Mincon Support Station

Transcription

1 Mincon Support Station Operation and Service Manual Copyright Mincon 2016, All Rights Reserved.

2 TABLE OF CONTENTS Table of Contents Introduction Safety Operation Setup and Operation of Support Station Confirm Contents of Support Station Crate Setup of Support Station Remote Control FCC Notice Care and Maintenance Remote Battery Change Operation of Remote Syncing the Remote Equipment Inspection Prior to Compressor Ignition Pressure Regulator Adjustment Oiler Adjustment Water Pump Adjustment and Operation Maintenance Electric Valve Troubleshooting Actuator Issues Valve Issues Regulator Troubleshooting Cleaning Regulator Air Motor Lubrication Flushing Air Motor Vane Replacement Disassembly General Instructions Disassembly of the Rear End Plate Disassembly of the Front End Plate Removal of the Rotor Assembly General Instructions Assembly of the Rear End Plate Assembly of the Front End Plate Assembly of the Motor Troubleshooting Mincon_Group_PLC_M _Support_Station_Manual_Rev_A2 Page 2

3 4.4 Water Pump After Use Maintenance Schedule Changing Crankcase Oil Pulsation Dampener Charge Pressure Diaphragm Replacement Valve Replacement Troubleshooting Oil Pump General Priming Pump Troubleshooting Parts Breakdown Support Station Air Motor Electric Valve Water Pump Main Pump Body Main Pump Body Tightening Torque Values Gearbox Gearbox Tightening Torque Values Control Unit Control Unit Tightening Torque Values Oil Pump Warranty Mincon_Group_PLC_M _Support_Station_Manual_Rev_A2 Page 3

4 1 Introduction Thank you for purchasing the Mincon Support Station. This document covers operation and maintenance of the Support Station. This equipment is used to deliver a mix of compressed air, water and rock drill oil to a drill machine for the proper operation of a pneumatic Down the Hole (DTH) hammer. It is important to read and comply with all the instructions within this manual. We have provided considerable information on what the original equipment manufacturers recommend to operate and maintain their components incorporated into your Mincon Support Station. As these recommendations affect the warranty of the components, they automatically become the recommendations of Mincon and failure to comply will also void Mincon s warranty of such items, and potentially other components should any failures be attributed to such noncompliance. 2 Safety SAVE THESE INSTRUCTIONS AS A PERMANENT RECORD OF YOUR MINCON PRODUCT. DO NOT DESTROY. Be sure to work safely at all times. Wear protective clothing and safety equipment and observe all safety regulations as prescribed by your employer, Government, or the site on which you work. Do not wear loose clothing that may get caught in rotating parts and cause serious personal injury. Prior to operating the Mincon Support Station, please take time to ensure you have fully read this operation and service manual and fully understand all aspects of the unit. When using the unit do not pump flammable or explosive fluids such as gasoline, fuel oil, kerosene, etc. Do not use in explosive atmospheres. Do not pump asphalt sealer, roofing compounds, concrete sealers, or any two-step curing products. The pump should only be used with liquids compatible with the pump materials. Failure to follow this notice can result in severe personal injury and/or property damage and will void the product warranty. Never use your hand to check the condition of hydraulic lines or hoses while the unit is pressurized. If hydraulic fluid penetrates the skin, get medical attention immediately. Failure to get proper medical attention may result in loss of limb or life. The safest way to check hydraulic lines is by holding a piece of cardboard next to the hydraulic line or hose. The sound pressure level of the water pump may exceed 80dBA. Observe all safety precautions when operating the pump within close proximity for extended periods by wearing hearing protectors. Extended exposure to elevated sound levels will result in permanent loss of hearing acuteness, tinnitus, tiredness, stress, and other effects such as loss of balance and awareness. Verify that pump shaft rotates freely prior to engaging the pump drive. Do not pump at pressures higher than the maximum recommended pressure. Optimal operation of the support station is between temperatures of 45 to 140 F [7 to 60 C]. Temperatures outside this range may adversely affect the unit. Always disconnect the Support Station from the compressor and ensure all pressurized air is discharged before servicing or working on the unit. Drain all liquids from the system before servicing. Check all hoses for weak or worn condition before each use. Make certain that all connections are tight and secure. Periodically inspect all the components. Perform routine maintenance as required (see maintenance). If repairing any hoses or manifolds, use only pipe, hose, and hose fittings rated for maximum rated pressure of the pump or the pressure at which the pressure relief valve is set at. Do not use pipe that has been previously used. 3 Operation 3.1 Setup and Operation of Support Station Prior to operation, the Support Station must be setup to ensure that correct and safe operation of the equipment is carried out. As mentioned previously, please take time to ensure you have fully read this operation and service manual and fully understand all aspects of the unit. NOTE For safe working conditions during operation of the equipment it is advisable to have received the appropriate training prior to starting up the equipment. If you are unsure how to operate the equipment, please seek advice from a Mincon representative. Mincon_Group_PLC_M _Support_Station_Manual_Rev_A2 Page 4

5 3.1.1 Confirm Contents of Support Station Crate Item Part Number Qty Description M Support Station Crate 1 M Support Station 2 M Foot x PSI High Pressure Hose with Hammer Lock Couplings 3 M Foot x PSI High Pressure Hose with Hammer Lock Couplings 4 M Foot x ¾ Water Hose with ¾ Camlock couplings 5 M Adaptor 6 M Remote Control 7 M Battery Cable 8 M Safety Whip Check Setup of Support Station Step 1: Unpack Support Station and check to make sure all components are present. Step 2: Support Station comes delivered with whip checks in place on both the air intake and discharge lines. Enlarge loop on the other end of the whip check on the air intake valve end and loop over air hose and release. Step 3: Connect air hose to Support Station air intake valve. Step 4: When completed pull whip checks back so that they are as shown above. Above picture shows air discharge side of support station. Step 5: Connect air hose to the compressor in the same manner. Connect other air hose to Support Station discharge line and to Drill also using the same procedure. Step 6: Connect battery cable to the Electric valve and test operation of valve with remote control. Step 7: Before Operation, check level of oil in the oil tank. Fill to the bottom of the fill tube. Mincon_Group_PLC_M _Support_Station_Manual_Rev_A2 Page 5

