Catalogo Pit Hog #1 1p66
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PHE 40hp Operation and Maintenance Manual
Serial Number: R2014‐107‐13‐1027 LWT, LLC 1750 Madison Avenue, New Richmond, WI 54017 WWW.LWTPITHOG.COM
+715‐246‐2888
OFFLOADING THE DREDGE Equipment Needed 4 Cable Slings – Rated at 10 tons 4 Shackles – Rated at 5 tons each 2 50-ft Guide Ropes – For guiding the dredge to prevent dredge from turning while being lifted. Crane (with crew) – An appropriately-sized crane to lift and place the dredge in the water from the closest stable location. Consult with a crane company to determine the size of crane needed. Rigging When unloading the dredge, be sure ONLY authorized personnel are present. Steps: 1. Position crane in a safe and stable area close to the basin. 2. Rig the cable slings and shackles on the lifting lugs of the dredge. 3. Attach the guide ropes at the front and back of the dredge. Have two authorized personnel at these ropes. Their job is to rotate and position the dredge. 4. Attach the slings to the crane. Utilizing proper lifting practices (per rigger) lift the dredge off the truck. This is a picture of an LWT PHE 20HP. All LWT PHE dredges have similar lifting points.
Lifting Points
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Operation and Maintenance Manual This manual should be considered a permanent part of this equipment. It should stay with the dredge while being operated to provide the operator important operating, safety and maintenance information. In the event this dredge is sold, this manual should be given to the new owner to provide them with necessary information for operation and maintenance. For additional copies of this manual, please : Liquid Waste Technology, LLC Attn: Parts & Service Department 1750 Madison Avenue New Richmond, WI 54017 Ph: (715) 246-2888 Fax: (715) 246-2573 All information, illustrations, and specifications in this manual are based upon the latest product information available at the time of printing. LWT reserves the right to make changes at any time without notice.
O & M Manual should remain with the dredge at all times!
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SAFETY INFORMATION
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SAFETY PROCEDURES Good safety procedures and practices should be observed at all times to avoid personal injury and lost time due to accidents. We recommend that a safety program with rules governing the assembly, operation and maintenance of the equipment be established and enforced for the benefit of all personnel. The importance of observing and maintaining good safety practices cannot be overemphasized. Appropriate rules and regulations governing the work site should be observed. National, Provincial, State and Industrial laws and applicable regulations should be observed. Safety Symbol This safety alert symbol indicates important safety messages in this manual. When you see this symbol, followed by “DANGER” or “WARNING”, be alert to the possibility of personal injury and carefully read the message that follows. Whenever the word “CAUTION” appears, follow the recommended procedure to avoid injury to personnel and damaging the equipment. Any message preceded by the word “NOTE” is an advisory to emphasize the content of the statement.
WARNING! SHUT OFF ELECTRICAL POWER TO THE DREDGE BEFORE PERFORMING ANY ON-BOARD MAINTENANCE TO ANY OF THE ELECTRICAL, HYDRAULIC OR MECHANICAL SYSTEMS! TURN OFF ELECTRICAL POWER ON-SHORE AND PLACE THE DISCONNECT SWITCH IN THE “DOWN” POSITION ON THE NEMA ENCLOSURE AT THE STERN OF THE DREDGE. THE AMBER INDICATOR LIGHT MUST NOT BE ILLUMINATED WHEN MAINTENANCE IS BEING PERFORMED!
