Professional Documents
Culture Documents
SECTION 1
SECTION 2
NOMENCLATURES
SECTION 3
SECTION 4
BASIS OF OPERATION
SECTION 5
SECTION 6
OPERATING INSTRUCTIONS
SECTION 7
MAINTENANCE INSTRUCTIONS
SECTION 8
WARRANTY STATEMENT
SECTION 9
SPARE PARTS
SECTION 10
PARTS LISTS
SECTION 11
SPECIFICATIONS
SECTION 12
SECTION 13
APPENDICES
Contents
1. INTRODUCTION AND CONTACT PERSONNEL ................... 3
1.1.
1.2.
2. NOMENCLATURES ................................................................ 5
2.1.
Glossary of terms:.......................................................................... 2
HUDBAY PERU
Contract No.
2172-0020
Contract title
Project
TM 4215
Contact information
:
:
:
08 9270 8555
08 9203 2501
sales@transmin.com.au
: Bob Campbell
: Spare Parts Manager
: +618 9270 8555
: Bob.Campbell@transmin.com.au
SERVICE ENQUIRIES
Name
Title
Phone No.
Email
: Peter Harris
: Service Manager
: +618 9270 8555
: Service@transmin.com.au
OTHER ENQUIRIES
Name
Title
Phone No.
Email
: Peter Warren
: Engineering Manager
: +618 9270 8555
: peter.warren@transmin.com.au
Please provide the following reference information when making enquiries to ensure a prompt
response:
Transmin job number
TM 4215
IOM manual
TM 4215-MAN-01
Equipment No.
Site
Rockbreaker
HPU
Constancia
Constancia
Transmin
Serial No.
RB-118
ME-316
To enquire about Transmins extensive range of bulk materials handling products and services, please
visit our website at www.transmin.com.au or contact our sales offices in Perth or Brisbane for assistance.
PERTH OFFICE
Phil Gilbert
Ph: +618 9270 8555
Fx: +618 9249 6116
Phil.Gilbert@transmin.com.au
BRISBANE OFFICE
Martin Holden
Ph: +617 3880 3874
Fx: +617 3880 3874
Martin.Holden@transmin.com.au
2. NOMENCLATURES
A number of warning icons may be used in this manual. Take note of their definition:
Use caution!
Mandatory isolating machine
Hudbay Peru
Client
Constancia (Project)
Site/Project Name
IOM
Site
Rockbreaker
HPU
HMI
PM
Preventative Maintenance
PLC
MCC
Be sure you have checked that all controls are in a safe state before starting work.
During operation always check and watch that all machine functions operate normally.
Report any abnormality or damage to your supervisor.
Never under any circumstances put your hands in the chute area to clear material
when in operation. Always use your plant "Tag Out" procedures.
Only qualified electrical personnel should carry out electrical installation, modifications,
repairs and wiring.
Personal protective equipment (i.e.; safety helmet, goggles, safety boots and ear
protection) must be worn when operating or carrying out any repairs per site
requirements
If the system is using hazardous material, know where the nearest safety
shower/emergency eye wash station is and ensure that the route to it is unobstructed.
The location of the Material Safety Data Sheets should be kept in a known secure
location so the appropriate first aid can be administered to injured personnel.
Covers and guards are fitted to the machine to prevent injury during
operation. The Rockbreaker and HPU should not be operated with the
covers removed for any reason.
Emergency Stops have been installed in the control cabinet or termination box and must be hard wired
back to the MCC to immediately de-energise all corresponding drives.
Any operator using this equipment must be fully trained and aware of the
contents of this manual, in particular all safety features must be reviewed
and understood before attempting to operate the Rockbreaker.
authorised to connect
Use safety glasses when operating or carrying out any repairs Always
keep your working area as clean as possible
Always carry out maintenance and repairs with qualified and experienced
labour. Do not attempt repairs that are not understood.
IF IN DOUBT ASK.
Welding of lifting lugs, enlargement of holes, or cutting of new holes to
facilitate lifts is strictly forbidden unless accepted or instructed by
Transmin personnel.
The Lifting Lugs provided are rated to allow the ROCKBREAKER and HPU
to be lifted in accordance with the lifting diagrams provided.
4. BASIS OF OPERATION
The Rockbreaker system installed over a primary crusher or grizzly at the mine site. The system
is used to manipulate and break oversize run of mine ore to manageable sizes, suitable for entry
into the primary crusher. The rockbreaker is available 24 hours per day, 365 days per year
The Rockbreaker is made up of a boom system which carries a hydraulic hammer, and is
powered by a Hydraulic Power Unit (HPU) which is a standalone unit connected to the
Rockbreaker by hydraulic, grease and electrical lines.
The control of the standard Rockbreaker system is via a dual joystick radio control transmitter.
The controls for the transmitter provide boom movement, hammer fire, power pack start and
emergency stop functions.
Any operator using this equipment must be fully trained and aware of the contents of this manual,
in particular all safety features must be reviewed and understood before attempting to operate
the Rockbreaker.
It is essential to read the Instructions manual before operating the hammer for the first time.
Boom system
The boom system is used to manipulate the hydraulic hammer into a position to either
BREAK or move oversized run of mine ore. It is moved via a combination of hydraulic
cylinders, providing the liner boom movements and hydraulically actuated planetary
gearboxes, providing the rotational movement.
4.1.2.
Radio Control
The control of the Rockbreaker boom system depends on the control system supplied.
The standard machine is controlled via a dual joystick radio control transmitter. The
joystick and push button controls for the transmitter provide boom movement, hammer fire,
power pack start and emergency stop functions.
Description
The hydraulic power unit (HPU) can be broken down into the following main components:
Oil tank - containing low level and temperature devices and hydraulic oil heater
Control panel - Various levels of cabinet complexity (from full control and starters to
termination only) are supplied, Refer to the specifications for the type of cabinet
supplied. The control panel can contain both, low voltage motor control (415V AC) and
24V DC power. The 415V AC supplies the motor circuit BREAKERs and motor
starters. The 24V DC supplies control devices, PLC (Programmable Logic Controller),
HMI (Human Machine Interface) and operator interfaces. The panel door is interlocked
10
with the main isolation switch, preventing the door from opening and thus the live
circuitry being accessible while the switch is on.
Rockbreaker grease lubrication pump (optional). This unit may be mounted on the HPU
or on a stand near the Rockbreaker depending on the location of the HPU.
The control panel consists of the following components:
HMI Panel
The HMI Panel is used to indicate operation of the power pack, alarms, shut-down
conditions and oil temperature.
11
The Rockbreakers and HPUs should only be lifted in accordance with the
lifting diagrams provided.
EACH Rockbreaker and HPU is normally packaged into the following major sub-assemblies for transport
to site. However the slew frame assembly, the Jib assembly and the hammer assembly may be shipped
as one assembly depending on the size of the Rockbreaker. Refer to the specific lifting and transport
drawings supplied with the Rockbreaker
HPU
Rockbreaker hammer
Additionally, the following items are removed and supplied loose for assembly on site: (These items are
palletized or crated as required)
Remove all items from the vehicle using the correct lifting equipment discussed previously and ensure
there is a clear flat surface for the rockbreaker to rest.
12
The Rockbreaker and HPU can be stored in an outdoor location. They must rest on an even surface to
stop any twisting of the frames.
Loose items should be stored indoors (with the exception of structural steelwork) and should remain
strapped to pallets or in the crates as delivered. If items are removed from sealed crates they should be
stored in an indoor, secure location.
If rubber components are to be stored outdoors for extended periods, they should be covered by
tarpaulins in order to reduce UV exposure and increase the life of the rubber components.
Where possible, machined surfaces have been wrapped in denso tape for protection, and all other
surfaces have been spray coated with an anti-rust compound. All exposed machined surfaces should be
checked daily for signs of rust. It is important that machined surfaces are coated with an anti-rust
compound regularly during storage. In addition, painted surfaces should be inspected regularly and
paint re-applied as necessary.
Any hydraulic oil tubing/piping and hosing which has free ends has been capped to prevent
contamination. If the caps have fallen off during transport or storage, the tubing/piping and hosing must
be removed and cleaned thoroughly before connecting on site and running.
Any grease tubing/piping and hosing which has free ends has been capped to prevent contamination. If
the caps have fallen off during transport or storage, clean grease must be flushed through before
connecting on site and running.
Refer to vendor manuals in section 10 for both short and long term storage of this equipment.
5.2.1.
The bearing has a protective coating and can be stored for up to six months in a roofed storage area or
up to twelve months in an enclosed temperature controlled area.
13
5.3.1.
Prepare the concrete pad and holding down bolts to the best possible surface, i.e. clean of all oils,
greases and loose debris and ensure that the surface is flat within approximately +/- 5mm. All holding
down bolts cast into the concrete should be fully cleaned and lightly lubricated to ensure that correct
torques can be obtained. By use of a crane set the boom system base over the holding down bolts and
pack underneath in a minimum of 4 places to provide a grout allowance of approximately 30mm. Check
the horizontal alignment of the base by the use of a level.
14
Nip all the bolts uniformly, using a hand spanner only, to achieve a uniform pull down onto the packers.
Insert a full width bed of quality non-shrink grout, such as EPIREZ EGII or EPIGEN 301, under the slew
base. It is essential that you work from one side and force the grout completely under to the other to
ensure a full support bed under the machine. Allow the recommended curing time to obtain full strength
of the grout bed. Tighten down all holding down bolts to a final torque of M36 grade 8.8 -2300 Nm.
It is recommended that the bolt projections remaining be heavily treated with grease or other protective
coating to ensure that if required in future, the nuts can be removed for major maintenance work to the
boom system assembly.
5.3.2.
Ensure the mounting structure is horizontal, flat and clear of any obstructions. Align the holes between
the Rockbreaker base and its mounting and secure with mounting bolts, washers and nuts. Tighten
evenly and progressively with a final torque of M36 grade 8.8 -2300 Nm.
15
16
10. The HPU is supplied with all instruments, oil cooler motor and oil heater connected to the
control cabinet or terminal box (depending on the specification. Make the electrical
connection from the plant to the control cabinet or termination box. Make the electrical
connection between the HPU and the Rockbreaker.
17
17. Purge the grease line by pumping grease through it until there is no sign of air in the
system.
18
Hydraulic fittings, tube and pipe are to be supplied and installed in accordance with Transmin drawings
and relevant client specifications.
5.4.2.
Pipe and tube shall be delivered to the job site with the bores free from scale and corrosion.
All piping and fittings shall comply with AS2671.
Pipe and fittings are to be acid de-scaled and phosphate treated in accordance with AS1627.
NOTE ON DE-SCALING AND NEUTRALISATION / PHOSPHATE TREATMENT
Acid de-scaling and neutralisation / phosphate treatment is usually carried out after all welding
of fittings and joins has been completed.
In some instances (particularly on remote sites) it may be deemed acceptable to have the pipe
de-scaled and phosphate treated before welding. When fittings are welded at the pipe ends
after cleaning, the scale is mechanically removed and all debris removed by pigging the pipe
several times in both directions.
NO BUTT WELDING OF PIPES SHOULD BE PERMITTED IN THESE INSTANCES AS THE
INTERNAL HEAT AFFECTED ZONES WILL NOT BE ACCESSIBLE FOR MECHANICAL
CLEANING.
It is recommended that the End User be consulted to determine whether this is deemed an
acceptable practice before proceeding in this manner.
Pipe and tube which has been pre-cleaned prior to delivery shall have the ends securely capped at all
times prior to installation to protect against the ingress of dirt.
Care should be taken to ensure that stainless steel materials (where applicable) are not in contact (or
have not been contaminated) with carbon steel during transport and storage
5.4.3.
All piping and fittings must be properly protected during storage and installation to prevent corrosion,
damage and deterioration up until commissioning of the system.
19
5.4.4.
Piping and fittings shall be inspected for scale and corrosion immediately prior to forming and / or
installation. Severely corroded piping must be reported to the client representative and may be rejected
and scrapped.
Pipe and fittings which have not been acid de-scaled and phosphate treated prior to delivery must be
acid de-scaled and phosphate treated in accordance with AS1627 prior to final assembly.
Where the bores of pipe, tube or fittings are found to be contaminated or have signs of corrosion they
shall either be mechanically cleaned or bath pickled and passivated depending upon the extent of the
contamination and its accessibility for cleaning.
Where chemical cleaning is deemed necessary, the procedures for chemical cleaning should be
submitted for review and approval by the client.
NOTE: It should not be necessary to carry out full circulation pickling, neutralisation and passivation on a
new hydraulic pipe installation if all pipe and fittings are pre-cleaned, acid de-scaled and phosphate
treated prior to installation.
After cleaning, piping shall be securely capped or plugged if it is not to be installed immediately.
5.4.5.
5.4.6.
General
ALL COMPONENT PORTS ARE TO REMAIN SEALED UNTIL THE SYSTEM PIPING HAS BEEN
FLUSHED TO THE SPECIFIED CONTAMINATION CLASS AND THE PIPING IS READY FOR
CONNECTION TO THE COMPONENTS.
Piping should be designed to discourage its use as a step ladder. External loads should not be imposed
upon piping.
All piping flanges and connections are to be fabricated in such a way that flanges and fittings match
without stress (i.e. all pipe joints are to align squarely and without a need to be sprung into place). Use
of a heating torch is prohibited in realignment (bending) of any piping due to the internal formation of
scale.
Prior to assembly, any coarse contamination (eg weld slag) is to be blown out using compressed air and
a backward facing nozzle.
When welding, an earthing lead is always to be attached to the work piece being welded. This will
provide protection against damage to the motors, pumps and valving.
Piping should be installed so that it is protected from predictable damage and does not restrict access for
adjustments, repairs and replacement of components.
20
Flange connections shall be accessible with standard tools without the necessity to disturb or remove
neighbouring pipes, equipment or components.
Piping should be installed so that it does not interfere with operations or walkways.
5.4.7.
All piping bends and offsets are to be cold formed in a standard pipe bending machine (i.e. the use of
oxy acetylene heating or cutting torches is not permitted).
Formed bends shall be used wherever possible. Proprietary elbows shall only be used where
specifically noted in the piping drawings and where space restrictions prevent the use of formed bends.
The preferred minimum bending radius for all piping is 5 times the outside diameter of the pipe.
5.4.8.
Gauge and bleed connections shall be made using proprietary welded fittings with BSPP internal threads.
