUTION

NOTE

NOTE

3.11

OPERATIONSTARTING INTERMEDIATE SUPERJETS

See page 3.19 for a detailed start-up while cascading.

Lead Superjet confirms that all concerned downstreamSuperjets have air flow and that the pressure controlvalve is set at the appropriate pressure. On commandfrom lead Superjet, intermediate Superjets will openthe hydraulic flow control valve. When the leadSuperjet opens its flow control valve, cable shouldmove forward. If not, lead Superjet may instruct allunits to set hydraulic pressure slightly higher repeatingthis procedure until cable moves.

Possible Problems• If the caterpillar tracks tend to slip, stop immedi-

ately and decrease the hydraulic pressure. Check tosee if the tracks or cable are covered with cablelubricant. Clean if necessary with alcohol.

• Stoppages can be caused by overheating of eitherthe cable, the duct, or accessories. In this case,shield exposed components from direct sunlightand allow to cool down. Once cooled, apply a lit-tle extra lubricant in the duct.

• Also, if stoppage occurs for no apparent reason, tryadding a small amount of lubricant in the ductand resume operation.

• For other problems see the troubleshooting charton Pages 5.1 and 5.2.

Never help the cable by pulling it, even to obtain thefinal 10 to 15 feet. Start the Superjet cascade fash-ion, working downstream to upstream, taking com-mands from the lead Superjet. Only start an inter-mediate point when the airflow is coming fromupstream.

Starting up after a pause. Same as outlined.

END OF DUCT SYSTEM

As the cable emerges, make sure to let it advanceenough to allow for splicing, before holding it back byhand and giving orders to stop jetting.

Nothing is more frustrating than having stopped alittle too soon and re-starting for just a few feet.

NOTE

CAUTION

3.12

OPERATIONSLACK COIL LOCATIONS

Starting at the end of the run and at the last pointwhere slack is required, remove the coupler or Superjetat that manhole location to “open” the duct. Instructall Superjets upstream to go at a slow speed in and feedthe desired amount of slack out of the open duct. Torepeat this process, continue as before working back-wards, upstream from slack location to slack location,working one manhole at a time until all locationrequirements are met. The Number One Superjetlocation will be the last location to finish, at whichpoint if slack is desired, it will be taken from the cablereel.

l Place cable to end of run.

l Working from the end to the front, remove thecoupler or superjet where slack coils are needed andfeed the cable to each location.

Superjets are placed at approximately 3,000 to6,000 foot intervals.

NOTE

EXAMPLE OF PLACEMENT OF SLACK COILS

3.13

OPERATIONPNEUMATIC SUPERJET SETUP

l Place the top of the cable pusher on the machineand tighten all the way until the handle will nottighten anymore.

l Place the counter/speed indicator on the machineand tighten the four bolts. Reset the counter. Holdin place until the counter shows zero.

l Connect the compressed air source hose (with 1"Chicago or Dixon fittings) to the air inlet on the aircontrol module.

l Connect the 1⁄2" air hose from the air control mod-ule to the Superjet connection.

3.14

OPERATION

l “Back off” the air motor pressure control knob(full counter clockwise) to zero PSI. (Pull the knobup to the unlocked position to adjust the air pres-sure.)

l At this point the air compressor should be runningwith the indicated pressure at the Superjet air inletchamber reading at least 100 PSI.

l Rotate the air motor pressure control knob “clock-wise” to set pre-determined motor pressure. 70 PSIis the recommended maximum pressure for dielec-tric cables under .60".

l With NO air pressure to the duct, advance thecable by pushing down and turning clockwise theair control valve. Cable speed should be deter-mined by proper field practice while staying with-in your guidelines for your particular cable.

3.15

OPERATION

l Watching the distance indicator, at 150 feet startthe air flow by rotating the air inlet valve at theSuperjet to the vertical position.

l At the intermediate position, all of the steps are tobe accomplished as outlined. The only differencewill be that the exhaust manifold will be outfittedwith proper size duct clamp in both the bottomand the top (See page 3.19 for cascading units).

l Duct sealing insert is secured in place in both thelower and upper sections. It is not necessary toplace the round rubber gasket in the exhaust man-ifold. The air exhaust gate should be in place and inthe closed position. Place the duct in the clamp andproperly seat it in the duct sealing insert. Tightenthe bolts on the duct clamp.

l Place the exhaust module and tighten the bolts.The top of the pusher is left off until after the cablearrives. When the cable is approaching the inter-mediate unit, the cable should be allowed toadvance approximately 100 ft. before calling for astop by the lead unit.

DuctSealing

Insert

3.16

OPERATION

l The top is then placed on the pusher and tightenedall the way down to a stop. Then restart will beaccomplished, as outlined, at the instruction givenby the operator of the lead unit. Air compressorshould be on with the air control valve open, withreading at the Superjet at 100 PSI minimum andthe air motor pressure setting at the pre-deter-mined setting. Inform upstream Superjets that youare “ready to go.”

l When operating the unit, (on older models) checkthe water separator for condensation. If necessary,“bleed off” the excess water by turning the valve onthe bottom of the reservoir counter-clockwise.When unit is stopped and there is NO air pressureon the system, remove the reservoir and empty.Reconnect the reservoir and continue.

Keep fingers clear of the air stream.

l While operating, check to be sure the drip feed onthe oil reservoir is set for 1 to 2 drops per minute.Increase or decrease by turning the clear lubricatorknob. The clear knob also acts as a drip viewer.

Be sure the reservoir never runs dry.

Use Texaco Regal Oil R&O 32 (premium grade) orconsult the operator’s manual for alternates.

NOTE

CAUTION

CAUTION

3.17

OPERATIONSTARTING INTERMEDIATEPNEUMATIC SUPERJETS

See page 3.19 for a detailed start-up while cascading.

Lead Superjet confirms that all concerned downstreamSuperjets have air flow and that the air motor pressurecontrol valve is set at the appropriate pressure.Intermediate unit pressures should be 2 to 5 PSI belowthat of preceding units when “in-line”. On commandfrom lead Superjet, intermediate Superjets will openair motor control valve. When lead Superjet opens itsflow control valve, cable should move forward. If not,lead Superjet may instruct all units to set air motorpressure slightly higher, repeating this procedure untilcable moves.

Possible Problems• If the caterpillar tracks tend to slip, stop immedi-

ately and decrease the air motor pressure. Check tosee if the tracks or cable are covered with cablelubricant. Clean if necessary with alcohol.

• Stoppages can be caused by overheating of eitherthe cable, the duct, or accessories. In this case,shield exposed components from direct sunlightand allow to cool down. Once cooled, apply a lit-tle extra lubricant in duct.

• Also, if stoppage occurs for no apparent reason, tryadding a small amount of lubricant in duct andresume operation.

• For other problems see the troubleshooting charton Pages 5.1 and 5.2.

Never help the cable by pulling it, even to obtain thefinal 10 to 15 feet. Start the Superjets cascade fash-ion, working downstream to upstream, taking com-mands from lead Superjet. Only start an interme-diate point when the airflow is coming fromupstream.

Starting up after a pause. Same as outlined.

END OF DUCT SYSTEM

As the cable emerges, make sure to let it advanceenough to allow for splicing, before holding it back byhand and giving orders to stop jetting.

Nothing is more frustrating than having stopped alittle too soon and re-starting for just a few feet.

NOTE

CAUTION

3.18

OPERATION

l After use and as units are disassembled, it is veryimportant that all components are carefully cleanedwith the air gun provided. Depending on theamount of dirt or mud or other foreign matter thatmight be present, it might be necessary to thor-oughly wash at a service center with high pressurewater. Make sure the chain and sprockets are ade-quately lubricated after each wash. Use white lithi-um grease for lubrication.

Keep grease and cable lubricants off of the rubbertracks as they may cause the cable to slip in thetracks, especially at intermediate positions. Rub-bing alcohol (Isopropyl) may be used to wipe sili-cone based lubricants and grease off of the rubbertracks.

l Caterpillar chain tension is pre-set at the factory,however, if the chain ever needs to be adjusted, thetensioning nut should only be finger tight.

Do not overtighten the chain.

l Pneumatic Superjet Set-up. Superjet pneumaticcontrols may be operated on the ground, in a man-hole, or secured to the case with the mounting rodsupplied.

CAUTION

NOTE

3.19

OPERATIONCASCADING

Cascading In Line Below GroundSet-up of Intermediate Positions

l Check duct integrity and lubricate prior to cablearrival at intermediate position.

l Connect exhaust module and flexible hose whennecessary.

l Wait for #1 control to inform you of cable locationas it approaches #2 location with top of pusherremoved, but unit in place.

l Guide cable through unit and into duct. Let go 30to 100 feet and ask for stop.

l Place top on unit and await order from #1 to start.

l Turn on air full, start power pack.

l Unit #1 will instruct what hydraulic pressure to set,follow instruction, and proceed.

l For all successive Superjets follow same procedure.

Cascading Above Ground with Duct Loop

l Set up intermediate unit(s) above ground behindmanhole or handhole.

l Bring upstream inner duct above ground and forma loop so duct can be installed in duct clamp andexhaust module at rear of unit.

l Bring downstream inner duct above ground andplace in front duct clamp as in regular set-up pro-cedure.

l Follow same operating procedure as Cascading inline.

When cascading above ground, it may be necessaryto make extension tubes of spare inner duct and anairtight coupler. After the installation, the extensiontube may be stripped off and slack cable exposed.

NOTE

Duct

Air Hose

Power Pack

Superjet

DC-10

Duct

Air Hose

Power Pack

Superjet

3.20

OPERATION

Cascading Above Ground with Cable Loop

l Set up intermediate unit above ground behindmanhole or handhole.

l With this method, the duct clamps on the exhaustend of the Superjet are not needed and should beremoved.

l Bring upstream inner duct up to top of manholeaway from any obstructions, i.e. ladders, otherducts, cables, etc.

l Bring downstream inner duct up above ground andconnect to front duct clamp as in regular set-upprocedure.

l To operate:l (a) Each unit will now operate independent of each

other.l (b) When #1 unit feeds cable, intermediate units

will form a slack cable loop.

l Monitor the loop size and adjust individual speedaccordingly to increase or decrease the diameter ofthe slack loop. This method is ideal for use at “slackcoil locations.”