Safety Practices The following safety practices are recommended as minimums to be in effect at all times during dredging operations: 1. Shut down electrical power before performing maintenance or repairs on board the dredge that could result in personal injury due to sudden or unexpected movement(s). 2
CAUTION! Personnel should wear life jackets and hard hats when in the workboat or on board the dredge. WARNING! Always disconnect the ECU before performing any welding on the MudCat. Failure to do so may result in serious injury or death. 2. Before starting the dredge, check to make sure personnel are clear of all machinery that rotates or moves when the dredge is running. 3. Do not operate machinery with safety guards removed. 4. Never attempt to remove an object from the auger cutter or the submersible pump when they are stalled and the hydraulic system is under pressure. 5. Keep the machinery surfaces clean and free of oil or other slippery substance. 6. Check all cables for wear and cable clamps for tightness at least on a weekly schedule. Operating Parameters The following precautions should be observed when operating the dredge: 1. The dredges should not be operated in open or unprotected waterways when the wind velocity exceeds 20 miles per hour. 2. The dredge should not be operated on any waterway when waves exceed 1.5 feet. DANGER! Personnel should not be on board the dredge during electrical storms. Typical Safety Decals and Labels To avoid serious personal injury, observe the various safety decals on the dredge and comply with the message(s). EXAMPLE:
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SPECIFICATIONS
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SPECIFICATIONS LWT Pit Hog “RUNT” Model RCLPES 40HP with VFD Electric Radio Controlled Dredge
Physical: Flotation –Two cylindrical pontoons, 28” Dia. x 20’-0” O.A.L x 10 gauge steel. Transportation Length - 24’-7 3/8” Transport Width - 8’-2 1/2” with auger motors removed Transportation Height – 6’-1/4” Operational Weight – 5,800 Lbs Maximum Digging Depth - 14’ Operational Draft - 16” Power: 460 VAC, 3 Phases, 60 Hz Electric Power Slurry Pump Electric Motor - 40 Hp Hydraulic System Electric Motor – 10 Hp
Dredge Controls: Radio Remote – Hand Held Transmitter (1000 feet max) Slurry Pump On/Off and Speed Control (VFD) Auger On /Off Travel Forward/Off/Reverse and Speed Control Boom Hoist Up/Down – Upward Elevation Limit Switch Multi-Color Light Tree – Colored Light for each function
Slurry Pump: Hayward Gordon XR4-11-S Pump w/ Submersible Motor Centrifugal, Solids handling Impeller Basic Construction – Super Ni-Hard ASTM A532 Pump Speed – 1750 RPM Suction Diameter – 6 Inches Discharge Diameter – 4 Inches Impeller Diameter, inches - 8.50” Sphere size, inches (max) 4”
Design -Capacity: For 40HP - 900 GPM @ 50 ft head (water)
Auger Head: Auger with Shroud - Welded Steel Construction Helix – 10” Dia. X 9” pitch – 3/8” Thick Flighting Speed 60 RPM Torque 3,400 In.-Lbs. Length, Overall - 8’-2 ½” Cutter Knives – 7 Left Hand and 7 Right Hand
Propulsion: Treble Sheave Hydraulic Winch w/ 3/8” Diameter Wire Rope Hydraulic Motor with Planetary Gear Reducer Drive Traverse Speed Variable from 0 to 30 FPM Hydraulics: Three Circuits – Auger-Cutter, Traverse Winch and Hoist Winch Flow Controls – 3-Position, 4-Way Directional Control Valves w/ Electronic Flow Control for Winch Speed Hydraulic Pump Output @1,750 RPM - 8 GPM Hydraulic Relief Pressure - 1,500 PSI (124 Bar) Hydraulic Reservoir Capacity – 30 US Gallons High Oil Temperature and Low Oil Level Shutdown Switch in Reservoir
Coating System: All weldments shall be sand blasted and given an epoxy powder prime coat followed by a polyester powder top coat for a total coating thickness of 5 mils minimum. Electric motors, hydraulic components etc. are installed as received with coatings applied by the original equipment manufacturer.
Liquid Waste Technology is an innovative leader in the design and manufacture of sludge handling equipment including Auger Dredges, Lagoon Pumpers, Submersible Chopper Pumps, Prop Agitators and Subsurface Land disposal Systems. Call 1-800-2431406, and e-mail at [email protected] or for more information, on the internet at www.lwtpithog.com Rclpes40hp
Rev: 11/21/08 5
GENERAL INFORMATION
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SERVICE POLICY The service and of LWT equipment in the field is one of our top priorities. We maintain an inventory of most of the replacement parts for our equipment. Whenever possible, we will fill parts orders as quickly as possible.
PARTS The Parts and Service Department’s normal operating hours are 8:00 AM to 4:00 PM (Central Standard Time or GMT -6), Monday through Friday. To place an order for parts, : •
Parts Department at 715-243-2132, toll free 800-243-1406 or via email: [email protected].
To insure we provide assistance specific to your equipment, please provide the following information when ing LWT: Equipment Model
Serial Number
RCLP 40HP
R2014-107-13-1027
If you wish to return an item purchased through the Parts Department, you must have a Return Authorization Number which will be assigned by the LWT Parts Department. A restocking fee may be charged on the returned parts based upon the reason for return. SERVICE For operational questions, troubleshooting assistance, or to schedule on-site service, : •
Customer Service at 715-243-2159, toll free 800-243-1406 or via email: [email protected].
