TECHNICAL MANUAL. Manual Part Number BreakerLube CML. Carrier Mounted Lubrication System

Transcription

1 TECHNICAL MANUAL Manual Part Number BreakerLube CML Carrier Mounted Lubrication System

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3 TABLE OF CONTENTS Section Page SECTION 1.0 INTRODUCTION. 1 SECTION 2.0 OVERVIEW.. 2 SECTION.0 GENERAL CONSTRUCTION SAFTY Operation, Maintenance and Repair Safety Working in High/Low Temperatures Working Underwater 5.4 Operator Safety Recommendations.. 5 SECTION 4.0 TECHNICAL DATA, DIMENSIONS AND DESCRIPTION Chisel Paste Dimensions... 7 SECTION 5.0 OPERATION Theory of Operation Operation of Low-level Control Low-level Control (Full Reservoir) Low-level Control (Empty Reservoir) Pump.. 9 SECTION 6.0 INSTALLATION Mount Install Pre-filled Hoses Assemble and Cut Long Length of Hose Routing of Long Hose Install and Cut Short Length of Hose Install Re-usable Hose Fittings How to Assemble Re-usable Hose Fittings Electrical Installation Mount Electrical Components Electrical Connections Electrical Diagram Electrical and Hydraulic Connections for Pilot Operated Systems Electrical Connections (Pilot Operated). 17 SECTION 7.0 MAINTENANCE Filling Reservoir Filling Reservoir Through Top (Alternate Method).. 18

4 Section Table of Contents (continued) Filling Reservoir Through Grease Fitting (Preferred Method) Bleed and Fill Lube Hose Maintenance Before Operation Operation. 20 SECTION 8.0 PUMP ELEMENT REMOVAL and INSTALLATION Pump Element Removal and Installation Pump Element Removal Pump Element Installation Adding Multiple Pump Elements Pump Element Arrangement Add 2 nd Pump Element With Single Lube Line Add 2 nd Pump Element With Dual Lube Lines Installation of Adjustable Pump Element Setting the Adjustable Pump Element.. 24 SECTION 9.0 TROUBLESHOOTING Inoperable Manual Lubrication Manual Lubrication with Lube Line Disconnected Manual Lubrication Through Lube Line.. 25 SECTION 10.0 REMOVAL AND STORAGE OF BREAKERLUBE CML Mechanical Removal of Reattaching After Idle Periods. 26 SECTION 11.0 PARTS INFORMATION 27 Components of the Installation Kit 27 Chisel Paste Part Numbers and Container Descriptions.. 27 Pump - Parts List Hose Kit - Parts List.. 2 Electrical Kit Parts List... Electrical Kit Additional Components Required for Pilot Operated Systems. 4 Add 2 nd Pump Kit Parts List 5 List of Installation Kits for Specific Hammer Models.. 6 Page

5 DOCUMENT REVISIONS Date Page Change Sep 1, , 5-6 Add adjustable pump element (optional) Aug 22, , 12 & 0 Update parts list, update electrical kit diagram Oct 15, 2004 Add Rammer hammers Jan 18, & 27 Now a WORD DOC. Place relay socket in electrical schematic. Update description item Nov 6, 2006 Update Table & 10 Add hose, update instructions, 5.2, 5.2.1, 2 update Figure Add circuit for hydraulic/electric installation 17 Section 6-6, add hammers to chart 19 Add Section 6.6. pump Instruction for larger-size hammer models Add Figure & 27 Update hose kit parts List. 28 Add parts for pilot circuit 0 Update table 9-1 for models BR2214, BR2518, BR088 & BR701 (M14, M18, G88 & G10) Apr 2, , 22 & 28 Add 12 Volt Electrical kit May 2, 2008 Model change over Jan. 19, Correct lubricant output

6 SECTION 1.0 INTRODUCTION This manual contains important information for the safe use, service and maintenance of the Allied BreakerLube CML. Read and thoroughly understand the information and procedures described in this manual before installing, operating or servicing the BreakerLube CML. This manual must be easily accessible to operators and service personnel. Store this manual in a convenient location. WARNINGS and CAUTIONS identified with this symbol are important for personnel safety and full service life of the BreakerLube CML. Follow these instructions carefully. WARNING Instructions given inside a WARNING box emphasize a potentially dangerous procedure, which may result in injury or death to the operator or any bystanders in the work area. Please read and follow these instructions carefully and heed all decals. CAUTION Instructions given inside a CAUTION box emphasize a procedure that may cause damage to the equipment if not performed properly. Read these instructions carefully before performing the procedure on the BreakerLube CML. Pay careful attention to all instructions and follow all governing regulations. Operation or service other than in accordance with these instructions may subject the BreakerLube CML to conditions beyond its design capability. Improper operation, service or the use of non-allied parts may result in BreakerLube CML failure or personnel injury. Responsibility for operation and safety lies at all times with the operator of the carrier. Allied assumes no liability for the results of actions not recommended in this manual and specifically any damages resulting from: Use of grease, which is not or is only conditionally pumpable. Allied Chisel Paste is recommended. Any unauthorized modification of the system components. Contact Allied s Technical Service Department if modification is necessary. Insufficient lubricant or irregular pump refilling. Contaminated lubricants. Improper disposal of used or contaminated lubricants. Inadequate maintenance of the BreakerLube CML. Use of service parts not approved or supplied by Allied. These exclusions apply to damage to the BreakerLube CML, associated equipment and personnel injury. Warranty does not cover conditions, which in the reasonable judgment of Allied, arise from misuse, negligence, alteration, accident, or lack of performance of necessary maintenance. Consult form for complete details of product warranty coverage. 1