End of Installation

l When cable reaches the end point, do not stopuntil all slack has been taken.

l Stop cable by holding at inner duct end or stoppingSuperjets by command.

Cable

Air Hose

Power Pack

Superjet

DC-10

3.21

OPERATIONDC-10 COUPLER INSTALLATION

If installing the DC-10 Coupler on externallyribbed duct, shave the ribs flush with the outer ductwall with a pocket knife or similar tool.

l Place each end of duct in clamp, butting the endsof duct together in the center. (Be sure duct endsare cut clean and square to insure a good seal.)

l Place one wrap of the rubber sealing materialaround the seam where duct ends meet, butting theends together. (Do not overlap the foam tape.)

l Hold bottom half of coupler in place and be sure ofproper fit. Be sure to mate the marked end (markedwith a black line) of the coupler for an exact fit.

l With bottom half of coupler in place, install tophalf with the four self-tapping bolts. Tighten untilsnug, then remove duct coupler clamp.

The DH-10 Duct Holder/Clamp is not absolutelynecessary, however it does allow for both of theinstaller’s hands to be free to install the coupler veryeasily. To order additional couplers, sealing materi-al, or holders, call 1-800-251-7780.

NOTE

NOTE

3.22

OPERATION

4.1

SERVICEGENERAL SERVICE

Close attention to proper preventive measures and ser-vice procedures will ensure and extend trouble-freeoperation of equipment. Proper lubrication and care-ful attention to the hydraulic system suction filter aretwo vital areas. The objective of scheduled serviceshould be to anticipate and prevent operational prob-lems before they require extended shutdown forrepairs.


The service guidelines outlined in this manual areeffective methods. These guidelines are not all inclu-sive. Anyone who performs service or repair on aSherman & Reilly machine must be completely sat-isfied that no one’s safety will be jeopardized andtake responsibility for these actions.

This manual will guide you in disassembling yourHydraulic or Pneumatic Superjet for repairs or routinemaintenance. If there are any questions about safety,procedure or precautions, contact Sherman & Reillyat 800-251-7780 before attempting to do the work.

Service should be scheduled to allowadequate time so the procedure canbe completed correctly. It must bedone by skilled, trained servicepersonnel with a good basicknowledge of equipment, pro-cedures, and safety practices.Accurate records should be keptof all service and repairs.

WARNING

SUPERJET

CABLEJET

4.2

SERVICESAFETY PRECAUTIONS

l Make sure the machine is locked out in accordancewith OSHA requirements.

l Make sure that all precautions are taken to supportcomponents before loosening or removing bolts.

l When working on any hydraulic connection orpart:

l • Be sure there is no pressure on fluid at the loca-tion of the work.

l • Make sure nothing will move or drop when loos-ening a connection.

l • Collect all the hydraulic fluid which will drainfrom the loosened connection.

l • Use oil-dry or some absorbentmaterial to soak up any fluidspills to keep working surfacesfrom becoming slippery.

l • Cover all open connectionsto prevent loss and contam-ination to the hydraulicsystem.

TOOLS REQUIRED TO DISASSEMBLE/ASSEMBLE SUPERJET AND CABLEJET

• 13mm T-handle Allen Wrench• 17-22mm Open End Wrench• 10mm Open End Wrench• 4mm T-handle Allen Wrench• 5mm T-handle Allen Wrench• Needle Nose Pliers• Circle Clip Pliers• Small Hammer• Adjustable Wrench• Flathead Screw Driver• Phillipshead Screw Driver• White Lithium Grease

l Take all fire prevention safetymeasures before using a welderor cutting device, includinggrinders. Have a fully chargedfire extinguisher near thelocation of the work.

l Be sure everyone involved in the maintenance, ser-vice or repair process understands what is beingdone and all of the safety precautions which needto be taken during the procedure.

l Make sure all lifting devices, chains, slings, andhooks are in good condition and have the ratedcapacity to do the job. Use guide lines when neces-sary for control during the lifting process.

l Always wear proper protective clothing and equipment whenperforming service: gloves, safety glasses, etc.

4.2

4.3

SERVICESUPERJET SERVICE REQUIREMENTS

l • Keep the Superjet clean and well lubricated.

l • Replace any worn or broken parts with factoryoriginal parts as soon as they are detected.

DAILY SERVICE REQUIREMENTS

Follow daily service procedures when unit is in con-stant use.

l Hydraulic Superjetl • Thoroughly pressure wash (with soap) both

chains, inlet and exhaust chambers (excludingthe footage counter) after each use. Running theunit at a low speed will aid in cleaning thechains. Allow to dry.

l • Check for proper chain tension: 1⁄4" to 1⁄2" slack atthe center of the chains.

l • Grease the chains, slide pads and sprockets withwhite lithium grease. The grease can be spreadmore evenly if the unit is running at a low rate ofspeed.

l • Spray a light lubricant (WD-40) on the toptightening screw, the tension adjusting linkageand rod, and the top and bottom of the cham-bers tightening nuts and bolts.

l • Note the condition of the drive chains.l • Remove any dirt or debris from the quick cou-

plers.l • Check oil, fuel and hydraulic fluid levels in the

power pack. See operating instructions for powerpack maintenance.

l Pneumatic Superjetl • Thoroughly pressure wash (with soap) both

chains, inlet and exhaust chambers (excludingthe footage counter) after each use. Running theunit at a low speed will aid in cleaning thechains. Allow to dry.

l • Check for proper chain tension: 1⁄4" to 1⁄2" slack atthe center of the chains.

l • Grease the chains, slide pads and sprockets withwhite lithium grease. The grease can be spreadmore evenly if the unit is running at a low rate ofspeed.

l • Spray a light lubricant (WD-40) on the toptightening screw, the tension adjusting linkageand rod, and the top and bottom of the cham-bers tightening nuts and bolts.

l • Note the condition of the drive chains.l • Remove any dirt or debris from the quick cou-

plers.l • Check the air control module for water and

empty as necessary.l • Check the air control module lubricator reser-

voir oil level. Oil must be maintained in thereservoir at all times or serious damage will occurto the air motors if not oiled properly.

l • Check the drip feed for the oiler and make surethe motors are getting at least 1 to 2 drips perminute. If not, adjust as necessary. Air motorsare expensive!

l • Check the air motor mufflers. If the mufflers areclogged or dirty, poor performance can beexpected.

EVERY 100 HOURS OF SERVICEHydraulic and Pneumatic Superjetl • Repeat Daily service requirements.l • Loosen the chains, inspect the slide pads and

make sure the chain rollers turn freely. Replacepads and chain if necessary.

EVERY 500 HOURS OF SERVICEHydraulic and Pneumatic Superjetl • Repeat Daily and 100-Hour service require-

ments.l • Remove the chains, inspect, thoroughly clean,

and check that the idler sprocket turns freely.Replace any item showing accelerated wear.Grease and reassemble.

NOTE

4.4

SERVICECABLEJET SERVICE REQUIREMENTS

l • Keep the Cablejet clean and well lubricated.

l • Replace any worn or broken parts with factoryoriginal parts as soon as they are detected.

DAILY SERVICE REQUIREMENTS

Follow daily service procedures when unit is in con-stant use.

l • Thoroughly pressure wash (with soap) both thetop and base of the Cablejet, especially the driveroller assembly in the base and the air inletchamber.

l • Check the condition of the drive washers andreplace as necessary. Worn out drive washerscause poor performance.

l • Grease the drive roller assembly thoroughly withwhite lithium grease.

l • Spray a light lubricant (WD-40) on the top andbottom of the chambers tightening nuts andbolts.

l • Check the water separator for water and emptyas necessary. On certain occasions during opera-tion, the water separator may need to be emptiedevery 15 to 20 minutes.

l • Check the motor lubricator reservoir oil level.Oil must be maintained in the reservoir at alltimes or serious damage will occur to the airmotor if not oiled properly.

l • Check the drip feed for the oiler and make surethe motors are getting at least 1 to 2 drips perminute. If not, adjust as necessary. Air motorsfor the Cablejet are expensive!

EVERY 100 HOURS OF SERVICEl • Repeat Daily service requirements.l • Remove the air motor and the drive roller assem-

bly from both the top and base of the Cablejetand thoroughly clean with soap and water.


l • Check the condition of the drive roller assemblysprockets as well as the air motor sprocket.

l • Grease the drive roller assembly thoroughly withwhite lithium grease and reassemble.

EVERY 500 HOURS OF SERVICEl • Repeat Daily and 100-Hour service require-

ments.l • Remove the air hoses, air motor, and the drive

roller assembly, from both the top and base ofthe Cablejet and thoroughly clean with soap andwater.

l • Completely disassemble the four driver rollerassemblies and clean all parts.

The assembly is under a preload of about 22 lbs.


l • Check the condition of the drive roller assemblysprockets as well as the air motor sprocket.

l • Grease the drive roller assembly with white lithi-um grease.

l • When reassembling the drive roller assembly inthe top and base of the Cablejet, inspect thenylatron housing for excessive wear. If the driveroller assembly has a lot of play in the base ortop, it may be necessary to replace the nylatrontop or base or both.

WARNING

NOTE

4.5

SERVICELOWER GEAR CASE DISASSEMBLY

l Disconnect hoses from drive motors.l Remove the exhaust section from the main body of

the Superjet by removing three 13mm nuts.l Completely remove upper cable feeder assembly.

l Line up master link with idler sprocket.

The master link is marked with an infinity sym-bol and color-coded black.

l Loosen chain adjustment nuts.l Remove master link from the drive chain.l Remove the chain by sliding it back in the direction

of the air inlet chamber.

l Remove four phillips head screws and slide pad.l Remove eight allen head screws and slide pad chan-

nel from the Superjet main body.l Remove the circle clip and washer from one side of

the idler sprocket shaft.l Slide the tightening fork forward and remove the

fork, idler sprocket, bearings and spacers.

l Expose the sprocket by removing the plug.l Using a 10mm wrench, remove the bolt, lockwash-

er and disc.l Pry the drive sprocket off the motor shaft, note key.l Remove three 4mm allen head screws and the

motor flange to remove the motor.