Field service is available at a flat daily rate plus expenses for travel, lodging and meals.
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LIMITED WARRANTY Liquid Waste Technology, LLC; hereinafter referred to as “LWT”, warrants equipment of its manufacture to be free from defects in material and workmanship for a period of one (1) year from the date of startup or twelve (12) months from the date of shipment, whichever occurs first. This limited warranty is effective only if the equipment has been installed and maintained in accordance with LWT’s instructions for the use and service for which it was designed, and is used as directed. This limited warranty does not extend to any condition arising from neglect, misuse, or abnormal use in any manner; or caused by an accident or force majeure; or from failure to properly maintain or service the product or regularly to inspect it; or where it has been modified in any way so as to affect its stability or reliability; or it has been altered or improperly repaired by someone other than LWT or its designee. Due to the widely varying conditions under which LWT products are used or installed, LWT offers no warranty, expressed or implied, as to the length of service life of equipment or parts. This warranty does not extend to such wear parts as, but not limited to, seals, slurry pump wet end components, bearings, tires, or any damages caused by any failure of such parts. Neither does this warranty extend to damages from corrosion due to extremes of either high or low pH, or from other chemical or electrolytic reaction caused by contents in the waters where the equipment is used. Equipment and accessories not manufactured by LWT, which are incorporated into any LWT equipment, are warranted only to the extent of the original manufacturer’s warranty or guarantee. As a condition of this warranty, the customer shall, promptly upon its determination of intent to make any claim against LWT, arising under this warranty, so notify LWT, in writing, specifically describing the part alleged to be defective; and further, upon request from LWT, shall ship such part to LWT, prepaid, as directed by LWT, for inspection by LWT. LWT may, at its discretion, send an authorized service representative, with transportation and expenses prepaid, to the customer’s site to perform such inspection. LWT’s sole obligation under this warranty, upon determination that such defectiveness did in fact exist within the period provided, shall be limited to, at LWT’s expense, either repairing or replacing such defective part. IN NO EVENT SHALL LWT BE LIABLE HEREINUNDER FOR LOSS OR CONSEQUENTIAL DAMAGES OF ANY KIND OR CHARACTER CAUSED BY DEFECTIVE PARTS OR OTHER CHARGES INCURRED BY THE CUSTOMER FOR BREACH OF ANY WARRANTY OR IN THE REPLACEMENT OR REPAIR OF DEFECTIVE PARTS. THIS WARRANTY IS LWT’S SOLE WARRANTY EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED OR STATUATORY IN ORIGIN, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR LIABILITIES ON THE PART OF LWT, AND NO REPRESENTATIVE OF LWT HAS THE AUTHORITY TO CHANGE THE OF THIS WARRANTY IN ANY MANNER WHATSOEVER, AND NO ASSISTANCE BY LWT OR ITS REPRESENTATIVES IN THE REPAIR OR OPERATION OF THE PRODUCTS COVERED BY THIS WARRANTY SHALL CONSTITUTE A WAIVER OF THIS WARRANTY, NOR SHALL SUCH ASSISTANCE EXTEND OR REVIVE IT.
