Easilube Product Manual Hyden Engineering Pty Limited 1/48 Racecourse Road RUTHERFORD NSW 2320 Telephone: (02) 4932 0111 Facsimile: (02) 4932 0222 E-mail:hyden@hydeneng.com.au ABN: 17 129 010 902 Manual Number: 06500635D Manual Date: November 2013 HYDEN500 Grease Pump Fill Filter Store Pump Distribute Monitor Date Printed: 04/11/2013 Commercial-in-Confidence Page Number: 1
Hyden Engineering Contents Reference Number Topic Page Number 1 2 1.1 1.2 1.3 2.1 2.2 2.3 2.4 2.5 The HYDEN500 Grease Pump General Description Options Ordering Code Product Details Pump Operation and Timing Settings and Adjustments General Assembly Drawing Detailed Assembly and Part Numbers Hydraulic Schematic 3 3 3 4 5 5 8 10 11 12 Date Printed: 04/11/2013 Commercial-in-Confidence Page Number: 2
Hyden Engineering For further system information, please refer to Easilube Background, Installation and Commissioning and Easilube Diagnostics manuals Fill Filter Store Pump Distribute Monitor 1 The HYDEN500 Grease Pump 1.1 General Description The HYDEN500 is a heavy-duty hydraulic powered grease pump which forms the backbone of an Easilube automatic lubrication system. It has a maximum displacement of 50-cc and works on a ratio of 2:1 so that the grease pressure achieved is twice the hydraulic pressure supply (capped by the Pressure Reducer setting, refer to section 2.1). The pump functions as a single-shot pump so that the quantity of grease delivered is dependent on the number of pump cycles and the quantity and settings of the distribution valves. The cycle rate of the pump is determined by the timing control method (refer to section 2.1). The HYDEN500 Grease Pump benefits from the following features: Rugged design making it suitable for use in harsh conditions. Utilization of hydraulic pressure to function, not requiring electric power source. Direct adaptation to compatible Easilube grease reservoirs. Easily tuneable grease output and various methods of pump timing. 1.2 Options Pressure reducing valve: protects the pump and grease system from overpressurising. Available set at 1200-psi (for 2400-psi grease pressure) and the most common setting of 1500-psi (for 3000-psi grease pressure). Pump timing: three basic control configurations are available for the control of the pump cycles (refer to section 2.1 for details). Grease reservoirs: a range of grease reservoirs are available that adapt directly to the HYDEN500 grease pump and can be ordered as a complete HYDEN500 assembly. These reservoirs can be fitted with the further options of grease filtration, over-fill protection, venting and low level warnings (see respective reservoir manuals for further information). Warning system: a system compromising of a pressure switch with a timer provides an audible and/or visible warning when the grease pressure fails to rise within a set period. The main application is to systems where the grease usage rate varies considerably and a regular routine for cartridge replacement or reservoir re-fill cannot be established. Low level sensing (electric or pneumatic) provides warning that the cartridge or reservoir is close to empty. Date Printed: 04/11/2013 Commercial-in-Confidence Page Number: 3
Hyden Engineering 1.3 Ordering Code Date Printed: 04/11/2013 Commercial-in-Confidence Page Number: 4
2 Product Details 2.1 Pump Operation and Timing Powering the Easilube Pump Hyden Engineering The HYDEN500 Easilube grease pump is powered purely by hydraulic pressure. The pump operates on a 2:1 ratio so the grease output pressure is twice that of the hydraulic pressure. This hydraulic pressure is capped by the setting of the pressure reducer which is available in the following two standard settings; i) 1200-psi which will result in a maximum 2400-psi grease pressure. ii) 1500-psi which will result in a maximum 3000-psi grease pressure The setting of 1500-psi is standard for the majority of applications. Refer to section 2.2 for the adjustment of this valve. The Pressure Reducer valve is located in the end-cap of all pump variations; Pressure reducing valve location Date Printed: 04/11/2013 Commercial-in-Confidence Page Number: 5