7 SECTION 2.0 OVERVIEW -MAX- 1 -MIN BreakerLube CML Main Components (Fig. 2-1) 1. Reservoir 2. Pump Element. Pressure Relief Valve 4. Lubrication Nipple (Manual Feed to Hammer s Tool and Bushing) 5. Power Cord Gray (Low-level hammer Shut Off Circuit) 6. Lubrication Nipple (Replenish Reservoir) 7. Power Cord Black (Motor Power Circuit). 2

8 2.0 Overview The Allied BreakerLube CML is designed to provide a simple, effective and inexpensive method of lubricating hydraulic hammers. The BreakerLube CML is a fully automated system and works integrally with the carrier and hammer, pumping chisel paste to the hammer front head every time the hammer is activated. Costly downtime and wasted lubricant are eliminated because the precise amount of lubricant, pumped by the electric motor, is delivered only while the hammer is in operation. Allied BreakerLube CML is the proven solution for lubricating hydraulic hammers. Advantages include: Convenient mounting near cab Installation Kits include mounting bracket, hardware, adapter fittings and pre-filled lube hose Low-level circuit automatically shuts hammer off and activates cab mounted warning indicator High-pressure pump capable of pumping NLGI No. 2 grease in cold weather Pumps are designed for use with Allied Chisel Paste Lubricant level can be monitored from operator s cab Electrically-operated (24 or 12Vdc) Adjustable output - Can drive up to pump elements Figure Gallon Reservoir Figure 2-1 Gallon Reservoir

9 SECTION.0 GENERAL CONSTRUCTION SAFETY CAUTION Read and follow all equipment and machinery instructions. Comply with all federal and local regulations regarding construction practices and public safety. Identification of and compliance to governing regulations are the responsibility of the owner and operator. In the United States, comply with the recommendations of the Occupational Safety and Health Administration standards of the U.S. Department of Labor. For OSHA construction guidelines contact your local federal government office or write: U.S. Government Printing Office Superintendent of Documents P.O. Box Pittsburgh, Pa Ask for Construction Industry OSHA Standards Stock # Operation, Maintenance And Repair Safety Use the BreakerLube CML only for dispensing chisel paste to hammer tool bushings. Do not under-lubricate tool. Shank of tool should always be wet, but not running, with chisel paste. Only authorized and trained personnel familiar with safety regulations shall perform repairs. Operate the BreakerLube CML ONLY with a fitted pressure relief valve. The BreakerLube CML must be regularly refilled with clean chisel paste. Always stop operation to fill the BreakerLube CML. Do NOT fill BreakerLube CML while it is running. Switch off power supply before filling the reservoir. Do NOT exceed the maximum filling mark. There is a risk of bursting if the reservoir is overfilled. Regularly check, every day, that lubricant is reaching the tool bushing. Also check the delivery lines for damage and replace them, if necessary Dispose of used lubricants in accordance with local environmental laws. Do not modify any existing safety equipment already fitted to the carrier. Keep the BreakerLube CML away from sources of heat. Adhere to the operating temperature. 4

10 .2 Working In High/Low Temperatures The safe operating temperature range of the BreakerLube CML is 1 F 150 F.. Working Underwater The entire BreakerLube CML and its holder must remain above the surface of the water. The fittings on the lubricant hoses must be tightened with particular care to avoid leaks. At no time shall the hammer be submerge underwater unless it has been modified in accordance with the instructions provided in the underwater kit. For further details on underwater operation, contact Allied s Technical Service Department..4 Operator Safety Recommendations Do not run any hydraulic hoses through the operator s cab; they may leak or even burst, injuring the operator. Relieve oil pressure before disconnecting or removing existing hoses on the carrier. Collect any oil or lubricant that leaks out and dispose of it in accordance with environmental laws. To avoid damage to the carrier and/or the BreakerLube CML, perform the following daily inspections. Before starting, visually inspect all hoses, fittings and fasteners for wear and looseness. Make necessary repair or correction. Check lubricant level in reservoir When welding, adhere to carrier manufacturer s welding instructions, including: Disconnect all battery cables from the carrier battery. Shield all hoses in the immediate welding vicinity to prevent risk of fire or damage due to excessive heat. 5

11 SECTION 4.0 TECHNICAL SPECIFICATIONS, DIMENSIONS AND DESCRIPTION Technical Specification Operating Temperature -1 F to 158 F -25 C to 70 C Storage Temperature -1 F to 176 F -25 C to 80 C Available Outlets Up to pump elements Pumpable Lubricants Greases up to NLGI grade 2 Reservoir Capacity 1 & 2 gal. 4 & 8 liter Operating Pressure (max) 600 psi 248 bar Piston Diameter.28 inch 7 mm Weight 1 gallon reservoir 2 gallon reservoir 21 lbs 22 lbs 9.5 kg 9.8 kg Motor Voltage 12Vdc or 24Vdc Input Current A Fuse 5 A (250V/5A Bussman) Motor Max. Power Input Speed D-C gear (interference-suppressed) 24Vdc, A 12Vdc, 6.5 A 17 RPM (approximate) Low-level control Switched current A Output/Min Per Element.244 in /min 4 cm /min Connection Thread 1/8 NPT (F) Pump Operating Time* 0 minutes max. Pressure Relief Valve 4000 psi (+/- 250) 276 bar (+/- 17) * The motor is designed for intermittent operation. (Run time is 0 minutes maximum). 4.1 Allied Chisel Paste Chisel Paste provides a protective barrier between the tool and bushing to help reduce the damage caused from excessive heat due to friction. Chisel Paste provides unsurpassed protection over ordinary grease because, unlike General or Multi-Purpose grease, Chisel Paste is specifically formulated to withstand the extreme loads generated at the tool and bushing. Protection against wear and galling is vastly improved with friction-reducing additives of molybdenum disulphide, copper and graphite. Allied Chisel Paste is available in tubes and bulk containers. Part No. Description Keg (15 Gal.) Bucket (5 Gal.) Tube Carton (14.5 oz.) Tube Case (14.5 oz.) 6