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ACCEPTANCE OF EQUIPMENT Equipment Model
Dredge Serial Number
RCLP 40HP
R2014-107-13-1027
Please initial items reviewed. CUSTOMER
LWT
1. Dredge Appearance
__________
__________
2. Dredge Maintenance
__________
__________
3. Dredge Functions
__________
__________
4. Dredge Operations & Safety
__________
__________
5. Warranty Policy
__________
__________
At completion of the above, Liquid Waste Technology, LLC certifies that all equipment has been reviewed with the representatives of ____________________________________ and is found to be totally satisfactory to all involved parties. Customer Signature: _________________________________________
Date:________________
Print Name: _________________________________________ Email: _________________________________________ Phone: _________________________________________ Address: ________________________________________________________________ Shipping Address: ________________________________________________________________ LWT Signature: _________________________________________
Date:_________________
Print Name: _________________________________________
Liquid Waste Technology, LLC 1750 Madison Avenue New Richmond WI 54017 Phone: (715)246-2888 Fax: (715)246-2573 Email: [email protected] Web: www.lwtpithog.com REV 0412
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OPERATION OVERVIEW
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OVERVIEW OF DREDGE OPERATION
The LWT Model 40HP RCLPES, an electrically-powered, remotely-controlled, auger dredge is designed to remove sediments from the bottom of natural waterways or man-made such as waste treatment ponds and settling lagoons. Solids that have settled or accumulated within these holding facilities are excavated and transported as slurry through a hose and/or piping system to a remote location. Steel pontoons provide the necessary flotation to the on-board machinery and equipment in the waterway. Principal features include the auger-head, submersible pump, boom, boom hoist, traverse winch, electrical and hydraulic system. The auger-head and the submersible pump are essential for effective solids removal. The boom hoist vertically positions the auger and submersible pump in the sediment while the traversing winch propels the machine forward and backward along a wire rope cable anchored at both ends. This proven design provides one of the most cost-effective means of hydraulically dredging sediments on the market today. Prior to operation of the dredge, an anchored cable harness is established for positioning and propelling the unit in the waterway. Generally, the harness is comprised of two lateral cables located on opposite ends (or sides) of the pond with a traverse cable stretched between them. The traverse cable is threaded through the treble sheave winch and fairlead (cable guide) near the bow and through the lead block (guide sheave) on the tail frame of the dredge. After pre-tensioning the cable to remove the slack, the traverse winch propels the unit in both the forward and reverse directions. After floating discharge hose and/or pipe are connected to the dredge, it is ready to operate. Generally, solids are excavated while traversing forward only. All dredge functions are remotely controlled from shore using a hand-held radio transmitter. A series of push buttons on the transmitter enables the operator to start and stop all on-board equipment. These functions include Dredge Pump “On” or “Off,” Dredge Pump Speed, Auger-Cutter “On” or “Off,” Boom Hoist “Down” or “Up,” Traverse Winch “Forward” or “Reverse,” and Traverse Winch Speed.
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At the starting point, near one end (or side) of the pond, the operator turns on the electrical power to the dredge, lowers the boom, turns the auger on, turns the slurry pump on and increases the speed, sets the travel control forward and adjusts the speed to the desired rate of travel. The dredge travels forward until it reaches the other end (side) of the pond or the operator stops it. At this point, operator raises the head to a position above the material and reduces the slurry pump to approximately one-half speed. NOTE: This keeps the hose pressurized and out of the path of the dredge during the reverse operating cycle. The operator then sets the travel switch in reverse and “dead-heads” the dredge back to the starting point. The traverse speed can be increased during this cycle to save time. Once the far end of the pond is reached, the control settings, including the digging depth or depth of cut, pump “on” and/or speed and traverse speed must be set before starting a new dredging cycle. When all of the bottom sediments have been excavated in a given area, the dredge is laterally repositioned and operations are resumed. This procedure is repeated as many times as necessary until the entire waterway has been cleaned.
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GENERAL OPERATING TECHNIQUE The function and/or operation of the dredge controls and displays are discussed in the Dredge Familiarization and Controls sections. The operator should become familiar with each of the controls and displays, and have a basic understanding of each of these before operating the dredge. With the dredge in position near one end or side of the pond and ready to commence dredging, perform the following steps to start and complete a typical dredge cycle. 1. Check all switches on the handheld radio transmitter to determine that all controls are in the OFF positions. 2. Turn on the shore-based power supply to the dredge. NOTE:
In case of an emergency or when shutting down the dredge, press the red EMERGENCY STOP button on the top left of the radio transmitter.
3. Release the Emergency Stop button on handheld and turn the handheld power switch to ON. Once the handheld transmitter has completed its start-up procedure, turn the power switch to start and release. This will link the transmitter to the receiver. When a link is established, the hydraulic power unit will turn on along with the flashing amber light on the light stack, located on the top of the dredge electrical enclosure. 4. Press the Boom Hoist DOWN switch to lower the boom and auger head. Pressing and releasing the switch will incrementally lower the boom. If shallow cuts are to be made, the boom should only be lowered a couple of feet below the surface of the liquid. When making successive es in the same cut, the boom and auger head must be lowered another increment at the start of the until the maximum digging depth of the dredge is reached. The dredge should not be operated below the maximum depth stated in the specifications. If the pontoons rise slightly out of the water, with the bottom is indicated. To avoid damaging the bottom, raise the boom and auger head assembly slightly until it can be observed that the bow (front) of the pontoons dip slightly into the water. This indicates that the auger is clear of the bottom. NOTE:
In very light sludge, it is best to plunge the auger head into the sludge blanket near the bottom of the pond. This will maximize the solids content of the slurry.