Holes made in the pipe shall be drilled and shall have any burrs removed.
5.4.9.
Mounting of Equipment
Piping should not be used to support any equipment. Where line mounted equipment is unavoidable,
the pipe shall be adequately supported either side of the equipment or the equipment itself shall be
adequately supported.
5.4.10.
Hoses
Where it is more economical to install hoses rather than bend and install tube or pipe for short runs.
Hoses shall be installed such that:
The hose length is sufficient to prevent sharp flexing and straining of the hose during
equipment operation
They are not subject to torsional loads (axial twisting), ie. Motion is to be preferably in
one plane only
21
Hose radii are not to be less than the manufacturers specifications and hoses shall be
installed in a manner which does not place bending or twisting strain on the hose ends
and fittings
If the failure of a hose assembly constitutes a whiplash hazard, the hose assembly
shall be restrained or shielded.
CAP / PLUG the hose ends to prevent ingress of dirt or foreign matter
5.4.11.
Installation of pipe support clamps shall be carried out concurrently with the laying of the piping. This will
minimise any risk of pipe misalignment problems.
All hydraulic piping is to be adequately supported and clamped to eliminate all visible vibration.
In accordance with AS2671, piping greater than 10mm diameter and up to and including 25mm diameter
should have supports spaced at no greater than 1.5m. Piping greater than 25mm diameter and up to
and including 50mm diameter should have supports spaced at no greater than 2m.
Support clamps are to meet the following requirements:
Flanges must be supported by at least one clamp as close as possible to the flange,
but allowing sufficient access to the flange bolts.
Pipe clamps shall incorporate suitable vibration dampening materials suitable for the
environment, e.g. Stauff Heavy Duty clamps or equivalent.
Pipe supports must be securely anchored to building structures either by welding or with the use of
chemset anchors. Anchoring to equipment should only be done with express written approval from the
manufacturer of the equipment and the client.
Supports for hydraulic piping should only be bolted to concrete where there is no suitable steelwork
available.
22
5.4.12.
23
5.4.13.
Bolted Connections
Ensure that bolted connections are progressively drawn up evenly to avoid distortion of the piping and
hydraulic components.
5.4.14.
Labelling
24
All piping shall be colour banded and the fluid service labelled in accordance with AS1345. Labels must
be located at a maximum distance apart of 8m and at all branches. Arrows shall indicate the direction of
flow.
If required, the full line number shall be incorporated into the label.
5.4.15.
System Flushing
5.4.16.
Preparation
In preparation for flushing, hydraulic cylinders, directional valves and other items susceptible to damage
should either be replaced with flushing blocks, by-passed by hoses or pipes or completely dismantled.
Any small parts dismantled should be stored in clean plastic bags. All parts should be stored in a clean
area.
TEMPORARILY RE-PLUG THE PORTS OF THE COMPONENTS DISCONNECTED.
In order to flush the isolation system efficiently and in a timely manner, it is recommended that the
following preparation is conducted:
Using a temporary hose connect the PRESSURE AND RETURN hoses at the
rockbreaker valve (i.e. so the rockbreaker valve is by-passed).
Remove any items from the circuit which can not tolerate any contaminants so that
they are not damaged. In their place, temporary bridging hosing or pipe spools should
be fitted which are rated to 330 Bar.
Ensure sufficient trays / buckets are available to collect any spillage of oil when hoses
are disconnected
Ensure facilities are available to clean filter elements and several spare filter elements
are readily available if required.
If oil cleanliness samples are required, have suitable clean sample containers from the
nominated testing laboratory ready for sample collection.
5.4.17.
Before filling, all oil bearing parts of the system, in particular oil tanks, filters and pipelines should be
checked for cleanliness.
25
A check should also be made that the piping circuit is complete and that all valves fitted are correctly in
the open or closed position according to their function and / or the requirements for the system flushing.
NOTE: Tank covers and air filters should be correctly secured to prevent the infiltration of unfiltered air
into the tank.
IMPORTANT NOTE 1:
Before operating the drive motor, all suction line valves must be in the
operating position.
IMPORTANT NOTE 2
Before start-up it must be certain that the hydraulic pump has been bump
started to confirm it is rotating in the correct direction. (A direction of
rotation arrow should be fitted to assist). This check needs to be
identified as completed on the Pre-Commissioning Checklist Form before
proceeding (See Important Note 3 below).
IMPORTANT NOTE 3
Before operating the system, the Installation and Pre-Commissioning
Checklist Form needs to be completed and signed by the Installation
Contractor and an authorised Client Representative to verify that the
installation has been completed in accordance with Transmins
requirements.A copy of this form is included in this manual. DO NOT
PROCEED UNTIL THIS FORM IS SIGNED AND APPROVED.
5.4.18.
System flushing is intended to ensure the removal of all weld slag, weld spatter, dirt and any other
foreign materials from the internal surfaces of the piping.
Subject to client requirements, it may be necessary to utilise a specifically designed high flow flushing
unit to carry out flushing of the system.
26
It is generally acceptable however to flush the system using the system power pack itself with the
specified filter element and to install additional return filters in the system where required to protective
sensitive equipment from damage due to dirt and foreign particles.
Where a return line filter is fitted to the hydraulic power unit, generally no additional filters are required if
the steps in Section 4.3.1 are followed.
If using a separate flushing rig, flushing is carried out progressively down to the lowest micron filter rating
in the system.
FLUSHING PROCEDURE
For each isolated flushing circuit, the following procedure should be followed:
In the Normal Flow direction, run the hydraulic power pack CONTINUOUSLY for 20
minutes to flush the lines
If a separate dedicated flushing rig is being used, the system should be run and flushed
continuously for 20 minutes for each progressive filter rating.
Once the 20 minutes is complete, the filter elements should be checked and cleaned if
necessary. If the filter has collected a large quantity of contamination, flushing should
be repeated for another 20 minutes. Flushing is usually deemed complete when visual
inspection shows no collection of contamination in the filter elements.
IMPORTANT NOTE
During flushing the oil circuit return line MUST ALWAYS REMAIN
COMPLETELY OPEN TO TANK. As a result, full system pressure will not
develop in the lines and this will allow the flow to be reversed in the
system as part of the flushing procedure if this is required.
PRESSURISING THE RETURN LINE FROM THE VALVE TO THE HPU WILL
RESULT IN BURST PIPES AND HOSES.
27
IMPORTANT NOTE
It will be necessary to progressively top-up the reservoir during the
flushing procedure until the entire system is filled with oil. ENSURE
THAT THE RESERVOIR LEVEL IS MAINTAINED AT THE CORRECT
OPERATING LEVEL AT ALL TIMES.
Flushing Completion
Upon the completion of flushing, remove any temporary filters, change or clean the filter elements in the
system (as appropriate) and then successively remove bridging pieces from the circuit and immediately
replace the items removed for flushing taking care not to introduce contaminants into the system.
The piping can be connected to the hydraulic cylinders, and the LOP assemblies can be connected to
the piping.
NOTE: Connect each element one at a time and immediately upon removing covers from ports or
blanking plates. Do not leave any piping or hosing disconnected longer than absolutely necessary and
ensure that no water or dirt enters the system as the piping is connected.
Any spilled oil should be immediately cleaned up in accordance with the site environment requirements
and then the oil reservoir should be topped up to the appropriate level.
5.4.19.
Once all the removed components are re-installed in the circuit after flushing, and the normal system
filter elements are cleaned and / or replaced, the system should again be run to ensure the entire system
is filled with oil.
NOTE: MONITOR THE HYDRAULIC POWER PACK RESERVOIR LEVEL AT ALL TIMES AS THE
CYLINDERS ARE OPERATED AND TOP UP AS REQUIRED.
All hydraulic cylinders should now be operated to ensure that the entire system of is filled with hydraulic
oil.
AGAIN, ENSURE THAT THE RESERVOIR LEVEL IS MAINTAINED AT THE CORRECT OPERATING
LEVEL AT ALL TIMES BY TOPPING UP AS REQUIRED.
CAUTION: DO NOT OVER FILL THE HYDRAULIC POWER UNIT. TAKE NOTE OF THE STATUS OF
THE CYLINDERS WHEN ASSESSING OIL LEVELS AS THE HYDRAULIC POWER UNIT LEVEL IS
LARGELY DEPENDENT ON WHICH CYLINDERS ARE OPEN OR CLOSED.
Air in the system will affect the performance of the machine. It can cause jerky movements and bounce
of the rockbreaker boom assembly.
The pipe circuit is fitted with a number of air bleed points to allow air to be bled from the system.
Whilst the system is operating, each of these bleed points should be opened to allow any trapped air to
escape.
Each of the bleed points is fitted with a ball valve and plug. The plug should be removed and a hose
connected to the valve to capture any oil discharged whilst bleeding the lines.
Once each point is bled, the valve should be closed, the drain hose removed and the plug firmly
replaced.
28
The rockbreaker is fitted with a number of bleed points to allow for the air to be removed or system
pressure checks. Refer to the IOM for details.
If there are no bleed points on the hydraulic cylinders they can be bled by operating the cylinder to the
end of its stroke and then cracking the hose end fitting at the same end. Then operate the valve very
slowly in the opposite direction until all air is out of the cracked fitting. Secure the fitting
Hydraulic oil and grease pressure within fittings, tubing, and hosing can
be dangerous. Ensure all lines are free of pressure before disconnecting.
5.4.20.
Pressure Testing
With all components installed into the circuit, the system should be brought up to full system pressure
and all connections should be visually checked for signs of leakage.
Pressure should be maintained for at least 10 minutes to ensure that any leaks can be located and
rectified prior to proceeding with the commissioning of the hydraulic power pack and isolation gates.
During commissioning, further inspections for any signs of leaks will be conducted.
5.5. Commissioning
Verification that the system has been installed in accordance with the drawings and this manual is to be
recorded on the Commissioning Records provided at appendix C.
It is a requirement of Transmins warranty that prior to use, the Commissioning checks as listed on these
forms are completed in full and signed by an authorized person. When completed, fax or email the final
sheet to Transmin and retain a copy for your own records.
Failure to complete these checks could result in damage to the equipment or injury to personnel.
IN THE EVENT OF A WARRANTY CLAIM, TRANSMIN WILL REQUIRE THIS FORM TO BE
PROVIDED AS PROOF THAT THE SYSTEM WAS INSTALLED AND COMMISSIONED CORRECTLY
29
6. OPERATING INSTRUCTIONS
6.1. Routine Operator Checks
To ensure that the Rockbreaker and HPU are operating correctly, operators should be instructed to carry
out the following visual checks at start up and during each shift:
Ensure that the oil temperature is at least 10C before attempting to move the
rockbreaker. On HPU start-up the immersion heater will warm the hydraulic oil.
During operation always check and watch that all machine functions operate normally.
Report any abnormality or damage to your supervisor
Check for any unusual noises during operation which may indicated loose fasteners or
inadequate lubrication,
Ensure that all safety guards are securely fitted and are in good condition,
Check for signs of hydraulic oil leaks, BUT DO NOT USE FINGERS,
Check the HPU filters are not indicating the elements need replacing,
Check that the hammer mounting bolts and hydraulic hoses are tight
Any potential problems should be reported immediately to the maintenance supervisor and (if necessary)
the machine stopped and isolated to investigate the problem to avoid damage to the machine or risk of
injury to personnel.
DO NOT USE FINGERS when checking for oil leaks, oil under pressure
can enter the skin and cause poisoning. Get a qualified hydraulics
technician to perform the detailed checks if oil is evident.
30
6.2.1.
To use the rockbreaker and the HPU for normal operation make sure the HPU and radio transmitter is
set to the following:
released
on
remote mode
HMI screen:
no alarms
released
6.2.2.
Press the P/PACK START on the radio transmitter once (battery indicator light starts
blinking).
The pump starts and the rockbreaker can be moved, using the joysticks on the radio
transmitter.
31
6.2.3.
Using the remote radio controller, park the rockbreaker in its dedicated parking position
and press the STOP button on the radio transmitter.
6.2.4.
To operate the hammer, press one of the HAMMER buttons on the radio transmitter when the
rockbreaker boom is positioned correctly on a rock.
When operating the hammer, the following guidelines should be followed for optimum use:
Before operating the hammer ensure that the tool is correctly fitted. The hammer
assembly must be positioned firmly down on top of the rock before operating the
hammer switch.
During activation of the hammer switch the operator should listen for the sound of the
blow when the hammer is running. A solid blow indicates that correct rockbreaking
action is occurring. A hollow blow indicates that the hammer is not correctly positioned
and not providing an efficient breaking action. Re-position the hammer on the rock
before operating the hammer switch again.
The HPU control system is fitted into a cabinet and mounted on the HPU frame. It contains switch gear,
safety system, client interface and a PLC unit with HMI.
The PLC unit controls the motors, valves and switch gear of the HPU, based on the status of external
signals, sensors, switches and safety system.
Power source of the HPU is a 460VAC 3phase mains supply.
The operator interface is integrated into the panel door and consists of the following components:
HMI Panel. The HMI Panel is used to indicate alarms and navigate through the HPU
functions.
6.3.2.
Emergency Stopping is achieved via a safety relay rated to Category 2, AS4024 (EN 954). The relay is
tripped via the emergency stop push button on the front of the control panel. This type of emergency
stop is a single channel monitored type circuit. It is designed to detect faults in the safety system;
however faults may lead to a loss of safety function. In order to guard against loss of safety function, the
emergency stop function shall be periodically operated as part of the maintenance routine. The period of
testing shall be determined by the end user based on the expected frequency of use of the Rockbreaker.
The RESET for the emergency stop is found in the HMI.
6.3.3.
33
The HPU has 3 operation modes which are selected with the selector switch located on the HPU
cabinet:
LOCAL mode
OFF mode
REMOTE mode
The OFF position prevents the HPU from operating. In REMOTE mode, the HPU can be started by an
external source such as the radio controllers. LOCAL mode can be used during maintenance or fault
finding, and individual motors and devices can be started locally to check their operation. Safety
interlocks such as emergency stop buttons will function in both modes.
6.3.4.
LOCAL Mode
In LOCAL mode, the motors and heater (if fitted) can be started and stopped individually. LOCAL mode
is available for use as a tool to assist in maintenance, fault finding and commissioning.
To operate in LOCAL mode, the control panel selector switch must be set to the LOCAL position. The
hydraulic pump and cooling fan can then be run individually by selecting the appropriate screen on the
HMI and selecting start from that screen. The motor can then be either stopped from the HMI screen or
by tuning the mode selector switch to OFF.
