Issue 1 - 7th May 2003 GB

TM

Maintenance Manual
Pyroban System Reference Number: S03325

This manual must be retained by the person in authority.

This manual must not be made available to the operator of the vehicle.

This manual must be read in association with the original vehicle manufacturers instructions.

If in any doubt, contact Pyroban Technical Support for advice.

‘PYROBAN’ is a Registered Trademark of Pyroban Limited.

© Copyright Pyroban Limited 2003

All rights reserved. No part of this technical manual may be reproduced, stored in a retrieval system, or transmitted
in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission
from Pyroban Limited.

Produced by:
Technical Publications Department, Pyroban Limited,
Endeavour Works, Dolphin Road, Shoreham-by-Sea, West Sussex,
BN43 6QG, United Kingdom.
 VEHICLE IDENTIFICATION LABEL

Pyroban Ltd., Endeavour Works,

Dolphin Road, Shoreham-by-Sea,
West Sussex, BN43 6QG
United Kingdom.
Tel: +44 (0) 1273 466200
Fax: +44 (0) 1273 465313

Systeem
System
Systeme : 5000DTM
System
Bouwjaar Serienr.
Boujahr Seriennr.
Annee de la fabr
: 04/03 No de serie
:-
Manufacturing date Serial No,
Gasgroep Categorie
Zundgruppe Kategorie
S03325A
Groupe de gaz
: IIA & IIB Categorie
: 3G S03325B
Gas group Category S03325C
Temp. klasse Zone S03325D
Temp. klasse Zone
Classe de temp.
: T3 Zone
:2 S03325E
Temp. class Zone S03325F
Voertuig Motor S03325G
Fahrzeug Motor S03325H
Vehicule Moteur
Vehicle Engine S03325 I
Merk Merk
Marke Marke
Marque
: TOYOTA Marque
: TOYOTA
Manufacturer Manufacturer
Type Type
Typ Typ
Typ
: 7FDF25 Typ
: 1DZ II
Type Type
Serienr. Serienr.
Seriennr. Seriennr.
No. de serie
: - No. de serie
:-
Serial No. Serial No.

14653 (S03325A) 0104587 (S03325A)

14657 (S03325B) 0104596 (S03325B)
14661 (S03325C) 0103590 (S03325C)
14668 (S03325D) 0070455 (S03325D)
14672 (S03325E) 0070890 (S03325E)
14679 (S03325F) 0103924 (S03325F)
14714 (S03325G) 0103845 (S03325G)
14716 (S03325H) 0103902 (S03325H)
14726 (S03325 I) 0103701 (S03325 I)
 CONTENTS

Introduction to System 5000D

General and Safety Information

Risk Assessed Components
Gas Sensing Head Warranty Statement
Main System 5000D Components on a Typical System
Main System 5000D Conversion Components

Operating Instructions

Equipment and Controls Layout

Pre-Start Checks
Starting the Vehicle
Starting the Engine
Stopping the Vehicle
Emergency Stop
To Power Down System 5000D
System 5000D Fuses
System 5000 Status Indicators

Routine Maintenance

Maintenance Schedule

Maintenance Information

System 5000D Test Gas Cylinder

Gas Sensing Head
Enclosures
Purge Points
Cables and Cable Glands
Battery
Earth Bond Connections
Brakes
Tyres
Forks
Manicooler Maintenance

Conversion Details

Introduction
Inlet System Installation and Parts List
Exhaust System Installation and Parts List
Coolant Circuit Installation and Parts List
Electrical System Parts List
System 5000D Parts List and Recommended Spares
Miscellaneous Parts List
 CONTENTS

Pyroban Service

AIM - All Inclusive Maintenance Scheme

SMS - Safesure Maintenance Scheme
ASA - Annual Safety Audit
Warranty
How to Contact Us

Wiring Diagram

Drawing 805655

Brake Modifications
 INTRODUCTION TO SYSTEM 5000D

General and Safety Information:

IT IS ESSENTIAL THAT THIS SECTION IS READ BEFORE OPERATING OR MAINTAINING THE

PYROBAN EQUIPMENT.