6 Step 8: Connect the ¾ camlock fitting of the 40 foot water hose to the mix unit being used to deliver fluid to the support station. Next open the water valve to bleed the air from the clear 1 hose. Connect the ¾ camlok fitting to the support station female connection point. Step 9: Open the Main door of the Support Station and locate the plastic union behind the water pump. un-screw the large plastic compression fitting at the top of the diaphragm pump. This fitting may be tight and you may have to use a pair of adjustable pliers. Remove the compression fitting and lift the 90 degree hose barb off the pump allowing the air to escape and the water to flow into the inlet of the water pump. Replace the 90 degree hose barb back into the inlet of the pump and tighten the large plastic compression nut hand tight. Step 10: Ensure the W.P. Air Motor and Oil Pump valves are switched to the off position as shown above. Mincon_Group_PLC_M _Support_Station_Manual_Rev_A2 Page 6

7 3.2 Remote Control Warning: The Remote control can only be used when connected to a 12V DC source. Using a 24V source will burn out the receiver so that it is inoperable and will require replacement. To use a 24V DC source the wired controller must be used FCC Notice This equipment has been tested and found to comply with the limits for a class C digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy and if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures: Reorient or relocate the receiving antenna. Increase the separation between the equipment and the antenna. Consult the dealer or an experienced radio/tv technician for help. The user is cautioned that changes and modifications made to the equipment without the approval of the manufacturer could void the user s authority to operate this equipment Care and Maintenance Your remote and receiver-harness assemblies have been tested and proven to be water resistant under normal conditions. Store the remote out of direct sunlight when not in use. The remote may be cleaned with a damp cloth. Do not use any solvent based cleaning agents. Do NOT pressure wash the receiver-harness assemblies located inside the back panel and exiting from the manifold on the electric valve side. The receiver-harness assemblies DO NOT run on batteries they get their power from the battery cable and should NOT be opened Remote Battery Change The remote uses 2 x AA alkaline batteries: 1. Remove the 12 screws (1) around the perimeter of the black backside (2) of the remote. 2. Remove the black backside of the casing. The batteries (3) will be revealed. 3. Remove the old batteries and replace with 2 new alkaline AA batteries. 4. Ensure that the gasket (4) is in place and replace the casing. Ensure the wires are not between the screws and casing as they can be accidentally pinched and severed. 5. Reinstall ALL 12 screws taking care not to over tighten. Not using all screws will allow moisture and dust into the remote. NOTE: After battery change, your remote may require a re-sync (Covered in Syncing the Remote) Operation of Remote The remote control can be programmed to control up to 10 different valves. Your remote control has been programmed to control only one valve, the electric valve on your Support Station. Press the on button to turn the remote control on. To open the valve, press the on button again. To close the valve, press the off button. If you wish to open the or close the valve partially, use the left and right arrow buttons on the remote control. With the valve closed, pressing the right arrow will incrementally open the valve with each press, and with the valve in the open position, pressing the left arrow will incrementally close the valve with each press. Mincon_Group_PLC_M _Support_Station_Manual_Rev_A2 Page 7

8 3.2.4 Syncing the Remote After the batteries of the remote have been changed, it may be necessary to sync the remote to the receiver. The receiver is mounted on the inside of the Support Station on the back panel. The procedure for syncing the remote is as follows: 1. With the Remote on, press the Sync button, and if the LED light number one illuminates solid, the remote is still synced. Go to step 3. If the LED light number one illuminates flashing, go to step Reach inside the Support Station with the Remote and press it against the center of the receiver (see below) and hold it there until the LED light number one turns solid. 3. Press the Sync button again and the LED light will go out. 4. The Remote and Receiver are now synced. If the Remote is being replaced with a new one, the procedure is as follows: 1. With the Remote on, press the Sync button, and the LED light number one will illuminate flashing. 2. Reach inside the Support Station with the Remote and press it against the receiver where the remote says Sync Here (see below) and hold it there until the LED light number one turns solid. Pressing the remote at the back of the Support Station to sync will not work. 3. Press the Sync button again and the LED light will go out. 4. The Remote and Receiver are now synced. If the Remote is being transferred to another Support Station, the procedure is as follows: 1. With the Remote on, press the Sync button, and the LED light number one will illuminate solid. 2. Press the OFF button to unsync the Remote and the LED light number one will illuminate flashing. 3. Reach inside the Support Station with the Remote and press it against the receiver and hold it there until the LED light number one turns solid. 4. Press the Sync button again and the LED light will go out. 5. The Remote and Receiver are now synced. In the case where a new Remote that has never been synced to a Receiver is being synced to your Support Station Receiver, when the sync button is pressed, the LED light number one will illuminate flashing. If you want to Sync a remote that has been synced with a different Receiver, press the Sync button, and the LED light number one will illuminate solid. Press the OFF button to unsync the Remote. Correct Method for Syncing Remote to Receiver Mincon_Group_PLC_M _Support_Station_Manual_Rev_A2 Page 8