12 Figure 4-. BreakerLube CML Dimensional Drawing 7

13 SECTION 5.0 THEORY OF OPERATION 5.1 Theory Of Operation The BreakerLube CML is used to provide continuous lubricate to the wear bushings and tool of a hydraulic hammer every time the hammer is operated. Each time the hammer is operated, the BreakerLube CML is activated and delivers chisel paste to the hammer front head (tool holder). Figure 5-2 Pump Element Draws in Lubricant 1. Eccentric. Spring 2. Piston 4. Check Valve Figure 5- Pump Element Delivers Lubricant Figure 5-1. Pump 1. Piston 2. Return Spring.. Check Valve The electric motor drives the paddle and the eccentric. (Figure 5-2) During rotation, the force from the return spring retracts the piston and draws in chisel paste. The check valve prevents back flow. (Figure 5-) Further rotation of the eccentric forces the piston to extend and chisel paste is pumped through the check valve. As the eccentric continues to rotate, the piston stroke is repeated and chisel paste is continuously pumped to the hammer s tool and bushing. 1. Eccentric. Spring 2. Piston 4. Check Valve The standard pump element is a fixed displacement output. To meet the demand of larger hammer models, up to three pump elements can be installed. An adjustable output element is available as an option. When the hammer is stopped, electric power to the pump is turned off and the BreakerLube CML stops operating. 8

14 5.2 Operation of Low-level Control The BreakerLube CML is designed for intermittent use with a maximum pump operating time of 0 minutes. Figure 5-2. Low-level Control Low-level Control (Empty Reservoir) During the rotation of the stirring paddle, the control cam () guides the magnetic switch out from the center of rotation. When the reservoir is empty, there is no lubricant pressure against the pivoting guiding plate. After the control cam has been over-run, the path of the magnetic switch crosses over the low level electromagnetic switch and triggers the relay in the automatic shut off circuit. As a result, hammer operation is locked out until power to the BreakerLube CML is cut off and the reservoir replenished. 1. Magnetic switch (attached to pivoting guide plate) 2. Electromagnetic switch (at intermediate plate). Control Cam Low-level Control (Full Reservoir) Refer to Figure 4-2. During operation, the motor spins the stirring paddle in a clockwise rotation. Attached to the stirring paddle is the pivoting guide plate with magnetic switch (1). With a full reservoir, the lubricant presses the magnetic switch backwards. The magnetic switch moves toward the center of rotation. The low level electromagnetic switch (2) cannot be activated. Figure 4- Electrical Diagram, Lowlevel Magnetic Floating Switch Pump The Allied BreakerLube CML is supplied with one fixed output pump element. Lubricant output is.171 cu. in. /min at 60 F. Up to three pump elements can be installed to increase lubricant delivery output. Refer to Section 8.4 for a list of Allied hammer models with the recommended number of pump elements. 9

15 SECTION 6.0 BREAKERLUBE CML INSTALLATION WARNING Disconnect the battery cables to prevent electric shock before performing any welding work. CAUTION When welding, shield all hoses in the immediate mounting vicinity to avoid risk of fire or damage due to excessive heat. CAUTION Nominal inside diameter of the lubricant supply hose MUST be at least.25 in. (8 mm) IMPORTANT A pre-filled lube hose is supplied with the BreakerLube CML Kit. Do NOT cut this hose until required lengths are determined during installation 6.1 Mount 1. Determine suitable mounting location for the BreakerLube CML (1) near, but not in, the carrier cab. Keep away from sources of heat. 2. Weld or bolt mounting bracket (2) to carrier.. Bolt BreakerLube CML to bracket with supplied 5/16-inch bolts, lock washers and nuts. CAUTION Do NOT block or obstruct the drain hose. This hose is designed to prevent moisture buildup in the housing. The hose was designed not to allow liquids to siphon up into the motor. Blocking the drain hose may result in unwanted moisture buildup and unwarranted motor failure. 6.2 Install Hoses The installation kit includes hoses that are pre-filled with lubricant. Some hammer models require two delivery hoses. Table 5-1 Pre-filled Lube Line Hammer Model BR422-BR1229 AR70-AR95B (Single lube line) BR2064, 2266, 2268 AR110-AR10B (Single lube line) G80, BR890 AR140B-160C (Single lube line) BR2214, BR2518, BR088 (Dual lube lines) BR4510, BR4511 AR170C-180C (Single lube line) BR701 2 CML units (2 pumps each) (Single lube line each unit) Hose

16 When installing hoses, route alongside the existing hammer hydraulic hoses. Adjust for proper slack at all joints. For easy installation and removal of the hammer, quick disconnect couplers are provided for the hose ends -MAX- 1 -MIN- 7 8 Cut to length A1 2A1 2 4 Cut to length 5 6 Figure 6-1 Install Hoses Table 6-2 Install Hoses (Figure 6-1) ITEM QTY DESCRIPTION BreakerLube CML 1A1 1 Power Cord Black (Motor Power Circuit) Housing 2A1 1 Power Cord Gray (Hammer Shut-off Circuit) 1 Relief Valve 4 1 Long Delivery Hose (1/4 Pre-filled) 5 1 Re-usable fitting (For ¼ Hose) 6 1 Quick Connect Coupler 7 1 Quick Connect Coupler 8 1 Re-usable fitting (For /8 Hose) 9 1 Short Hammer Hose (/8 Pre-filled) 10 1 Seal 11

