INDECO LUBEMAXX. Operating and Assembly Manual INDECO LUBEMAXX

Transcription

1 INDECO INDECO TM Operating and Assembly Manual AUGUST 5, Research Drive, Milford, CT USA Office: (203) Fax: (203)

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3 INDECO INDEX Section A General Safety Information p.4 Regulations p.4 Warranty p.4 Section.0 Safety Instructions p.5. Emphasis p.5.2 Personnel Training & Qualification p.5.3 Hazards p.5.4 Operating Staff Instructions p.6.5 Maintenace & Assembly Instructions p.6.6 Alterations Without Authority p.6.7 Allowed Methods of Operation p.6.8 General Risk Reference p.6 Section Use of Hydraulic Hose Lines p Transport & Storage p Disposal p.7 Section General Description p Technical Data p Hydraulic Circuit Diagram p Pump Assembly p Installation Dimensions p. Section 4.0 OPERATION & REPAIR 4. Principle & Functional Description p Start Up Procedures p Maintenance & Repair p Shutdown & Disposal p Troubleshooting p Spare Parts Drawing p Spare Parts List p.20 3

4 INDECO SECTION A - Introduction A.I General Safety Information These operating and assembly instructions contain all the information that is necessary for the installation and operation of the Greasing System. Before operating this INDECO NORTH AMERICA product, please read carefully the enclosed information.it will help you become familiar with the system and avoid unecessary risks, product damage and downtime. We urge you to keep this operating manual close to your work site. All personnel operating this system should read and understand the contents of this manual. A.II Regulations The use of the system is only allowed when:! it is integrated or attached to a hydraulic breaker it is operated according to the technical data found in this manual all required maintenance has been routinely performed by trained and authorized personnel A.III Warranty Indeco North America warrants the system for operational safety, reliability and performance only under the following conditions: assembly, installation and maintenance are only carried out by authorized speciality staff appropriate protection against hazardous parts (e.g., hot or moving parts) has been utilized! repair and retrofit of the system has only been perfomed by Indeco authorized personnel no published technical specifications have been exceeded the system is operated according to this manual Please note all warranties for damage will expire if improper lubricants or grease have been used. 4

5 INDECO SECTION.0 - Safety Instructions General Safety Information READ THIS OPERATIONS & INSTRUCTIONS MANUAL BEFORE ASSEMBLY, START-UP AND OPERATION PROCEDURES KEEP THIS MANUAL CLOSE TO YOUR JOB SITE OBSERVE ALL WARNINGS AND SAFETY INSTRUCTIONS. Emphasis Please pay attention, not only to the safety instructions under this section, but also to related security content which is included throughout this manual. This symbol warns of electrical voltage. Safety ínstructions which, íf not complied with, may endanger people, are marked specífically with the general hazard symbol. Warnings against hot surfaces are marked with this symbol. Warníngs of suspending loads are marked with this symbol. Attention Note! This heading is used if non-compliance with the operating lnstructions could result in damage. Points out special information. Notes attached directly at the unit, must be strictly followed and kept in legible condition!!.2 Qualification and training of personnel The personnel charged with operation, maintenance, inspection and assembly must have the necessary qualifications for this work. The operator must completely understand the contents of this manual..3 Hazards Non-observance of safety information can lead to danger for people, the environment and machines. Non-observance of the safety information can lead to the loss of any and all claims for damages. 5

6 INDECO.4 Safety information for operating staff lf hot or cold machine parts lead to danger, the customer must secure them against touch. The protective measures on moving or rotating parts must not be removed. Drain dangerous materials in a way that does not endanger people or the environment. Comply with a l l regulations. Eliminate any danger due to electrical energy. A copy of this manual must be available at the central lubrication system..5 Safety information for maintenance, inspection and assembly work All maintenance, inspection and assembly work may only be done by trained specialists who have read this user manual. All work must be done only when the hydraulic pump is at a standstill and the user is wearing appropriate protective clothing. All the safety and protective equipment must be replaced immediately after completing work. Media that endangers the environment must be disposed in accordance with the relevant official regulations..6 Alterations and manufacture of spare parts without authority Rebuilding and modifications may only be done by Indeco North America. For components retrofitted by the operator, Indeco does not assume guarantee nor claims for damages. Use only original spare parts..7.8 Allowed methods of operation Operational safety of the plant is only guaranteed if it is operated in accordance with the operating instructions. The limit values stated in the technical data must not be exceeded under any circumstances. General risk reference The hydraulic pump should only be operated within the stipulated intended use and only in a technically fault-free condition. Please observe all compliance and safety regulations and regularly please check the pump and its attachments for possible damage or leakage. 6