NOTE

Exhaust Sectionw/Counter

Drive Motors

SuperjetMain Body

Upper CableFeeder Assembly

Master LinkDriveChain

SlidePad

Slide PadChannel

Tightening Fork

Idler Sprocket

Idler Sprocket Bearing

Spacers

Circle Clip

Idler Sprocket Shaft

Washer

Plug

Lockwasher

Disc

Bolt

Drive Motor

Drive Motor Shaft

Drive Sprocket

MotorFlange

Screw

Key

Circle ClipSlide Chain ThisDirection to Move

4.6

SERVICELOWER GEAR CASE ASSEMBLY

l Bolt the motor to the main body using three 4mmallen head screws and the motor flange.

l Place the key in the motor shaft and mount thedrive sprocket to the motor.

l Secure the sprocket with the disc, bolt and lockwasher.

l Insert the plug into the main body.

l Position the tightening fork in the main body.

l Put the idler sprocket bearings in the sprocket,position the sprocket and spacers inside the tight-ening fork.

l Insert the idler sprocket shaft through the bearingsand secure with washers and circle clips.

l Insert the slide pad channel into the main body,and belt in place with eight allen head screws.

l Put the slide pad inside the channel and secure withfour phillips head screws.

l Slide the drive chain in place in the slide pad.

l Connect the chain with the master link.

The master link is marked with an infinity symboland color-coded black.

l Install both chain adjustment nuts on the tighten-ing fork threaded rod.

l Tension the chain by rotating the chain manually asyou tighten the chain tightening fork with the nutuntil the chain will not move. Loosen the nut 11⁄4revolutions. This will give you the proper chaintension on the upper gear case.

Overtightening the chain will cause excessive pre-mature wear. Leaving the chain too loose maycause the chain to bind or lock up.

CAUTION

NOTEPlug

Lockwasher

Disc

Bolt

Drive Motor

Drive Motor Shaft

Drive Sprocket

MotorFlange

Screw

Key

Tightening Fork

Idler Sprocket


Spacers

Circle Clip

Idler Sprocket Shaft

Washer

Master LinkDriveChain

SlidePad

Slide PadChannel

Circle ClipSlide Chain ThisDirection to Move

4.7

SERVICE

l Install the upper cable feed assembly.

l Attach the exhaust section to the main body withthree 13mm nuts.

l Connect drive motor hoses.

CHAIN ASSEMBLY

l Position the chain so the connector can be startedin the two end links.

l Insert and align spacer links. The center spacer linkwill be one thick spacer or two thin spacers; theoutside spacer link will always be one thin spacer.

l Push connector through the center spacer link(s).Continue pushing connector until you are able toattach the outside spacer link to the connector.Both chain ends should be connected with connec-tor and spacer links in place.

l Align master link over the assembled connector.Push the master link down on the connector. Thiswill require some effort to get the master link tosnap over and hold the connector. Make sure theoutside spacer link is captured and held into placeby the master link. The two pins on the connectorshould be aligned with the holes on the master linkon both sides of the chain.


NOTE

Exhaust Sectionw/Counter

Drive Motors

SuperjetMain Body

Upper CableFeeder Assembly

Master LinkConnector

Center Spacer Link

Outside Spacer Link

4.8

SERVICEUPPER CABLE FEEDER DISASSEMBLY

l Disconnect drive motor hoses.

l Line up the master link with the idler sprocket.


l Loosen and remove chain adjustment nuts andwasher.

l Remove the master link from the drive chain.

l Slide the drive chain back and remove.

l Remove four phillips head screws and the upperslide pad.

l Remove the 5mm allen head screw and the slidepad pivot bushing, allowing the slide pad pivot tobe removed.

l Remove the circle clip and washer from one side ofthe idler sprocket shaft.

l Slide the tightening fork forward and remove thefork, idler sprocket bearings and spacers.

l Remove the plug to expose the sprocket.

l Use a 10mm wrench to remove the bolt, lockwash-er and disc.

l Pry the drive sprocket from the motor shaft notekey.

l Remove three 4mm allen head screws and motorflange to remove the motor.

NOTE

Slide Pad Pivot

5mm Allenhead

Pivot Bushing

Slide Pad

FrameUpper Cable Feeder

Master Link

Drive Chain

Upper Cable Feeder Cable Adjustment Nuts

Idler Sprocket


Spacer

IdlerSprocket

Shaft

Washer

CircleClip

Tightening

Plug

Lockwasher

Disc

Bolt

Drive Motor

AllenheadScrew

MotorFlange

Key

DriveSprocket

Upper Cable Feeder

4.9

SERVICEUPPER CABLE FEEDER ASSEMBLY

l Attach the motor to the frame with three 4mmallen head screws and the motor flange.

l Put the key on the motor shaft and mount the drivesprocket to the motor.

l Secure the sprocket with the disc, bolt and lockwasher.

l Insert the plug into the frame.

l Position the tightening fork in the frame.

l Put the idler sprocket bearings into the sprocketand position the sprocket and spacers inside thetightening fork.

l Insert the idler sprocket shaft through the bearingsand secure with washers and circle clips.

l Insert the slide pad pivot into the frame with thepivot pushing and bolt in place with 5mm allenhead screw.

l Attach the slide pad to the slide pad pivot with fourphillips head screws.

l Slide the drive chain in place.l Connect the chain with the master link.l Lubricate unit.

The master link is marked with an infinity symboland color-coded black.

l Install both chain adjustment nuts on the tighten-ing fork threaded rod.

l Tension the chain by rotating the chain manually asyou tighten the chain tightening fork with the nutuntil the chain will not move. Loosen the nut 11⁄4revolutions. This will give you the proper chaintension on the upper gear case.

Overtightening the chain will cause excessive pre-mature wear. Leaving the chain too loose may causethe chain to bind or lock up.

CAUTION

NOTEPlug

Lockwasher

Disc

Bolt

Drive Motor

AllenheadScrew

MotorFlange

Key

DriveSprocket

Upper Cable Feeder

Upper Cable Feeder Cable Adjustment Nuts

Idler Sprocket

Idler Sprocket Bearing Spacer

IdlerSprocket

Shaft

Washer

CircleClip

Tightening

Slide Pad Pivot

5mm Allenhead

Pivot Bushing

Slide Pad

FrameUpper Cable Feeder

Master Link

Drive Chain

4.10

SERVICECABLEJET DISASSEMBLY

l Remove air inlet and exhaust chamber upperhalves.

l Remove all air lines by pressing in on blue lockingrings and pulling the hose out of the fitting.

l Remove hex screws, pillow cover and motor fromthe frame under. With hex screws removed, pullmotor. It may require some force to unseat theassembly.

l Remove the cover.

l Gently pry the drive roller assemblies away fromthe “frame upper” and “frame under”.

l Clean all components thoroughly.

l Remove the circle clip from the gear end of thedrive roller assembly.

The drive roller assembly is under a spring load.

l Use the gear puller to remove the gear wheel fromthe drive shaft.

l Inspect the drive roller assembly and replace wornparts as necessary.

l Remove three T-10 torx head screws to remove thedrive washer from the brass drive roller.

l Check drive washers for excessive wear. Check shaftand brass driving roller for wear, movement orloose fit.

CAUTION

Air Inlet Chamber

Exhaust Chamber

Base Plate

Pillow Cover

Pneumatic Motor

Frame Under

HexScrew

Cover

O-Ring

Frame UpperO-Ring

Cover

HexScrew

Drive Roller Assembly

4.11

SERVICE

l Check bearings for wear and movement.

l Check all gear wheels for tooth wear. The wheelshould move with very little play.

When reassembling the drive roller assembly, useholding clamps to contain the parts and compres-sion springs while inserting circle clips.

Check for movement when inserting the drive rollerassembly into the frame upper/frame under. If thefit is loose the Nylatron Frame may need to bereplaced.

NOTENOTE

DRIVE MOTOR DISASSEMBLY

l Remove the sock-screw, spring washerand washer from motor shaft end.

l Use gear puller to remove gear wheelfrom motor shaft (note key).

l Unscrew the motor from the pillowcover.

Circle Clip

Washer

Socket, Green

Brass Driving Roller

Brass Driving Roller

Oil Seal

Socket, Green

Washer Circle Clip

Washer

Leaning Socket

Compression Spring

Driving Washer

Drive Shaft

Driving Washer

Compression Spring

Gear Wheel

Bearing

Sock-screw

Spring Washer

Washer

Gear Wheel

Key

Washer

Hex Screw

Pillow Cover

Pneumatic Motor

Pivot

Sock-screw

Spring Pin

4.12

SERVICEDRIVE MOTOR ASSEMBLY

l Screw the motor into the pillow cover.

l Insert key on motor shaft and install gear wheel.

l Position washer, spring washer and secure the gearwheel to the motor shaft with sock-screw.

When reassembling the drive motor assembly andframe under, take care to line up teeth on the gearwheel to prevent damage to the unit when the boltsare tightened.

l Check the water separator filter and wash or replaceit as necessary. Make sure the o-ring is on top of thereservoir during reassembly.

CAUTION

Pillow Cover

Pneumatic Motor

Frame Under

HexScrew

Check

Filter

O-Ring

Reservoir

4.13

SERVICECOUNTER REMOVALl The Footage Counter

and Speed Indicatorcounters are locateddirectly behind the rec-tangular cover on theindicator. Use the3mm allen wrenchprovided with the stan-dard tool package toremove the two sockethead cap screws on thecorners of the cover.

l The counters are nowexposed.

BATTERY REPLACEMENT (Meter batteries — Use Eveready E-CR2032, 3 voltlithium or equal)

l In order to expose the battery, the socket on theback of the countersmust be removed bysliding them up-ward.

l Remove the cover onthe back of the counterby inserting a coin andturning counterclock-wise.

l Remove the old batteryand insert a new onewith the positive (+)pole facing upward.

l Replace the cover.

BATTERY REPLACEMENT (Transmitter battery — Use Energizer A23 or anyequal alkaline 12 volt battery)

l Remove the fourscrews from the bot-tom of the footagecounter using the TorxDriver provided withthe standard tool pack-age.

l Remove the cover byturning a flat headscrew driver counter-clockwise.

l Remove the old batteryand insert a new onewith the positive (+)pole facing outward.

l Replace the cover withthe four screws.