Any shutdown signal will cause the local start to unlatch. This requires a restart from the HMI once the
cause of the shutdown has been cleared.
When the control panel selector switch is set to the LOCAL position, the remote stop/start control is
locked out. However, all interlocks such as Emergency Stop buttons and thermal overloads remain
operable to prevent the operation of motors where necessary to protect equipment from damage.
6.3.5.
REMOTE Mode
When set to REMOTE mode the HPU is started and stopped via the radio transmitter.
When operated in REMOTE mode the cooling fan, oil heater and unloading valve is controlled
automatically by the PLC.
The following interlocks are preventing a REMOTE start or trip the operation of the HPU:
34
6.3.6.
HMI Screens
The HMI screen with its function keys is used to show the HPU conditions, warnings and alarms and to
operate the HPU in local mode. The reset function is assigned to a function key as well.
There are 8 screens, to navigate through the first 7 screens, use the function keys F9/F10. Screen 8 can
be accessed via the function keys mentioned on screen 7. To operate the HPU, access alarm pages and
swap between screens, use the function key as noted on each individual screen (see Figure 8)
Figure 8 - HMI Screens
Screen 1: main.
Line 1: HPU mode information
Line 2: HPU status information
Line 3: oil temperature
35
36
37
6.3.7.
The following shutdown devices are utilised to protect the hydraulic power unit from damage:
All shutdown devices are arranged for failsafe operation and the associated PLC input must be
energised for the power unit to run.
When tripped, these shutdown devices will cause:
Release the Power unit Healthy dry contact to the Client's Plant Control System (PLC
or DCS (Distributed Control System)).
The RESET button (on HMI screen) will reset all alarms, reset all shutdown devices and reset all output
signals to healthy and reset the emergency stop relay. However, if the shutdown condition has not been
rectified, the shutdown device will re-trip.
The alarm reset button is located on the HMI.
To obtain access and reset any motor circuit BREAKER or thermal overload, the isolation switch must be
turned to the OFF position and the panel door opened.
6.3.8.
Alarms
The following alarms are displayed on the HMI panel. These alarms will cause the power unit to shut
down and the Power unit Healthy dry contact to be switched off:
38
The following warnings are displayed on the HMI panel. These warnings will not cause the power unit to
shut down:
Grease Low
All alarms and warnings are reset from the HMI. Pressing RESET will reset all alarms and reset all
output signals to healthy. However, if the alarm condition has not been rectified, the alarm will re-trip.
6.3.9.
Grease Pump
The Transmin supplied grease and lubrication system is a standard option. If this is not fitted, then the
grease pump inputs are bridged out. For grease pump and injector information refer to appendix F
39
7. MAINTENANCE INSTRUCTIONS
7.1. Introduction
This section details the minimum preventive maintenance required to keep your machine in a safe and
serviceable condition. Careful performance of this maintenance will ensure long machine life.
The maintenance schedule lists the maintenance items with their recommended intervals. The intervals
are based on standard operating conditions and an average eight-hour operating day or approximately
2000 operating hours per year. Under no circumstances should the recommended intervals be
exceeded. When operating under extreme weather conditions and/or higher operating rates, the intervals
should be reduced accordingly.
CAUTION: ENSURE that all motors are switched off and isolated and
that pressure is released before attempting to service hydraulic
components and piping
40
41
7.4.1.
Hydraulic Oil
The recommended oil for the HPU and Rockbreaker depends on the operating environment, site
conditions and whether an oil heater is fitted in the HPU tank. Refer to section 11.2 specification for tank
capacity.
42
7.4.2.
Filtration
The maintenance schedule in appendix C sets the frequency of maintenance tasks. As a guide the filters
should be replaced in accordance with Table 1
Description
Frequency
Pressure Filter
First Change
Return Filter
Filling Filter
Hydraulic Tank
Breather
Third Change
500 hrs
Thereafter
Slew Gearbox
Breather
7.4.3.
Lubrication
Regular and correct lubrication is essential to ensure correct and reliable operation of the Rockbreaker. It
is extremely important that the lubrication schedules in appendix E are followed to avoid cross
contamination of incorrect oil. Should conditions vary during the life of the Rockbreaker, please contact
Transmin for a review of the lubricants that are recommended.
43
Before replacement, ensure that all motors are switched off and isolated
and that pressure is released before attempting to service hydraulic
components and piping
Transport
This large diameter bearing (see Figure 11) requires careful handling. It should be transported and
stored in the horizontal position; if it must be transported vertically, it will require cross bracing. Impact
loads, particularly in a radial direction, must be avoided.
7.6.2.
Storage
The bearing has a protective coating and can be stored for up to six months in a roofed storage area or
up to twelve months in an enclosed temperature controlled area.
7.6.3.
Installation
The bearing support surface must be absolutely flat. The upper and lower ring must make perfect
contact and this must be checked using a levelling instrument or a feeler gauge. If the out-of-flatness
exceeds 0.2 mm the contact surfaces may require re-machining.
44
7.6.4.
Assembly procedure
Clean bearing taking care not to allow any solvent to penetrate into the bearings.
Fit bearing to slew base first. Locating dowels, 4 off, must be used to correctly locate
the bearing to the to the slew base. These dowels must remain in position until all
remaining capscrews have been torqued to their final setting.
Fit all capscrews to holes and fit plain nut to every 6th capscrew using 3/4 drive rattle
gun to tighten sequentially crosswise.
Fit cone lock nuts using Loctite 262 and tightening using pneumatic nut runner to
correct setting, tightening sequentially crosswise.
Fit and purge slew bearing grease lines prior to final assembly of mounting face to slew
bearing (check all hoses are labeled and lengths recorded).
Using locating dowels position bearing onto fixed base, these are to remain in position
until all other capscrews have been torqued to their final setting.
Fit all capscrews to holes and fit plain nut to every 6th capscrew using 3/4 drive rattle
gun to tighten sequentially crosswise.
Fit cone lock nuts using Loctite 262 and torquing using pneumatic nut runner to correct
setting, tightening sequentially crosswise to their final setting of 1395 Nm.
Gear teeth - At the point of maximum deviation of the pitch circle three teeth are marked in green. This
allows the satisfactory adjustment of the backlash. Refer to instructions on setting the backlash. After the
final tightening of the bearing capscrews the bearing gear should be checked around the entire
circumference.
7.6.5.
Lubrication
The first re-lubrication of the raceway must be carried out immediately after installation.
The raceway should be lubricated with grease such as Shell Superplant M or equivalent. The bearing
must be liberally greased so that a collar of fresh grease forms at the gaps and seals around the whole
circumference. The bearing should be rotated during re-lubrication. The gear teeth should be manually
lubricated with Moluballoy - open gear heavy or equivalent.
45
7.6.6.
Wear measurement
For assessing the condition of a bearing, it is recommended that its normal wear rate is determined. The
wear present in the raceway system shows itself by a change in the axial motion of the bearing. The first
measurement should be performed when the equipment is put into operation in order to obtain a base
value for subsequent repeat measurements.
The measuring points should be marked around the circumference, in four places 90 apart, while the
boom is kept in a specified position. Measurements are taken, as close to the bearing as possible,
between the underside of the bearing and the underside of the slewing frame. Slew the boom to the next
position and repeat the measurement procedure. When all positions have been measured, record the
base values.
The measurements should be repeated at regular periods, every six months is recommended, under
identical conditions to the base values. The difference between the values measured represents the
wear that has occurred. Once the wear reaches 0.6 mm it is recommended that the bearing be rotated
by unbolting the bearing and rotating the lower ring to even out the wear. When the wear reaches 2.0
mm it is recommended that the bearing be replaced
7.6.7.
If the bearing is to be re-positioned, the unhardened zone (soft spot) must be positioned outside the
main area of load.
46
The gearbox shaft is eccentric to the gearbox flange spigot so that the
correct backlash of the pinion to slew bearing can be achieved. If
reinstalling the same box and pinion make sure the gearbox is installed in
the same position and then check the backlash.
If a new gearbox and or pinion are installed the backlash must be set
Disconnect the hydraulic hoses at the motor ports and plug both the ports and the hoses. Remove the
bolts holding the gearbox to the slew frame.
To service or repair the gearbox, please contact Transmin.
Refitting the gearbox is the reverse of removal EXCEPT THAT THE BACKLASH BETWEEN THE
PINION AND SLEW BEARING MUST BE CORRECTLY SET.
7.7.1.
Setting of Backlash
The gear teeth on the slew bearing are marked in green on three (3) teeth that have the maximum
deviation from the pitch circle. Rotate the Rockbreaker carefully until these teeth are central in the bore
for the gearbox.
Thoroughly clean the faces of the slew bearing teeth and the pinion teeth. Fit the gearbox and pinion into
the bore and make sure the flange and spigot are fully seated, do not fit the gearbox retaining bolts at
this time.
Through the opening in the bottom of the slew frame (remove the cover if this has not already been done)
check the backlash between the pinion and bearing teeth.
The backlash is correct if it is between
Series 100
Series 130
If the backlash is not within specification rotate the gearbox assembly until the specification is achieved.
Fit the retaining bolts and recheck the backlash for the entire working slew range. When the backlash is
correct fit the gearbox retaining bolts with Loctite 243 and tension to M16 grade 8.8 190 Nm.
Coat the pinion with Moluballoy 777-2 open gear heavy duty grease and refit the cover to the bottom of
the slew frame.
47
7.7.2.
Slew Pinion
The gearbox(s) on Rockbreaker Series 100, 130 and 160 are fitted with a removable pinion.
To remove the pinion from the gearbox. Remove the 3 bolts holding the pinion retaining cap. If the same
pinion is to be fitted to the same gearbox, mark both the pinion and shaft so they can be reassembled in
the same place. This prolongs the spline life. Slide the pinion from the splines on the gearbox shaft.
To refit the pinion, or fit a new pinion. Grease the gearbox splines with general purpose grease. Slide the
pinion onto the gearbox splines, refit the retaining cap and tighten the retaining bolts to a torque of M14
grade 8.8 - 122Nm.
The gearbox shaft is eccentric to the gearbox flange spigot so that the
correct backlash of the pinion to slew bearing can be achieved. If
reinstalling the same box and pinion make sure the gearbox is installed in
the same position and then check the backlash.
If a new pinion is installed the backlash must be set as stated in the slew
gearbox section.
When the backlash is correct, coat the pinion with Moluballoy 777-2 open gear heavy duty grease and
refit the cover to the bottom of the slew frame.
7.7.3.
Slew Motor
If the pump motor requires replacement or repairs, please contact the Transmin Service Department.
Ensure that all motors are switched off and isolated and that pressure is
released before attempting to service hydraulic components and piping.
7.7.4.
Hammer
To replace the hammer, refer to the Vendor manual in appendix G. For service or replacement of
the hammer and/or hammer parts, please contact the Transmin Service Department.
Ensure that all motors are switched off and isolated and that pressure is
released before attempting to service hydraulic components and piping
48
7.7.5.
Pump motor
If the pump motor requires replacement or repairs, please contact the Transmin Service Department.
7.7.6.
If the oil cooler motor requires replacement or repairs, please contact the Transmin Service Department.
Hydraulic Pump
If the hydraulic pump requires replacement or repairs, please contact the Transmin Service Department.
Ensure that all motors are switched off and isolated and before attempting
to replace the hydraulic components and piping
7.7.8.
Cooling Pump
If the cooling pump requires replacement or repairs, please contact the Transmin Service Department.
Ensure that all motors are switched off and isolated and before attempting
to replace the hydraulic components and piping
49
7.7.9.
To service or repair the grease lubrication pump or injectors, refer to the Vendor manual appendix F.
Pump and Injector settings should not be changed unless Transmin is consulted first. Transmin must
assess the necessity and site conditions to warrant the change.
7.8.1.
Removal
Remove the three locking screws and disc-lock washers from both sides of the pivot
pin
Replace the screws into the jacking position and screw in evenly thus prising the taper
bush out. Repeat the operation on the other side until the pivot pin is released
7.8.2.
Assembly
Firstly, the assembly should be carried out by ensuring that the pin is located centrally and that the holes
in the taper bush align with the corresponding holes in the pin. The tapered surface of the pin and bush
should be lightly sprayed with CRC 5.56, DWF or equivalent. The bush retaining screws should be
treated with an anti-seize compound. The taper bushes should then be tapped lightly into place ensuring
that they protrude equally from each boss and the measured depth from the outside of the bush to the
pin is the same on each side. Once this set-up is correct, the following tightening procedure should be
adhered to:
Having fitted a pair of disc-lock washers to each locking screw (ensuring teeth are
inter-locking together), snug tighten all screws on both sides (lightly tapping the bush if
necessary) ensuring that pin and taper bushes sit evenly each side.
50
Torque all M12 locking screws alternately to 100Nm (It is important to torque screws
evenly on both sides of the pin, checking the pin depth regularly to ensure even
tightening), then alternately to 120Nm. Finally tighten all screws to 135Nm
Torque all M16 locking screws alternately to 100Nm (It is important to torque screws
evenly on both sides of the pin, checking the pin depth regularly to ensure even
tightening), then alternately to 200Nm. Finally tighten all screws to 270Nm
51
7.9. Pivot & cylinder pin removal and replacement tooling (optional extra)
Tooling is available for easy removal of the pivot pins for maintenance or replacement (see Figure 14).
For the purchase of this item, please contact the Transmin Service Department.
7.9.1.
Removal
Ensure there is adequate support around the pivot pin to be removed. After the taper bushes have been
removed as described in the previous section, an adapter is attached to the pivot pin using the existing
taper bush bolts.
The adapter used must be the same diameter as the pivot pin to be
removed.
The threaded rod assembly is then fed through the ram and puller and
screwed fully into the adapter. The hand pump is then activated to pull
the pivot pin out.
7.9.2.
Assembly
Assembly is exactly the same as the above procedure with the pivot pin being pulled in from the opposite
side. Ensure the pin is pulled through enough to be positioned centrally about the pivot.
52
53
8. WARRANTY STATEMENT
Goods supplied by TRANSMIN and warranted for a period of 18 months after delivery or 12 months from
commencement of operation, whichever is sooner.
Any goods in storage shall be inspected at 6 monthly intervals, by Transmin, to maintain the warranty
period. Any additional requirements for storage stipulated by Transmin shall be maintained for the
duration of storage.