To enable this vehicle to be operated in hazardous environments it has been fitted with the System 5000D
gas detection system. This level of protection will not be maintained unless the vehicle and Pyroban
equipment is operated and serviced in accordance with the vehicle manufacturers instructions and the
instructions supplied by Pyroban.

System 5000D will provide an audible and visual alarm followed by vehicle shut down in the event of high
surface temperature or hazardous concentrations of flammable gas or vapour being detected. To ensure
the integrity of System 5000D, the control module carries out an automatic gas test and system calibration
procedure each time System 5000D is restarted.

Before using the Pyroban equipment, the ‘Operating Instructions’ section of this manual must be read and
understood.

If the Pyroban equipment fails to operate or if it shuts the vehicle down while operating, do not attempt to
restart until permission has been granted by the person in authority. If it is suspected that flammable vapour
has entered an enclosure, the battery must be isolated and the vehicle moved in a safe manner to a
non-hazardous area where the enclosure must be purged. Do not restart System 5000D until this
procedure has been completed and permission granted by the person in authority.

Person in authority: Employee of a company taking full responsibility for the safety, welfare and
supervision of all other employees under their control.

If braking performance is suspect or if a squealing sound is heard when the brakes are applied, contact
the person in authority immediately.

Only Pyroban trained, qualified personnel may carry out any maintenance or repair work on the Pyroban
equipment.

All personnel are expected to employ safe engineering practices and observe their company safety policy
and all relevant safety requirements, regulations and directives applicable to the country or locality in which
the equipment is being used.

Before carrying out any maintenance or repair work, the vehicle must be moved in a safe manner to a
non-hazardous area and the vehicle battery must be isolated.

A record should be kept of all maintenance and repair work.

Do not remove connectors or plugs from any of the System 5000D components with the battery
connected. All connectors and plugs must be reconnected before reconnecting the battery.

Only Pyroban approved replacement parts may be fitted to the Pyroban system. These should be obtained
direct from Pyroban. No responsibility will be accepted by Pyroban in the event of unapproved replacement
parts being fitted. The warranty protection issued with the Pyroban equipment will also be invalidated.

Water or high-pressure jets must not be used to clean the System 5000D equipment or Pyroban
enclosures.

A damp cloth should be used to clean any plastic components, including System 5000D gas detection
system components.

After any maintenance or repair work, the person in authority must inspect and approve the Pyroban
equipment before returning the equipment to service.
 INTRODUCTION TO SYSTEM 5000D

Risk Assessed Components:

Original equipment manufacturers’ components which have been risk assessed by Pyroban are individually
identified with a label as shown below:

or

Components marked with this label have been assessed and if necessary modified. If a replacement
component is required, it is the responsibility of the authorised person to ensure the replacement part is
of equal specification, and is modified in the same manner as the original part. After-market ‘pattern
parts’ should not be used. Pyroban offer a service to assess / modify parts if required.

As the Pyroban risk assessment covers the entire vehicle, other components have been assessed safe
for the application without modification. The person in authority must therefore ensure that all other
components are replaced with original manufacturer’s components. If this is not possible, the person in
authority must seek advice from Pyroban as to the suitability of an alternative component.

Pyroban can not accept responsibility for the integrity and certification of the conversion if this policy is
compromised in any way.

Gas Sensing Head Warranty Statement:

The Pyroban gas sensing head may be impaired by certain materials, necessitating more frequent
replacement. Typical materials are silicones and chlorines.

Where such materials are present in the environment in which System 5000D is operating, the gas sensing
head will not be covered by the normal Pyroban warranty protection.

The gas sensing head must be protected when cleaning the vehicle or using silicone sealant to seal
enclosures etc.
 INTRODUCTION TO SYSTEM 5000D

Main System 5000D Components on a Typical System (Not to Scale):

For specific wiring details relating to this vehicle, refer to the wiring diagram at the rear of this manual.