RESETTING THE METERSl Push the AC button on

the back of the meterto clear and reset thecomputer. The ODOdisplay will appearwith a zero (0) figure.

l Press and hold the redbutton until a fourdigit number appearswith the last numberflashing.

l Press the yellow button to increase and decrease theflashing number and the red button to change theposition.

Distance Counter in feet (left) 0526Speed Counter in feet (right) 0876

Distance Counter in meters (left) 1596Speed Counter in meters (right) 1596

l Press the red button several times until returning to

4.14

SERVICEa screen with only (1) zero and the letters ODO inthe bottom left corner.

l Press the yellow button (4) times. The letters DSTshould appear in the bottom left corner.

INDICATOR REASSEMBLY

l Reverse the steps fol-lowed in sections 1 and2.

l Be sure to place thetwo washers under thecover plate.

TESTING THE DISTANCE COUNTER

l In order to test the distance counter for accuracy aftersetting, put a mark on the counter wheel and rotate it20 times. The distanceshould increase by tenfeet (20 rotations equalsten feet). If the distancedoes not increase by tenfeet after 20 or 21 revo-lutions of the wheel, goback and reset the counter and check the setting val-ues.

RESETTINGDISTANCEINDICATOR

l Press and hold down thered button on the top ofthe outside cover.

If the counter stands idle on a job, the display willblank out. The footage number is in memory and willshow up again when the counter is used the next time.

NOTE

5.1

TROUBLESHOOTINGPROBLEM POSSIBLE CAUSE(S) REMEDY

No Cable Movement • Obstruction in duct • Remove obstruction and repair duct asnecessary.

• Cable in bind in Superjet • Remove cover, realign cable, install cover.

• Duct needs lubricating • Add proper amount of lubricant to ductand re-start.

• Air leakage in duct causing • Check duct splice points (couplers)loss of energy in system • and repair as necessary.

Slow Cable Movement • Overheating of cable, (due to • Shield cable reel from direct sunlightexposure), duct or equipment • Allow duct or equipment to cool,

• lubricate and resume.

• Low air inlet pressure • Increase compressor pressure or getshould be 100 PSI minimum • another compressor.

Caterpillar Tracks Slip • Overdriving the system • Decrease the hydraulic or pneumaticmotor pressure.

• Lubricant on tracks • Remove with rag, use proper amount oflubricant.

• Tracks are loose • Tighten adjusting nuts on track mecha-nism. Chain should be firm and fingertight but not overtight.

• Too low of compression setting • Adjust cylinder to higher setting.Hydraulic Superjet only.

Air Leakage at Air • Improper size duct sealing insert • Check diameter of duct for proper ductInlet Chamber • sealing insert size. See chart inside of

Superjet case or in manual and installproper size.

• Duct is in between duct sealing • If duct is slightly smaller than closest• insert sizes • insert size, place a few wraps of vinyl tape

around duct for proper seal.

• Sealing materials not properly • Check rubber cord in air inlet chamber.installed, or worn • Check rubber cord at duct sealing inserts.

Be sure ends are cut flush.• Check that cable seals are in place.• Replace cords and seals when necessary.

• No cable or dummy cable plug • Insert cable thru Superjet and into plugsealing air inlet chamber • duct, or use dummy cable plug to seal

chamber.

5.2

TROUBLESHOOTINGPROBLEM POSSIBLE CAUSE(S) REMEDY

Slow Motor Speed • Low hydraulic or air motor pressure • Increase to proper level.

• Obstruction or restriction • Check under tracks for debris, foreign• in caterpillar unit • objects, etc. Remove and restart.

• Low RPM on power-pack • Set throttle full. Hydraulic Superjet only.

• Dirt in caterpillar tracks/ • Pressure wash, lubricate, check chain• need for lubrication • tension/restart.

• Worn slide pads • Check under chains for wear and • replace if necessary.

• Excess water in system • Drain water trap and filter.

• Obstruction in exhaust port • Remove obstruction.

Pressure Loss or Decrease • Faulty compressor • Check for proper flow and pressureat Air Inlet Gauge • and repair as necessary.

• Leakage in duct system • Check duct, splice points, couplers, etc.and repair as necessary.

• Duct section may be shorter than • None, if performance is normal.normal creating pressure drop.

Pressure Rise or Increase • Obstruction in duct • Remove and repair as necessary.at Air Inlet Chamber

• Severe restriction in duct, • Repair to airtight and proceed.• crushed or kinked duct

• Water in duct system • Blow air thru system, then follow withfoam plugs until only a mist remains.Lubricate and begin installation.

PARTS

6.1

PARTSWater Separator Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2Lubricator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.411⁄4" and 2" Air Cutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.61", 11⁄4", 11⁄2", 2" Air Cutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8Base Plate and Air Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10Air Inlet and Drive Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12Upper Gear Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14Lower Gear Case and Chain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16Chain Wheel Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18Hydraulic and Pneumatic Pressure Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19Pneumatic Motor and Air Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20Air Inlet Chamber Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22Footage Counter/Speed Indicator (Version D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.24Exhaust Chamber Upper and Lower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.26Water Separator Assembly (ACM-10 Control Module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.28Lubricator Assembly (ACM-10 Control Module). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.30Air Cooler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.32Filter/Regulator/Lubricator Assembly (AC-10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.34HRC-10 Hydraulic Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.36Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.38Oil Cooler/Air Supply Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.39Hydraulic Oil Cooler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.40Hydraulic Fluid Reservoir, Power Pack 5.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.42Frame Assembly, Power Pack 5.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.43Reservoir and Frame Assembly, Power Pack 8/9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.44Engine/Pump Assembly, Power Pack 5.5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.45Engine/Pump Assembly, Power Pack 8/9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.46Cable Sealing Inserts and Cable Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.47Duct Sealing Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.48Miscellaneous Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.49Sonic Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.50Tools and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.52

Table of Contents

6.2

PARTS

Water Separator AssemblyC66CF01610

T76FF00310

T76FF00310

C58LD21220

T76WA00020

P270.358

C57BC22010

T72BJ12000

T72BJ02000

T76FF00307

T76FF00308

C32CC03020

T76FF00302

N270.143

T76WA00020

T76FF00309

6.3

Part # Description Qty.