54
(vi) In respect of all claims Transmin shall not be liable to compensate the Customer for
any delay in either replacing or repairing the workmanship/Goods or in properly assessing
the Customers claim.
(vii) Where Transmin elects to replace faulty parts, this warranty covers the supply of the
replacement parts only and does not cover the change over costs of replacement parts.
(viii) Transmin does not provide any warranty with regard to any Customer specified or
supplied Equipment or materials unless specifically approved in writing and will endeavor
to have the supplier provide any warranties on these Goods direct to the Customer.
(ix) Warranties will be conditional upon carrying out the site pre-commissioning inspection
and commissioning in accordance with Transmins requirements as detailed in the IOM
manuals as a minimum, and the timely submission of properly completed forms to
Transmin prior to any warranty claims.
8.3. Exceptions
The warranties given by TRANSMIN herein to the extent permitted by State and Federal law do
not cover:
(a)
Failure not reported to TRANSMIN within the warranty period specified here in.
(b)
(c)
Failures due to operation, either intentional or otherwise, above or below rated capacities
or in an otherwise improper manner.
(d)
Products which have in any way been tampered with or altered by anyone other than an
authorised representative of TRANSMIN.
(e)
55
9. SPARE PARTS
9.1. Ordering information
To order spare parts please quote the following information to help us provide prompt responses
to your Spare Parts enquiries.
Reference should be made to the recommended Spare Parts List at appendix B when ordering
parts.
It is strongly recommended that the recommended spare parts are held on site and maintained in
good condition in stores at all times during the operation of this plant. A number of these items
are long lead components, which could lead to significant down time if required in the event of
failure.
Equipment type
TM4215
Part number
Refer to appendix B.
Description of part
(Number of parts)
56
PART No.
DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
R601192
R600071
R600801
R600702
R600319
R600766
R600077
R600600
R600625
R601221
R601222
SLEW
GEARBOX & MOTOR
130 SERIES 5m BOOM
130 SERIES 5m JIB
130 SERIES BR3288 HAMMER BRACKET
BOOM CYLINDER
JIB CYLINDER
HAMMER CYLINDEER
HAMMER BR3288
LOCKING VALVE KIT, BOOM
LOCKING KIT, JIB
QTY.
1
1
1
1
1
1
1
1
1
1
1
57
58
PART No.
DESCRIPTION
1
2
3
4
5
6
13
14
18
20
22
23
24
25
R600031
R500077
R601193
R600034
R600638
R600152
R600636
R300878
44873
R600342
R601194
R600831
R600853
R508128
FIXED BASE
BEARING - SLEW
SLEW FRAME
RETAINING PLATE
PINION COVER PLATE
RETAINING PLATE - SPECIAL
ELECTRICAL BOX MOUNTING BRACKET
INDUSTRIAL ENCLOSURE PANEL
GREASE INJECTOR
PINION GREASE TUBE
ROCKBREAKER CONTROL VALVE
SLEW DOOR ASSEMBLY R.H.
SLEW DOOR ASSEMBLY L.H
MOTION CONTROL VALVE
QTY.
1
1
1
5
1
1
1
1
2
1
1
1
1
1
59
60
61
PART No.
DESCRIPTION
1
110
2
3
4
100
101
R600081
R600539
R600082
R600012
R500884
R600538
R500883
GEARBOX ASSEMBLY
BOLT HEX, HD
HYDRAULIC MOTOR
20 TOOTH PINION, 12 MODULE
PINION RETAINING PLATE
HYDRAULIC MOTOR BOLTS
PINION RETAINING PLATE BOLTS
QTY.
1
15
1
1
1
4
3
62
63
5m BOOM ARRANGEMENT
ILLUSTRATION No. IPBR00022 & IPBR00023
ITEM No.
1
2
3
4
5
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
100
101
102
PART No.
DESCRIPTION
R600801
R600189 P01
R600189 P02
R600189 P03
R600189 P04
R600243
R508210
R600186
R600185
R600180
R508202
R600175
R600789
R600558
R502282
R502281
44872
R601217
QTY.
1
1
2
1
5
6
2
2
2
12
1
1
1
4
12
6
2
2
4
12
4
12
4
6
16
2
2
2
16
48
64
65
5m JIB ARRANGEMENT
ILLUSTRATION No. IPBR00024
ITEM No.
PART No.
DESCRIPTION
QTY.
1
2
3
4
5
6
R600764
R600763
R600558
R600180
R600179
R508211
PIPE, HAMMER
130 SERIES, 5m JIB
THREADED ADAPTOR, ELBOEW
BUSH
BUSH
TAPERED CAP, HAMMER CYLINDER (NOT
SHOWN)
2
1
2
2
2
2
7
9
10
12
13
14
15
16
17
18
19
20
22
23
101
102
103
R5082010
R508204
R508202
R601212
H200500
H200067
H100006
44871
2
1
1
2
4
4
4
2
2
4
1
4
4
4
4
16
16
66
67
PART No.
DESCRIPTION
QTY.
1
2
3
4
5
6
R600584
R508204
R600172
R600712
R508211
R508210
1
1
1
2
2
2
7
8
9
10
11
12
50
51
R508209
R502281
44873
R600558
SET SCREW
WASHER DISC LOCK
3 INJECTOR MANIFOLD
THREADED ADAPTOR, ELBOW
THREADED ADAPTOR
THREADED ADAPTOR
SCREW, HEX HD, M12x45
SCREW, HEX HD M10x50
12
12
1
3
2
3
8
2
68
PART No.
DESCRIPTION
QTY.
1
2
3
4
5
6
42738
R600653
R504484
R500429
R501235
R502839
VALVE, BALL
GAUGE, LEVEL
GAUGE ADAPTOR
TEST COUPLING
BREATHER, AIR
VALVE, BALL
1
1
1
1
1
1
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
R505369
R601136
R505497
R402271
R600134
R601112
R600136
R600137
R600138
R600139
R600140
R600324
R600146
R600147
R600148
R601082
R601086
49369
R600144
44875
R402272
R300622
R600911
R501082
R600316
R600323
42852
R501239
R402244
R600145
R402244
R600269
R601020
49374-02
R601137
VALVE, BALL
PRESSURE GAUGE
VALVE, BUTTERFLY
SPACER, SIDE PORTED
DRIP TRAY
MOTOR SUPPORT FRAME
OIL COOLER FRAME
HYDRAULIC OIL RESERVIOIR
ROOF
INSPECTION COVER
ADAPTOR PLATE
SUPPORT BRACKET
TANK OUTLET ADAPTOR
SUCTION PIPE
COOLER SUCTION PIPE
OIL COOLER
MOTOR/PUMP ASSEMBLY
ELECTRICAL CONTROL CABINET
SUPPORT BRACKET, LUBRICATION UNIT
8 L LUBRICATION UNIT
DROP TUBE
TEMP SENSOR
FILLER STRAINER MTG PLATE
FILLER C/W STRAINER
RETURN FILTER GASKET
FILLER STRAINER GASKET
TEST HOSE
IMMERSION HEATER
SWITCH, THERMOSTAT
HEATER COVER
VISUAL INDICATOR
MOUNTING PLATE, ELECTRICAL CABINET
MOUNTING PLATE
NAMEPLATE
FILTER, RETURN
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
69
42
43
44
45
46
47
48
49
50
51
R600251
49374-03
R507652
R601207
R601206
R601226
R601238
R601239
43246
FILTER, PRESSURE
AUTOMATIC LUBRICATION PANEL
INLINE CHECK VALVE
GASKET, RETURN FILTER
SPACER PLATE, RETURN FILTER
SPACER BRACKET
PRESSURE PIPE, FILTER INLET
PRESSURE PIPE, PUMP OUTLET
TEST COUPLING
THREADED ADAPTOR
1
1
1
1
1
1
1
1
1
1
70
71
72
PART No.
1
2
3
DESCRIPTION
QTY.
R504016/01 Battery
R507736/01 Bellows - Joystick
R507736/03 Carry Belt - Hip
2
2
1
PART No.
DESCRIPTION
QTY.
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
3
73
R300215
R300286
CIRCUIT BREAKER 1P 4A DC
RCD 10A 30mA 2 P
2
2
R300213
R300292
R300410
R300411
R300720
R300721
R300722
R300623
R300231
R300240
R300241
R300238
R300239
R300222
R300225
R300723
R300226
R300227
R300228
R300229
R300276
R300277
R300433
CIRCUIT BREAKER 1P 2A
CONTACTOR 3P 9A 240VAC COIL
RELAY 2 POLE 24VDC
RELAY BASE 2 POLE
CONTROLLER BASE UNIT
CONTROLLER EXPANSION 16IN
CONTROLLER EXPANSION 8OUT
TRANSMITTER TEMPERATURE
AUXILLARY CONTACT MOTOR CB
TERMINAL 2.5mm2 SINGLE STACK
TERMINAL 2.5mm2 DOUBLE STACK
TERMINAL ENDPLATE
TERMINAL ENDPLATE DOUBLE STACK
TERMINAL STOPPERS
TERMINAL BLOCK LABELS
SAFETY RELAY
CABLE DUCT SLOTTED 25x80
CABLE DUCT SLOTTED 40x80
CABLE DUCT SLOTTED 80x80
DIN RAIL 35mm
TERMINAL COVER FOR ISOLATOR
TERMINAL COVERS
TERMINAL COVERS FOR CONTACTOR
TRANSFORMER 460:220 2200VA
AUXILIARY CONTACT CONTACTOR
1
3
2
2
1
1
1
1
2
R300230
1
1
2
1
4
74
75
11. SPECIFICATIONS
11.1. Scope of Supply
Transmins Scope of Supply for the Rockbreaker System comprises the following:
One (1) 110kW non-submerged power pack c/w control panel (derated to 97 kW)
Sandvik BR3288
Hammer Tools
1 x Blunt
Lubrication System
NA
NA
Faster Slew
NA
NA
NA
Options / Variations
NA
NA
:
76
Colour
Steel
HPU1100S
110 kW
Tank Capacity
600 L
Carbon Steel
Pump Type
Pump Model
Linde HPR
Control Valve
NA
Hydraulic Connections
Oil Cooler
Oil Heater
Yes
Yes
No
Yes
No
No
Hoses
Duffield
77
Filling Point
Parker
Filter Magnet
No
Cleanliness Level
17/15/12
Breather
Yes, Parker
No
Isolation
Transmin Standard
Control Panel
Motor Starters
Yes
Spill Tray
Yes
Yes
Additional Requirements
No
Oil Details
Shell Tellus S2 M 32
Surface Treatment
Colour
Power requirements
78
Transmin Doc
Reference
49243
R600191
49232
49232
49234
49234
General Arrangement
49233
49233
Reach Profile
49244-SH1
49244-SH1
49244-SH2
49244-SH2
49247
49247
49248
49248
Transport Diagram
49249
49249
49250
49250
49251
49251
Lubrication Schematic
49374-SH1
49374-SH1
49374-SH1
49374-SH1
49693
49693
49401
49401
Document Title
Boom Mounting and Loading Details
79
DRAWING No.
REVISION
260
250 CRS
TYP.
5
TYP.
GENERAL NOTES:
1. ALL LETTERING TO BE ENGRAVED BOLD.
2. ALL LETTERING TO BE COLOUR BLACK
5
TYP.
49374-SH1
0
4-HOLES O4.5 THRU'.
70
ROCKBREAKER NAMEPLATE
PART No
49374-01
DESCRIPTION
190 CRS
TYP.
90
ITEM
REMARKS
110
49374
200
12 TEXT
TYP. 3-LINES
45
7 TEXT
TYP. 5-LINES
155
170
185
1:1
170 CRS
TYP.
5
TYP.
350
5
TYP.
170 CRS
TYP.
49374-02
DESCRIPTION
70
REMARKS
170 CRS
TYP.
PART No
12 TEXT
TYP.
ITEM
45
90
180
HPU NAMEPLATE
12 TEXT
105
7 TEXT
TYP. 5-LINES
120
135
150
165
1:1
AUSENCO PROJECT No:
2172-0020
1
0
B
A
REFERENCE DRAWINGS
REV
DATE
BY
DESCRIPTION
APP'D REV
19/06/2012
RK
RK
DB
DB
AS BUILTS
ISSUED FOR CONSTRUCTION
UPDATED TO CLIENT MARK UPS
ISSUED FOR REVIEW
DATE
BY
DESCRIPTION
18/04/2013
18/04/2013
27/06/2012
THIRD ANGLE
COPYRIGHT
THIS DRAWING IS THE PROPERTY OF
TRANSMIN PTY LTD FOR WHICH WE
RESERVE ALL RIGHTS INCLUDING THOSE
RELATING TO PATENTS OR REGISTERED
DESIGNS. IT MUST NOT BE REPRODUCED
OR USED OTHERWISE OR MADE
AVAILABLE TO ANY THIRD PARTY
WITHOUT PRIOR PERMISSION IN WRITING.
35 DENNINUP WAY
MALAGA. W.A. 6090
PH. (08)9249 5755
FX. (08)9249 6116
DRAWN:
DATE:
APP'D:
DATE:
DB
19/06/2012
DH
19/06/2012
SHEET
1:1 UNO
TM4215
JOB NUMBER
ROCKBREAKER
EQUIPMENT NAMEPLATES & LABELS
DETAILS
CHK'D: DH
DATE: 19/06/2012
SCALE:
OF
DRAWING No.
49374-SH1
A1
REVISION
DRAWING No.
REVISION
49374-SH2
GENERAL NOTES:
1. ALL LETTERING TO BE ENGRAVED BOLD.
2. ALL LETTERING TO BE COLOUR BLACK
110
REMARKS
316 S/S
12 TEXT
TYP.
QTY
DESCRIPTION
1 1.6SHT 110x50
4
TYP.
DRG REF
49374
50
PART No
49374-03
34 CRS
ITEM
3
8
TYP.
55
TEXT CRS
1:1
6 SLOT
TYP.
8
TYP.
160
49374-04
49374
DESCRIPTION
1.6SHT 160x50
REMARKS
12 TEXT
TYP.
4
TYP.
QTY
50
DRG REF
34 CRS
PART No
80
TEXT CRS
8
TYP.
ELECTRICAL CONTROL
PANEL LABEL
ITEM
94
SLOT CRS
316 S/S
1:1
8
TYP.
6 SLOT
TYP.
144
SLOT CRS
8
TYP.