Vehicle Operation
(Power ‘On’)

System Error Gas Warning /

Vehicle Shutdown

Park Brake Over Temperature

Test 3 Indicator
Test 1 Indicator sys te m
co ntro l m o du le

Test 2 Indicator Power Indicator

Temperature
Input Lead
Key Receptor On / Off
12345
12345
12345

Power
Cable Operator Key
Assembly (Blue)
Gas Sensing Head
Cable Assembly

Supervisor Key
Relay (Red)
Unit

Power Supply Gas Tubing

Shutdown 12V to 96V dc
Relay Output 25VA max
Gas
Sensing
Temperature Head
Input Module
Test Gas Cylinder

Over-Temperature Sensor
Number Codes for this Vehicle:
1= Coolant
2= Exhaust
3= Not Used
4= Not Used Sparking or High Temperature
5= Not Used Components mounted within
Restricted Breathing Enclosures
 INTRODUCTION TO SYSTEM 5000D

Main System 5000D Conversion Components:

 OPERATING INSTRUCTIONS

Equipment and Controls Layout:

Reset Lever Control Module

Pneumatic Horn
Battery Isolator

Emergency Stop Switch Relay Unit

Ignition Key Switch Temperature Input Module (TIM)

 OPERATING INSTRUCTIONS

Equipment and Controls Layout:

Air Filter

Remote Solenoid Operated Valve

(Typical Installation)

Expansion Tank

Engine Cooling Fan

Gas Sensing Head

 OPERATING INSTRUCTIONS

Equipment and Controls Layout:

Flashing Beacon (OEM) Guarded

Front Work Light
(Guarded)

OEM Rear Left Hand Cluster OEM Rear Right Hand Cluster Lights
Lights (Guarded) (Guarded)

Valve

Regulator
Pressure Gauge

Front Wiper Motor

Test Gas Cylinder

Rear Wiper Motor

 OPERATING INSTRUCTIONS

Pre-start Checks:

Carry out any pre-start checks recommended by the vehicle manufacturer.

Check the general condition of the vehicle and Pyroban equipment, including electrically conductive tyres,
stainless steel fork cladding and coolant.

Ensure that the valve on the Pyroban test gas cylinder is turned to the on position.

Ensure that there is sufficient gas in the Pyroban test gas cylinder.

If there is any doubt as to the satisfactory condition of the vehicle or Pyroban equipment, the
person in authority must be consulted and any faults rectified before the vehicle may be used in
a hazardous area.

Starting the Vehicle:

Before the vehicle can be operated, the System 5000D gas detection system must be started.

Ensure that the pre-start checks described above have been carried out.

Place the blue operator key onto the receptor on the Pyroban control module. A sounder will be heard and
all indicators on the control module will be illuminated simultaneously for a short period to confirm correct
operation.

The green ‘TEST 1’, ‘TEST 2’ and ‘TEST 3’ indicators will flash and then illuminate in turn to confirm the
progress of the automatic gas test. The test will take approximately 40 seconds to complete.

Once the three green ‘TEST’ indicators have extinguished and the ‘VEHICLE OPERATION’ indicator
illuminates, the vehicle may be started in accordance with the original vehicle manufacturers instructions.

Starting the Engine:

1. Ensure that the park brake is in the 'ON' position and neutral gear is selected.

2. Carry out all of the usual pre-start checks.

3. Ensure that the emergency stop button is in the ‘ON’ position.

4. Turn the ignition key switch to the first position.

(An indicator will illuminate if glowplugs or inlet air heaters are fitted).

5. Reset the SVD-S inlet shutdown valve moving the reset control lever
to the reset position.

If glowplugs are fitted: Wait for the glowplug indicator to go out.

If inlet air heaters are fitted: Wait ten seconds for the inlet air heaters to warm up. (continued)
 OPERATING INSTRUCTIONS

Starting the Engine: (continued)

6. Start the engine in accordance with the original vehicles manufacturers instructions.

The starter motor must not be cranked continuously for more than 10 seconds.
After cranking, the starter motor must be given a minimum of 10 seconds rest.

7. Wait ten seconds for the engine oil pressure to build up. Wait for a further seven
seconds then return the reset control lever to the neutral position.

Please Note: To prevent excessive battery drain, the vehicle ignition

should be turned OFF when the vehicle is not in use.

Stopping the Vehicle:

Stop the engine in the normal way.

It is recommended that System 5000D is left switched on during the normal work cycle.