9 3.3 Equipment Inspection Prior to Compressor Ignition CAUTION: The following walk around check should be carried out prior to starting the compressor. Step Specific Equipment Required State Compliant ( ) 1 Hose connecting Drill to Support Station. RED Air flow arrow goes to Drill. Hose connected to outlet valve which is manual. 2 Hose connecting compressor to Support Station. Connected at electric inlet valve. 3 Inlet and Outlet Valve Connections. 4 Inlet and outlet valves on Support Station Whip Checks. 5 Hose to compressor connection. 6 Hose to compressor connection Whip Check. 7 Hose to Drill connection. 8 Hose to Drill connection Whip Check. Wing nuts tightened using hammer turning clockwise. Connected correctly as described in above sections. Wing nuts tightened using hammer turning clockwise. Connected correctly as described in above sections. Wing nuts tightened using hammer turning clockwise. Connected correctly as described in above sections. 9 Water Hose to Support Station connection. Water hose connected to water inlet. 10 Water hose to water supply. Water hose connected to water supply. 11 Water filter. Filter clean and clear of debris. 12 Oil Tank. Oil tank filled. 13 Water Pump Crankcase. Check Oil Level. 14 Water Pump Reduction Gearbox. Check Oil Level. 15 Water Pump Control Unit. Correct expected Pressure setting. 16 Water Pump. Primed. 17 Main Air Discharge valve (2 Valve to Drill). Closed (Perpendicular to Valve Body). 18 Pulsation Dampener. Pressure Set to 20% of working PSI. 19 Power Connections for Electric valve actuator and receiver. 20 Electric Valve Operation. 21 Remote Control. 22 Electric Valve. Connected to 12V Battery ONLY Black to NEGATIVE (-) and Red to POSITIVE (+). Operating correctly Arrow on valve actuator turns and points parallel to manifold when open. Operating correctly, on button opens valve, off button closes. Valve Closed Arrow on valve actuator points perpendicular to manifold when closed. 23 W.P. Air Motor Valve. Turned off in the upright position. 24 Oil Pump Valve. Turned off in the upright position. Mincon_Group_PLC_M _Support_Station_Manual_Rev_A2 Page 9

10 3.4 Pressure Regulator Adjustment On a new support station, the pressure regulator should be set at 90 PSI. To adjust the pressure after the walk around inspection and the compressor is operational, turn the Air Discharge Valve (Valve to Drill - 2 ball valve) off, Turn electric valve on to pressurize the system. Adjust the regulator clockwise to turn air pressure up and counter clockwise to turn pressure down. Set pressure gauge to 90 PSI. After adjustment turn electric valve off (red light) and turn Air Discharge Valve on, handle parallel to the valve body. CAUTION; Operating at higher pressures can cause damage to oil pump. 3.5 Oiler Adjustment The Support Station s oil pump delivers 16cc of rock drill oil per pulse or cycle every time it injects oil into the air manifold. You can adjust this by opening or closing the OIL VOLU. Needle valve on the front panel of the support station as shown. The oil injection circuit works by building to the maximum pressure of close to 600 PSI when the air regulator is set at 90PSI. You can then control the rate of injection by adjusting the needle valve that allows the oil into the air manifold. Counting the pulse rate of the oil injection pump will give you an estimated rate of oil usage. For example the pump delivers close to 16cc s per pulse or cycle. There are 3,785cc s in a gallon of oil and we would like to see an average of 3-4 pints per hour of operation when using water with the air hammers. A pulse rate of one pulse every seconds will give you an estimated 4 pints per hour of oil consumption. Turn the Oil Pump Valve to the open position and adjust the needle valve until you can count seconds between pump pulses. 3.6 Water Pump Adjustment and Operation It is recommended that you use the rigs water pump when available to inject water/foam mixtures into the air delivered to the air hammer. The Mincon Support Station does have a water pump built into it. The pump will deliver up to 9 gallons per minute depending on the air pressure being supplied to the air hammer. Higher pressures will limit the water from being injected into the air manifold. The maximum the diaphragm water pump will build is 550 psi (37.9 BAR). The air pressure being used may limit or decrease the water pumps ability to deliver the maximum rated flow. Before operation, carry out the following: 1. Check and make sure oil is halfway up to the clear oil sight tube of the water pump. If necessary, fill to the correct level with a high-grade, nondetergent, SAE 30 weight oil formulated to prolong pump life. 2. Make sure the suction hose barb is tightly screwed onto the suction union and that there are no air leaks on the inlet side of the pump. 3. Check the charge pressure on the pulsation dampener before starting the pump. The pressure is checked with a standard automotive air gauge. The pressure should be at approximately 20% of the maximum pressure that you will be operating the pump at. Exercise caution when checking pressure to avoid losing pre-charge. 4. Determine the operating pressure and adjust the pressure of the Control unit (9910-GS40GI) by clamping the relief valve adjustment lever down. With the bale hook in the number one position, the pressure is about 100 psi (6.9 BAR); number two is about 250 psi (17.2 BAR); number three is about 450 psi (31.0 BAR); number four is about 550 psi (37.9 BAR). These pressures can be adjusted by using the fine adjustment knob located on top of the relief valve spring. The fine adjustment knob can be rotated when the relief valve lever is in the up position. Once the Support Station is operating, the pressure can be fine-tuned using the pressure valve attached to the Control Unit (9910-GS40GI). Caution: Ensure that all pressure has been released from the unit prior to making adjustments. 5. Turn the Water Pump Air Motor (W.P. AIR MOTOR) valve to the open position to start the pump. Adjust the Water Volume Valve to get the desired flow in US gallons per minute. One US gallon = 16 fluid ounces. Mincon_Group_PLC_M _Support_Station_Manual_Rev_A2 Page 10

11 4 Maintenance The following sections will describe regular maintenance and troubleshooting of the main operating components in the Mincon Support Station. 4.1 Electric Valve Caution: If using the remote control receiver with this actuator valve, it is imperative that only 12V DC Power be used Troubleshooting Actuator Issues SYMPTOM PROBABLE CAUSE(S) CORRECTIVE ACTION Actuator will not run at all a) Limit switch problem. a) Check and adjust limit switches per instruction b) Cam assembly problem. b) Check and adjust cams per instructions c) Integrated circuit breaker tripped c) Disconnect power to unit for 20 seconds; reconnect power. d) Dead or open short in control harness. d) Check harness for cuts in insulation or sharp pinch point. Check for continuity of each wire in the e) Dead or open short in actuator control circuit. harness. Check connectors for damage or corrosion. Repair or replace as needed. e) Check actuator housing for damage or missing hardware. Check actuator for internal corrosion. Check for loose motor lead. Clean circuit with electrical contact cleaner and compressed air. Solder connections if necessary. Replace circuit board assembly if required. f) Disconnect motor leads at circuit board or motor. Apply power directly to motor terminals. Motor should run continuously when power is applied. Replace motor if rotation is not smooth Mincon_Group_PLC_M _Support_Station_Manual_Rev_A2 Page 11