110
55
TEXT CRS
PART No
DRG REF
QTY
49374-05
49374
DESCRIPTION
1.6SHT 110x50
REMARKS
12 TEXT
TYP.
4
TYP.
ITEM
34 CRS
50
6 SLOT
TYP.
8
TYP.
94
SLOT CRS
REV
DATE
BY
DESCRIPTION
APP'D REV
19/06/2012
RK
RK
DB
DB
AS BUILTS
ISSUED FOR CONSTRUCTION
UPDATED TO CLIENT MARK UPS
ISSUED FOR REVIEW
DATE
BY
DESCRIPTION
18/04/2013
18/04/2013
27/06/2012
THIRD ANGLE
COPYRIGHT
THIS DRAWING IS THE PROPERTY OF
TRANSMIN PTY LTD FOR WHICH WE
RESERVE ALL RIGHTS INCLUDING THOSE
RELATING TO PATENTS OR REGISTERED
DESIGNS. IT MUST NOT BE REPRODUCED
OR USED OTHERWISE OR MADE
AVAILABLE TO ANY THIRD PARTY
WITHOUT PRIOR PERMISSION IN WRITING.
35 DENNINUP WAY
MALAGA. W.A. 6090
PH. (08)9249 5755
FX. (08)9249 6116
DRAWN:
DATE:
APP'D:
DATE:
DB
19/06/2012
DH
19/06/2012
SHEET
1:1 UNO
TM4215
JOB NUMBER
ROCKBREAKER
EQUIPMENT NAMEPLATES & LABELS
DETAILS
CHK'D: DH
DATE: 19/06/2012
SCALE:
OF
DRAWING No.
49374-SH2
A1
REVISION
DRAWING No.
49401
REVISION
1
ITEM
PART No
DRG REF
QTY
ITEM
PART No
DRG REF
QTY
10
49374-01
49374
DESCRIPTION
REMARKS
40
49374-02
49374
20
49374-04
49374
50
49374-03
49374
30
49374-05
49374
DESCRIPTION
REMARKS
40
10
50
20
1
0
A
REFERENCE DRAWINGS
REV
DATE
BY
DESCRIPTION
APP'D REV
20/06/2012
RK
RK
DB
AS BUILTS
ISSUED FOR CONSTRUCTION
ISSUED FOR REVIEW
DATE
BY
DESCRIPTION
18/04/2013
18/04/2013
THIRD ANGLE
COPYRIGHT
THIS DRAWING IS THE PROPERTY OF
TRANSMIN PTY LTD FOR WHICH WE
RESERVE ALL RIGHTS INCLUDING THOSE
RELATING TO PATENTS OR REGISTERED
DESIGNS. IT MUST NOT BE REPRODUCED
OR USED OTHERWISE OR MADE
AVAILABLE TO ANY THIRD PARTY
WITHOUT PRIOR PERMISSION IN WRITING.
35 DENNINUP WAY
MALAGA. W.A. 6090
PH. (08)9249 5755
FX. (08)9249 6116
DRAWN:
DATE:
APP'D:
DATE:
DB
20/06/2012
DH
20/06/2012
SHEET
1:1
TM4215
JOB NUMBER
CHK'D: GN
DATE: 20/06/2012
SCALE:
DRAWING No.
49401
OF
A1
REVISION
80
13. APPENDICES
A.
B.
C.
D.
E.
F.
G.
Troubleshooting Guide
Spare Parts Lists
Commissioning Records
Maintenance Schedule
Lubrication Schedule
Lincoln Grease pump and injectors
Sandvik Hydraulic hammer
81
A. Troubleshooting Guide
The following sections are intended to provide a guide to help identify problem areas.
The charts are as follows:
In most instances, simple common sense will provide the location and cause of the problem.
However, in some cases, other causes such as low voltage supply and blocked hydraulic
filters may not be easily recognised and cause problems similar to those caused by other
conditions. Please contact Transmin engineers should you have any problems regarding
this issue.
The Stauff Mini Mess test points fitted throughout the hydraulic system are a powerful tool for
troubleshooting and setting up the machine to effect its best performance and life. The following
section shows the location of the points and the results that should be obtained if the system is
operating correctly.
82
C
D
NO MOVEMENT
No hydraulic pressure
Remedy 1, 5, 6 & 7
Worn or Damaged
cylinder
Remedy 3
Mechanical Binding
Remedy 2 & 3
Broken hose
Remedy 3
A
B
SLOW MOVEMENT
Low Flow
Remedy 1,2 & 5
Worn or Damaged
cylinder
Remedy 3
A
B
C
D
ERRATIC MOVEMENT
Erratic pressure
Remedy 1 & 5
Worn or Damaged
cylinder
Remedy 3
Air in Fluid
Remedy 1 & 6
No Lubrication of
Linkage
Remedy 4
REMEDIES
1.
Fluid
83
PUMP NOISY
Cavitation
Remedy 1 & 2
Coupling misaligned
Remedy 3 & 5
Air in fluid
Remedy 2
Pump worn or damaged
Remedy 5
REMEDIES
1. Any or all of the following:
3. Align unit to within 0.1mm parallel alignment and check condition of seals and bearings.
4. Check with pressure gauge and adjust to correct pressure
5. Recondition.
84
PUMP HEATED
A
Air in fluid
Remedy 2
Excessive load
Remedy 3
Cavitation
Remedy 1
Fluid heated
Remedy 1
Pump worn or damaged
Remedy 4
D
E
ELECTRIC MOTOR
HEATED
Motor worn or damaged A
Remedy 4 & 6
Excessive load
Remedy 3
C
D
E
FLUID HEATED
System pressure too
high
Remedy 1 & 5
Relief valve or valves
constantly blowing
Remedy 4
Fluid dirty or low level
Remedy 5
Incorrect fluid viscosity
Remedy 5
Faulty fluid cooling
system
Remedy 4
Worn Pump, valve,
motor, cylinder or other
component
Remedy 4
REMEDIES
1.
2.
3.
Fill reservoir
Install clean filters
Clean clogged inlet line
Clean air breather
Change system fluid
Align unit to within 0.1mm parallel alignment and check condition of seals and bearings.
85
Replace or recondition
86
No flow
Remedy 1, 2,
3&5
LOW PRESSURE
A
ERRATIC
PRESSURE
Air in fluid
Remedy 2
Pressure relief
valve blowing
Remedy 1, 2 & 4
Excessive
external leakage
Remedy 2 & 5
Worn relief
valve
Remedy 5
Contamination
in system
Remedy 1
Worn pump or
cylinder
Remedy 5
EXCESSIVE
PRESSURE
Relief valve
maladjusted
Remedy 4
Worn or
damaged relief
valve
Remedy 5
REMEDIES
1. Install clean filters and check fluid level.
2. Any or all of the following:
87
NO FLOW
Pump not receiving fluid
Remedy 1
Pump drive coupling
sheared
Remedy 3
Pump drive motor turning
in the wrong direction
Remedy 7
Directional control set in
wrong position
Remedy 6
LOW FLOW
Flow control set too low
or failed to open
Remedy 4
Relief or unloading
valve set too low
Remedy 4 & 5
External leak in system
Remedy 2
EXCESSIVE FLOW
Flow control set too high
Remedy 4
REMEDIES
88
89
DESCRIPTION
PART NO
RECOMMENDED
QUANTITY
UNIT COST A$
TOTAL PRICE A$
R600282
$ 128.00
$ 256.00
R600807
$ 428.00
$ 856.00
R508155
$ 360.00
$ 720.00
R508175
$ 325.00
$ 650.00
*5
R600495
$ 425.00
$ 425.00
*6
R600494
$ 468.00
$ 468.00
Motor Slew
R600082
$ 1,983.00
$ 1,983.00
*6
Relief Valve
R600277/220
$ 207.00
$ 207.00
*7
R501238
$ 184.00
$ 184.00
*8
R501234
$ 254.00
$ 254.00
Test Coupling
R500429
$ 47.00
$ 188.00
10
R600634/H20
$ 575.00
$ 1,150.00
11
R600634/H21
$ 447.00
$ 894.00
PLEASE NOTE :- All prices quoted are Ex-works Transmin`s factory, Malaga Western Australia.
All prices quoted remain valid until 30th December 2012 ( GST not included )
One of each item marked * required for commissioning
90
DESCRIPTION
PART NO
RECOMMENDED
QUANTITY
UNIT COST A$
TOTAL PRICE A$
R501234
$ 254.00
$ 254.00
R501238
$ 184.00
$ 184.00
R600082
$ 1,983.00
$ 1,983.00
R600766
$ 23,821.00
$ 23,821.00
R600077
$ 22,477.00
$ 22,477.00
R600600
$ 21,646.00
$ 21,646.00
R508204
$ 466.00
$ 932.00
R508202
$ 597.00
$1,194.00
R600172
$ 1,763.00
$ 1,763.00
10
R600789
$ 660.00
$ 1,320.00
11
R600175
$ 1,885.00
$ 1,885.00
12
R600174
$ 2,402.00
$ 2,402.00
13
R600180
$ 988.00
$ 3,952.00
14
R600179
$ 862.00
$ 1,724.00
15
R600186
$ 428.00
$ 1,712.00
16
R600185
$ 415.00
$ 1,660.00
17
R508210
$ 368.00
$ 1,472.00
18
R508211
$ 338.00
$ 1,352.00
91
19
Setscrew M12
R508209
42
$ 10.00
$ 420.00
20
Setscrew M16
R600208
12
$ 12.00
$ 144.00
PLEASE NOTE :- All prices quoted are Ex-works Transmin`s factory, Malaga Western Australia.
All prices quoted remain valid until 30th December 2012 ( GST not included )
92
DESCRIPTION
PART NO
RECOMMENDED
QUANTITY
UNIT COST A$
TOTAL PRICE A$
21
R502281
42
$ 4.50
$ 189.00
22
R502282
12
$ 5.50
$ 66.00
23
R508172
$ 177.00
$ 354.00
24
R508152
$ 318.00
$ 636.00
25
R600791
$ 441.00
$ 882.00
26
R508176
$ 14.00
$ 28.00
27
R508156
$ 33.00
$ 66.00
28
R600790
$ 39.00
$ 78.00
29
R508128
$ 1,646.00
$ 1,646.00
30
R600081
$ 14,225.00
$ 14,225.00
31
R600281
$ 462.00
$462.00
32
R600282
$ 128.00
$128.00
33
R600280
$ 176.00
$ 176.00
PLEASE NOTE :- All prices quoted are Ex-works Transmin`s factory, Malaga Western Australia.
All prices quoted remain valid until 30th December 2012 ( GST not included )
93
DESCRIPTION
PART NO
RECOMMENDED
QUANTITY
UNIT COST A$
TOTAL PRICE A$
1.
155206
$ 2,369.00
$ 2,369.00
2.
Top Buffer
154317
$ 876.00
$ 876.00
3.
Side Buffer
155438
$ 492.00
$ 984.00
4.
153235
$ 625.00
$ 1,250.00
5.
Tool - Chisel
881
$ 2,090.00
$ 8,360.00
6.
Tool Blunt
884T2
$ 2,190.00
$ 8,760.00
7.
Wear Plate
162598
$ 837.00
$ 1,674.00
8.
Wear Plate
162597
$ 1,155.00
$ 2,310.00
9.
Retaining Pin
155553
$ 265.00
$ 265.00
10.
Plug
104530
$ 186.00
$ 372.00
11.
Retaining Ring
153236
$ 29.00
$ 29.00
PLEASE NOTE: - All prices quoted are Ex-works Transmins factory, Malaga, Western Australia
All prices quoted remain valid until 30th December 2012 - (GST Not Included)
94
COMMISSIONING SPARES
110KW ROCKBREAKER POWERPACK
ITEM
DESCRIPTION
PART NO
RECOMMENDED
QUANTITY
UNIT COST
TOTAL PRICE
R600252
A$
$ 516.00
A$
$ 516.00
R600254
$ 446.00
$ 446.00
R501253
$ 328.00
$ 328.00
R505476
$ 467.00
$ 467.00
PLEASE NOTE: - All prices quoted are Ex-works Transmins factory, Malaga, Western Australia
All prices quoted remain valid until 30th December 2012 - (GST Not Included)
95
DESCRIPTION
PART NO
RECOMMENDED
QUANTITY
UNIT COST A $
TOTAL PRICE A $
Battery
R504016/01
$ 356.00
$ 712.00
Bellows - Joystick
R507736/01
$ 144.00
$ 288.00
R507736/03
$ 424.00
$ 424.00
PLEASE NOTE: - All prices quoted are Ex-works Transmins factory, Malaga, Western Australia
All prices quoted remain valid until 30th December 2012 - (GST Not Included)
96
DESCRIPTION
PART NO
RECOMMENDED
QUANTITY
UNIT COST A$
TOTAL PRICE A$
R601140
$ 330.00
$ 660.00
R508158
$ 320.00
$ 640.00
R508178
$ 310.00
$ 620.00
R601139
$ 295.00
$ 590.00
R500866
$ 285.00
$ 570.00
R501297
$ 275.00
$ 550.00
ERP1
$ 3,350.00
$ 3,350.00
R501029
$ 524.00
$ 624.00
R501168
$ 65.00
$ 130.00
10
R501026
$ 235.00
$ 235.00
11
R501167
$ 245.00
$ 245.00
12
R501182
$ 255.00
$ 255.00
13
R501169
$ 265.00
$ 265.00
R501254
$ 765.00
$ 765.00
PLEASE NOTE: - All prices quoted are Ex-works Transmin`s factory, Malaga Western Australia.
97
All prices quoted remain valid until 30Th December 2012 (GST Not Included)
98
C. Commissioning Records
99
-1-
: _________________________
Revision
: _________________________
Contract No.
2172-0020
Project
: TM4215
Site
: Constancia Project
Description
A)
NAMEPLATE CHECK
ME-316
3111-LU-002
HP1100S
350 Bar
______________
Manufacturer:
TECO
Installed Power:
Speed:
1780 RPM
Frame Size:
D280S/M
164A
460V 60HZ
______________
J:\JOBFOLDERS\TM4200-4299\TM4215 HUDBAY PERU AUSENCO (CONSTANCIA PROJECT) Rockbreaker\3 VDDR Documentation\3.22 Commissioning record
(COM)\COMMISSIONING RECORD (HYDRAULIC SYSTEM).doc
-2-
B)
All interconnecting hydraulic hosing, tube / pipe between hydraulic power pack has been installed
correctly.