EMERGENCY STOP

Depress the emergency stop button

or

Select ‘Emergency Stop’ with the ‘Reset / Emergency Stop’ control.

To Power Down System 5000D:

Place the blue operator key onto the receptor on the Pyroban control module. System 5000D and the vehicle
will be powered down.

The automatic gas test must be carried out each time System 5000D is restarted.

System 5000D Fuses:

These fuses are housed in the Pyroban System 5000D relay unit.

The relay unit must only be opened in a safe area.

The right hand fuse protects the vehicle voltage entering the relay unit. Failure of this fuse will be indicated
by the ‘Power’ indicator on the control module not illuminating.

The left hand fuse is for the power out to the Pyroban System 5000D equipment. If System 5000D switches
on but there is no power to the vehicle, this fuse should be checked.
 OPERATING INSTRUCTIONS

System 5000D Status Indicators:

denotes that the status indicator flashes on and off.

Low concentration of flammable gas or vapour detected (<10% LEL).

The vehicle must be removed from the hazardous area immediately and
the person in authority informed.
: System 5000D will automatically reset when the concentration of flammable gas
or vapour detected returns to a safe level.

High concentration of flammable gas or vapour detected (>25% LEL).

Vehicle shut down.
The person in authority must be informed.
If it is suspected that flammable vapour has entered an enclosure, the battery
must be isolated by depressing the battery isolator red knob and the vehicle

:
moved in a safe manner to a non-hazardous area where all enclosures must be
purged. Do not restart System 5000D until this procedure has been completed
and permission granted from the person in authority. System 5000D may then
be reset by placing the red supervisor key on to the key receptor on the control
module. Restart System 5000D in the normal way, using either the red supervisor
key or the blue operator key.

Over-temperature condition detected.

Vehicle shut down.
The person in authority must be informed.
The number displayed on the control module identifies the item of equipment that
2 is over-temperature. Refer to the table on the ‘Introduction to System 5000D -
Main System 5000D Components’ page of this manual.
The item of equipment in question should be allowed to cool before attempting to

: reset System 5000D.

System 5000D may then be reset by placing the red supervisor key on to the key
receptor on the control module. Restart System 5000D in the normal way, using
either the red supervisor key or the blue operator key.
Repeated over-temperature conditions may indicate a fault or service requirement
which should be investigated.

Automatic gas test failed. Investigation required.

Pyroban equipment and vehicle disabled.
The person in authority must be informed.

The three green ‘Test’ indicators will show the point at which the gas test failed.

‘Test 1’ flashing indicates that the gas sensor was warming up. There is no fault
associated with this phase of the gas test.

‘Test 2’ flashing indicates that the test gas was being injected. The test gas is
injected for a period of ten seconds after which an automatic gain control circuit
is triggered. The automatic gain operates for 6.5 seconds to adjust the output to
the required level. This level may be achieved even if the head is not responding
to the test gas. If this is the case then Test 3 will fail. If the required level is not
achieved then the test is halted with the Test 2 and the amber is illuminated.
Continued.....
 OPERATING INSTRUCTIONS

System 5000D Status Indicators:

Potential reasons for failure on Test 2.

* Test gas cylinder empty.

* Test gas regulator output pressure adjusted incorrectly.
* Test gas tube disconnected or kinked.
* Faulty gas sensing head
* Faulty control module.
* Gas sensing head lead disconnected or faulty.

‘Test 3’ flashing indicates that after injection of the test gas the signal from the
gas sensing head should start to drop off as the gas diffuses from the sensing
head. The signal should fall to the required level within a defined period. If the gas
sensing head output signal does not drop off in time then the test is halted with
Test 3 and amber illuminated.

Potential reasons for failure on Test 3.

* Test gas cylinder empty.

* Test gas regulator output pressure adjusted incorrectly.
* Test gas tube disconnected or kinked.
* Faulty gas sensing head
* Gas sensing head blocked or obstructed.
* Vapour present in the area of the gas sensing head.

Warning: If either Test 2 or Test 3 are marginally within the limit then the gas
test will be passed and the Green tick illuminated so that the vehicle may be
driven, however the corresponding Test indicator will remain flashing.

The person in authority must be informed.