7 INDECO 2. Use of Hydraulic Hose Lines SECTION Hoses, Transport, Disposal If hydraulic hose lines are installed at the pump, the operator has to observe and make sure of the following: lnspections regarding proper assembly and function have been carried out according to regionally applicable guidelines. Inspections have been scheduled and carried out as recommended Damaged hose lines have been replaced immediately Due to wear, hydraulic hose lines have been exchanged regularly according to manufacturer details 2.2 Transport & Storage The hydraulic pump is packed according to appropriate local specifications and specific customer guidelines. Do not throw or shock the central lubrication system Use a suitable hoist for transport. Store the system at a temperature between -40ºC to +70ºC. Please pay attention to all current safety and accident prevention instructions during system transport. 2.3 Disposal Note! Observe all disposal regulations when changing the lubricant! Collect cloths that are contaminated with lubricant and dispose of them properly. The disposal of the hydraulic pump itself must be executed properly according to all applicable national laws and regulations. 7

8 INDECO SECTION 3. - General Description Overview Note! The system is used to lubricate hydraulic hammers or other construction machinery demolition attachments. Due to its compact design, it can be mounted directly to the attachment. Powered by a hydraulic motor (item 9, fig. ), the system delivers a continuous supply of lubricant. The delivery rate is adjustable via a throttle (item 8, fig. ). In the event of a hydraulic system failure, a grease nipple is integrated for manual greasing (item 5, fig. ). Transparent plastic cartridges (item 7, fig. ) serve as a storage reservoir. The grease level is checked optically by the position of the visible follower piston. For supply, the grease pump is connected with a bypass line to the supply and return lines of the carrier hydraulic system. This can done via the hose lines or by direct flange connection. Functionality can be checked via the visible eccentric shaft (item 2, fig. ). At the time of delivery, the securing bolts, inlet screw couplings and plug screws are supplied with the pump in loose condition, together with the appropriate seals. Depending on the application, minor assembly work may be required before commissioning. - In the case of the hose connection model, the enclosed screw couplings must be mounted. As a result the grease pump's supply and return lines must be connected to the carrier's hydraulic system via a bypass line. G/4" screw couplings are required for the connection of the oil and lubricant lines. - In the case of the flange connection model, the G/4" threads must be closed by the enclosed plug screws and packing rings. The enclosed 0-rings are used to seal the flange connections. Figure 8

9 INDECO SECTION Technical Data & Hydraulic Circuit Assembly Technical Data Hydraulic motor: Supply: Hydraulic hammer circuit, bar Difference pressure in operation: Admissible return pressure: Displacement: Default speed of the eccentric with oil ISO VG 46 at 20º C Hydraulic oil: Temperature range: Speed can be adjusted with throttle Pumping element : Delivery rate/ stroke PE20FH Default stroke number: Stroke number can be adjusted with throttle General: Weight: Lubricant container : Cartridge type: min. 70 bar max. 20 bar max. 2 /min 4 rpm - at,8 l/min. ISO VG O to +7Oº C O,2 cm 3 4 strokes/min. approx. 3,9 kg Cartridge Type S Lubricant: EP-grease without solid contents or chisel pastes up to NLGI class 2 Attention! Note! Manual lubrication is necessary at temperatures below Oº C, until the operating temperature is reached and the pump operates independently. A greasing nipple for manual greasing is available. The pump s supply connector comprises a filter and an orifice to limit the supply flow. Both elements are interchangeable. Attention! The return socket may be subject to a maximum back pressure of 20 bar. This value should not be exceeded as the pump will not work at optimum efficiency if pressures go beyond specification. Hydraulic Circuit Diagram: : Filler 2: Orífice 3: Throttle 4: Hydraulic motor 5: Pumping element 9