:
____________________
All site run piping, hosing and fittings is as per design drawings, registers and installation procedures
followed.
:
____________________
Isolation valves from power pack have been opened and locked in position. Ref to site rep for site specific
isolation lock requirements.
:
____________________
Correct Hydraulic oil grade used as per Transmin specifications. Note if different to Transmin
specifications Transmin must approve the oil in writing.
:
SHELL TELLUS S2 M 32
____________________
____________________
Correct Grease grade used as per Transmin specifications. Note if different to Transmin specifications
Transmin must approve the grease in writing.
:
SHELL ALBIDA HDX2
____________________
____________________
____________________
____________________
YES / NO / NA
**Only do above if contaminates were introduced during install. All parts are cleaned and sealed prior to
dispatch.**
____________________
Purge air from load sensing line from power pack test point. :
____________________
Purge air from load sensing line from control valve test point. :
____________________
____________________
____________________
J:\JOBFOLDERS\TM4200-4299\TM4215 HUDBAY PERU AUSENCO (CONSTANCIA PROJECT) Rockbreaker\3 VDDR Documentation\3.22 Commissioning record
(COM)\COMMISSIONING RECORD (HYDRAULIC SYSTEM).doc
-3-
C)
____________________
____________________
Signature
YES / NO
YES / NO
All motors should be bump started to confirmation that direction of rotation is in accordance with labels.
Direction of Rotations checks are to be recorded below:
Cooler fan blades are concaved when viewed from fan motor Non drive end . IE pull air through matrix
and blow past cooler fan motor (if fitted)
: ______________
______________
______________
Signature
Signature
J:\JOBFOLDERS\TM4200-4299\TM4215 HUDBAY PERU AUSENCO (CONSTANCIA PROJECT) Rockbreaker\3 VDDR Documentation\3.22 Commissioning record
(COM)\COMMISSIONING RECORD (HYDRAULIC SYSTEM).doc
-1-
Project
Site
: Constancia Project
Document No. :
Revision
:
Contract No.
:
Transmin Job No. :
Description
:
A)
_____________________
_____________________
2172-0020
TM4215
Rockbreaker boom assembly
NAMEPLATE CHECK
Hammer
RB-118
3111-BK-001
______________
B)
PRE-START CHECK
STEEL / CONCRETE
STEEL STRUCTURE
: YES / NO / NA
: Correctly installed
Confirm bolt spacer has been fitted to slew base hold bolt.
do not proceed)
CONCRETE FOOTING
Confirm grout spacers have been fitted and levelled.
: YES / NO / NA
: Correctly installed
Confirm M36 grade 8.8 slew base hold down studs have all been torque to spec:
do not proceed)
J:\JOBFOLDERS\TM4200-4299\TM4215 HUDBAY PERU AUSENCO (CONSTANCIA PROJECT) Rockbreaker\3 VDDR Documentation\3.22 Commissioning record
(COM)\COMMISSIONING RECORD (ROCKBREAKER BOOM).docx
-2-
ALL ROCKBREAKERS
Confirm jib assembly has been correctly installed to the boom. Cap bolts torque correctly as per
specification, hydraulic hoses, grease hoses and electrical connections correct.: YES / NO (If NOT,
do not proceed)
All hydraulic cylinders in good condition. (INSPECT ROD AND BARREL FOR SIGNS OF IMPACT)
: YES / NO (If NOT, do not proceed)
C)
______________
Obstructions
All personnel cleared and safety procedures put in place including area bunting as required.
: YES / NO (If NOT, do not proceed)
______________
Signature: ___________________
Date: ______________
J:\JOBFOLDERS\TM4200-4299\TM4215 HUDBAY PERU AUSENCO (CONSTANCIA PROJECT) Rockbreaker\3 VDDR Documentation\3.22 Commissioning record
(COM)\COMMISSIONING RECORD (ROCKBREAKER BOOM).docx
-3-
D)
OPERATION TEST
Ensure all electrical, control devices and check lists have been fitted, tested & completed prior to proceeding:
Operate rockbreaker and cycle through complete range of all hydraulic cylinders 4x .
Slew fully left & right to check for clashing on the structure. :
Confirm that hoses interconnecting hoses from hose support stand have enough length when slewing
through the full range.
: YES / NO (If NOT, do not proceed)
Check rockbreaker, power pack & interconnecting tube work for any leaks
do not proceed)
______________
Signature
Signature
J:\JOBFOLDERS\TM4200-4299\TM4215 HUDBAY PERU AUSENCO (CONSTANCIA PROJECT) Rockbreaker\3 VDDR Documentation\3.22 Commissioning record
(COM)\COMMISSIONING RECORD (ROCKBREAKER BOOM).docx
D. Maintenance Schedule
Compliance with the following maintenance schedule is essential for the correct, safe and reliable
operation of the rockbreaker, HPU and associated equipment.
100
MaintenancePeriod
SubSystem
Activity
Afterfirstdayof
operation
Boom
HPU
All
TightenallM36basemountingboltsto2300 Nil
Nm
TightenallM24hammertopplatemounting Nil
boltsto640Nm
ChangeHydraulicOil
Fillerfilter
Checkforhydraulicleaks
HPU
1stchangepressureandreturnfilters
Boom
Inspectallpivotpinsexternallyandcheck
lockingscrewsfortightness
Inspecthydrauliccylinderglandsandfittings
forleaks
Checkallpointssuppliedbytheautomatic Nil
pivotgreaserarebeinggreased.
50hrsafter
commissioning
40hoursorweekly
Lubrication
HPU
Hammer
100hours
150hoursorMonthly
Drainslewgearbox/es,flushandrefill
All
Physicallycheckfastenersaretorqued
correctly:
pins
fixedbase
hammer
slewframe
Visuallycheckallotherfastenersforsignsof
looseconnections
Inspectallstructuralfeaturesfordamage
Hammer
Hydraulics
Pressure&Return
FilterElement
Consumeables SpecialTools
Remarks
required
Required
Nil
Torque
Wrench
Nil
Torque
Wrench
asrequired
Nil
Tightenfittingsorreplacepartsas
required
Nil
Freshgreaseshouldbeevidentat
allpivotpoints
Checkhydraulicpump,filters,tank,
hydrauliclinesandfittingsforleaks.
Checkthesepartsfortightness
Performhammermaintenanceasdescribed
inhammerinstructionmanual
Boom
Boom
SparePartsRequired
Torque
Wrench
Drainoilwhenhot
23L(nom)Filltomidpointof
sightglass
DONOTtightentheslewbearing
socketheadcapscrewswhichhas
beenfactoryfittedwithloctite.
Tightenanyloosefasteners
Checktheslewgearboxoillevel.Ifmorethan
1litre(~5%)requiredfortopup,thencheck
forleaks
Checkthehammertoolshankandtoll
bushingsforwear
Checktheconditionofallhydrauliclines
DONOTmixoilsofdifferenttypes
orgradeevenofthesamemake
Replaceifdamaged
Tightenfittingsorreplaceif
necessary
Checkforleakinghydraulicfluid
250hours
HPU
2ndchangepressureandreturnfilters
Pressure&Return
FilterElement
Nil
Nil
DocReference
Consumeables SpecialTools
Remarks
DocReference
required
Required
Nil
Subsequent,filterchangesat500
hrsintervalsorwhenindicatedby
filtergauge
Nil
Nil
MaintenancePeriod
SubSystem
Activity
SparePartsRequired
500hoursorQuarterly
HPU
3rdchangepressureandreturnfilters
Pressure&Return
FilterElement
ChangeHydraulicTankBreather
HydraulicTank
Breather
SlewGearboxBreather Nil
ChangeSlewGearboxBreather
Installation
Piping
1000hoursorsixmonthly Electrical
Boom
2000hoursorannual
servicing
Boom
Boom
HPU
Nil
Subsequent,filterchangesat
2000hrsintervalsorwhen
indicatedbyfilter
Checkforleaks
GreaseHPUMotorBearings
Checkslewdrivebacklash
Removepivotpinstoexaminewearonpins
andbushes
TightenallM24hammertopplatemounting Nil
boltsto640Nm
Drainslewgearbox/es,flushandrefill
27gofMobilPolyrexEM103
Adjustifnecessary
Nil
TECOTechnicalCatalogue
Torque
Wrench
Drainoilwhenhot
23L(nom)Filltomidpointof
sightglass
TightenallM36basemountingboltsto2300 Nil
Nm
Changehydraulicoil
FillerFilter
Cleantheinsideofthereservoirthoroughly
Nil
Torque
Wrench
Changeallfilters
Returnfilter
Pressurefilter
Fillingfilter
Hydraulictank
breather
Slewgearbox
breather
nil
nil
Changefillingfilter
fillingfilter
Nil
nil
Changehydraulictankbreather
HydraulicTank
Breather
Nil
Nil
Rockbreakermustbeparkedin
standardparkingpostion
RoutineInterval
Whenhydraulicoilis
replaced
HPU
Boom
Drainslewgearbox/es,flushandrefill
every500hrs
HPU
changepressure&returnfilters
every2000hrs
HPU
changehydraulictankbreather
every4500hrs
Electrical
GreaseHPUMotorBearings
Drainoilwhenhot
23L(nom)Filltomidpointof
sightglass
Pressure&Return
FilterElement
HydraulicTank
Breather
Nil
Nil
Nil
Nil
27gofMobilPolyrexEM103
MotorTechnicalCatalogue
E. Lubrication Schedule
101
Confidential
15/06/2012
Page 1
REVISION: A
LUBRICATION SCHEDULE
EQUIPMENT No.
DOCUMENT:4215-LBS-01
INITIAL LUBRICATION
QUANTITY (EACH)
Gearbox Oil
TBC
SHELL OMALA EP
23 litres
Gearbox pinion
TBC
N/A
Apply manually
Gearbox pinion
TBC
N/A
0.016 cc
Automatic
Slew Bearing
TBC
N/A
0.016 cc
Automatic
Pivot pins
TBC
N/A
0.016 cc
Cylinder pins
TBC
N/A
0.016 cc
Hammer
TBC
N/A
0.016 cc
Automatic
TBC
1000 hours
ITEM DESCRIPTION
MODEL NUMBER
MAINTENANCE PERIOD
COMMENTS
Page 1 / 1
102
With Follower
JULY 2009
Without Follower
Form 404034
Section
- C8
Page
- 321
Table of Contents
Page
Introduction
Explanation of Symbols Used ..................................................3
Users Responsibility ..............................................................3
Environmental Protection ........................................................3
Service ......................................................................................3
Safety Instructions
Appropriate Use ........................................................................4
Misuse ......................................................................................4
Exclusion of Liability .........................................................4
Regulation for Prevention of Accidents .....................................4
General Safety Instructions .....................................................4
Operation, Maintenance and Repair ........................................4
Repair ...............................................................................4
Disposal .............................................................................4
Operation / Maintenance .....................................................5
Installation..............................................................................5
Assembly and Maintenance of the Hydraulic Hoses ............5
Description of Pump..............................................................6
Description of Operation...........................................................9
Pump Element Operation........................................................10
Pump with Internal Pressure Switch ........................................11
Pump with Internal and External Pressure Switch .................11
Pump with Internal Pressure Transducer ...............................12
Pump with Internal and External Pressure Transducer..............12
!
Filling Reservoir with Grease...................................................13
Air Expel Procedure................................................................13
Pump with Folllower Plate......................................................13
Pump without Follower Plate...................................................14
Keypad and Display.................................................................15
"
#
$
Acknowledging a Fault............................................................19
Programming the Pump.........................................................20
Review of Pump Parameters...................................................25
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+$#
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8:
#
$-
List of Lubricants.....................................................................32
Dimensions .............................................................................35
.........................................................39
Mounting Template.................................................................40
Troubleshooting Guide.........................................................41
Parts List...............................................................................42
Page Number - 2
Form 404034
Introduction
Explanation of Symbols Used
Users Responsibility
Safety Instructions
Structure of safety instructions:
8
$
8
# <
8
=
8
8
><
?
The following pictograms are used in this manual and are com8
bined with corresponding signal words:
Environmental Protection
8)%%@%B
8)C%B
8')JN
8)%%@%B
8)C%B
8')JN
8B%@
8:BJ%)%
Service
The personnel responsible for the handling of the pump/sys8
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assistance, training, etc. Please contact the Technical Service
department for assistance.
In the event of inquiries pertaining to maintenance, repairs
Y<`$
V
Technical Services to clearly identify the components of your
pump/system.
Therefore, always indicate the part, model and series
number.
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manual:
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Listing of applicable statements
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1. Determination of the number or sequence of contents
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Form 404034
Page Number - 3
Safety Instructions
Appropriate Use
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8:
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the automatic lubrication of commercial vehicles, industrial,
construction and agricultural machines and wind power plants.
The P653S pump has been designed for intermittent opera8
tion and is not suitable for continuous operation. The pump is
capable of supplying lubricants up to NLGI # 2 grades. (see
!(
(
$$ |
Misuse
Any use of the P653S pump that is not expressly mentioned
in this User Manual will be regarded as misuse. If the P653S
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any claim for warranty or liability will be null and void.
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CAUTION !
( W$
$
8
curs as a result of inappropriate operation,
(e.g. if the safety instructions are ignored
or resulting from an incorrect installation
of the P653S pump), no claims or legal
actions may be taken against Lincoln
Industrial
Exclusion of Liability
The manufacturer of the P653S pump will not accept any li8
ability for damages caused by:
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the use of contaminated lubricants
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the use of greases which are not or only conditionally
pumpable by P653S pump
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inadequate disposal of used or contaminated lubricants
as well as of components that have been in touch with
lubricant
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(
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the use of unapproved parts
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operation without adhering to the minimum pause time
and respectively the maximum lubrication time (see chap8
ter Technical Data)
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Install the components of the P653S pump in such way
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pump reservoir.
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ments under follower plate.
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operate automatically. However, a regular check (approx.
every 2 days) should be made to ensure that lubricant is
pumped to all lubrication points.
Disposal
Dispose of used or contaminated lubricants as well as of parts
that were in touch with lubricant according to the legal regu8
lations pertaining to environmental protection. Make sure to
observe the safety data sheets of the lubricants used.
Page Number - 4
Form 404034
Installation
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WARNING!
Pump P653S must be installed by
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V
to the National Electrical code. Before
installing or working on the pump,
disconnect and lock out the incoming
power.