If the automatic timeout facility is enabled, the vehicle and System 5000D will shut
down automatically after one hour if no vehicle movement is detected.
An audible warning will also be provided for the last 10 minutes prior to shut down.

:
System 5000D may be reset by placing the blue operator key on to the key
receptor on the control module.
 ROUTINE MAINTENANCE

Maintenance Schedule:

The level of protection provided by System 5000D will not be maintained unless the vehicle and Pyroban
equipment is operated and serviced in accordance with the vehicle manufacturers instructions and the
instructions below.

The ‘Introduction to System 5000D’ section of this manual must be read and understood before carrying
out any maintenance or repair work on the Pyroban equipment.

The following checks must be carried out at the earliest interval stated.

Daily: Carry out the pre-start checks as described in the ‘Operating Instructions’ section of this
manual.

50 hours: Ensure that the gas sensing head is clean, correctly positioned and free from damage
(Weekly) or obstructions.

100 hours: Check SVD inlet shutdown valve and linkage and lubricate.
(2 Weeks)

500 hours: Check overspeed setting of SVD inlet shutdown valve.

(3 Months) (Must be undertaken by Pyroban trained engineer)
Check the mechanical integrity of all inlet / exhaust system pipework / components
and joints.
Ensure that all cable glands are tight and secure.
Ensure that all cables are in good condition and securely fixed in the correct position.
Ensure that all enclosures are tightly sealed and free from damage.
Check the operation of the vehicle brakes. Investigate any excessive brake noise or poor
braking performance.
Check tension of fan / pump belt(s).

1000 hours: Ensure that the complete installation is in good working order and that all fixings are
(6 months) secure.
Ensure that the temperature sensors are tight in their sockets.
Disconnect the cable from the temperature sensors and check that the system operates
shutdown.

Major overhauls: Remove carbon deposits from the exhaust manicooler. The frequency of attention to
(2 years) this item will vary with the type of usage and should be assessed in service.

As required: Clean element of inlet flametrap.

After any maintenance or repair work, the person in authority must inspect and approve the
Pyroban equipment before returning the equipment to service.
 MAINTENANCE INFORMATION

System 5000D Test Gas Cylinder:

A long-life test gas cylinder has been installed.

A replacement test gas cylinder should be ordered when the test gas cylinder registers a pressure of
20 bar. It is advisable to hold a spare test gas cylinder to ensure uninterrupted operation.

UK customers may order spare or replacement cylinders from direct from Pyroban (quoting Pyroban part
number 450541) or from Cryoservice UK, Tel. 01905 754500 or Fax. 01905 754060 (quoting Cryoservice
part number 17/1309). Non-UK customers are recommended to order spare or replacement cylinders
from Air Products Limited, quoting the following details:

Bottle: 1 litre lecture bottle fitted with Din 14 valve.

Contents: Gas 0.5% propane in air.

To replace the test gas cylinder, turn off the test gas cylinder valve then disconnect the test gas pipe at the
regulator. Undo the cylinder retaining screw on the mounting bracket and remove the cylinder. Unscrew
the regulator from the test gas cylinder (left hand thread) and fit the regulator to the replacement test gas
cylinder.

Place the replacement cylinder into the mounting bracket and secure the retaining screw. Refit the test gas
pipe to the regulator, turn on the test gas cylinder valve and check for leaks.

The initial charge indicated on the test gas cylinder gauge should be between 200 and 250 bar pressure.

Gas Sensing Head:

Maintenance or servicing of gas sensing head must only be undertaken by a Pyroban trained engineers.

The gas sensing head must be fitted between 20° and 60° from the horizontal.

M6 Locknut and Washer

Horizontal

20°

60°
Enclosures:

Enclosures must not be opened in a hazardous area.

The method of sealing employed for each enclosure on the vehicle is stated in the ‘Conversion Details’
section of this manual.

When using silicone sealant, the Pyroban gas sensing head must be protected from any vapour to avoid
damage.

Do not use water or vapour pressure jets to clean enclosures.