12 Motor runs continuously. a) Limit switch problem. b) Cam assembly problem. c) Defective or damaged circuit board component. a) Check and adjust limit switches per instruction. b) Check and adjust cams per instruction. c) Replace circuit board assembly. Constantly tripping integrated circuit breaker or blowing of line fuse. a) Valve operating torque excessive; tight from incompatible valve or media, or buildup. b) Defective or damaged circuit board component. c) Failed gear motor. a) Remove motorized actuator from valve. Manually turn valve with torque wrench when possible. Confirm that valve torque is within actuator capability. Refer to Actuator Information chart in engineering section of catalog. Disassemble and clean valve. b) Many models have internal relays. Listen for audible click upon activation. Bypass circuit board assembly to test motor, see c) Failed gear motor Replace circuit board assembly if needed. d) Disconnect motor leads at circuit board or motor. Apply power directly to motor terminals. Motor should run continuously when power is applied. Replace motor if rotation is not smooth Valve Issues SYMPTOM PROBABLE CAUSE(S) CORRECTIVE ACTION Valve is leaking past ball. a) Seats damaged or worn out. b) Valve is not stopping at proper closed position. Valve stem leaks a) Worn stem seals b) Damaged stem or stem bore. Valve body leaks a) Excessive operating pressure. b) Defective body seals. Valve operating torque excessive. 4.2 Regulator Swollen seals or particulate buildup in valve chamber. a) Install valve repair kit. b) Adjust limit switches of actuator. a) On metal valves: tighten stem packing nut ~ ¼-½ turn. CAUTION! Over tightening stem nut could cause excessive operating torque and trip internal circuit breaker. If leak continues or for plastic valves, install repair kit. b) Replace valve stem if available, otherwise replace valve. a) Confirm application is within recommended pressure ratings. b) Install repair kit or replace valve. Install repair kit or replace valve. The Regulator installed on the Mincon Support Station is a high capacity regulator that provides a uniform output pressure independent of supply pressure variation. The Regulator does not require field adjustments. Refer to the exploded view following the procedure when working on the Regulator Troubleshooting SYMPTOM PROBABLE CAUSE(S) CORRECTIVE ACTION Regulator Leaking a) Cracked Body. a) Check to see if body is cracked from b) Diaphragm leak. over tightening. b) Check diaphragm assembly for damage or wear. High Bleed Damage or contamination of Relief Pintle and Relief Seat. Check Relief Pintle and Relief Seat for damage or contamination. Valve Chatter Lack of lubrication of Seal Ring Lubricate Seal Ring Cleaning Regulator To clean the Regulator, use the following procedure: 1. Before disassembly, shut off the valve that is supplying air to the regulator. This is to prevent air from escaping. It is not necessary to remove the regulator from the air line. 2. Remove the two Screws (22) from bottom of the unit. 3. Pull out the Inner Valve Assembly (19). Wash the Seat on the Inner Valve Assembly carefully. 4. Wipe off any particles that may be attached to rubber Seat Ring (17) in Body. Mincon_Group_PLC_M _Support_Station_Manual_Rev_A2 Page 12

13 5. Replace the assembly carefully. 6. Keep the vent hole in the Bonnet clear for proper Regulator operation. Lubricate the adjusting screw with Molycote G. For more information, see exploded view. Notes: Avoid such solvents as acetone, carbon tetrachloride and trichloroethylene. If the standard maintenance procedure does not correct the problem install a service kit. Mincon_Group_PLC_M _Support_Station_Manual_Rev_A2 Page 13

14 4.3 Air Motor Lubrication 1. Disconnect the air line 2. Pour 6 to 8 cc of a high quality non-detergent SAE 10 motor oil into the air inlet. 3. Reconnect the air supply line, slowly increase the air pressure to ensure all internal parts of motor will be covered with a film of oil Flushing Air Motor If the motor operates sluggishly, flush it with a clean, non-toxic, non-flammable commercial solvent in a well-ventilated area. To flush the motor: 1. Disconnect the air line and muffler. 2. Pour 6 to 8 cc of solvent into each inlet. 3. Rotate the rotor shaft by hand in both directions several times to ensure all internal parts of motor are thoroughly cleaned. 4. Apply air pressure to the inlet and slowly increase the air flow until there is no trace of the solvent in the exhaust. 5. After flushing, shut off the air supply and disconnect air supply line. 6. Pour 6 to 8 cc of a high quality non-detergent SAE 10 motor oil into the air inlet. 7. Reconnect the air supply line, slowly increase the air pressure to ensure all internal parts of motor will be covered with a film of oil. 8. If the motor is still low in power, check for damaged vanes or foreign material in the vane slots in the Rotor Vane Replacement Vanes will last 5,000 to 15,000 hours of operation, depending upon the speed of the motor, operating pressure, lubrication and preventative maintenance. Periodically, you should check the Vanes for wear, and replace them if the width of the Vane is equal to or less than the replacement width shown below: -Width of new Vane: 13/16 inch (20.6 mm) -Replacement width: 25/32 inch (19.8 mm) Always replace Vanes in sets; never replace an individual Vane. Replace Vanes as follows: 1. Disconnect the air line at the motor. 2. Unscrew and remove the Rear End Cap Screws and Rear End Cap. 3. Unscrew and remove the Rear End Plate Cap Screws. 4. Using a puller, pull the Rear End Plate along with the Rear Rotor Bearing from the motor. 5. Wipe each of the new Vanes to be installed with a thin film of light oil. 6. Rotate the Rotor by hand to place two of the Vanes in a horizontal position. 7. Obtain a stiff piece of wire or length of key stock that will slide into the vane slots, and grind one end of it to a gentle, sloping bevel. You will use this for depressing the Vane Pins while changing Vanes. 8. Insert the depressing tool in the vane slot along the bottom edge of the Vane so that it passes between the Vane and the Vane Pin. 9. Depress the Vane Pin toward the center of the Rotor and, while holding it in this position, withdraw the worn Vane and install the new Vane with its notched side toward the center of the Rotor. 10. Repeat the procedure with each Vane. The use of other than genuine Select Series replacement parts may result in decreased tool performance and increased maintenance, and may invalidate all warranties. Always wear eye protection when operating or performing maintenance on this motor. Always turn off air supply and disconnect supply hose before installing, removing or adjusting any accessory on this motor, or before performing any maintenance on this motor Disassembly Please refer to the following Cutaway section when disassembling and assembling the air motor for maintenance. Mincon_Group_PLC_M _Support_Station_Manual_Rev_A2 Page 14