WARNING!
Failure to observe the safety instruc8
tions, (e. g. touching electrically charged
parts when the pump is opened, or
improper handling of the pump P653S)
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are exceeded, the device may overheat.
It may damage the pump P653S and
thus impair the electric safety.
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CAUTION!
Do not use the pump in potentially explo8
sive applications.
Form 404034
Page Number - 5
Description
Pump with Follower Plate
11
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stationary industrial type of applications requiring lubrication
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Pump basic model can be supplied with follower plate or
without follower plate. Follower plate is recommended in
stationary industrial type applications with heavy consistency
greases (NLGI #1 and #2) and for pumps used at low
temperatures applications in all installations.
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can lubricate more than 35 bearings.
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that are appropriate for the programmed/set
system pressure.
78#
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Page Number - 6
Pump P653S
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pumps greases up to NLGI 2 (per approved list) at
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develop maximum pressure up to 3,500 psig (240 bar)
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pressure transducer.
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Electrical connection
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cable is provided by installer.
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For mobile applications P653S pumps are equipped with
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connector.
Form 404034
Code example
p
P653S - 4
F 8 24 - 2A - AS06
Pump
p model,, basic
4 = 4L, transparent plastic
8 = 8L, transparent plastic
15 = 15L, transparent plastic
20 = 20L, transparent plastic
X = Grease pump
L = Low-level control
BO = Without follower
F = With follower
Power supply
pp y
24 = 24 VDC
AC = 110 - 240 V ; 50 - 60 Hz
Electrical cord and connections
1A DC;
- 33 ft. (10 m) cord, 7 conductors
2A DC;
- 33 ft. (10 m) cord, 7 conductors
- 33 ft. (10 m) cord, 4 conductors with bayonet
plugs for external pressure switch or transducer
2A = AC;
- 33 ft. (10 m) cord, 7 conductors
- 4-pole square plug
2A1 = AC;
- 7 poles bayonet plug
- 4-pole square plug
3A = AC;
- 33 ft. (10 m) cord, 7 conductors
- 4-pole square plug,
- 33 ft. (10 m) cord, 4 conductors with bayonet
plugs for external pressure switch or transducer
Pressure control,, PCB setting
g
AS01 - AS08 = Pressure switch (see jumper
setting table)
AS09 - AS16 = Pressure transducer (see jumper
setting table)
Example: P653S-4XLF-24-2A-AS06:
Pump consists of the following:
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Form 404034
Page Number - 7
Jumper
p setting
g combinations - Centro-Matic p
pumps
p
Pump combinations
Application:
Industrial
(S) -o; Mobil
(M) - x
Time (TC)
or count
control (CC);
TC -o; CC - x
Number of
pressure
Low-level F1 fault relay; F2 fault relay;
switches or
control;
(31) switch to (31) switch to
transducers. NO- o; NC - x ground - x
ground - x
o - one; x - two
AS04
AS05
AS06
AS07
AS08
Pressure transducer
AS09
AS10
AS11
AS12
AS13
AS14
AS15
AS16
Industrial (AC)
(S)
AS03
Mobile (DC)
(M)
Pressure switch
AS02
Industrial (AC)
(S)
AS01
Mobile (DC)
(M)
An external pressure switch or external pressure transducer is included with the pumps that have the feature of external pres8
sure monitoring. Also included is a 33 ft (10m) cord to connect the external monitoring device to the pump.
Page Number - 8
Form 404034
Description of Operation
Pump Operation
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lubrication lines
Drive
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The pump housing consists of the following components:
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connected together by internal passages and vent valve.
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transducer.
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to drive the pumping elements and to control the internal
vent valve (Fig. 4).
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Vent valve is a two way normally closed spring biased
valve.
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(240 bar).
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psig (240 bar). Pressure setting of the pressure trans8
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($Y77
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bar) in 100 psig (6.9 bar) increments.
Lube Cycle/Pressurization
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tion cycle. As soon as pump starts to operate, the display
rotating segment is turning clockwise also (Fig. 20).
Maximum time to build the preset pressure is 12 minutes.
If pump does not build preset pressure, fault signal E1 or
E2 will appear on the display.
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Vent valve (1) is normally closed and stays closed during
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reservoir (see Fig. 4).
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The output of three pump elements (4) (Fig. 3) is com8
bined by internal passages.
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The eccentric drives the pump elements to pump the lubri8
cant from the reservoir and build the line pressure.
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Supply line can be connected to any one of the pump ele8
ment outlets. The remaining two pump elements outlets
should be plugged.
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Form 404034
Page Number - 9
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valve (4) is open to pass the lubricant to supply lines.
The body of the pump element has a lateral outlet (5) (Fig. 12)
for lubricant crossporting to the internal material passages to
combine the outlet of all three pump elements.
Any one of the three elements can be used as a pump outlet.
The remaining two elements should be closed with plug (A)
(Fig. 12).
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Fig. 13
Fig. 14
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Page Number - 10
Pump
p with internal and external p
pressure switch:
Internal pressure switch will close at 3500 psig and open at
2600 psig. The external pressure switch will close at 2500 psig
and open at 1900 psig
After pump starts a lubrication cycle, motor stops when pres8
sure at pump reaches preset pressure of 3,500 psig (240 bar).
Pump can go through three holding periods, H1, H2 and H3.
Holding Time (H1)
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tive seconds before going to H2. If the internal pressure
switch opens during the 15 seconds, the pump will restart
and run until the internal pressure switch closes.
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both the internal and external pressure switches are open
an H3 will appear on the display. Pump will turn on again
and pump until the internal pressure switch is closed.
When both the internal and external pressure switches are
closed a vent cycle will take place.
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but the external pressure switch is open, the pump will
turn on for 2 seconds and then stop and wait until the
external pressure switch closes. An H3 will appear on
the display. When both the internal and external pressure
switches are closed a vent cycle will take place.
Possible Faults
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E1 Fault A failure to build pressure at the pump within
the allotted 12 minutes of pumping time.
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Form 404034
@!"
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ply line.
@-"
)(
?
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pressure switch has 10 seconds to open when the motor
reverses to locate the vent position.
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The external pressure switch must be open before the
next lube cycle takes place.
Page Number - 11
Pump
p with internal pressure
p
transducer only:
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The internal pressure transducer is factory set to close at 3500
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The internal pressure transducer is set to open at 900 psig (62
bar) below the point where it closed at.
After the pump starts a lubrication cycle, the motor stops when
pressure at pump reaches the preset pressure. The pump will
go through two holding periods, H1 and H2. The following will
use the factory setting of 3500 psig (241 bar) and the opening
(!j77*V|
Holding Time (H1)
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Internal pressure transducer must reach 3500 psig and
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onds before going to H2. If the internal pressure trans8
ducer drops below 2600 psig during the 15 seconds, the
pump will restart and run until internal pressure transducer
reaches 3500 psig (241 bar).
Holding Time (H2) - Will last for 30 seconds
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At the end of 30 seconds, if the internal pressure trans8
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vent cycle.
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Pump
p with internal and external p
pressure transducer:
The internal pressure transducer is factory set to close at 3500
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ments. The internal pressure transducer is set to open at 900
psig (62 bar) below the point where it closed at.
The external pressure transducer is set to close at 2500 psig
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777
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is factory set to open at 900 psig.
After the pump starts a lubrication cycle, the motor stops when
pressure at the pump reaches preset pressure of 3,500 psig
(240 bar). The pump can go through three holding periods,
H1, H2 and H3.
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Holding Time (H1)
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Internal pressure transducer must reach 3500 psig and
stay above 2600 psig for 15 consecutive seconds before
going to H2. If the internal pressure transducer drops be8
low 2600 psig during the 15 seconds, the pump will restart
and run until the internal pressure transducer reaches
3500 psig.
Holding Time (H2) - Will last for 30 seconds
Z
At the end of H2, if the internal pressure transducer is
above 2600 psig and the external pressure transducer
has reached 2500 psig, the pump will begin a vent cycle.
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Possible Faults
Z
E1 Fault A failure to build pressure at the pump within
the allotted 12 minutes of pumping time.
Z
Page Number - 12
Form 404034
Stirring paddle
The stirring paddle (3) (Fig. 2) is attached to the motor and ro8
tates during the lubrication cycle. The paddle is working grease
in the reservoir to make it more pumpable and at the same
time pushing the grease down into the housing and pumping
elements to prevent cavitation.
Low-level control
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grease control as a standard feature.
Possible Faults
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E1 Fault A failure to build pressure at the pump within
the allotted 12 minutes of pumping time.
Venting Cycle/Depressurization
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After pump completes preset pressure hold time and
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vent cycle. Hr will be displayed momentarily.
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The motor will turn counterclockwise to engage and open
the vent valve. Motor will stop in a position to hold vent
valve open.
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The display rotating segment is turning counter clockwise
as well.
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valve passage of the supply line to the reservoir.
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from the system. The valve stays open during pause time.
Filling reservoir with grease
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Make sure no air is trapped under the follower plate. Grease
should be in full contact with the surface of the follower. Its
recommended to run the motor by initiating the lubrication
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running motor will help to evenly spread the grease under fol8
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central rod of the reservoir. The switch is sealed and does not
have any contact with grease.
The follower plate bushing has a magnet. As soon as the
follower reaches the preset position at the bottom of the reser8
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level of the grease. The control panel display LL will be on.
The pump can be operational for some time since there is a
small amount of grease left under follower in the reservoir and
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capacity. The LL display should be off as soon as pump is
Caution!
Make sure there is no air trapped under
follower plate. Grease should be in full
contact with surface of the follower. Use
Air Expelling Procedures if necessary.
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for air trapped under the follower. Use a plastic wire tie to expel
the air: push plastic tie between the follower seal and wall of
the reservoir and push the follower with hand until it completely
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Form 404034
Page Number - 13
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1. Pivot bracket with round magnet
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(when the reservoir is empty).
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Page Number - 14
Form 404034
)
$<& ?
8
ments and decimal points are illuminated for 2 seconds.
NOTE
If *EP* is displayed after the display test,
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pad is defective.
Form 404034
Operating mode
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is only one segment at the bottom this indicates that the
ignition switch is open.
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ment in the display window lights up (Fig. 19).
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minated segment appears in the display window of the
membrane key pad (Fig. 20).
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If the power supply is interrupted during the pause time,
the pause time continues at the point of interruption after
switching power on again.
Z
If the power supply is interrupted during the lubricating
time the operating time will start at the beginning after
switching power on again.
Page Number - 15
^<8?
&?
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&<&^^
IMPORTANT
(<8?
&V
8
ing time, the current operating cycle will still
be completed. However the pump does not
switch on automatically any more. It can only
be switched on again by a manual lube cycle.
Furthermore, it is not possible to change to
Malfunctions
Z
If there is no feedback from the pressure switch or pres8
sure transducer within 12 minutes of pumping time, the
pump switches off immediately. One of the fault signals
@
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display of the membrane key pad.
IMPORTANT
If a malfunction is present, E1, E2, E3 or E4
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on automatically any longer. It can only be
triggered via an additional lubrication cycle.
Furthermore, a change to the programming
mode is not possible while in alarm.
Page Number - 16
Form 404034
Form 404034
NOTE
Existing fault signals (Fig. 21 to 26) must
be acknowledged before triggering an
additional lubrication cycle.
Page Number - 17
01
Pause time
0 to 59 hours
00
Pause time
0 to 59 minutes
Output of both fault relays
NO
no (normally open)
nc (normally closed)
o2
SP
Option to have the pump start with a pause time or a lube cycle.
SP Pump starts with a pause time
SO Pump starts with a lube cycle
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35
09
Page Number - 18
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pressure transducer. (Reading x 100)
09 x 100 = 900 psi. 900 psi is where the external pressure transducer will open (VENT)
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Form 404034
Acknowledging a Fault
Display
Press
< 2 sec.
< 2 sec.
To acknowledge
g a malfunction:
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&& @Y@!Y@-Y@^^
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into permanent light.
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Messages which have been acknowledged but have
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switched off and on again.
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After fault has been acknowledged no more lube cycles
will take place until a successful manual lube cycle has
taken place.
< 2 sec.
< 2 sec.
< 2 sec.
Form 404034
Page Number - 19
Function
Key
Press
> 4 sec.
Step 2
IMPORTANT! Pump
Power must be on to
start programming.
Step 1
Display
Function
Pause time:
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0 59 minutes
4 minutes
59 hours 59 minutes
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Step 3
P2: Setting minutes
Press button, so that P2 appears in the display.
Press button.
Settings are made in one direction:... 0, 1, 2, 3, 4, 5, .... 59 min
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IMPORTANT
If Hours are set to 00, the display will
show minimum pause time of 4 minutes.
Page Number - 20
Form 404034
Press
Press button.
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contact will open.
Step 5
Factory Setting
Form 404034
Page Number - 21
Press
P6: Upon applying power to the pump you can program
whether it starts with a pause time SP or starts with a lube
cycle SO.
Press button, so that P6 appears in the display.
The currently set values appear as to whether the cycle is to
start with the pause time or the lubricating time.
The default setting for the pump is set to start with a pause
time SP (Start Pause time).
Press button.
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bricating time SO (Start Operation|)(
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time the preset pause time will be valid.
Step 7
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ating mode once again.
Page Number - 22
Form 404034
Press
Step 7
IMPORTANT
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have a pump that has an internal pressure
transducer.
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ducer will close. This is the maximum pressure that the pump
can reach. Factory setting is 3,500 psi.
Press button to change value.
Reading x 100 = Transducer setting in psi
35 x 100 = 3500 psi.
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increments.
Step 8
IMPORTANT
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appear if you have a pump that has an
external pressure transducer connected.
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able from 200 psi to 1,000 psi in 100 psi increments. Factory
set opening point (vent pressure) is 900 psi. The closing point
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psi.
Press button to change value.
Reading x 100 = Transducer setting in psi
9 x 100 = 900 psi.
Form 404034
Page Number - 23
Page Number - 24
Form 404034
NOTE
The following display sequence is shown
once. The change of display occurs every
two seconds. Example of the pump set to
lubricate each 12 hours 30 minutes and
remaining pause time (rP) is 5 hours 10
minutes.
Pause Time
12 .
(hours)
. 30
(minutes)
rP
5.