17 6.2.1 Assemble Long Length of Hose IMPORTANT Do NOT cut hose supplied with BreakerLube CML Kit until required lengths are determined during installation. For models requiring single pump and single delivery hose: 1. If not already installed, refer to pump assembly instructions in section 8. Refer to figures 8-5 and Locate the long hose (4) equipped with the 1/8 NPT end. Assemble hose (4) to fitting () located on the pressure relief adapter. Fitting () is a push/pull type. Refer to figure 6-1. For models requiring two pump elements and single delivery hose: 1. If not already installed, refer to pump assembly instructions in section For proper assembly, refer to Figures 8-5, 8-6 and Locate the long hose (4) equipped with the 1/8 NPT end. Assemble hose (4) to fitting () located on the pressure relief adapter. Fitting () is a push/pull type. Refer to figure 6-1. For models requiring two pump elements and two delivery hoses: 1. If not already installed, refer to pump assembly instructions in Refer to figures 8-5, 8-6 and Locate the long hose (4) equipped with the 1/8 NPT end. Assemble hose (4) to fitting () located on the pressure relief adapter. Fitting () is a push/pull type. Refer to figure 6-1. Repeat assembly with 2 nd hose. For models requiring three pump elements and single delivery hose: 1. If not already installed, refer to pump assembly instructions in section Locate the long hose (4) equipped with the 1/8 NPT end. Assemble hose (4) to fitting () located on the pressure relief adapter. Fitting () is a push/pull type. Refer to figure 6-1. For models requiring two BreakerLube units. Each unit is equipped with two pump elements and each unit requires a single delivery hose: 1. If not already installed, refer to pump assembly instructions in section For proper assembly, refer to Figures 8-5, 8-6 and Locate the long hose (4) equipped with the 1/8 NPT end. Assemble hose (4) to fitting () located on the pressure relief adapter. Fitting () is a push/pull type. Refer to figure Repeat assembly with second CML unit and hose Routing of Long Hose 1. With the hose connected to the CML unit, route hose(s) along carrier s boom and stick. Adjust for slack at joints. 2. Cut hose(s) (4) to length, at the end of the stick. 12

18 . Install re-usable fitting (5) into the hose (4). Item 5 is for ¼ hose 4. Install QD Plug (6) to the reusable fitting (5). 5. Secure all hoses 6.2. Install Short Hose IMPORTANT Do NOT cut hose supplied with BreakerLube CML Kit until required lengths are determined during installation. For BR2214 and BR2518: 1. Locate the lubrication manifold mounted on the mid-section of the Hammer Box. Remove the flange head plugs. Install seals (Fig. 6-1 item 10) and connect the hose s (9). Refer to Hammer s Parts Manual for manifold and flange head plug location. For BR701: 1. Remove the two grease nipples and reducers located on the top mounting bracket. Install the hose s (9) with the seals (10). B A Install Re-usable Hose Fittings (Refer to Figure 6-2.) Figure 6-2. Re-usable Fitting Locate the short hose (9) with /8BSPP end. For Hammer Models with Top Mounted Lube Port 1. Locate and remove the flange head plug at the lubricating port on the hammer. Install the hose (9) with the seal (10). Refer to model s Operating Manual to identify the location of the lubricating port. Typically, the lubricating port is located on the valve housing, near the pressure IN port. For some, the port is marked G. 1. With the hose connected to the hammer s grease port, layout hose to reach QD connection point of the long hose. Adjust hose slack to accommodate full pivot range of hammer. 2. Cut hose(s) (9) to length.. Install re-usable fitting (8) into the hose (9). Item 8 is for /8 hose. 4. Install QD Plug (7) to the reusable fitting (8). 5. Secure all hoses How to Install Re-usable Hose Fittings (Refer to Figure 6-2.) 1. Thread part A onto hose. 2. Insert stem end of part B into hose and part A. Turn part B until tight. 1

19 CAUTION When a different attachment is used instead of the Allied hammer, the BreakerLube CML must be disconnected electrically by removing the 5-amp fuse. If the BreakerLube CML is not disconnected, grease will continue to be pumped out of the unit. CAUTION When the hammer foot switch on the carrier is used for a cruncher or other application, a relay must be installed to disengage the BreakerLube CML from operating while other devices are in use. Consult the Allied Technical Service Department. 6. Electrical Installation (Refer to Figure 5-A) If there is a hammer already installed, disconnect the electrical connection from the hammer valve at the foot switch. It will be re-attached later in step # Mount Electrical Components 1. Install warning light so it is visible to the operator when the hammer is operated. 2. Install 24Vdc (or 12Vdc) DPDT relay in a protected location, inside cab.. Install the fuse holder in a convenient location for service Electrical Connections (Refer to Figure 5-A) 1. Route the customer supplied hook-up wire from the switched side of the foot switch to one end of the fuse holder. Connect a branch wire from fuse holder to the socket relay terminal #5. 2. Locate Black power cord [plug 1A1]: Connect red wire, [plug terminal #1] (+) to the free end of fuse holder. Connect brown wire, [terminal #2] (-) to ground (negative side of battery).. Locate Gray power cord [plug 2A1]: Find suitable location between ignition/accessory switch and foot switch to connect wire marked #1, [plug terminal #1] to power source. Next, from same wire, attach a branch wire to socket relay terminal #6. Connect wire marked # wire [plug terminal #] to socket relay terminal #7 and socket relay terminal #4. 4. Connect hammer valve to socket relay terminal #1. 5a. Connect wire from warning light to socket relay terminal #4. 5b. Connect remaining wire from warning light to Ground. 14