If it is suspected that flammable vapour has entered an enclosure, the battery must be isolated and the
vehicle moved in a safe manner to a non-hazardous area where the enclosure must be purged.
 MAINTENANCE INFORMATION

Purge Points:

Where purge points are fitted, these are identified in the ‘Conversion Details’ section of this manual.
This must be done in a non-hazardous area.

After purging, the purge point plugs must be replaced securely using thread sealant.

Do not restart System 5000D until this procedure has been completed and permission granted by the
person in authority.

Cables and Cable Glands:

Cables must be maintained in a good condition, securely fixed and properly fitted in to any cable glands.

Cable glands must be securely fitted and should grip the cable tight enough to ensure correct operation.

Battery:

Do not disconnect or reconnect the battery in a hazardous area. Batteries should be maintained in
accordance with the original manufacturers instructions.

System 5000D must be switched off during battery recharging.

Earth Bond Connections:

Where earth bond connections have been fitted, these must be maintained in a good condition and
replaced if damaged or removed.

Brakes:

The original brake linings have been assessed and approved by Pyroban, without modification.

The brake system must be checked at the intervals recommended in the vehicle manufacturers
instructions.

The brake linings, brake drums and brake mechanisms must be inspected immediately in the event of
deterioration in the performance of the brakes, if a squealing sound is heard when the brakes are applied.

DO NOT OPERATE THE VEHICLE IF BRAKING IS SUSPECT.

Replacement brake linings must be of identical specification.

Tyres:

To maintain electrical conductivity to earth, vehicles operating in hazardous areas must be fitted with at
least one pair of electrically conductive tyres

Once fitted, the tyres must be tested to ensure the required level of conductivity has been achieved
(as defined in EN1755 : 2000).
 MAINTENANCE INFORMATION

Forks:

To eliminate sparking caused by impact between metallic and non-metallic bodies, the vehicle forks are
clad in stainless steel.

Wear indicators have been fitted to the underside of the forks. Red marks will appear when the cladding
becomes excessively worn

If the cladding is damaged or excessively worn, the forks must be returned to Pyroban for repair.

Failure to observe this requirement may result in ignition of a flammable atmosphere if impact sparking
occurs.

Manicooler Maintenance:

Manicoolers are heavy items of equipment and proper lifting gear should be used to handle them.

On major overhauls or in the event of shutdown due to excessive exhaust temperature not reconciled by
other checks, clean the manicooler interior with a carbon removing solvent.

It is essential to clean the manicooler whenever the carbon build-up inside it exceeds a thin
layering of surfaces in the exhaust gas flow.

The frequency of cleaning is dependent on local operating conditions, but where regular idling of an engine
is experienced, cleaning should be more frequent.
 CONVERSION DETAILS

Introduction:

The vehicle has been converted so that the engine exhaust gas temperature at outlet and the
exposed engine surface temperature does not exceed 200°C.

Maximum engine rpm before and after conversion: As OEM standard settings.

The Pyroban safety system fitted consists of:

INLET SYSTEM incorporating:

* Inlet manifold.
* Pyroban SVD-S inlet shutdown valve with an integral flame arrestor and remote solenoid operated
valve giving automatic shutdown on engine overspeed.
* Manual reset / emergency stop cable control.

EXHAUST SYSTEM incorporating:

* Exhaust manicooler.
* Exhaust outlet box.

COOLING SYSTEM incorporating:

* Fan
* Expansion tank.
* Electrically conductive fan belt.

ELECTRIC SYSTEM incorporating:

* Original battery.
* Original starter motor wipe-sealed using low-odour silicone sealant and purge point fitted.
* Alternator (compliant to Cat 3G Zone 2).
* Battery isolator.
* Emergency stop.
* Front work lights.
* Rear work / reversing light.
* Original flashing beacon.
* Original rear light clusters wipe-sealed using low-odour silicone sealant and guarded.
* Original wiper motors modified and wipe-sealed using low-odour silicone sealant.