15 ITEM DESCRIPTION 1 Cylinder 2 Front End Plate 3 Rear End Plate 4 Rotor 4A Drive Key 5 Vane (4) 5A Vane Spring (2) 5B Vane Pin (4) 6 Rear Rotor Bearing 6A Front Rotor Bearing 7 Rotor Shaft Seal 8 End Plate Gasket (2) 9 Rear End Cap 10 Rear End Cap Screws 11 End Cap Gasket 12 Muffler Assembly 13 Front End Plate Cap Screw (6) 14 Rear End Plate Cap Screw (6) 15 Shield 16 O-Ring 17 Shield Cap Screws General Instructions 1. Always disconnect the air line at the motor before attempting any disassembly. 2. Do not disassemble the motor any further than necessary to replace or repair damaged parts. 3. The Vanes are spring loaded. Do not withdraw the Rotor from the Cylinder unless it is absolutely necessary. Vanes can easily be replaced without withdrawing the Rotor. (See Vane Replacement section) 4. When grasping a part in a vice, always use leather-covered or copper-covered vice jaws to protect the surface of the part and help prevent distortion. This is particularly true of threaded members and housings. 5. Do not remove any part which is a press fit in or on a subassembly unless the removal of that part is necessary for repairs or replacement. 6. Important: After these motors were assembled at the factory, Cylinder Dowel alignment pins were pressed into the End Plates and Cylinder. During disassembly, these pins will usually remain with the Cylinder. Do not remove them Disassembly of the Rear End Plate 1. Unscrew and remove the Rear End Cap Screws and remove the Rear End Cap (9). 2. Unscrew and remove the Rear End Plate Screws (14). Mincon_Group_PLC_M _Support_Station_Manual_Rev_A2 Page 15

16 3. Using a puller, pull the Rear End Plate (3) along with the Rear Rotor Bearing (6) from the motor. 4. The Rear Rotor Bearing is a slip fit in the Rear End Plate. Slide or push it from the bearing recess Disassembly of the Front End Plate 1. Unscrew the Front End Plate Cap Screws (13). 2. Using a puller, pull the Front End Plate (2) along with the Front Rotor Bearing (8A) from the rotor shaft. 3. The Rotor Shaft Seal (7) is pressed into Shield (15). Do not remove these parts unless you have a new Seal on hand. This Seal is always destroyed in the removal process. If you have to remove the Rotor Shaft Seal, unscrew and remove the Shield Cap Screws (17). Pull the Shield from the Front End Plate. If you have to remove the Rotor Shaft Seal, pry it out of the Shield with a large screwdriver. 4. The Front Rotor Bearing is a slip fit in the Front End Plate. Slide or push it from the bearing recess. 5. Carefully remove O-Ring (16) from Shield, taking care not to cut O-Ring Removal of the Rotor 1. If the Rotor (4) must be withdrawn from the Cylinder, remove the Rear End Plate as previously described. 2. Unscrew the Front End Plate Cap Screws. 3. Carefully withdraw the assembled Front End Plate and Rotor from the Cylinder. Caution: As you withdraw the Rotor, grasp the rotor body so that the Vanes (5), Vane Springs (5A) and Vane Pins (5B) do not fly. 4. After withdrawing the Rotor, remove the Vanes, Vane Springs and Vane Pins. 5. Support the Front End Plate as close to the rotor body as possible, and press the Rotor from the Front Rotor Bearing Assembly General Instructions 1. Always wipe all parts with a thin film of oil before installing them in the motor. 2. Always press on the inner ring of a ball-type bearing when installing the bearing on a shaft. 3. Always press on the outer ring of a ball-type bearing when pressing the bearing into a bearing recess. 4. Whenever grasping a part in a vice, always use leather-covered or copper-covered vise jaws to protect the surface of the part and help prevent distortion. This is particularly true of threaded members and housings Assembly of the Rear End Plate 1. Support the Motor on the Front End Plate (2). 2. Place End Plate Gasket (8) on the rear face of the Cylinder (1), making certain that it is properly oriented relative to the Cylinder Dowels and tapped holes in the Cylinder. Note: If you are installing a new Gasket, you will have to punch or cut two holes in it to accommodate the Cylinder Dowels. Do this by placing the Gasket on the Gasket on the Rear End Plate to determine the location of the dowel holes. Use a proper size gasket punch to cut the required dowel holes. 3. Align the dowel holes in the Rear End Plate (3) with Cylinder Dowels in the Cylinder and, using a plastic hammer, tap the Rear End Plate into place against the Gasket. 4. Using a sleeve that contacts only the inner ring of the Bearing, press the Rear Rotor Bearing (6) onto the rotor shaft until it seats in the bearing recess in the Rear End Plate. Caution: Do not bind the End Plate against the Rotor. 5. Rotate Rotor (4) by hand. It should rotate freely with no binding or rubbing against the Cylinder. If the Rotor rubs or binds, tap the top edge of the Rear End Plate with a plastic hammer in the area midway between the inlet and outlet ports. Tap the End Plate gently. The Rotor needs only inch (0.038 mm) clearance from the top of the Cylinder. If the Rotor continues to rub, it may be contacting the Front End Plate due to pressing on the Rear Rotor Bearing. Lightly tap the keyed end of the rotor shaft with a plastic hammer. The Rotor needs about inch (0.051 mm) clearance between the rotor body and each End Plate. 6. When the Rotor turns freely, install the End Plate Cap Screws (14). Tighten them to 8 to 10 ft-lb (10.8 to 13.5 Nm). 7. Slip End Cap Gasket (11) on the end of Rear End Plate (3). Place the Rear End Cap over the Gasket and Screw the Rear End Cap Screws (10) into the Rear End Plate. Tighten to 8 to 10 ft-lb (10.8 to 13.5 Nm) Assembly of the Front End Plate 1. Support the Motor on the Rear End Plate. 2. Place an End Plate Gasket on the front face of the Cylinder, making certain that it is properly oriented relative to the Cylinder Dowels and tapped holes in the Cylinder. Note: If you are installing a new Gasket, you will have to punch or cut two holes in it to accommodate the Cylinder Dowels. Do this by placing the Gasket on the Gasket on the Rear End Plate to determine the location of the dowel holes. Use a proper size gasket punch to cut the required dowel holes. Mincon_Group_PLC_M _Support_Station_Manual_Rev_A2 Page 16