20 24VDC FROM IGNITION SWITCH -MIN- -MAX- 1A1 Black Cable CUSTOMER SUPPLIED HOOK-UP WIRES Red (+) 2A1 Brown (-) Black (gnd) 1A1 Black Cable 2A1 Gray Cable Gray Cable Wire AMP 1A1 2A1 FOOT SWITCH Red Brown Black M RELAY DPDT B D C E 1 2 A F RELAY SOCKET NORMAL OPEN NORMAL CLOSED TO WA LIGHT I ON RNING NSTALLED DASH TO HAMMER VALVE Figure 5-A 15

21 Hydraulic & electric schematic for +24 vdc, pilot operated system HYDR FOOT PEDAL AUX VALVE To Hammer Pressure CUSTOMER SUPPLIED HYDRAULIC LINES C1 B2 A To Drain -MAX- Way Valve PN MIN- Pressure Switch PN A1 Black Cable Red (+) Brown (-) Black (gnd) 1A1 Black Cable CUSTOMER SUPPLIED HOOK-UP WIRES 2A1 Gray Cable 2A1 Gray Cable Wire AMP 24VDC FROM IGNITION SWITCH NEGATIVE SIDE OF BATTERY Red Brown Black C 1A B 1 2 M A F 2A D E 2 1 RELAY DPDT RELAY SOCKET NORMAL OPEN TO POSITIVE SIDE OF WARNING LIGHT INSTALLED ON DASH. Figure 5-B 6.. Pilot Operated Systems (Refer to Figure 5-B) When a hydraulic foot pedal is used to actuate the hammer, it is necessary to install a pressure switch into the pilot circuit. Power to the BreakerLube CML is connected and disconnected by the pressure switch as the foot pedal is depressed. An electric -way valve is wired to the low-level control. Hydraulic connections are made between the foot pedal and hammer valve. When the switch closes on the low-level control, the -way valve is energized and the hammer will stop operating. The hammer will not start up again until the reservoir is replenished. Connection points for the pressure switch and -way valve are shown in Figure 5-B. PART No. DESCRIPTION Pressure Switch way Valve 24Vdc 16

22 CAUTION When a different attachment is used instead of the Allied hammer, the BreakerLube CML must be disconnected electrically by removing the 5-amp fuse. If the BreakerLube CML is not disconnected, grease will continue to be pumped out of the unit. CAUTION When the hammer foot switch on the carrier is used for a cruncher or other application, a relay must be installed to disengage the BreakerLube CML from operating while other devices are in use. Consult the Allied Technical Service Department. 5. Part 1. Locate Gray power cord [plug 2A1] terminal #, wire #. Connect to socket relay #7. Part 2. Add branch line from socket relay #7 to socket relay #4. Part. Connect solenoid wire from -way valve to socket relay #4. Part b. Connect remaining solenoid wire to ground. Part 6. Connect wire from warning light to socket relay terminal #4. Part 6b. Connect remaining wire from warning light to Ground Electrical Connections (Refer to Figure 5-B) 1. Locate a suitable location off the ignition/accessory switch and connect fuse holder. 2. Route the customer supplied hook-up wire from fuse holder to pressure switch. Add a branch line over to socket relay terminal #6.. Part 1. Locate Black Power Cord [plug 1A1] terminal #1 (+). Connect the red wire to the remaining connection off the pressure switch Part 2. Add branch line off previous wire connection to Gray Power Cord [plug 2A1] terminal #1 4. Connect brown wire, located on Black Power Cord [plug 1A1] terminal #2 (-) to ground (negative side of battery). 17

23 SECTION 7.0 BREAKERLUBE CML MAINTENANCE 7.1 Filling Reservoir There are two methods for filling the reservoir. The first is the alternate method and the second is the preferred method. 1. Alternate Method: Remove lid and fill reservoir. 2. Preferred Method: Using a hand pump, attach to the lubrication nipple on the housing of unit. This is the preferred method because there is no chance of contaminating the grease or the reservoir. Removing the reservoir lid should be done only when absolutely necessary. Refer to Figure 6-4. CAUTION DO NOT allow contaminants in the reservoir when filling with Chisel Paste. Cover unused portions of Chisel Paste and store in a clean dry area. Contaminates will be forced through the BreakerLube CML resulting in damage and faulty operation. Grease must remain free of contaminants and must not change consistency over time. CAUTION Always refill reservoir as soon as lowlevel signal is triggered. DO NOT allow the grease level in the reservoir to fall below the pump. Air pockets will form, stopping grease flow to the hammer. Filling through the grease nipple is preferred as there is no chance of contaminating the grease or the reservoir To avoid air pockets in the system, do not allow the reservoir to run dry of grease. Stop the BreakerLube CML and refill reservoir when the low-level indicator on the dash lights. WARNING Shut off power supply before servicing IMPORTANT Use benzene or petroleum for cleaning the system. Do not use triperchloroethylene or similar solvents. Do not use polar organic solvents such as alcohol, methylacohol, acetone or similar chemicals. CAUTION DO NOT exceed the max. fill mark. The reservoir could burst if overfilled Filling Reservoir Through Top 1. Clean area surrounding lid. 2. Remove lid from reservoir. Fill reservoir with Allied Chisel Paste. 4. Replace lid reservoir Filling Reservoir Through Grease Nipple (Preferred Method) 1. Attach grease gun to manual fill grease nipple; refer to Figure Fill reservoir. 18