10 INDECO SECTION Pump Assembly Pump Assembly The pump can be positioned with the cartridge in a horizontally or vertically suspended position. If the cartridge is in a vertical position, please make sure that dirt or other contaminants do not fall into the intake area below the cartridge. Attention! The location and type of pump installation must be coordinated with the manufacturer of the carrier unit. Before commissioning the unit, please make sure to fill the lubricant lines via the grease nipple (item 5, fig. )! Connecting the Pump Attention! First close the bore holes for the flange connection model F-F3 (fig. 3) on the back of the pump by means of the supplied hex socket screw M4x, using the Cu seals 4x8x. Note! The O-rings 9x2.5, plug screws G/4 and packing rings 3x8x.5 are not required for this application. The lubricant is connected to the S connection (fig.3) in the standard version. Connect a bypass line to the hydraulic system of the carrier unit for supply of the grease pump - the pressure line at S3 (fig. 3). Two hex bolts M4x4 with lock washers are included in the scope of supply for fastening the pump. These must be tightened using a torque qrench (0 Nm) Flange Connection Model Drill the connection and the attachment bores according to the drilling pattern in the lower right of Fig. 3. Attention! First close the bore holes for the hose connection model S-S3 on the pump by means of the plug screws G/4 enclosed, using the Cu seals 3x8x.5. Note! Check whether the connecting bore holes are in the required area according to the drill pattern in fig. 3. Insert the O-rings 9x2.5 supplied in the bore holes F-F3, making sure the seating surfaces are extremely clean. Two hex bolts M4x0 with lock washers are included for fastening the pump. These must be tightened using a torque wrench (0 Nm). 0

11 INDECO SECTION Installation Dimensions

12 INDECO SECTION 4. - Functional Description Functional Description The hydraulic pump is connected to the hydraulic system of the carrier unit via the pressure pipe P fig. 5). The hydraulic oil is routed through a filter with cover (item 7, fig. 5), via the setting throttle (item 8, fig. 8) and to the hydro motor (item 6, fig. 5), which ensures a continuous drive. The hydraulic oil is returned to the hydraulic circuit via the return line R (fig. 5). To enable regulation of the hydraulic motor s speed and thus the stroke rate of the delivery plunger or the delivery flow, the oil throughput can be adjusted via a throttle (item 8, fig. 5). The hydraulic motor drives a worm shaft, (item 5, fig. 5), which transmits the revolutions to the eccentric unit (item 4, fig. 5). Eccentricity gives rise to the suction and delivery stroke of the delivery plunger of the pumping element (item 3, fig. 5). An integrated non-return valve (item 2, fig. 5) prevents the pumping medium from being sucked back. Via the pressure channel D, the lubricant is supplied to the various outlets which are either open or closed, depending on their installation location or position. Lubricant cartridges serve as supply tanks for the lubricant (item, fig. 5). 2

13 INDECO SECTION Start Up Procedures 4.2. Changing the Cartridge After initializing the equipment, fill the lubricant line using the lubrication nipple at the front of the pump (see item 4, fig. 9). Next, slightly grease the O-rings in the adapter (item 2, fig. 0) and then install your first cartridge. To accelerate priming, first remove the cap from the cartridge opening; then, using the cartridge follower piston (item 3, fig. 5), press out the grease by 5 mm to 0 mm (fig. ). Following priming, insert the cartridge in the cartridge holder (item, fig. 9) by pressing it slightly and fastening it by hand. Attention! When replacing the cartridge, please make sure that no contamination enters the intake area of the cartridge! Adjusting the Delivery Quantity Please note that the system must be depressurized before adjustment! Before adjustment, you must remove the plug screw (item 2, fg. 3). Afterwards, you can release the throttle (item 4, fig. 3) using a slotted screwdriver. By unscrewing the throttle, you can increase the flow rate, thus enhancing the delivery rate (fig. 4). You can check for proper working condition via the visible eccentric shaft (item 5, fig. 2). Determining the number of revolutions of the eccentric shaft or the number of strokes of the delivery plunger enables calculation of precise delivery rates. Before recommissioning the pump, reposition the plug screw with the Cu sealing ring (item2 and 3. fig. 3). 3

14 INDECO SECTION Start Up Procedures The following diagram shows the guide values for adjustment of the throttle. Before adjusting, screw the throttle clockwide (inwards) to its stop. By unscrewing the throttel counter-clockwise, you can adjust the required delivery rate. Figure 4 Adjustment of the revolutions of the eccentric (pump delivery rate) is made via an adjusting throttle, the oil flow rate requiring adjustment on each pump individually. The values of the throttle rotations in the table above are to assist adjustment. If the required delivery rate is not known, you can assume a range between 0.5 and.0 cm3/min. for most hydraulic hammers Changing the Filter and Orifice Ventilate the whole lubrication system after the first operation and after each lubricant exchange Ventilation is done at pressure less operation and open outlets of the system Operate the pump until lubricant comes out of the pressure connection without air inclusions 4