17 3. Align the dowel holes in the Front End Plate with the Cylinder Dowels in the Cylinder and, using a plastic hammer, tap the Front End Plate into place against the Gasket. 4. Using a sleeve that contacts only the inner ring of the Bearing, press the Front Rotor Bearing (6A) onto rotor shaft until it seats in the bearing recess in the Front End Plate. 5. Rotate the Rotor by hand. It should rotate freely with no binding or rubbing against the Cylinder. If the Rotor rubs or binds, tap the top edge of the Front End Plate with a plastic hammer in the area midway between the inlet and outlet ports. Tap the End Plate gently. The Rotor needs only inch (0.038 mm) clearance from the top of the Cylinder. If the Rotor continues to rub, it may be contacting the Rear End Plate due to pressing on the Front Rotor Bearing. Remove the Rear End Cap and lightly tap the end of the rotor hub with a plastic hammer. The Rotor needs about inch (0.051 mm) clearance between the rotor body and each End Plate. 6. When the Rotor turns freely, install the Front End Plate Cap Screws (13). Tighten them to 8 to 10 ft-lb (10.8 to 13.5 Nm). 7. Moisten the lip of a new O-Ring (16) and slip onto groove on Shield (15). Press Seal (7) into Shield (15) to bottom of recess. 8. Moisten the lip of a new Rotor Shaft Seal (9) and O-Ring (16) with O-Ring lubricant and press the Shield into the Front End Plate. 9. Install the Shield Screws. Tighten to 8 to 10 ft-lb (10.8 to 13.5 Nm) Assembly of the Motor 1. Position the Rotor vertically on the table of an arbor press so that the short hub is upward. 2. Place the Rear End Plate, flat side first, on the short hub of the Rotor. 3. Place a inch (0.051 mm) thick shim on each side of the Rotor between the rotor body and the Rear End Plate. 4. Using a sleeve that contacts only the inner ring of the Bearing, press the Rear Rotor Bearing (8) onto the hub of the Rotor until it seats in the bearing recess in the Rear End Plate. 5. Withdraw the shims. 6. Stand the assembled Rotor and End Plate upright on on the hub of the Rear End Plate. 7. Place a Vane Spring (5A) in the center of each cross-hole in the rotor body. Place a Vane Pin (5B) at each end of each Vane Spring. 8. Moisten each Vane (5) with film of light oil. 9. Place a Vane, notched side first, in each vane slot. 10. Place a rubber band around the rotor body to hold the Vanes, Vane Springs and Vane Pins in place. 11. Place an End Plate Gasket on the rear face of the Cylinder, making certain that it is properly oriented relative to the Cylinder Dowels and tapped holes in the Cylinder. Note: If you are installing a new Gasket, you will have to punch or cut two holes in it to accommodate the Cylinder Dowels. Do this by placing the Gasket on the Rear End Plate to determine the location of the dowel holes. Use a proper size gasket punch to cut the required dowel holes. 12. Slide the assembled Rotor and Rear End Plate into the Cylinder until the End Plate contacts the Cylinder Dowels. 13. Using a wire hook inserted between the End Plate Cylinder, pull the rubber band free of the Rotor, thus leaving the Vanes, Vane Springs and Vane Pins trapped in the Cylinder. 14. Align the dowel holes in the Rear End Plate with the Cylinder Dowels in the Cylinder and, using a plastic hammer, tap the Rear End Plate into place against the Gasket. 15. Install the Front End Plate as described in Steps 1, 2, 3 and 4 in the section titled Assembly of the Front End Plate. 16. Rotate the Rotor by hand. It should rotate freely with no binding or rubbing against the Cylinder. If the Rotor rubs or binds, tap the top edge of the Rear End Plate with a plastic hammer in the area midway between the inlet and outlet ports. Tap the End Plates gently. The Rotor needs only inch (0.038 mm) clearance from the top of the Cylinder. If the Rotor continues to rub, it may be contacting the Rear End Plate due to pressing on the Front Rotor Bearing. Lightly tap the end of the rotor hub with a plastic hammer. The Rotor needs about inch (0.051 mm) clearance between the rotor body and each End Plate. 17. When the Rotor turns freely, install the End Plate Cap Screws (13, 14) and tighten them to 8 to 10 ft-lb (10.8 to 13.5 Nm). 18. Install the Rotor Shaft Seal (7), Shield and Front End Cap as described in Step 8 in the section titled Assembly of the Front End Plate. 19. Install the Rear End Cap (9) as described in Step 7 in the section titled Assembly of the Rear End Plate. 20. Again, check the Rotor to see that it rotates freely. Make certain it is rotating freely before connecting the air supply line Troubleshooting SYMPTOM PROBABLE CAUSE(S) CORRECTIVE ACTION Low power or low free speed Low air pressure at the inlet Check air pressure at the inlet. For top performance and durability of parts, the air pressure must be 90 psig (6.2 bar/620 kpa) at the inlet. Worn or broken Vanes Install a new set of Vanes. Improper lubrication or dirt building up in the Motor Lubricate as instructed under Lubrication. If this does not help, flush the Motor as instructed under Flushing Motor. Output drops and the pump is noisy. The oil level is too low. Add oil to the correct level (halfway up the Mincon_Group_PLC_M _Support_Station_Manual_Rev_A2 Page 17