(hours)
. 10
(minutes)
Form 404034
Page Number - 25
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SP
or
Page Number - 26
Form 404034
Technical Data
Electrical data for DC pump
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Electrical data for AC pump
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End of line pressure transducer
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End of the line transducer vent pressure is factory preset at 900
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Operating temperature
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Operating temperature
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Number of outlets
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Lubricant .................................. up to NLGI grade 2 1)
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(24.6 cm3/min)
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Form 404034
Pump elements K7
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Number of Pumping Elelments............... 3
(connected together)
Tightening torques
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Weights
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The weights above include the following equipment:
Pump kit with three pump elements, pressure relief valve,
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Packing (cardboard box)
Attaching parts
Operating Instructions
Installation
Z
Use only high pressure 5,000 psig minimum hydraulic
hose for supply lines.
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Note #1: See the list of the approved and recommended lubricants.
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backpressure 1,450 psig (100 bar). Different pressures, temperature
and grease can change the output results.
Page Number - 27
Page Number - 28
Form 404034
** Must connect red and black wires together if no machine switch is used.
V
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Form 404034
Page Number - 29
Page Number - 30
Form 404034
8C:N>BC#N-C:@^@:@%#|
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Form 404034
Page Number - 31
<
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tions.
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The proven lubricants (see following tables) have been
tested by Lincoln with regard to their pumpability and venting
behavior. Lincoln can recommend them for an application up
to the indicated minimum delivery temperature
8
Matic lubrication systems. During the tests these lubricants did
not cause any damage due to incompatibility with the material
used by Lincoln.
The lubricants Lincoln recommends on the basis of the
manufacturers data sheet (see following tables) can be used
in Lincolns lubrication systems up to the indicated minimum
delivery temperature.
IMPORTANT
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lubrication system can accept no liability
for:
8 $
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that are not or only conditionally
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systems.
8 $
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lubrication system caused by chemical
or biological changes of the lubricant
used.
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with other materials.
The liability is limited to pumpable
V
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systems.
IMPORTANT
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Proven Lubricants
Manufacturer
Designation
Thickener
CATERPILLAR
CA-Complex
CATERPILLAR
-40 F (-40 C)
CATERPILLAR
Auto-Lube NLGI #1
Ca-Complex
10 F (-12 C)
Li/Ca
-13 F (-25 C)
"C>#
N
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Li
-40 F (-40 C)
FUCHS
Renocal FN 745
Ca-12-OH-stearat
-13 F (-25 C)
FUCHS
Renoral FN3
Ca
-4 F (-20 C)
FUCI-IS
Renolit LZR 2 t l
Li
-4 F (-20 C)
FUCHS
Renolit HLT 2
Li
-13 F (-25 C)
MOBIL
Li-complex
-13 F (-25 C)
SHELL
Retinax EPL 2
Li-12-OH-stearat
14 F (-10 C)
SHELL
Retinax CSZ
Li/Ca
-31 F (-35 C)
Page Number - 32
Form 404034
IMPORTANT
^
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Form 404034
Page Number - 33
IMPORTANT
^
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Page Number - 34
Form 404034
Form 404034
Page Number - 35
Page Number - 36
Form 404034
Form 404034
Page Number - 37
Page Number - 38
Form 404034
Caution!"
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with grease is very critical for proper
pump operation. The pump may be
shipped with a small amount of Fuchs
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going to use and remove the test grease
if necessary.
Pump with follower plate:
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no air is trapped under the follower plate. Grease should be in
full contact with the surface of the follower. Its recommended
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of the reservoir. The stirring paddle of the running motor will
&
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(<$ $
pockets. The reservoir has a vent hole (11) (Fig.1). Fill grease
to the maximum follower position until follower seal will slightly
cross the vent hole. If air is still trapped under the follower, add
some more grease to expel air through the vent hole.
Pump without follower plate:
C
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Its recommended to run the motor by initiating the lube cycle
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running motor will help to evenly distribute grease in the reser8
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Caution! There is a risk of reservoir
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mark.
Pump cleaning:
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organics such as alcohol, methyl alcohol, acetone or similar
solvents.
Form 404034
Page Number - 39
Page Number - 40
Form 404034
Troubleshooting
Mode of failure
Pump motor does not run. No green right corner segment lit on
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Solution
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Pump does not deliver lubricant but runs if manual lube switch
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lube cycle.
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manual lube cycle. Investigate and correct possible causes
air pockets, broken line, connections leakage, worn pumping
element, failed internal pressure switch or pressure transduc8
er. Initiate manual lube cycle.
&<
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} <
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manual lube cycle. Investigate and correct possible causes
air pockets in lubrication line, connections leakage, grease
consistency changed with low temperatures, failed end of line
pressure switch or pressure transducer.
&<
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manual lube cycle. Investigate and correct possible causes
pump eccentric did not stop in a proper position, vent valve
failed
&<
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manual lube cycle. Investigate and correct possible causes
restriction in lubrication line, grease consistency changed
with low temperature, failed end of line pressure transducer or
pressure switch.
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pressure switch.
Form 404034
Page Number - 41
Form 404034
Form 404034
Page Number - 43
Description
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Page Number - 44
Form 404034
or
55
Page Number - 45
Form 404034
Description
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Form 404034
Page Number - 47
Americas:
One Lincoln Way
#
^Y:Bj-!78z
USA
& -j*!77
"=77!z-z*
Page Number - 48
Europe/Africa:
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Printed in USA
Web site:
www.lincolnindustrial.com
Form 404034
Model No. 85770-1, -2, -3, -4, -5, -6, 85771, 85772
85780-1, -2, -3, -4, -5, -6, 85781 and 85782
85785-1, -2, -3, -4, -5, -6, -7, -8, -9, -10
SL-V INJECTOR
Series B
SINGLE AND MANIFOLD TYPE INJECTORS
for dispensing fluid lubricants and greases not
exceeding Lincoln ventmeter viscosity of 600 psi.
SPECIFICATIONS
Minimum operating pressure 1850 psi [128 bar]
Maximum operating pressure 6000 psi [413 bar]
Recommended operating pressure 2500 psi [172 bar]
Maximum vent (recharge) pressure 1000 psi [69 bar]
Temperature Range - -40F to 180F [-40C - 80C]
Lubricant output (adjustable):
SL-V - 0.015 to 0.080 cu. in. [0.25 to 1.31 ccm]
SL-V XL - 0.015 to 0.305 cu. in. [0.25 to 5.00 ccm]
Injectors can be mounted in any position and can be used
in circuits with SL-1, SL-11, SL-32 and/or SL33 injectors.
OCT - 2008
Copyright 2007
Printed in USA
Web site:
www.lincolnindustrial.com
- C8
Page - 301E
Section
Form 403786
Model No. 85770-1, -2, -3, -4, -5, -6, 85771, 85772
85780-1, -2, -3, -4, -5, -6, 85781, 85782
85785-1, -2, -3, -4, -5, -6, -7, -8, -9, -10
SL-V INJECTOR
Injector
SL-V
SL-V XL
Type
Dimension A
Dimension B
in.
[mm]
in.
[mm]
85770-1
2-1/2
[63.5]
85770-2
[76.2]
85770-3
1-1/4
[31.8]
4-1/4
[108]
85770-4
2-1/2
[63.5]
5-1/2
[140]
85770-5
3-3/4
[95.3]
6-3/4
[171]
85770-6
[127]
[203]
85771
Replacement Injector
N/A
Dimension C
in.
[mm]
8-3/4
[222]
11-3/16
[284]
N/A
85780-1
2-1/2
[63.5]
85780-2
[76.2]
85780-3
1-1/4
[31.8]
4-1/4
[108]
85780-4
2-1/2
[63.5]
5-1/2
[140]
85780-5
3-3/4
[95.3]
6-3/4
[171]
85780-6
[127]
[203]
85781
Replacement Injector
N/A
N/A
Model
Type
Dimension D
in.
Page Number - 2
[mm]
SL-V
85772
7-3/4
[191]
SL-V XL
85782
10-3/16
[248]
Form 403786
Model No. 85770-1, -2, -3, -4, -5, -6, 85771, 85772
85780-1, -2, -3, -4, -5, -6, 85781, 85782
85785-1, -2, -3, -4, -5, -6, -7, -8, -9, -10
SL-V INJECTOR
SPECTRUM ADJUSTMENT
SYSTEM
Adjusting Screw
Ratio from
Sleeve
in
Output
(cc)
Minimum Ouput
Maximum Output
Color
0.015
(0.25)
0.2
N/A
85785-1
0.03
(0.50)
0.4
Red
85785-2
0.045
(0.75)
0.6
Silver
85785-3
0.06
(1.00)
0.8
Gold
85785-4
0.075
(1.25)
1.0
Green
Part #
N/A
Output
Ratio from
Ratio from
Sleeve
N/A
0.015 (0.25)
Minimum Output
Maximum Output
Color
0.050
N/A
85785-1
0.03
(0.50)
0.100
Red
85785-2
0.045 (0.75)
0.150
Silver
85785-3
0.06
(1.00)
0.200
Gold
85785-4
0.075 (1.25)
0.250
Green
85785-5
0.112 (1.87)
7.5
0.375
Black
85785-6
0.15
10
0.500
Purple
in
(cc)
(2.50)
85785-7
0.188 (3.12)
12.5
0.625
Blue
85785-8
0.225 (3.75)
15
0.750
Orange
85785-9
0.262 (4.37)
17.5
0.875
Brown
20
1.000
Yellow
85785-10
Form 403786
0.3
(5.00)
Page Number - 3
Model No. 85770-1, -2, -3, -4, -5, -6, 85771, 85772
85780-1, -2, -3, -4, -5, -6, 85781, 85782
85785-1, -2, -3, -4, -5, -6, -7, -8, -9, -10
SL-V INJECTOR
**
13*
1
12
2
14
3
15
4
14
16
5
6
17
7
8
9
18
10
19*
11a
(SL-V)
20
Torque to
30-40 In. Lbs.
11b
(SL-V XL)
21
* Etched surfaces of #13 and #19
must be aligned and face to the front
of the manifold assembly.
** The SL-V injector is designed with a weep hole
which indicates worn or damaged internal seals.
Please refer to the Centromatic System Planning
Manual for a more detailed description of this design
characteristic. The weeping which occurs is a slow
release of grease which may bypass the lower seal
over many cycles. This weeping may always be
present to a small amount on the injector. The weep
becomes a leak when the amount of grease increases
each time the injector cycles. When this occurs it is an
indication that the injector requires attention and should
be serviced soon.
Indicates change
Page Number - 4
22
25
Torque to
40 - 45 Ft. Lbs.
23
24
Torque to
40-45 Ft. Lbs.
MANIFOLD
INJECTORS
SINGLE UNIT
INJECTOR
Form 403786
Model No. 85770-1, -2, -3, -4, -5, -6, 85771, 85772
85780-1, -2, -3, -4, -5, -6, 85781, 85782
85785-1, -2, -3, -4, -5, -6, -7, -8, -9, -10
SL-V INJECTOR
SERVICE PARTS
Item
Description
Qty.
No.
Part No.
SL-V
O-ring (nitrile)
Adjusting Screw
Lock Nut
SL-V XL
273088
273089
*
272803
272819
11624
273090
273091
O-ring
Backup Washer
U-cup (polyurethane)
O-ring (polyurethane)
10
Piston Assembly
273092
*
273987
11a
O-ring (polyurethane)
N/A
11b
U-cup (polyurethane)
N/A
12
Fitting Assembly
13
Injector Body
*
90471
275330
275331
14
O-ring (fluorocarbon)
15
O-ring (fluorocarbon)
16
Spring
17
Spring
18
Spring Seat
272798
19
275332
20
272796
21
Gasket
22
12658
11962
11963
11964
11965
246965
23
Gasket
24
Adapter Bolt
273097
25
Adapter
273098
Form 403786
Page Number - 5
Model No. 85770-1, -2, -3, -4, -5, -6, 85771, 85772
85780-1, -2, -3, -4, -5, -6, 85781, 85782
85785-1, -2, -3, -4, -5, -6, -7, -8, -9, -10
SL-V INJECTOR
Stage 1
The injector starts in its normal or rest position.
Incoming lubricant is directed through the slide
valve to both sides of the piston. The pressure
of the incoming lubricant acting on both sides of
the piston causes the piston to move downward
against the shoulder and fills the measuring
chamber. The indicator stem is fully retracted
away from the stop of the adjusting screw.
Piston
Springs
Stage 2
Further increase in pressure causes the slide
valve to move against the force of the springs. As
the slide valve moves, it closes passage 1 and
opens passage 2 to the outlet port. The pressure
of the incoming lubricant is now acting only upon
the bottom of the piston. The incoming lubricant
displaces the piston which forces the lubricant in
the measuring chamber to be dispensed through
passage 2, through the slide valve and through
the outlet port to the lube point.
Slide
Valve
Lubricant
Supply
STAGE 1
Stage 3
Passage 1
Outlet
Port
Passage 2
Slide
Valve
STAGE 2
Adjusting
Screw
Indicator
Stem
Stage 4
As the pressure in the supply line vents to 1000
psig [69 bar], the slide valve moves downward
and closes passage 2 and opens passage 1. The
lubricant pressure in the supply line is now acting
upon both sides of the piston causing it to move
downward. As the piston moves downward, a
volume of lubricant flows from the underside of
the piston, past the slide valve, through passage
1 and to the upper side of the piston. Since the
volume on top of the piston is greater than the
volume under the piston, an additional volume of
lubricant flows from the supply line to the upper
side of the piston. This volume of lubricant leaving
the supply line causes the pressure to drop very
quickly. The piston may or may not fully return
to the shoulder, depending upon the volume of
lubricant in the supply line. The injector is now
ready for the next cycle.
Piston
Slide Valve
STAGE 3
Page Number - 6
Passage 1
Passage 2
Lubricant
Supply
STAGE 4
Form 403786
Model No. 85770-1, -2, -3, -4, -5, -6, 85771, 85772
85780-1, -2, -3, -4, -5, -6, 85781, 85782
85785-1, -2, -3, -4, -5, -6, -7, -8, -9, -10
SL-V INJECTOR
Form 403786
Page Number - 7
Model No. 85770-1, -2, -3, -4, -5, -6, 85771, 85772
85780-1, -2, -3, -4, -5, -6, 85781, 85782
85785-1, -2, -3, -4, -5, -6, -7, -8, -9, -10
SL-V INJECTOR
Paul Conley,
Chief Engineer
Page Number - 8
Form 403786
103