C32CC03020 O-Ring 30x2 1

C57BC22010 Plug R1/4 6

C58LD21220 Elbow 1⁄4" Con 1

C66CF01610 Pressure Gauge 2

N270.143 Pipe and O-Rings 1

— O-Rings 2

P270.358 Holder, Plate 1

T72BJ02000 Distributor 4 NL 2 1


T76FF00302 Filter-Pressure Red-Valve NL 2 1

T76FF00307 Filter Element 1

T76FF00308 Filter Element Holder 1

T76FF00309 Drain Valve 1

T76FF00310 Pressure Control Knob Assembly 1

T76WA00020 Screw, Clip, and O-Rings 2

— Clip 2

— O-Rings 2

PARTS

Water Separator Assembly

6.3

6.4

PARTS

Lubricator AssemblyC66CF01610

P270.058

C58UB00820

A410G01305

T76WA00020

C32CC03020

N270.143

T76LF01402

T76WA00020C58LD21220

T72BJ02000

PARTS

Lubricator Assembly

6.5


A410G01305 Washers 2

C32CC03020 O-Ring 30x2 1


C58UB00820 Coupling 1

C66CF01610 Pressure Gauge 1

N270.143 Pipe and O-Rings 1

— O-Rings 2



T76LF01402 Lubricator NL 2 1

T76WA00020 Screw, Clip, and O-Rings 2

— Clip 2

— O-Rings 2

6.6

PARTS

11⁄4" and 2" Air Cutoff Valve

5-339-004

4-238-004

C58UJ02000

5-340-004

C58UJ02000

5-339-004

1-474-004

5-722-004

5-723-004

5-723-004

5-723-004

5-722-004

4-394-004

6.7


1-474-004 Bushing, 11⁄4" NPT Male – 1" NPT Female Brass 1

4-238-004 Valve, Ball with Lever Handle, 1" 90° Open, 1" NPT 1

4-394-004 Valve, Ball with Lever Handle, 11⁄4" 90° Open, NPT 1

5-339-004 Coupling, Universal Air, Air King No. AM-12 3

5-340-004 Clip, Safety, Air King No. AC1 8

5-722-004 Coupling, Universal Air 2", Air King 3

5-723-004 Nipple, 11⁄4" NPT x Close Brass 2

C58VJ02000 Large Rubber Grommets 3

PARTS

11⁄4" and 2" Air Cutoff Valve

6.8

PARTS

1", 11⁄4", 11⁄2", 2" Air Cutoff Valve

5-339-004

5-414-004

2-529-004

C58VJ02000

5-340-004

4-238-004

5-431-004

1-474-004

5-719-004

5-718-0045-723-004

4-394-0045-717-004

2-529-004

5-414-004

5-340-0045-716-0045-722-004

5-718-0045-723-004

6.9


1-474-004 Bushing, 11⁄4" NPT Male - 1" NPT Female Brass 1

2-529-004 Elbow, 1⁄8" NPT 45 1

4-238-004 Valve, Ball, w/Lever Handle, 1" 90° Open, 1" NPT 1

4-394-004 Valve, Ball, w/Lever Handle, 11⁄4" 90° Open NPT 1


5-340-004 Clip, Safety, Air King No. AC1 2

5-414-004 Gauge, Air Monnier 13524, 1-160 PSI, 1.5" Face, 1⁄8" NPT 1

5-431-004 Nipple, 1" NPT x Close Brass 1

5-716-004 Coupling, Universal Air 2", Air King AM-23 1

5-717-004 Valve, Ball, w/Lever Handle, 11⁄2" 90° Open NPT 1


5-719-004 Bushing, 11⁄2" NPT Male - 11⁄4" NPT Female Brass 1

5-722-004 Coupling, Universal Air 2", Air King No. AM-18 1


C58VJ02000 Large Rubber Grommet 1

5-754-004 Air Valve Assembly, 1" 1

5-755-004 Air Valve Assembly, 2" (11⁄4") 1

5-756-004 Air Valve Assembly, 2" (11⁄2") 1

PARTS

1", 11⁄4", 11⁄2", 2" Air Cutoff Valve

6.10

PARTS

Base Plate and Air Motor AssemblyC61DS65208

A400B00408

P270.072

P270.358

A120C05010

A852A12120

A430B00510

P270.103

A121B08080

P270.116

P270.115 A130C06016 A130C06016

P270.111

A430B00408

A130C04008

C58LD21220

C58LD21220

T72JJ01100

A131C05035

A131C05030

C58LD21220

P270.443

P270.244

P270.443

P270.114

N270.112

A120C08008

A410C00801

A410C00801

P270.077

P270.109

A530C03012

A131C04030

A430B00613

A130C06016

A402D00616

P270.202

KEY

A115B08030

6.11


A115B08030 Screw-Stud M8x30 Sock Set+H-dog 1

A120C05010 Hex-Screw M5x10 1

A120C08008 Hex-Screw M8x8 2

A121B08080 Hex-Screw M8x80/22 1

A130C04008 Sock-Screw M4x8 13


A131C04030 Sock-Screw M4x30/20 1



A400B00408 Washer 4,3/9x0,8 13

A402D00616 Washer 6,4/18x1,6 1

A410C00801 Washer 8,4/16x2,3 2

A430B00408 Spring-Washer 4/7,6x0,8 13

A430B00510 Spring-Washer 5/9,2x1 1


A530C03012 Spring-Pin 3x12 1

A852A12120 Tight-Ring 12/12 1


C61DS65208 Handle 1

N270.112 Pneumatic Motor 224 1

— Key (furnished with N270.112) 1

P270.072 Holder 1

P270.077 Pillow, Cover 1

P270.103 Pivot, Support 1

P270.111 Holder, Pivot 2

P270.114 Stud 1



P270.109 Pivot 1

P270.202 Gear Wheel Z:15 1

P270.244 Clamp-Screw 13


P270.443 Hex-Nut 1

T72JJ01100 Control Valve 5w2pos 1

PARTS

Base Plate and Air Motor Assembly

6.12

PARTS

Air Inlet and Drive Roller Assembly

A650B01010

C01BP01012

A420A01011

P270.070

P270.073

P270.003

A153A03006

P270.249N270.122

P270.074

C30BC01410

C30BC01410

P270.074P270.071

P270.249N270.122

A153A03006

P270.003

P270.073

P270.100

C01BP01012

A650B01010

A420A01011

N270.193

C32CV04000

A130C06016

C32CG02327

A130C06030

C61DQ11400

A153A03008

P270.443

P270.432

P270.435

C32CC05930

P270.078

P270.076

A124B08040

P270.080

C58LD21220

C32CV04000

6.13


A124B08040 Hex Screw M8x40 2

A130C06016 Sock Screw M6x16 2

A130C06030 Sock Screw M6x30 2

A153A03006 CSK Screw 6

A153A03008 Screw M3x8 4

A420A01011 Washer 10/22 2

A650B01010 Circle Clips 2

C01BP01012 Bearing 2

C30BC01410 Oil Seal 2

C32CG02327 O-Ring 23,81x2,62 1

C32CC05930 O-Ring 59x3 1

C32CV04000 Cord, 4mm 1


C61DQ11400 Handle 1

N270.122 Driving Washer, Set of 8 Washers 8

N270.193 Drive Roller Assembly, Single 4

N270.053 Drive Roller Assembly, Set of 4 for One Complete Cablejet 4

P270.003 Compression Spring 2

P270.070 Leaning Socket 1

P270.071 Shaft, Drive Roller 1

P270.073 Socket, Green 2

P270.074 Driving Roller, Brass 2

P270.076 Cover 1

P270.078 Frame, Upper 1

P270.080 Frame, Under 1

P270.100 Gear Wheel Z:21 1

P270.249 Driving Washer 2

P270.432 Block 17/3x27 4

P270.435 Cover (New Style) 1

P270.443 Clamp-Nut M8h12 (New Style) 4

PARTS

Air Inlet and Drive Roller Assembly


5-342-004 Quick Connect 3⁄8" Male ANV-38-NPT-M 3

5-343-004 Quick Connect 3⁄8" Female ANV-38-NPT-F 3

5-411-004 3⁄8" British Standard Pipe Male with O-Ring #6JIC Male 4

5-412-004 Hose Assembly #6JIC Female Swivel Both Ends x 25" long 1

5-413-004 Hose Assembly #6JIC Female Swivel Both Ends x 60" long 2

5-674-004 Extension Hose Assembly Complete with Fittings, 10 Feet 2

A120C06016 Hex Screw M6x16 1

6.14

PARTS

Upper Gear Case Assembly

5-413-004T08RE19331

5-411-004

5-412-004

5-413-004 5-343-004

5-342-004 5-413-004

5-342-004 5-343-004

P265.213

A152A06018

P265.168

C01BP01510

P265.133

P265.168

C01BP01510

P265.116

A152A06018 A430A00816

P265.145

P265.119

C33KK02410

P265.165

C61DF03530

P265.167P265.144

C61DF03530

A401B00816

A300C00800

P265.215

A131B06060

A430A00613

A410B00702

A430A00613

A120C06016

C37BD06320

P265.151P270.309

A600A05520P265.203

A150B05012P265.195

P265.141

P265.122

P265.201P265.202P265.200

6.15


A131B06060 Sock-Screw M6x60/24 1

A150B05012 CSK Screw M5x12 Cross 4

A152A06018 CSK Screw M6x18 Sock Head 10

A300C00800 Hex Nut M8 2

A401B00816 Washer 8,4/15x1,6 1

A410B00702 Washer 7/25x1,8 1

A430A00613 Spring-Washer 6/11,8x1,3 2


A600A05520 Flat Key 5/5x20A Pneumatic Superjet Only 1

C01BP01510 Ball Bearing 15/32x9 2rs 2

C33KK02410 V-Seal 24-27/W4x9 1

C37BD06320 Plug 1

C61DF03530 Speric Handle 35/10 2

N265.042 Chain Wheel, Set 1

P265.116 Slide-Bar 2

P265.119 Block-Guide 1

P265.122 Holder, Guiding, Upper 1

P265.133 Chain-Wheel Z:12 1

P265.141 Spacing-Bushing 1

P265.144 Barrel 1

P265.145 Hex Screw M8x55/22 2

P265.151 Chain Wheel Z:12 Hydraulic Superjet Only 1

P265.165 Adjusting-Nut 1

P265.167 Tightening Fork 1

P265.168 Spacing-Bush 2

P265.195 Chain-Guide 1


P265.201 Washer 2

P265.202 Washer 2

P265.203 Key Hydraulic Superjet Only 1

P265.213 Flange, Hydraulic Motor Only 2

P265.215 Gear-Case, Upper 1

P270.309 Chain Wheel Z:12 Pneumatic Superjet Only 1

T08RE19331 Hydraulic Motor Danfoss OMM32 2

PARTS

Upper Gear Case Assembly

6.16

PARTS

Lower Gear Case and Chain Assembly


3-651-004 Nut, HH Lock, 5⁄16" UNC, STL, Pltd 4

5-353-004 Bumper, Rubber Stud, McMaster 9377 K42 4

5-466-004 Screw 12mm x 30 2

N265.049

P265.168

P265.117

C01BP01510

P265.133

T53LS22612

A120F05008

A150B05012 P265.195

P265.164

A401B00816

A300C00800

P265.167

P265.168

C01BP01510

A100B00811

P265.115

A152A06018

P265.166

A430A00510A130C05010

A600A05520P265.203

P265.151C37BD06320

A120C06016

A430A00613

A410B00702

P265.089

A305B00800A100B00820

5-466-004

A650B01510A400B01525

3-651-004

SJ-1

SJ-1P265.214

P265.209

6.17


A100B00811 Stud M8x35/10/22 3

A100B00820 Stud 3

A120C06016 Hex Screw M6x16 1

A120F05008 Hex Screw M5x8 8

A130C05010 Sock Screw M5x10 Head Cap 8

A150B05012 CSK Screw M5x12 Cross 4

A152A06018 CSK Screw M6x18 Socket Head 4

A300C00800 Hex Nut M8 2

A305B00800 Hex Nut M8 3

A401B00816 Washer 8,4/15x1,6 1

A410B00702 Washer 7/25x1,8 1

A430A00510 Spring-Washer 5/9,2x1 8


A600A05520 Flat Key 5/5x20A Pneumatic Superjet Only 1