PNEUMATIC HORN
 CONVERSION DETAILS

Inlet System Installation:

Air Filter

1 2 3 4

Air Filter

Item No. Part No. Description

1. 202169 Gasket: Cylinder Head / Inlet Manifold

2. 803829 Inlet Manifold
3. 301701 Gasket: Inlet Manifold / SVD-S Inlet Shutdown Valve
4. 29209 SVD-S Inlet Shutdown Valve with Oil Control
5. 29042 Reset Cable Control Assembly

Items not shown:

80653 Remote Solenoid Operated Valve Assembly

471220 Cap: Air Filter
 CONVERSION DETAILS

Exhaust System Installation:

Exhaust Temperature Sensor

Item No. Part No. Description

1. 806039 Manicooler
2. 805575 Gasket: Outlet Box / Manicooler
3. 805837 Outlet Box

Items not shown:

202173 Gasket: Manicooler / Cylinder Head

 CONVERSION DETAILS

Cooling System (Typical Coolant Circuit):

ARROWS INDICATE DIRECTION OF COOLANT FLOW

T = Thermostat
P = Pump
123456
123456
= Bypass

Expansion
Tank Vent

123456789012345
123456789012345
123456789012345 Bottom Hose
123456789012345
123456789012345
123456789012345
123456789012345
123456789012345 ð ð ð
123456789012345
123456789012345
123456789012345
123456789012345
123456789012345
123456789012345
ï
123456789012345
123456789012345
123456789012345
ò
1234567
1234567
123456789012345 1234567
123456789012345
123456789012345
123456789012345
1234567
P ð
1234567
1234567 ð ò
123456789012345 1234567
123456789012345
123456789012345
123456789012345
123456789012345
123456789012345
123456789012345
123456789012345
123456789012345
123456789012345
ò Engine
123456789012345
Radiator
123456789012345
123456789012345 123456
123456789012345
123456789012345 123456
123456
123456789012345
123456789012345
123456789012345
*
12123456
123
12
123 T ï
123456
123456 ï ò
123456789012345 12 123456
123456789012345 12
123456789012345 12
123456789012345
123456789012345
123456789012345
12
12
12
ò 12
123456789012345 12 12
123456789012345
123456789012345
123456789012345
123456789012345
12
12
12
1234567890123456789012345678901212345678901234567
12
1234567890123456789012345678901212345678901234567 ï
123456789012345
123456789012345
123456789012345
123456789012345 Manicooler
123456789012345
123456789012345
123456789012345
123456789012345
ò ï
123456789012345
123456789012345
123456789012345
123456789012345
123456789012345
123456789012345
123456789012345
123456789012345
ï
123456789012345
123456789012345 Top Hose

* Coolant Temperature Sensor

Part No. Description

806614 Radiator Cowling

490868 Fan: 430/160/10/RA
402001 Spacer: Fan
805745/0/P Radiator Expansion Tank: 1.6 Litre
490389 Cap: Radiator 13 psi
490479 Cap: Radiator Blanking 13 psi
80657 Remote Thermostat Assembly
806696 Gasket: Thermostat
490777 Fan Belt: Electrically Conductive: B45 Notched
420064 Hose: 38mm x 300mm x 34mm
420023 Hose: Elbow 90° x 1 1/2"
 CONVERSION DETAILS

Electric System Parts List:

Part No. Description

994062 Alternator

802303 Split Bush: Alternator

805293 Pulley: SPB

992863 Work Light: 12V 55W

941346 Switch: Temperature 100°C

941324 Switch: Temperature 195°C
943033 Switch: Battery Isolator
941349 Switch: Emergency Stop 3A
941359 Switch: Plunger V3 Mechanical
941415 Switch: Micro V3 Lg Lev
993125 Switch: V3 IP67
941004 Switch: Toggle IP67 SPDT
941398 Switch: Rocker IP67 SPDT
946032 Switch: Roller Action

961031 Diode: Power IN5401

920628 Relay: 12V with Diode

920605 Relay Base

941237 Actuator: Black

932014 Connector: 1 Way Battery Heavy Duty Negative

 CONVERSION DETAILS

System 5000D:

Part No. Description Recommended Spares

805601/5 Control Module 1 spare unit for every 10 systems on site

804987/4 Key: Operator -
804987/2 Key: Supervisor -
804990/5 Power Cable -

805645/NK Relay Unit 1 spare unit for every 10 systems on site

805615 Temperature Input Module (TIM) 1 spare unit for every 10 systems on site
805593/3 Lead: Temperature Input -

806643 Gas Sensing Head 1 spare unit for every 10 systems on site
804993/3 Cable: Gas Sensing Head -

450539 Test Gas Cylinder: 1.0 Litre Lecture Minimum of 1 spare unit
450540 Regulator Din 14 Stem 1 spare unit for every 10 systems on site
807148 Bracket: Test Gas Cylinder -
471032 Clamp: Stainless Steel -
500886 Tube -

807447 Label: Instruction -

301836 Label: Reset Dashboard -

Miscellaneous:

Part No. Description

450327 Horn: Pneumatic

806030 Adjuster: Alternator Mounting

410405 Seal Shaft: 1/2” o/d

 PYROBAN SERVICE

Located throughout the UK, our network of fully trained service engineers can confidently attend site or
assist to rectify any service or maintenance issues.

We also provide a technical hot-line service to offer dedicated support for users of Pyroban equipment and
Pyroban trained engineers.

In mainland Europe, Pyroban service support is offered through Pyroban BV (Netherlands) with their own
fully trained engineers on stand-by.

Outside of Europe, local service support can be arranged via one of our authorised distributors or agents.

To ensure compliance with the ATEX workers Directive 1992/92/EC, it is the responsibility of the user to
ensure that all machinery used on site is maintained in accordance with the manufacturers recommendations.

In support of this, Pyroban offer the following service schedules in the UK:

AIM - All Inclusive Maintenance Scheme

Our all inclusive maintenance contracts provide the customer with fully paid service and
maintenance support throughout the contract period. The all inclusive contract also provides
for a thorough inspection of all mechanical, electric and electronic safety systems by a fully
qualified Pyroban service engineer every six months. Consumable and non-consumable parts
and labour are included in the annual charge (refer to contract for details). An approved safety
certificate will be issued.

SMS - Safesure Maintenance Scheme

The Pyroban Safesure Maintenance Scheme allows for a through inspection and service of
all mechanical, electric and electronic safety systems by a fully qualified Pyroban service
engineer every six months. All consumable service parts and labour are included. Any non-
consumable parts and associated labour are chargeable. An approved safety certificate will
be issued once any maintenance issues have been rectified.

ASA - Annual Safety Audit

A safety audit conducted by a fully qualified Pyroban service engineer. The purpose of the ASA
is to ensure that the integrity and safety of the Pyroban system by conducting a thorough
inspection of all safety critical components on an annual basis. Any faults or problems with the
safety system will be identified and reported with a quotation for any rectification work. Once
the vehicle is confirmed as safe for operation within potentially explosive atmospheres,
Pyroban will issue an approved safety certificate.
 PYROBAN SERVICE

Warranty:

The System 5000D equipment is supplied with 12 months warranty protection.

In the event of a claim, the customer is requested to contact the Pyroban Service Department with full
details of the claim, quoting the Pyroban system reference number stated on the front page of this
maintenance manual.

Refer to the ‘Introduction to System 5000D - General and Safety Information’ section of this manual for
special warranty conditions relating to the gas sensing head(s).

How to Contact Us:

Pyroban UK General Enquiries: Tel.: +44 (0) 1273 466200

Fax: +44 (0) 1273 465313
Email: customerservice@pyroban.com

Pyroban UK Technical Support: Tel.: +44 (0) 1273 466200

Fax: +44 (0) 1273 465313
Email: service@pyroban.com

Pyroban UK Parts Department: Tel.: +44 (0) 1273 466204

Fax: +44 (0) 1273 465313
Email: parts@pyroban.com

Pyroban UK Service Department: Tel.: +44 (0) 1273 466245

Fax: +44 (0) 1273 465313
Email: service@pyroban.com

Pyroban SARL: Tel.: +33 (0) 4.37.47.86.00

(France) Fax: +33 (0) 4.37.47.86.01
Email: pyrobanfr@pyroban.com

Pyroban BV: Tel.: +31 (0) 78 6819377

(Rest of Europe) Fax: +31 (0) 78 6818213
Email: sales@pyroban.nl

Pyroban Web Site: www.pyroban.com

WIRING DIAGRAM