Timing the Easilube Pump Hyden Engineering The Easilube grease pump can be timed in a variety of ways; a) Alternating dual pressure sources: Two alternating pressure supplies ( P1 and P2 ), such as those to a steering cylinder, can be used and a sequential and individual rise and fall in the two supply pressures will result in a full pump cycle (fire and reset). The pump fires when pressure is supplied to port P1 and resets when supplied to P2. It is usual to select supply pressures relating to a critical bearing area so that, for example, the steering cylinder pressures may be used when the artic bearings are identified as the key lubrication area. Refer to image for port locations. Note: The pressure reducer valve only controls the pressure supply to port P1. P2 P1 b) Rising and falling single pressure source: A single intermittent pressure source such as that to an implement cylinder can be used for a pump fitted with a sequence valve. As the pressure supply passes the sequences valves pressure setting the pump will fire, conversely as the pressure falls below the setting the pump will reset. A tank return line from the pump is generally routed back to a common tank line in the machines hydraulic circuit. Again, it is usual to select the supply pressure relating to a critical bearing area. For example, on a loader the bucket crowd cylinder pressure may be selected when the bucket pin bearings are identified as the key lubrication area. Refer to image for port and valve locations. T Sequence valve P Date Printed: 04/11/2013 Commercial-in-Confidence Page Number: 6
Hyden Engineering c) Constant single pressure source: A single constant pressure supply source can be used for a pump fitted with a solenoid valve and electronic timer. Intermittent pressure supplies can still be used via an accumulator arrangement allowing a constant pressure to be seen by the pump. A tank return line from the pump is generally routed back to a common tank line in the machines hydraulic circuit. Override button The cycle rate of the pump is determined by the setting of the timer (refer to section 2.2.c) which operates the solenoid valve. When no voltage is being supplied to the solenoid valve the pump will be in reset mode. Supply of voltage or pressing the manual override button will fire the pump. Timer not shown in image. T P Solenoid valve Refer to image for port, valve and manual override button locations. Typical timing methods for various machine types The following table lists the generic timing methods for various machines. Note that this is a guide only and in specific applications/scenarios alternative timing methods may be more suitable. Timing Method a) Alternating dual pressure supply P1/P2 Easilube pump b) Rising and falling single pressure source Easilube pump with sequence valve c) Constant single pressure source Easilube pump with solenoid and timer Continuous miner Continuous miner Scrapers Loaders Graders Trucks short haul Crusher feeders Dozers Machine Shuttle cars and U/G loaders Excavators Trucks long haul Pressure Source Steer cylinders Boom raise cylinder with load hold Stab jacks with load hold Conveyor swing cylinder Eject cylinder Bucket crowd cylinder Blade lift cylinder Tray lift cylinder Conveyor motor Ripper cylinder Pump outlet port Pump outlet port Date Printed: 04/11/2013 Commercial-in-Confidence Page Number: 7
2.2 Settings and Adjustments Hyden Engineering Refer to machine specific manuals or contact Hyden Engineering for recommended machine specific settings. a) Pressure Reducing Valve: Note: Adjustment generally not required, standard setting of 1500-psi. * Field Adjustment: turn pressure adjusting screw all the way IN until it stops and turn OUT; No. of Turns 4.75 4 3.25 2.5 1.5 Hydraulic Pressure (PSI) 500 750 950 1200 1500 Approx. Grease Pressure (PSI) 1000 1500 1900 2400 3000 b) Sequence Valve: * Field Adjustment: turn sequence valve adjustment screw all the way IN until it stops and turn OUT; No. of Turns 6 7 7.75 9 Pressure (PSI) 1200 1100 900 700 Date Printed: 04/11/2013 Commercial-in-Confidence Page Number: 8
Hyden Engineering c) Solenoid timer: * Standard setting for trucks: 1-min on / 4-min off * Standard setting for excavators: 1-min on / 2.5-min off (Contact Hyden Engineering for unique application/machine settings). Dipswitch time range and On time settings are the same for trucks and excavators as shown below. Off time settings are unique as labelled. Unit must be supplied a constant 12-24V across the (+) and (-) terminals. (shown set for truck) truck excavator Date Printed: 04/11/2013 Commercial-in-Confidence Page Number: 9
2.3 General Assembly Drawing Hyden Engineering HYDEN ENGINEERING PHONE: 0249 320 111 P/N: HYDEN500- S/N: P2 P1 HYDEN ENGINEERING PHONE: 0249 320 111 P/N: HYDEN500- S/N: T P HYDEN ENGINEERING PHONE: 0249 320 111 P/N: HYDEN500- S/N: T P Date Printed: 04/11/2013 Commercial-in-Confidence Page Number: 10
HYDEN ENGINEERING PHONE: 0249 320 111 P/N: HYDEN500- S/N: 00010115 P2 P1 Hyden Engineering 2.4 Detailed Assembly and Part Numbers Please contact Hyden Engineering for current prices and availability of components. Date Printed: 04/11/2013 Commercial-in-Confidence Page Number: 11
Hyden Engineering 2.5 Hydraulic Schematic Date Printed: 04/11/2013 Commercial-in-Confidence Page Number: 12