C01BP01510 Ball Bearing 15/32x9 2rs 2

C37BD06320 Plug 1

N265.042 Chain Wheel, Set 1

N265.049 Chain 2 12,7/7,75x8,51-63, Including Master Link 1

P265.089 Fork, Guiding 1

P265.115 Slide-Bar 2

P265.117 Slide 1

P265.133 Chain-Wheel Z:12 1

P265.151 Chain Wheel Z:12, Hydraulic Superjet Only 1

P265.164 Rope Guide, Green 2

P265.166 Holder, Guiding, Under 1

P265.167 Tightening Fork 1


P265.195 Chain-Guide 1

P265.203 Key, Hydraulic Superjet Only 1

P265.209 Rope Guide, Hydraulic and Pneumatic Superjet 1

P265.214 Gear-Case, Under 1

P270.309 Chain Wheel Z:12, Pneumatic Superjet Only 1

SJ-1 Stabilizing Feet 2

T53LS22612 Master Link 1

PARTS

Lower Gear Case and Chain Assembly


N265.042 Chain Wheel Set 1

*Included In Set

6.18

PARTS

Chain Wheel Set*

*

*

6.19


5-460-004 1⁄8" NPT Male, 3⁄8" OD Tee 1

N265.034 Pressure Tube 1

P265.123 Lever, Right 1

P265.127 Lever, Left 1

P265.134 Screw 4

P265.137 Screw M10x22 2

P265.146 Washer 12/18x0,5 2

P265.205 Lever, Right 1

P265.206 Lever, Left 1

T44DC05050 Pneumatic Thruster 2-Action 50x50 1

T76SB00410 Damper G 1⁄8" 1

PARTS

Hydraulic and Pneumatic Pressure Tube Assembly

P265.137

P265.137

P265.146

P265.146

P265.134

P265.134

N265.034

P265.127

P265.206

P265.123 P265.146

P265.137

P265.134

P265.134

P265.134

P265.146

P265.134P265.137

T44DC05050

5-460-004

T76SB00410

P265.205

6.20

PARTS

Pneumatic Motor and Air Fittings

3-651-004

5-457-004

5-353-004

5-459-004

5-458-004

5-459-004

5-339-004

A305B00800P264.008

P270.318

P265.209

A130C06012

N270.232

5-459-004

5-461-004

5-462-004

P270.359

KEY

6.21


3-651-004 Nut, HH Lock, 5⁄16" UNC, STL, Pltd 4


5-353-004 Bumper, Rubber Stud, McMaster C 9377 K42 4

5-457-004 1⁄2" NPT Male, 1⁄4" NPT Male, Straight Adapter 1

5-458-004 1⁄4" NPT Female Tee 1

5-459-004 1⁄4" NPT Male, 3⁄8" OD Tube 90° 4

5-461-004 3⁄8" OD Plastic Tubing 3ft

5-462-004 Air Muffler, Allied Witan No. B28 2


A305B00800 Hex Nut M8 3

N270.232 Pneumatic Motor 226 (Key Included) 2

N270.232-ES Pneumatic Motor 226 for Exchange 2


P265.209 Rope Guide, Hydraulic and Pneumatic Superjet 1

P270.318 Holder 1

P270.359 Flange, Air Motor 2

PARTS

Pneumatic Motor and Air Fittings

6.22

PARTS

Air Inlet Chamber Assembly

P270.137

P270.244

P270.138

P270.140

C32CV04000

C32CC05740

A153A03008

P270.443

P270.432

P270.434

C32CG01526

P270.085

A130C06012

P270.407

C66CP01600

P270.084

P270.437

A130C06016

A130C04008

A430B00408

A400B00408

P270.409

6.23


A130C06012 Sock-Screw M6x12 HD Cap 2



A153A03008 Screw M3x8 4

A400B00408 Washer 4,3/9x0,8 6


C32CC05740 O-Ring 57x4 1

C32CG01526 O-Ring 15,08x2,62 4

C32CV04000 Cord 4 NBR70SH A 1

C66CP01600 Pressure Gauge 16 Bar 1

P270.084 Half Flange, Under 1

P270.085 Holder, Rope Guide, Upper 1

P270.137 Connection 1

P270.138 Holder 1

P270.140 Pivot Holder 1


P270.407 Protection, Gauge 1

P270.409 Holder, Rope-Guide, Under 1

P270.432 Block 17/3x27 4


P270.437 Half Flange, Upper (New Style) 1

P270.443 Clamp-Nut M8h12 4

PARTS

Air Inlet Chamber Assembly

6.24

PARTS

Footage Counter/Speed Indicator (Version D)

A130B05008

A430B00510

A650C00607

E351010023

C65ST04300P270.465

P270.443

P270.432

P270.436

A130C06016

P270.466

A116C06010

P270.212

A115B06016

P270.213

P270.211

P177.659

A401B00816

P270.470

A650C00808

C15HD01251

A650C00808

A153A03006

P270.469

P270.246

P270.417

A650C00808

P270.207

P270.471

A153A03008

ECR-2032

A23-12

6.25

PARTS


A115B06016 Screw M6x16 1

A116C06010 Screw M6x10 1

A130B05008 Sock-Screw M5x8 2

A130C06016 Sock-Screw 4

A153A03006 Screw M3x6 4

A153A03008 Screw M3x8 4

A23-12 12 Volt Battery 1

A401B00816 Washer, 8,4/15x1,6 1

A430B00510 Spring-Washer 5/9x2,1 2

A650C00607 Circle Clip, E 6x0,7 SW 1

A650C00808 Circle Clips E 8x0,8 4

C15HD01251 Bearing-Bushing 12/17x12 2

C65ST04300 Length and Speed Counter 2

E351010023 Hex Spacer M5x10/10 4

ECR-2032 5 Volt Battery 2

N270.237 Version D Footage Counter/Speed Indicator Complete 1


P270.207 Rope Guide, Blue 1


P270.212 Screw 1

P270.213 Frame, Under 1

P270.246 Spindle 1

P270.417 Wheel 1

P270.432 Block 4

P270.443 Clamp Nut 4

P270.436 Cover 1

P270.465 Holder, Counter 1

P270.466 Enclosure 1

P270.469 Terminal Plate 1

P270.470 Lever 1

P270.471 Spindle 1

Footage Counter/Speed Indicator (Version D)

6.26

PARTS

Exhaust Chamber, Upper and Lower

P270.010

P270.011

A153A03008

P270.443

P270.432

A130C06016

P270.409

C32CC05740P270.244

P270.437

P270.084

P270.138

P270.140

A130C06016

A130C04008

A430B00408A400B00408

A501C06050

P270-085

P270.434

N270.220

6.27




A153A03008 Screw M3x8 4

A400B00408 Washer 4,3/9x0,8 6


A501C06050 Cylinder Pin 4

C32CC05740 O-Ring 57x4 1

N270.220 Exhaust Module, Upper Without Insert 1

P270.010 Connection, Exhaust 1

P270.011 Exhaust Tube 1

— O-Ring (Included with Item P270.011, Exhaust Tube) 1

— Lower Mount (Included with Item P270.011, Exhaust Tube) 1

P270.084 Half Flange, Under 1

P270.085 Holder, Rope Guide, Upper 1

P270.138 Holder 1

P270.140 Pivot Holder 2


P270.409 Holder, Rope Guide, Lower 1

P270.443 Clamp-Nut M8h12 4

P270.432 Block 17/3x27 4


P270.437 Half-Flange, Upper 1

— Telejet Adapter Kit Complete 1

PARTS

Exhaust Chamber, Upper and Lower

6.28

PARTS

Water Separator Assembly (ACM-10 Control Module)

F4-550350

F4-550349

5-946-004

F4-550390

F4-551186

CS-7

5-382-004

5-386-004

5-385-004

F4-551501

CS-4

6.29


5-382-004 Regulator, Filter with Float #703-W3000-10N 1

5-385-004 T-Bracket Assembly 2

5-386-004 Air King AMB-3⁄8" NPT Male 1

5-946-004 F4-550678 Flout Drain 1

CS-4 Control Stand Weldment 1

CS-7 Control Stand Rod 1

F4-550349 O-Ring, Bowl 1

F4-550350 Element, Standard 5 Micron 1

F4-550390 Bowl, Poly 1

F4-551186 Bowl, Guard 1

F4-551501 Pressure Gauge 1

PARTS

Water Separator Assembly (ACM-10 Control Module)

6.30

PARTS

Lubricator Assembly (ACM-10 Control Module)

5-383-004

F3-550349

F3-550330

F3-551220

Fill Plug

F4-550091

5-389-004 5-388-004

5-387-004

5-388-004

5-384-004

Adjusting Dome

6.31


5-383-004 Lubricator, Miller #703-L3000-10N 1

5-384-004 Valve, Lock Out, Miller #703-V3010-10N 1

5-387-004 Fitting 1

5-388-004 Hose 1

5-389-004 Connect, Quick, Faster Male #TNL-08-NPT-M 1

F3-550330 Bowl, Poly 1


F3-551220 Bowl, Guard 1

F4-550091 O-Ring, Fill Plug 1

— Adjusting Dome 1

— Fill Plug 1

PARTS

Lubricator Assembly (ACM-10 Control Module)

6.32

PARTS

Air Cooler AssemblyACD-7

ACD-3

AC-3

5-335-004

2-041-004

5-326-004

5-336-004

5-338-004

5-327-004

5-337-004

5-328-004AC-5

AC-2

67081

66133

66124

5-333-004

AC-4

5-545-0044-117-004

5-809-004

66116

3-242-004

ACD-10

5-954-004

5-510-004

4-517-004

6.33


2-041-004 Detent Pin 8

3-242-004 3⁄4"–10 Lock Nut 2

4-117-004 3⁄4" Flat Washer 2

4-517-004 Nipple, Close, 1⁄2" 1

5-326-004 Thermal Transfer 1

5-327-004 Separator, Water 1

5-328-004 Float Drain 1

5-333-004 1⁄4" MP – #8 M-JIC 1

5-335-004 2" MP - 1" FP Bushing, NPT 1

5-336-004 2" MP - 11⁄2" FP Bushing, NPT 1

5-337-004 11⁄2" MP - 1" FP Bushing 1

5-338-004 11⁄2" Close Nipple, NPT 1

5-510-004 Adapter, 1⁄4" MP – #8 MJ, 90° 1

5-545-004 Tire and Wheel Assembly 2

5-809-004 3⁄4"–10 x 8" Hex Head Capscrew 2

5-954-004 Air Muffler, ATO 1

66124 Fan Blade 1

66133 Grill Guard 1

67081 Motor, Air 1

66116 Motor, Electric 110 Volt 1

AC-2 Filter/Regulator/Lubricator Mount 1

AC-3 Thermal Transfer Guard 1

AC-4 Leg Assembly with Axle Mount 2

AC-5 Leg Assembly 2

ACD-3 Handle 1

ACD-7 Handle Crossbar 1

ACD-10 Handle Bracket 1

PARTS

Air Cooler Assembly

6.34

PARTS

Filter/Regulator/Lubricator Assembly (AC-10)

5-331-004

F4-551186

F4-550349

F4-550350

5-332-004

5-334-004

5-385-004

F4-551501

5-383-004

5-334-004

5-330-004

4-517-004

F4-550091

F3-550349

F3-550330

F3-551228

Adjusting Dome

6.35


4-517-004 #8 Close Nipple, NPT 1

5-329-004 Filter/Regulator/Lubricator Assembly, Complete *

5-330-004 Valve, Brass Ball with Lever Handle 1⁄2" 1

5-331-004 3⁄8" 100R2, #8FS-JIC, #8FS-JIC, 17" 1

5-332-004 3⁄8" 100R2, #8FS-JIC, #8FS-JIC, 20" 1

5-334-004 8MP, 8MJ 90° 2

5-383-004 Lubricator, Miller 703-L3000-10 N 1

5-385-004 “T” Bracket Assembly 2

F3-550330 Bowl, Lubricator 1


F3-551228 Guard, Bowl 1

F4-550091 O-Ring, Fill Plug 1


F4-550350 Element, 5 Micron 1

F4-551186 Guard, Bowl 1

F4-551501 Gauge, Pressure 1

Dome, Adjusting 1

PARTS

Filter/Regulator/Lubricator Assembly (AC-10)