24 7.2. Bleed and Fill Lube Hose Always refill reservoir as soon as lowlevel signal is triggered. DO NOT allow the grease level in the reservoir to fall below the pump. Air pockets will form, stopping grease flow to the hammer. Filling through the lube fitting is preferred as there is no chance of contaminating the grease or the reservoir. If hoses are replaced or pumped dry, normal pumping will take a long time. Bleed air and fill hose as follows: 1. Disconnect lube hose at hammer. 2. Attach grease gun to lube fitting on pump, refer to Figure Pump until grease flows from hammer end of hose. Dispose of used lubricants in accordance with local environmental laws. 4. Attach hose to hammer. MAIN GREASE FILL -MIN- -MAX- RESEVOIR FILL WITH GREASE GUN MANUAL LUBRICATION BLEED & FILL Figure 7-4. Lubrication Fittings Reservoir Fill Kit (Optional) PART NO. DESCRIPTION A Manual Grease Fill Pump 19

25 7. Daily Maintenance Before Operation 1. Tighten all loose fittings and fasteners. 2. Replace all damaged tubes or hoses.. Check the lubricant level in the BreakerLube CML. CAUTION Use the Allied BreakerLube CML only for dispensing lubricant to the hammer tool and bushings. Allied recommends the use of Chisel Paste. Do not use Chisel Paste on bearings - Damage will result CAUTION Do not let reservoir run dry of grease. Always refill reservoir as soon as lowlevel signal is triggered. 7.4 Operation NOTE: The hammer shuts down on empty signal from BreakerLube CML. The hammer valve remains inoperable until the machine is shut down and the reservoir is filled. Once the BreakerLube CML is installed correctly, it will operate automatically, lubricating the hammer as the hammer is operated. The foot switch activates the hammer simultaneously with the BreakerLube CML. When the BreakerLube CML is empty, an indicator, installed in the cab, lights and the hammer valve is rendered inoperative. The BreakerLube CML continues operating as long as the foot switch is depressed. Stop operation (switch off power supply) and fill the reservoir with Chisel Paste (see Section 7.), then resume operation. DO NOT allow the grease level in the reservoir to fall below the pump. Maintain the grease level above the pump element to avoid air pockets in the system. Air pockets disrupt the flow of grease and are time-consuming to purge. 20

26 SECTION 8.0 PUMP ELEMENT INSTALLATION AND REMOVAL 8.1 Pump Element Removal And Installation. Tighten to 18 lbf. Ft. (25Nm). WARNING Shut off power supply before servicing. Electrical shock could occur. IMPORTANT Use only Allied spare parts for repair on the pumps 8.2 Pump Element Removal CAUTION Exercise caution while removing pump element assembly from housing. DO NOT leave piston, spring, or washer lying in the grease. The reservoir must be disassembled and pieces removed. DO NOT leave pump parts in the housing; they may block the motor. 1. Remove pressure relief valve from the pump element. 2. Unthread pump element from housing. The pump element assembly (Figure 8-5) should come out in one piece. Do NOT leave pump parts inside housing. All pieces must be removed or damage may result. 8. Pump Element Installation 1. Install new pump element as shown in Figure 8-5. The sealing ring can be re-used if not damaged. Figure 8-5. Pump Element Assembly 1. Pump Head 2. Seal (re-usable). Spring 4. Washer 5. Piston 8.4 Adding Multiple Pump Elements The BreakerLube CML will accept up to three pump elements. Hammer Model Pump Qty BR422-BR1229; AR70- AR95B (Single lube line) 1 BR2064, 2266, 2268; AR110- AR10B (Single lube line) G80, BR890; AR140B-160C (Single lube line) 2 BR2214, BR2518, BR088 (Dual lube lines) BR4510, BR4511 (Single lube line) BR701 2 CML units (2 pumps each) 2+2 (Single lube line each unit) 21

27 8.4.1 Pump Element Arrangement (Refer to Figure 8-6.). Thread adapter (2) into pump (1). 4. Thread reducer (6) into adapter (2). 5. Thread elbow () into reducer (6) Thread hose (4) into elbow (). 7. Unthread and remove grease line from pressure relief valve (8). Figure 8-6 Arrangement of Pump Elements. When there is only one pump element, it can be installed in any position; standard position is Number 1. nd When a 2 pump element is added, follow the arrangement shown in Figure 8-6. With the first pump located in position 1, install the second pump in position Add 2 nd Pump Element (Refer to Figure 8-7), Single Lube Line 1. Remove closure plug from port at pump position as shown in Figure Thread pump element (1) into port as shown in Figures 8-5 and Remove pressure relief valve (8) from pump. 9. Thread tee fitting (5) into pump. 10. Thread adapter (2) into branch of tee fitting (5). 11. Thread reducer (6) into adapter (2). 12. Thread swivel adapter (7) into reducer (6). 1. Thread hose assembly (4) into swivel adapter (7). 14. Thread pressure relief valve (8) into tee (5). 15. Connect lubrication line to pressure relief valve (8). 16. Tighten all connections. 22

28 -MAX MIN (ref) Figure 8-7 Installation of 2 nd Pump, Single Lube Line 8.4. Adding 2 nd Pump Element (Refer to Figure 8-8), Dual Lube Lines 1. Remove closure plug from port at pump position as shown in Figure Thread pump element (1) into port as shown in Figure Thread adapter (2) into pump (1). 4. Thread pressure relief () into adapter (2). 5. Connect 2 nd lubrication line to pressure relief valve (). 6. Tighten all connections. -MAX MIN- Figure 8-8 Installation of 2 nd Pump, Dual Lube Line 2