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5. Press the pump ON switch to start the pump. To stop the pump, press the switch a second time. 6. If the dredge is equipped with a VFD, adjust the slurry pump speed as necessary. 7. Press the auger switch to start the auger. To stop the auger, press the switch a second time. MAKE CERTAIN ALL PERSONNEL ARE CLEAR OF THE AREA AROUND THE AUGER HEAD BEFORE STARTING THE AUGER CUTTER. 8. Set the travel winch switch in the FORWARD direction. Jog (press and release) the travel speed increase switch until the appropriate rate of travel is obtained – this is normally 6 to 10 feet per minute while dredging. The maximum rate of travel is 30 feet per minute. If the switch is pressed and held for 7 seconds, this rate of travel will be achieved. Therefore, jog the switch two or three times (or hold for 2 to 3 seconds) and observe the movement of the dredge. If too slow, jog the switch again. If too fast, jog the travel speed decrease switch to slow it down. 9. Observe the operation of the dredge as it moves forward on the travel cable. If everything goes smoothly, no further adjustments will be necessary and the dredge will advance until it reaches the opposite end or side of the pond. At this time the dredge must be stopped and returned to its starting position in the pond. To STOP the dredge, press Travel Forward again. NOTE:
It might be necessary to raise or lower the depth of the auger as the dredge advances if the bottom contour is irregular. If the dredge stops moving forward as indicated by fish-tailing or the stern raising out of the water, raise the boom slightly until it begins to move forward again.
10. Press the slurry pump switch once to stop the pump. NOTE:
If the dredge is equipped with a VFD, it is generally necessary to keep the pump running at about half speed to maintain pressure in the floating discharge line so that it stays out of the path of the dredge when it is traveling in reverse.
11. Press the auger switch once to stop the auger. 12. Press the boom hoist UP switch to raise the boom slightly. 13. Press the travel winch reverse switch to start the dredge moving in the reverse direction.
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NOTE:
It might not be possible to travel in reverse at the maximum rate of speed of 30 feet/minute in some applications. Once the dredge has returned to its starting point, the dredge cycle is complete. Adjust the reverse travel speed so the dredge is moving back as quickly as possible but make sure to reduce speed as you get near the rear stopping point.
14. Repeat steps 3 through 5 to start another cycle. 15. Press the red EMERGENCY STOP button on the top left side of the radio transmitter to shut off the dredge. 16. Place the electrical power disconnect on the shore-based power supply in the OFF position.
DREDGING PRACTICES AND OPERATING HINTS 1. In soft material, both organic and inorganic, and fluid-like sediments, it is oftentimes advantageous to plunge the boom into the material prior to starting the main pump. This minimizes dilution of the slurry and eliminates the pumping of clear fluids. 2. If the auger cutter is stalled due to an obstruction preventing its rotation, the auger hydraulic pressure relief valve, located on the reservoir, will be tripped. This can be difficult to detect when the dredge is unmanned and the controls are shore-based. One indication might be if the dredge fish-tails (moves side to side) or if the dredge starts rising out of the water. Stop the travel winch and try stopping and starting the auger cutter a few times to see if the obstruction can be cleared. If this procedure is successful, start dredging again. 3. If the auger cutter is not cleared after stopping and starting, stop the auger cutter, slurry pump and travel winch. Raise the boom until the auger cutter assembly is accessible at the surface of the water. Press the Emergency Stop switch to shut down all functions and place the shore-based electrical disconnect switch in the OFF position. Go out to the dredge and check the auger circuit hydraulic pressure on the gauge located on the reservoir. If the gauge reads zero pressure, use whatever tools and devices necessary to remove the obstruction from the auger. After removing the obstruction, return to shore, turn the electrical power back on and start the auger cutter. If the auger head is rotating freely, resume dredging. WHENEVER IT IS NECESSARY TO WORK AROUND THE AUGER HEAD, STOP ALL OF THE FUNCTIONS AND PLACE THE POWER DISCONNECT SWITCH ON THE ELECTRICAL IN THE “OFF” POSITION. NEVER WORK AROUND THE AUGER WHEN THE AMBER LIGHT IS FLASHING!