6.36

PARTS

HRC-10 Hydraulic Remote Control

SpeedAdjustmentHandle

1-020-002

5-351-004

4-220-004 4-220-004

5-675-004 (3.5)5-728-004 (5.0)

5-350-004

RS2-1

5-344-004

5-342-004

5-343-0045-344-004

1-136-004

RS2-6

5-341-004 (3.5)

5-350-004

5-345-004

5-346-004

5-349-004

5-353-004

3-651-004

5-342-004

5-347-004

5-343-004

5-348-004

2-053-004

5-726-004 (3.5)5-727-004 (5.0)

175-0043-279-004

120-004

6.37


1-020-002 Hand Knob for AIA Machined for PP & HRC-10 1

120-004 Nut, Hex Head, 1⁄4"-20 UNC, Steel Plated 2

175-004 Washer, Lock 1⁄4" Steel Plated 2

3-279-004 Bolt, 1⁄4" NF x 21⁄4" Long 2

3-651-004 Nut, Hex Head Lock, 5⁄16" UNC, STL, PLTD 4

4-220-004 Screw, Set 10-32x1⁄4" Cup Point 2

5-341-004 Manifold, HRC-10 1

5-342-004 Quick Connect, 3⁄8" Male, ANV-38 NPT-M 2

5-343-004 Quick Connect, 3⁄8" Female, ANV-38 NPT-F 2

5-344-004 Adapter, Straight 3⁄8" NPT Male-3⁄8" NPT Male 2

5-345-004 Plug, Hex Head 3⁄8" NPT 2

5-346-004 Fitting, 3⁄8" NPT Male-3⁄8" NPT Male 90° 1

5-347-004 Nipple, Black Pipe 3⁄8" NPT x 31⁄2" Long 1

5-348-004 Nipple, Black Pipe 3⁄8" NPT x 5" Long 1

5-349-004 Valve, Steel Ball, 3⁄8" NPT Female 1

5-350-004 Hose, 10" Long 1

5-351-004 Gauge, Pressure, 0-2000 PSI, Wika 1

5-352-004 Decal Package - ID Products No. HRC-10 1

5-353-004 Bumper, Rubber Stud, McMaster C9377 K42 4

5-675-004 Relief Cartridge, HRC-10-3.5, DF-FCP-00-3.5 1

5-726-004 Flow Splitter Only, HRC-10-3.5, DF-FCP-00-3.5 1

5-727-004 Flow Splitter Only, HRC-10-5, DF-FCP-00-5 1

5-728-004 Relief Cartridge, HRC-10-5, DF-FCP-00-5.0 1

RS2-1 Housing Weldment 1

RS2-6 Housing Cover Weldment 1

— Speed Adjustment Handle 1

5-725-004 Manifold with 5.0 Splitter, 3000 PSI, Relief Cartridge, HRC-10-5 1

5-730-004 Manifold with 3.5 Splitter, 1500 PSI, Relief Cartridge, HRC-10-3.5 1

HRC-10 Hydraulic Remote Control

PARTS

6.38

PARTS


1-020-002 Hand Knob 1

175-004 Washer, Lock 1⁄4" 2

2-282-004 Bolt, HHCS 1⁄4" NF x 2" 2

4-220-004 Screw, Set 10-32 x 1⁄4" Cup Point 2

5-218-004 Fitting, 3⁄8" MP x 6 MJ 90° 1

5-291-004 Bushing, 3⁄8" MP x 1⁄4" FP 1

5-342-004 Quick Connect, 3⁄8" ANV - 38 NPT-M 1

5-344-004 Adapter, 3⁄8" MP - 3⁄8" MP 2

5-346-004 Fitting, 3⁄8" MP x 3⁄8" MP 90° 2

5-349-004 Valve, Steel Ball with Lever, 3⁄8" NPT 1

5-393-004 Gauge, Pressure, 0-2000 PSI 1

5-394-004 Valve Body, Delta 30102006 1

5-399-004 Fitting, 3⁄8" MP x #6 MJ 2

5-400-004 Fitting, 3⁄8" FP x 3⁄8" FP x 3⁄8" FP Tee 1

5-404-004 Hose, 3⁄8" x 10" Long (5.5HP) 1

5-405-004 Hose, 3⁄8" x 181⁄2" Long (5.5HP) 1

5-684-004 Relief Cartridge, Delta DE-RVD 00-2000 1

5-688-004 Hose, 3⁄8" x 15" Long (8HP & 9HP) 1

5-689-004 Hose, 3⁄8" x 26" Long (8HP & 9HP) 1

5-405-004(5.5HP)

5-218-004

5-400-004

5-291-004

5-393-004

5-344-004

5-404-004(5.5HP)

5-399-004

5-394-004

1-120-002

4-220-004

5-684-004

5-349-004

5-344-004 5-346-004

175-004 5-342-004

2-282-004

Control Valve Assembly

5-689-004(8HP & 9HP)

5-688-004(8HP & 9HP)