18 Oil comes out of the discharge port or oil is a milky color. One or more diaphragms have split. sight tube). Remove the manifold and heads. Drain the oil and clean the crankcase of water. Replace the diaphragms, heads, and manifold. Refill with high-grade, nondetergent, SAE 30 weight oil. 4.4 Water Pump After Use It is essential that after usage, the pump is flushed with clean water to ensure no residue is left in the pump. Failure to do so can result in a build-up of debris and cause the pump to stop operating. For winter storage or if a freezing condition will be encountered, flush the pump with a 50/50 mixture of water and antifreeze Maintenance Schedule Regular Service Period Performed at every indicated month or operating hour interval, whichever comes first First Use Each Use First month or 40 hours Every 3 months or 500 hours Item Task Crankcase Oil Check Level X X Replace X X Gearbox Oil Check Level X X Replace X X Pulsation Dampener Pressure Set to 20% of working PSI X Check X X Diaphragms Replace X Valves Check X Replace O-Rings Check X Replace Every 6 months or 1000 hours X X Changing Crankcase Oil The water pump comes with oil in the crankcase. Mincon recommends changing the oil after 40 hours of break-in operation and every three months or 500 hours, whichever comes first. Use high-grade, non-detergent, SAE 30 weight oil formulated to prolong pump life. To drain the oil, remove the drain plug ( ) and the oil sight glass covers, and rotate shaft until the oil stops flowing out. Reinstall the drain plug. To fill the pump with oil, slowly pour oil into sight tube while turning the pump shaft. Turning the pump shaft purges all the air out of the crankcase. Always change oil when replacing diaphragms. The oil capacity of the crankcase is 18 oz (532 ml) Pulsation Dampener Charge Pressure It is important to periodically check the charge pressure on the pulsation dampener before starting the pump. The pressure is checked with a standard automotive air gauge. The pressure should be at approximately 20% of the maximum pressure that you will be operating the pump at. Exercise caution when checking pressure to avoid losing pre-charge Diaphragm Replacement The manufacturer of the pump recommends changing the diaphragms every 500 hours or three months, whichever comes first. To do this: 1. Drain oil from crankcase as instructed previously. 2. Remove pump head bolts and heads. 3. Remove the bolt securing the diaphragm (See Figure 11). 4. Remove the old diaphragm and the washer (See Figure 11). 5. Install a new diaphragm; then turn the crankshaft to bring the piston to its down-stroke and seat the diaphragm into the sleeve groove. 6. Install the washer and bolts removed in steps 3 and Replace the pulsation dampener diaphragm by first bleeding the air from the dampener. Remove the bolts from the dampener cover and replace the diaphragm. Reassemble the cover in place and charge the dampener to 20% of the operating pressure. Mincon_Group_PLC_M _Support_Station_Manual_Rev_A2 Page 18

19 8. Refill the crankcase with high-grade, non-detergent, SAE 30 weight oil. Rotate the shaft to distribute the oil, and fill to proper level Valve Replacement Occasionally debris may cause improper seating of the valves or damage to the o-rings. To check for this problem, follow these steps. Remove the pump manifolds. With the manifolds removed, the valves can easily be removed and inspected for debris and wear. Replace valves, o-rings and manifolds Troubleshooting SYMPTOM PROBABLE CAUSE(S) CORRECTIVE ACTION The pump does not draw water. One or more valves are seating improperly. Remove valve and check for debris. Remove any debris found. Examine the valve seats and clean them. Suction line is plugged or collapsed. Clean Examine and clean the suction The liquid flow is irregular. Clogged strainer. The charge in the pulsation dampener is incorrect. line. Clean the strainer. Check the pressure in the pulsation dampener. (It should be 20% of your operating pressure) One or more valves are seating improperly. Remove valve and check for debris. Remove any debris found. Examine the valve seats and clean them. Output drops and the pump is noisy. The oil level is too low. Add oil to the correct level (halfway up the Oil comes out of the discharge port or oil is a milky color. 4.5 Oil Pump General One or more diaphragms have split. sight tube). Remove the manifold and heads. Drain the oil and clean the crankcase of water. Replace the diaphragms, heads, and manifold. Refill with high-grade, nondetergent, SAE 30 weight oil. The oil pump operates quite simply, using a known pressure intensification principle. A piston with a large surface area is actuated by compressed air. Attached to it is a piston with a smaller surface area, which is driven in a hydraulic chamber generating a high level of hydraulic pressure. The continuous pumping action is produced by compressed air being switched alternately to the top and bottom of the air piston by a valve. By regulating the compressed air supply pressure from 20 psi to 100 psi, the maximum hydraulic pressure can be adjusted using the ratio of the pump. The pump being used is a 6:1 ratio, so with the regulator set at 90 psi, the output pressure of the oil should be 540 psi which is sufficient to be able to enter the air stream and lubricate the hammer Priming Pump Should the pump be removed for servicing, air may become trapped and the pump may need to be primed. After the pump suction is connected to the oil tank, connect the compressed air supply at a low pressure (20 PSI recommended). Allow the pump to operate slowly until it is primed and oil comes through to the output port. Now shut off the air supply to the pump and securely connect the outlet hardline. Switch on the air supply again and allow the pump to run in order to bleed all the air from the oil circuit. With the circuit fully primed, the air supply pressure can be increased to the level required for the intended operating pressure. Remember to ensure the safety of all persons in the vicinity when this procedure is undertaken and allow for any highpressure leakage there may be during the testing phase Troubleshooting SYMPTOM PROBABLE CAUSE(S) CORRECTIVE ACTION Pump does not cycle or only runs slowly a) Air valve spool stuck in its mid position. b) Formation of ice on the exhaust side. a) Clear blockage or replace valve assembly. b) Shut off the pump for a short time and drain water from air filter. c) Remove the muffler/breather, clean or replace. d) Shut off air supply, dismantle and clean air filter. Air escaping from muffler or breather Worn air valve or air piston seal Replace valve or seal Excess oil leakage from Muffler/breather Worn hydraulic seal. Replace seal. Mincon_Group_PLC_M _Support_Station_Manual_Rev_A2 Page 19