29 8.5 Installation of Adjustable Pump Element Follow removal and installation instructions in section The dimension "S" in Figure 8-9 can be found by using the delivery diagram shown in figure Setting the Adjustable Pump Element (refer to Figure 12-1) 1. Unscrew the coupling nut for fixing the safety valve. 2. Loosen counter nut (2) while holding the pump element body () in position with a second wrench.. Change the position of the adjusting spindle (1) with a wrench.. Figure 8-9 NOTE The Adjustable Pump Element is factory set at the maximum lubricant output 0.18 [.0] [0.18] 0.16 [2.7] [0.16] 0.15 [2.4] [0.14] 0.12 [2.0] 0.10 [1.7] 0.09 [1.4] 0.06 [1.0] 0.04 [0.7] [0.12] [0.10] [0.08] [0.06] [0.04] A B [25.5] [26.0] [26.5] [27.0] [27.5] [28.0] [28.5] [29.0] Dimension "S" - inch [mm] A=Lubricant output in /m in B=Lubricant output in /stroke [cm /min] [cm /stroke] Delivery Diagram (Fig.8-10) 24

30 SECTION 9.0 TROUBLESHOOTING WARNING When correcting faults, follow referenced procedures; pay particular attention to all CAUTIONS and WARNINGS. Problem Cause Remedy No Lubrication at Lubricant reservoir empty. Lubrication Point Fill Reservoir with chisel paste. Trigger a lube cycle and allow pump to operate until grease dispenses from lubrication point. (Depending on ambient temperature and/or sort of lubricant it may take up to 10 minutes of operation before the pump elements reach their full output) Pump motor does not run. Power supply interrupted. Check power supply and fuse. Rectify fault. Replace motor If necessary. 9.1 BreakerLube CML Inoperable If the BreakerLube CML fails to work properly and the cause cannot be determined, contact Allied s Technical Service Department for further assistance. 9.2 Manual Lubrication If the BreakerLube CML is out of service, the hammer can be manually lubricated by either method: Manual Lubrication with Lube Line Disconnected 1. Disconnect hose (9) (Figure 6-1) from the hammer connection. 2. Remove adapter (11) from hammer and plug.. Lubricate using a hand-held grease gun at front head. (See hammer s Operator s Manual for specific location and instructions.) Manual Lubrication Through Lube Line 1. With a hand-held grease gun, pump chisel paste through grease nipple located near relief valve. Refer to Figure

31 SECTION 10.0 REMOVAL AND STORAGE OF BREAKERLUBE CML 10.1 Mechanical Removal Of BREAKERLUBE CML 1. Disconnect lubricant hose(s) (4) from the BreakerLube CML at fitting () located on the pressure relief adapter. Fitting () is a push/pull type. Refer to figure Unthread lubricant hose from the lubrication port on the hammer.. Plug the fittings with tapered plugs to provide protection from dirt and debris. 4. Disconnect electrical connections. 5. Unthread the two attachment bolts from BreakerLube CML mounting plate. 6. Remove the complete BreakerLube CML and store in a secure place Reattaching BREAKERLUBE CML After Idle Periods 2. Clean all fittings before connecting.. Refer to SECTION 6.0, BreakerLube CML Installation. IMPORTANT The reservoir must be replenished BEFORE it is empty. If not, air pockets could form and result in tool and bushing damage caused by inadequate lubrication. If a lubrication line is replaced, it must be pre-filled with lubricant before the hammer is operated. Refer to Section 7.2. for procedure to bleed air and fill hose. The chance of air pockets forming is minimized when the reservoir is replenished through the grease nipple located on the pump housing, (Figure 6-4). When following this method, it is not necessary to prime or bleed air from the pump or lines. 1. Clean the lubricant hose and remove any blockages formed by residual lubricant. 26

32 SECTION 11.0 PARTS INFORMATION. -MAX MIN (40') or (60) or (80) (20') seal Kit Figure 11-1 Table 11-1 Kit - Configured Part Number ITEM QTY. PART NO. DESCRIPTION Lube Pump w/ Single Pump (One of the following) A gallon Reservoir, 24Vdc 1 1 A gallon Reservoir, 24Vdc gallon Reservoir, 12Vdc Hose Kit (One of the following) Ft 2 1 A Ft. 80 Ft. 60 Ft. - Includes 2 Lube Lines, 2 nd pump & relief Mounting Bracket Electrical Kit (One of the following) Operating Voltage - 24Vdc Operating Voltage - 12Vdc Allied Chisel Paste is available in tubes and bulk containers. Part No. Description Keg (15 Gal.) Bucket (5 Gal.) Case of 12 Tubes (16 oz.) Case of 6 Tubes (16 oz.) 27

33 Pump Fig

34 Parts List Sheet 1 of 2 (Fig. 11-2) PART NO. A A Lube Pump (w/o hoses) 2 Gallon, 24V w/ Single Pump 1 Gallon, 24V w/ Single Pump 1 Gallon, 12V w/ Single Pump ITEM QTY PART NO. DESCRIPTION Top Cap Gallon Fixed Paddle Gallon Fixed Paddle Gallon Reservoir Gallon Reservoir Hose 10 cm Stirring Paddle O-Ring 210 x Adapter Ring Control Cam Bearing Ring Bearing O-Ring 144 x Intermediate Plate 1 1 A10777 Shim 10 mm x 16 mm x 1.2 mm Snap Ring Pressure Ring mm x 7mm x 1 mm Eccentric Cam Hex Screw M6 x 25 C Washer 19 A10782 O-Ring 6 mm x 2 mm Housing, from S/N & c Housing (20), Cover (29), Screw (0) Kit Pump Element, Chisel Paste Pump Element, Adjustable (option) Gasket Seal 29