15 INDECO SECTION Maintenance & Repair Maintenance STOP the voltage feed before initiating any maintenance or repair operations. Maintenance and repair work should only be done at standstill of the central lubrication pump and in pressureless conditions. lways weat heat-resistance gloves and protective goggles as the surface may be hot! Soiled surfaces have to be cleaned before work and you should wear protective clothing, if necessary. Always make sure that you protect the device against unintentional reactivation during maintenance and repair operations General Maintenance Retighten all fittings six weeks after start-up Check all components for leakage and damages every four weeks If leakages are not repaired, lubricant can come out with high pressure. Remove possible leakages of lubricant immediately Refilling with Lubricant Always make sure that the environment is as clean as possible when refilling! Attention! Check the level regularly and refill if necessary (see the START-UP Section of this manual) Only use lubricants that are suitable for the lubricating machine and meet your specific application requirements If ordering lubricant from other manufacturers, make sure the quality is similar to that previously used and drain and clean the reservoir completely as a precaution Changing the Filter and Orifice To replace the filter and orifice, first remove the plug screw (item, fig. 5 and fig. 6) using a wrench (SW3). Then, release the thrust piece (item 3,fig. 6), the O-ring (item 4, fig. 6) and the strainer (item 5, fig. 6). Then unscrew the orifice (item 6, fig. 6) using a slotted screwdriver. Attention! When reinstalling, make sure that the sealing edge of the orifice is not damaged. After having screw-fastened the orifice again, you can reinstert the strainer, the O-ring and the thrust piece, fastening them with the plug screw and the Cu seal (item 2, fig. 6). Fig. 5 5

16 INDECO SECTION Maintenance & Repair Changing the Pumping Element Before removing the pumping element, make sure that the system is depressurized. To remove the pumping element, first take out the lock screw on the front of the pump housing (item, fig. 7 and fig. 8) using the 8 mm key. Then pull out the pumping element (item 2, fig. 8) utilizing the pulling device (fig. 9) supplied with the system. To accomplish this, screw the pulling devng device into the thread (item 3, fig. 8) on the front of the pumping element. Pull the pump element from the housing bore. Make sure that all components (items 4, 5 and 6, fig. 8) are moved. and 6, fig. 8) are moved. Attention! When installing the new pumping element, please exercise care to make sure that no dirt gets into the pump. The intake bore (item 7, fig. 8) must be directly below the lubricant bore of the grease cartridge (item 8, fig. 8). Clamp the pump element again with the closure screw (item, fig. 8). Slightly grease the O-ring on the closure screw (item 9, fig. 8). Attention! When using copper paste, please note that you must replace the pumping element after approximately 000 service hours due to the solids content. 6

17 INDECO SECTION Shutdown & Disposal Shutdown Procedures: Relieve the central lubrication pump from pressure Shut down electrical current Separate the central lubrication pump from the electrical supply NOTE: this can only be done by certified profressional electricians Remove all pipes and hoses from the device and loosen all fastenings for demounting Disposal: All textile materials and clothing contaminated with the lubricant must be collected in a specially marked receptale and disposed of according to national laws and regulations 7

18 INDECO SECTION Troubleshooting

19 INDECO SECTION Spare Parts Drawing 33 9

20 INDECO SECTION Spare Parts List Pos Quantity Description Hydraulic motor 2,2 cm'/u 0-ring 036,5x for hydraulic motor Straight coupling GEBS G/4" Plug screw G/4" CU-Sealing ring 3x8x,5 Filter complete (Consisting of items 6 to ) Plug screw filter CU-Sealing ring 3x8x,5 Thrust piece for filter 0-ring 07,5x,5 Strainer Orifice Plug screw CU-Sealing ring 2x6x Throttle complete Scalloped ring ZJO Valve sleeve Eccentric cover outside Hexagon screw with hexagon socket M6x6 Radial shaft sealing ring 20x35x6x6,5 0-ring 048x2 Gear cover inside, incl. O-ring Eccentric unit complete Hex. bolt M4x0 Lock washer NL4 Grease nipple A M0xk Cover screw for pumping element PE-20 FH, incl. 0-Ring Pumping element Hex. socket screw M4x2 CU-Sealing ring 4x8x 0-ring 09x2,5 f. flange connection 0-ring for cartridge type J Flat seal far cartridge type S Pulling device far PE-20FH Order number 2576GM F2576/ F2576! F2576/57-00 F2576/ GD F2576/ A GG000 09i GE F

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