20 Pump cycles without pumping oil. a) Blocked suction line. b) Bad connection on suction line. c) Check valves blocked or worn. Pump functions but only generates low pressure and does not stall at maximum pressure. a) Internal leakage in the circuit downstream. b) Suction valve seats damaged and leaking. c) Output valve seats damaged and leaking. d) Worn air seal a) Clean out filter. b) Check for bad connections or air leaks on suction line. c) Clean or replace valves. a) Find leak source and repair or change component. b) Replace suction valve parts. c) Replace output valve parts. d) Replace seal. Mincon_Group_PLC_M _Support_Station_Manual_Rev_A2 Page 20

21 5 Parts Breakdown 5.1 Support Station Mincon_Group_PLC_M _Support_Station_Manual_Rev_A2 Page 21

22 Mincon_Group_PLC_M _Support_Station_Manual_Rev_A2 Page 22

23 ITEM PART NO. QTY DESCRIPTION M Mincon Support Station 1 M Sight Glass 2 M Oil Tank 3 M Tank Cap 4 M Hose Assy 5 M Fitting 6 M Oil Pump 7 M /8"-UNF X 1.5" Socket HD 8 M Fitting 9 M Fitting 10 M Hose Assy 11 M /4" Close Nipple Strainer 12 M Adaptor 13 M Electirc Valve 14 M " Nipple 15 M Hose Assy 16 M Fitting 17 M Washer 18 M M16 Lockwasher 19 M HHCS M16X25 21 M Fitting 22 M Hose Assy 23 M Fitting 24 M Check Valve 25 M Fitting 26 M Check Valve 27 M Fitting 28 M " Ball Valve 29 M " Manifold - R 30 M " Check Valve 31 M Coupling 32 M Nipple 33 M " Manifold - L 40 M Muffler 41 M /2" 90 Deg Elbow 42 M Hose Assy 43 M Hose Assy 44 M Water Pump 45 M Water Inlet Hose 46 M Clamp 48 M /8" Flat Washer 49 M /8" Lockwasher 50 M HHCS 3/8"-UNC X 1.5"L 51 M Fitting 52 M Fitting 53 M Fitting 54 M /4" Tee C/W Mounting Bracket 55 M Nipple 56 M Water Inelt Strainer 57 M Nipple 58 M /4" 90 Deg Elbow 59 M /4" Ball Valve 60 M Camlock 61 M Hose 62 M Clamp 64 M Hose Assy 65 M Fitting 66 M Water Pump Mt Bracket 67 M M8 X 25 Socket HD Screw 68 M M8 Lockwasher 69 M HHCS 3/8"-16 UNC X 7/8" 70 M Motor Mt Bracket 71 M Air Motor 72 M HHCS 5/16"-UNC X 3.5"L 75 M Gauge 76 M Fitting 77 M Hose Assy 78 M Front Panel 79 M HHCS 1/4"-20 X 5/8" Mincon_Group_PLC_M _Support_Station_Manual_Rev_A2 Page 23

24 80 M /4" Lockwasher 81 M /4" Flat Washer 82 M Regulator 83 M Hose Assy 85 M Fitting 86 M Panel Valve 87 M Needle Valve 88 M Panel Valve 89 M Panel Valve 90 M Hose Assy 91 M HHCS 1/4"-20 X 1.5" 92 M Spacer 93 M Hose Assy 94 M Fitting 95 M Water Flow Meter 96 M Hose Assy 97 M Door 101 M Side Cover - L 102 M HHCS M12X M M12 Flat Washer 104 M M12 Lock Nut 105 M Side Handle 106 M #8-32 X 3/8" Screw 107 M #8 Flat Washer 108 M Handle 109 M Top Cover 110 M Pin 111 M Handle 112 M Spacer 113 M Back Cover 114 M HHCS 1/4"-UNC X 7/8"L 115 M Side Cover - R 116 M U-Clamp 117 M /16" Flat Washer 118 M /16" Lock Nut 119 M Wheel 120 M Cotter Pin 121 M Valve Mt Bracket 122 M Frame 123 M Sp Striker Plate 124 M /4"-UNC X 3/4" Socket HD Screw (LOW HD) 150 M Clamp Channel 151 M /8"-UNC Nut 152 M /4" Hose Assy 153 M Filter 154 M /4"MNPT X #4MJIC Bulkhead STR 155 M Clamp U-Bolt 156 M #4 MJIC x #6 Morb STR. 157 M M10 Fender Washer 160 M Safety Whip Check 161 M Adaptor 162 M Remote Control 163 M Receiver 164 M Battery Cable 165 M Label Set Optional 130 M Control Box Mincon_Group_PLC_M _Support_Station_Manual_Rev_A2 Page 24

25 5.2 Air Motor ITEM DESCRIPTION 1 Cylinder 2 Front End Plate 3 Rear End Plate 4 Rotor 4A Drive Key 5 Vane (4) 5A Vane Spring (2) 5B Vane Pin (4) 6 Rear Rotor Bearing 6A Front Rotor Bearing 7 Rotor Shaft Seal 8 End Plate Gasket (2) 9 Rear End Cap 10 Rear End Cap Screws 11 End Cap Gasket 12 Muffler Assembly 13 Front End Plate Cap Screw (6) 14 Rear End Plate Cap Screw (6) 15 Shield 16 O-Ring 17 Shield Cap Screws Mincon_Group_PLC_M _Support_Station_Manual_Rev_A2 Page 25

26 5.3 Electric Valve ITEM PART NO. Qty DESCRIPTION Bracket, SS Valve, 2" 2-Way SS Bolt, Hex Head, Serrated Flange UNC-2A x Coupler, SS Coupler, SS Nut, Hex Head, Coated Serrated Flg UNC-2B Bolt, Hex Flange ¼ - 20 x 1/2" Coated 7 1 EH2 Actuator Mincon_Group_PLC_M _Support_Station_Manual_Rev_A2 Page 26