6.39

PARTS


3-525-004 16 FP – 16 FP – 16 FP Tee 1

5-339-004 Coupling, Universal Air King 1" MP 4

1" Rubber Grommet –

5-340-004 Clip, Safety Air King –

5-722-004 Coupling, Universal 2" Air King 2

2" Rubber Grommet –

5-723-004 Nipple, 11⁄4" NPT Close, Bypass 2

5-724-004 11⁄4" FP – 11⁄4" FP – 11⁄4" FP Tee 1

6-036-004 Hose Assembly

5-340-004

5-339-004

3-525-004

5-722-004

5-723-004

5-723-004

5-722-004

5-724-004

5-339-004

5-340-004

5-339-004

Oil Cooler/Air Supply Fittings

6.40

PARTS

Hydraulic Oil Cooler Assembly

OC-9

5-342-004

OC-12

5-660-004

5-663-004

5-667-004

5-659-004

5-666-004

5-218-004

5-343-004

5-664-004

5-665-004

5-657-004

OC-13

OC-6

6.41

PARTS


5-218-004 3⁄8" MP – #6 MJ, 90° 1

5-342-004 Coupler, Quick Connect, 3⁄8" Male 1

5-343-004 Coupler, Quick Connect, 3⁄8" Female 1

5-657-004 Heat Exchanger 1

Rubber Mount 2

Bolt, HHCS, 5⁄16" x 5" NF 2

Washer, Square 2

5-659-004 Ball Valve, Brass with Lever, 1⁄4" 1

5-660-004 Regulator, 1⁄4" 1

Gauge 1

5-663-004 Quick Connect, 1⁄4" Male 1

5-664-004 3⁄8" MP – 3⁄8" MP, 45° 1

5-665-004 Bushing, 3⁄8" FMP – 1⁄2" MP 1

5-666-004 Adapter, 3⁄8" MP – 1⁄4" MP 1

5-667-004 Adapter, 1⁄4" MP – 1⁄4" MP 1

OC-6 5.5 HP/Clamp Mount 2

OC-9 Cooler Cover Weldment 1

OC-12 Fin Cover Plate 1

OC-13 8HP/Clamp Mount 1

Hydraulic Oil Cooler Assembly

6.42

PARTS

Hydraulic Fluid Reservoir, Power Pack 5.5


1-499-004 Filler/Breather Cap Assembly 1

5-343-004 Quick Connect 3⁄8" Female 1

5-346-004 3⁄8" MP – 3⁄8" MP Adapter, 90° 1

5-403-004 Bushing 12MP – 6 FP 1

5-404-004 3⁄8" 100R2, #6FS-JIC, #6FS-JIC Hose 10" 1

5-602-004 #6MP – #6 MJ, 45° 1

5-603-004 #6FP – #6FP – #6MP Tee 1

5-615-004 3⁄4" MP – #8 MJ Adapter 1

PP-14 Hydraulic Fluid Reservoir Weldment 1

PP-14

1-499-004

5-404-004

5-603-004

5-602-004

5-403-004

5-346-004

5-343-004

5-615-004

6.43

PARTS

Frame Assembly, Power Pack 5.5


1-696-004 Nut Lock, 1⁄4" 4

1-699-004 Bolt, HHCS, 1⁄4" x 11⁄4" NF 4

3-651-004 Nut Lock, 5⁄16" NC 4

3-705-004 Washer, 1⁄4" 4

5-353-004 Bumper, Rubber Stud 4

5-752-004 Hose Assembly with Quick Connect, 20 feet 1

5-753-004 Hose Assembly with Quick Connect, 10 feet 1

PP-9 Upper Frame Assembly 1

PP-13 Base 1

5-753-004

5-353-004

3-651-004

1-696-004

PP-13

1-699-004

PP-9

5-752-004

3-705-004

6.44

PARTS


1-499-004 Filler/Breather Cap Assembly 1

3-651-004 Nut, Lock 5⁄16" NC .4

4-284-004 Magnetic Plug 1

5-343-004 Quick Connect 3⁄8" Female 1

5-346-004 6 MP – 6 MP 90° 2

5-353-004 Bumper, Rubber Stud 4

5-399-004 6MP – 6MJ Nipple 1

5-403-004 Bushing, 12MP – 6 FP 2

5-658-004 Filter Assembly 1

5-687-004 3⁄4" MP – #10 MJ Adapter 1

5-688-004 3⁄8" 100R2, #6FS-JIC, #6FS-JIC Hose 1

5-691-004 12MP – 12FP – 12FP Street Tee 1

9PP-1 Reservoir 1

9PP-2 Power Pack Frame 1

5-346-004

5-688-004

5-346-004

1-499-004

5-353-004

5-343-004

9PP-1

9PP-2

3-651-004

5-658-004

5-403-004

5-399-004

5-403-004

5-691-004

4-284-004

5-687-004

Reservoir and Frame Assembly, Power Pack 8/9 hp

6.45

PARTS


113-004 Washer, Lock 5⁄16" .8

4-816-004 Coupling, Insert, Flexible 1

4-944-004 Coupling, Flex, 3⁄4" Bore, 3⁄16" Key 1

5-390-004 Pump, Mount 1

5-391-004 Engine, Honda 5.5 HP with Pull Start 1

5-392-004 Pump 1

5-397-004 Coupling, 7⁄16" x 3⁄32" 1

5-399-004 Fitting, 3⁄8" MP x #6 MJ 1

5-405-004 Hose, 3⁄8" x 181⁄2" 1

5-406-004 1⁄2" 100R1, #8FS-JIC, #8FS-JIC, 90°, 21" 1

5-469-004 Fitting, 3⁄8" MP x #8 MJ 1

540-004 Bolt, HHCS, 5⁄16" x 1" .4

911-004 Bolt, HHCS 5⁄16" x 4 . 4

4-944-004

5-397-004

4-816-004

540-004

113-004

5-390-004

5-392-004

5-391-004

5-406-004

5-469-004

911-004

5-405-004

5-399-004

Engine/Pump Assembly, Power Pack 5.5 hp

6.46

PARTS

Engine/Pump Assembly, Power Pack 8/9 hp


5-075-004 Coupling, Flex 5⁄8" Bore 1

5-076-004 Coupling, Insert 1

5-434-004 Coupling, Flex 1" Bore 1

5-681-004 Pump Mount 1

5-682-004 Engine, Honda 9HP with Pull Start –

5-683-004 Pump, 5 GPM 1

5-685-004 6MB-6MJ-90° 1

5-686-004 4MP-10MJ Nipple 1

5-689-004 3⁄8" 100R2, #6FS-JIC, #6FS-JIC, 26" 1

5-690-004 5⁄8" 100R2, #10FS-JIC, #10FS-JIC 90°, 24" 1

5-709-004 Engine, Honda 8 HP with Electric Start –

5-076-004

5-681-004

5-434-004

5-075-004

5-683-004 5-690-004

5-689-004

5-685-004

5-686-004

5-682-0045-709-004

6.47

PARTS

Cable Sealing Inserts and Cable Seals

Cable Insert Part # Cable Seal Seal Dimension Cable Seal

9-11 mm N270.074 #10 10 / 16 x 4 N270.123

11-12.5 mm N270.075 #12 12 / 18 x 4 N270.124

12.5-14 mm N270.076 #14 14 / 22 x 4 N270.125

14-15.5 mm N270.077 #14 – #15 15 / 22 x 4 N270.126

15.5-18 mm N270.099 #16 16 / 26 x 5 N270.151

#19 19 / 26 x 5 N270.127

17.5-22 mm N270.079 #18 18 / 30 x 6 N270.128

#20 20 / 30 x 8 N270.144

#22 22 / 30 x 6 N270.145

22-24 mm N270.080 #23 23 / 32 x 5 N270.129

24-28 mm N270.096 #25 25 / 38 x 7 N270.130

#28 28 / 38 x 7 N270.146

28-32 mm N270.230 #30 30 / 48 x 10 N270.226

#32 32 / 48 x 10 N270.227

32-36 mm N270.225 #35 35 / 50 x 10 N270.228

#38 38 / 50 x 10 N270.229

Cable Sealing Insert (Red) & Cable Seal

Rope Guide,Outer Insert

(Black)P270.146

6.48

PARTS

Duct Sealing Inserts

Duct Clamp Air Inlet Duct Sealing Insert Exhaust Duct Complete Set(Silver) (Red) Part # (Red) Part # Sealing Insert Duct Sealing

Diameter Part # Top Half Bottom Half (Blue) Inserts

25mm N270.105

32mm P270.088 P270.102 P270.106 P270.118 N270.066

34mm P270.153 P270.150 P270.151 P270.152 N270.067

37mm P270.134 P270.123 P270.124 P270.125 N270.068

40mm P270.135 P270.126 P270.127 P270.128 N270.069

42mm P270.185 P270.182 P270.183 P270.184 N270.070

48mm P270.203 P270.204 P270.205 P270.206 N270.071

50mm P270.089 P270.101 P270.105 P270.119 N270.072

60mm P270.189 P270.186 P270.187 P270.188 N270.073

63mm P270.220 P270.219 P270.218 P270.261 N270.100

Duct Clamp (Silver) Air Inlet Duct Sealing Insert (Red) Exhaust Duct Sealing Insert (Blue)

6.49

PARTS

Miscellaneous Parts


A130C04008 Socket Screw 4mm M4x8 3

A132C06016 Socket Screw 4mm Allen 30

A400B00408 Washer 4,3/9x0,8 3

A430B00408 Spring Washer 4/7,6x0,8 3

N270.118 4mm Small Rubber Cord (Air Inlet Chamber) 10 ft.

N270.119 6mm Large Rubber Cord (Duct Sealing Inserts) 10 ft.

N270.131 Set of Four Cable Guides (Two Each of Item P270.201 and P270.260) 1

N270.147 Set of Two Closing Plugs (One Each of Item P270.227 and P270.228) 1

P270.201 Large Cable Guide (Half Tube) 2

P270.227 Small Closing Plug 1

P270.228 Large Closing Plug 1

P270.234/1 1mm White Spacers for Drive Rollers 8

P270.234/3 3mm Green Spacers for Drive Rollers 8

P270.234/5 5mm Black Spacers for Drive Rollers 8

P270.260 Small Cable Guide (Half Tube) 2

N270.147 (Set of Two)

P270.228

N270.131 (Set of Two)

N270.118

N270-119

A430B00408

A400B00408

A130C04008

P270.234/5P270.234/3

P270.234/1

A132C06016

P270.227 P270.201P270.260

6.50

PARTS

Sonic Head Assembly

A116C06006

P271.028

P271.029

P271.040

P271.027

P271.074

P271.073

P271.026

A116C06008

P271.036

P270.039

P271.034

P271.076

P271.075

P271.033

P271.071

P271.028

A116C06008

A116C06006

P271.035

P271.047

P271.050

P271.045

P271.044

P271.072

P271.046

A116C06008

A116C06006

P271.035

N271.004

N271.003

N271.005


A116C06006 Set Screw M6x6 Sock Set+cup 6

A116C06008 Set Screw M6x8 Sock Set+cup 6

C86EI03000 Hex Socket-wrench 3 1

6.51

PARTS


C86TF00341 Box 185 x 140 x 80 1

C86TF00343 Box 136 x 87 x 55 1

N271.003 Sonic Head, 32-40mm –



P271.026 Nut 3

P271.027 Piston 1

P271.028 Cable Fixation 1

P271.029 Frame, Air Shaft 1

P271.033 Nut 1

P271.034 Piston 1





P271.045 Piston 1




P271.051 Label Sonic Head 26-32mm 1


P271.055 Label sonic Head 40-51mm 1

P271.071 Collar 40/19mm (32-40mm Sonic Head) 3









P290.019 Fork Wrench 24 1



Sonic Head Assembly

6.52

PARTS

Tools and Accessories

RSB-1

Safety Basket

CAL-6

RS-1

RS-2

RSB-2

CEC-(size)

5-416-004

4-659-004

4-658-004

DH-105-677-004

5-678-004

AMO-1016

FT-50CJL-1032CJLWG-1032

DC-20-(size)

DC-10-(size)

6-016-004

6.53

PARTS


4-658-004 Duct Slitter (Longitudinal Cutting) 1

4-659-004 ALIS Double-Sided Replacement Blade for Slitter 1

5-416-004 9" Rubber Straps 4

5-677-004 Grease Gun 1

5-678-004 Grease Replacement Cartridges (2-pack) 1

6-016-004 ALIS Advanced Longitudinal Interduct Slitter 1

AMO-1016 Air Motor Oil – 16 Oz. Bottle 1

CAL-6 6" Digital Calipers 1

CEC-(size) Cable End Cap (.41, .49, .54, .60, .67, .74, .88, .92, 1.01) 2 ea.

CJL-1032 Cablejet Lube Quart 1

CJLWG-1032 Cablejet Lube Quart (Winter Grade) 1

DC-10-(size) Duct Coupler for 1.06" to 1.97" OD Ducts 1

DC-20-(size) Duct Coupler for 2.24" to 2.45" OD Ducts 1

DH-10 Duct Holder Tool 1

FT-50 Foam Tape – 50 Ft. Roll 1

RS-1 Duct Cutters for up to 1.66" OD 1

RSB-1 Replacement Blade for RS-1 Cutter 1

RS-2 Duct Cutters for up to 2.37" OD 1

RSB-2 Replacement Blade for RS-2 Cutter 1

Safety Basket 1


6.54

PARTS


*C86JE01010

C86E50S000

P290.002

C86CS01355

*P290.003

*6-002-004 P270.244

*6-009-004

C86ES04000

C86EIO3000

C86FH02100

C86CQ01315

P290.016

N270.116

P290.016-02

P290.016-05

P290.016-03

6.55

PARTS


6-002-004 Needle Nose Pliers 1

6-009-004 4" Flat Head Screwdriver 1

C86CQ01315 13mm to 17mm Open End Wrench 1

C86CS01355 13mm Hex Socket T-Handle 1

C86EI03000 3mm Allen Wrench 1

C86ES04000 4mm Allen T-Handle 1

C86ES05000 5mm Allen T-Handle 1

C86FH02100 Torx Driver T-10 1

C86JE01010 Circle Clip Pliers 1

N270.116 Air Spray Gun 1

P270.244 Clamp Screw 2

P290.002 Insert Removal Tool 1

P290.003 Spacer Tool 1

P290.016 Aluminum Accessory/Tool Box 1

P290.016-02 Foam Tray for Inserts, Bottom 1

P290.016-03 Foam Tray for Air Gun/Oil, Center 1

P290.016-05 Foam Tray for Tools and Seals, Top 1

*Cablejet Only


6.56

PARTS

SHERMAN & REILLY, INC.P.O. Box 11267 • 400 West 33rd StreetChattanooga, TN 37401 USAPhone 423•756•5300Fax No. 423•756•2948WATS 800•251•7780Web Site www.sherman-reilly.com

Manual No. SuperjetCablejet Printed in the U.S.A. by Rogers Printing Solutions

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