35 BreakerLube CML Pump Fig

36 Parts List Sheet 2 of 2 (Fig. 11-2) PART NO. A A Lube Pump (w/o hoses) 2 Gallon, 24V w/ Single Pump 1 Gallon, 24V w/ Single Pump 1 Gallon, 12V w/ Single Pump ITEM QTY PART NO. DESCRIPTION 2 1 A10787 Check Valve Adapter Extension, 04BSPT Pressure Relief Assembly Power Cord, Gray 27 8 A10789 Screw, BZ x 10 C Plug Cover, from S/N & C Screw, M x 25 mm Drain Hose Vdc Motor Vdc Motor Plug, Motor Woodruff Key, x A10798 Radial Seal, BA 10 x 22 x A10799 Lube Fitting Magnetic Switch, Low Level Sealing Plug, M x A10802 O-Ring 1 x Closure Plug, M22 x 1.5 x Plug Self Tapping Screw,.9 x 6.5 C Power Cord Socket Flat Packing 1

37 Hose Kit Figure 11- Table 11- Hose Kit PART NO. DESCRIPTION Single Lube Line Single Lube Line Dual Lube Line (Includes 2 nd hose, 2 nd pump & 2 nd relief valve) Single Lube Line Hose Kit Includes Items 1-8 ITEM QTY PART NO DESCRIPTION Hose /8 MBSPP x Plain End Bonded Seal 1 Pre-filled Lube Line (One of the following) Hose 1/8 MNPT Fitting x Plain End Hose 1/8 MNPT Fitting x Plain End Hose 1/8 MNPT Fitting x Plain End QD Coupler Plug QD Coupler Socket Hose Fitting, Re-usable 04MNPT /8 Hose Hose Fitting, Re-usable 04MNPT ¼ Hose Nylon Tie Strap (not Shown), 2

38 -MIN- -MAX- 1A1 Black Cable Red (+) Brown (-) Black (gnd) 1A1 Black Cable CUSTOMER SUPPLIED HOOK-UP WIRES 2A1 Gray Cable 2A1 Gray Cable Wire VDC FROM IGNITION SWITCH FOOT SWITCH 5 AMP Red Brown Black C 1A B 1 2 M A F 2A D E 2 1 RELAY DPDT RELAY SOCKET NORMAL OPEN TO WARNING LIGHT INSTALLED ON DASH Electrical Kit Fig. 11-4a NORMAL CLOSED TO HAMMER VALVE Table 11-4 Electrical Kit for ITEM QTY. PART NO. DESCRIPTION Electrical Kit 24Vdc Electrical Kit 12Vdc Lamp 28Vdc Lamp 14Vdc Indicator Lamp RED VDC Relay DPDT 24Vdc Relay DPDT 12Vdc Socket Relay Fuse Holder Knob type ¼ inch Fuse 250V/5A Bussman

39 Hydraulic & electric schematic for +24 vdc, pilot operated HYDR FOOT PEDAL AUX VALVE To Hammer Pressure CUSTOMER SUPPLIED HYDRAULIC LINES B2 C1 A To Drain -MAX- Way Valve PN MIN- Pressure Switch PN A1 Black Cable Red (+) Brown (-) Black (gnd) 1A1 Black Cable CUSTOMER SUPPLIED HOOK-UP WIRES 2A1 Gray Cable 2A1 Gray Cable Wire AMP 24VDC FROM IGNITION SWITCH NEGATIVE SIDE OF BATTERY Red Brown Black C B 1A M 2 2 A F A1 D E RELAY DPDT RELAY SOCKET NORMAL OPEN TO POSITIVE SIDE OF WARNING LIGHT INSTALLED ON DASH. Pressure Switch and -way Valve Fig. 11-4b Table 11-5 Optional Components for Pilot Operated Foot Pedal ITEM QTY. PART NO. DESCRIPTION Optional Pressure Switch Optional -way valve 24Vdc If the BreakerLube CML is installed to a carrier that utilizes a hydraulic foot pedal, additional components are required for the electrical and hydraulic systems. In figure 11-4B, a pressure switch and - way valve were added. The pressure switch functions as the on/off switch for the BreakerLube CML. The -way valve will stop the hammer from operating if the low-level control is activated. Neither of these components is included with the BreakerLube CML kit. These items are available at an extra cost. 4

40 -MIN- -MAX (ref) 4 7 Add 2 nd Pump Kit (Fig. 11-5) Table 11-4 Add 2 nd Pump (Optional) ITEM QTY. PART NO. DESCRIPTION Add 2 nd pump kit (Includes Pump & Installation Kit) Pump (Fixed Delivery) Installation Kit (Includes Items 2 through 7) Adapter 04FNPT 04MBSPT Elbow street 02FNPT 02MNPT Hose 02 high pressure 02MNPT x 02MNPT Tee Fitting 04FBPT X 04FBPT X 04MBPT Reducer Adapter 02FNPT 04MNPT Swivel Adapter 02FNPTSW 02MNPT 5

41 Refer to Table 11-5 for model specific installation kits. Table 11-5 Model Specific Installation Kits HAMMER MODEL PART No. NOTES BR422-BR1229; AR70-AR95B --- Specify 12 or 24Vdc BR BR2266, BR2268; AR110-AR10B G80, BR890; AR140B-160C BR (Ser No. 125R & below) BR (Ser No. 140R10060 & below) BR2214, BR2518, BR BR4510, BR4511; AR170C-AR180C BR CML units (2 pumps each) Table 11-6 contains a partial list of parts included in the installation kits shown in Table Table 11-6 Hose Length, Hose Quantity, Pump Quantity Hammer Model Pumps Pump Hose Hose Hose (Qty) (Kit) Kit (Ft) (Qty) BR422-BR1229; AR70-AR95B BR2064, 2266, 2268; AR110-AR10B A G80, BR890; AR140B-160C 2 (102602) BR2214, BR2518, BR BR4510, BR4511; AR170C-AR180C (570954) BR701 (2 CML units w/2 pumps each) 2+2 (102602) x Note: For models BR2214, BR2518 and BR088, the 2 nd hose, 2 nd pump, along with the 2 nd relief valve, is packaged with the hose kit. 6

42