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4. The no-load auger hydraulic circuit pressure is 600 to 700 PSI. In soft materials, there is likely to be only a slight increase in the auger hydraulic circuit pressure when dredging. This pressure can be observed on the pressure gauge mounted on the hydraulic control valve on the power unit. 5. If the material spills over the top or the sides of the auger, slow down the rate of travel or stop travel completely and let the pump and auger continue to operate momentarily. This is most likely to happen when making initial cuts in shallow water. 6. If the discharge line is plugging, it can normally be cleared by stopping the auger, raising the boom slightly and pumping clear liquid. This is most likely to occur when pumping heavy materials such as sand through a long pipeline or to an elevated disposal area, or a combination of these conditions. 7. When cutting in shallow water, cutting a shoreline or cutting materials projecting above the water surface, care should be taken to prevent loss of pump prime. The suction inlet must always be submerged below the liquid surface. In extremely shallow water, it may be necessary to make several forward cuts in order to create adequate depth for the machine to float. It takes approximately 16 inches of water to float the machine. 8. At the end of any operational period the auger head should be raised to its upper limit at or near the surface of the water and water pumped to clear the line. This will also prevent freshly cut areas from collapsing and trapping the auger head. 9. The speed of forward travel varies with the type of material being dredged. Optimum operation matches the auger cutter’s ability to excavate solids at the flow rate of the slurry pump. If the dredge moves into the material too rapidly, the unit may tend to plow materials around or over the auger. If material is more densely packed, the unit may tend to “stand on its nose” and begin to dig down into the solids. Either action would result in an uneven . 10. The travel speed will generally be the most commonly used control to optimize production. It is not possible to pump solids at more concentrated rates than they exist in the solids bed. 11. The pump must be in the sludge to move solids. With lighter sludge it is possible to lower the auger head down to the bottom and excavate a large bank of solids that will continually slough down to the pump. With more rigid or heavier solids it is best practice to take solids in layers with multiple cuts across the waterway at increasingly lower depths. 12. Heavier solids and more viscous slurries require higher pressure to move the slurry through the pipeline. Dilute slurry to increase flow rate.
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DIAGNOSING OPERATING PROBLEMS 1. The flow rate at the end of the discharge pipe is less than it has been. a. Plugging of discharge pipeline. b. Plugging can generally be found by listening to each pipe t while pumping clear liquid. A hissing noise will be heard at the obstruction. Such obstructions can occur at the main pump discharge elbow or in the discharge pipe leading to the side of the machine. Consequently this portion of the discharge piping system should not be overlooked. c. Plugged pump suction. d. Obstruction in the impeller. 2. Vibration of the machine and discharge pipe. a. Obstruction in the pump impeller. 3. Travel cable slipping on winch drive sheave. a. Travel cable is too loose. b. Auger cutter assembly is digging into bottom or it is too deep in material. 4. Loss of pump prime. a. Cutting too close to liquid surface. b. Material viscosity is too thick to flow into the pump. c. Gas entrapped in material is causing vapor binding. HIGH WINDS High winds can affect the dredge, traverse and anchoring system. To counter the effects of the wind on the system while maintaining operations, adjust the lateral movement cables as necessary to align the path of the dredge in the pond. NOTE:
Placing stakes at the ends of the pond will provide reference points for locating the ends of the traverse cable on successive cuts.
If winds are too intensive to operate the dredge, move the dredge unit close to shore and tie it off to a suitable anchor. Check that all electrical cabinets are closed and locked.
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SETUP AND RIGGING
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DREDGE SET-UP, RIGGING & HOSE ASSEMBLY OFF-LOADING THE DREDGE 1. During preparation for launching into the pond, the dredge, floating hose and power cable should be unloaded on the bank close to the starting location. The gussets at the base of the head and tail frames have holes for this purpose. Use a crane of adequate size to handle a 5,800-pound (2630.84 kg) weight at the swing radius required to place the dredge in the pond. Once the dredge and accessories are off-loaded, the preparations prior to launching into the pond can commence. 2. The Status Indicator Signaling Light on the NEMA electrical enclosure is normally removed in preparation for shipping. Install this light on top of the electrical enclosure at the stern of the dredge and connect the wires, (use the plug-in electrical connectors, if provided). 3. Check and tighten all bolted connections that might have loosened during shipment. 4. Wire the 4-conductor power cable and the control cable between the shore based power supply and the NEMA electrical enclosure at the stern (rear) of the dredge in accordance with the electric schematic supplied in this manual. Perform the initial functional tests listed below.
DANGER! ONLY QUALIFIED PERSONNEL SHOULD PERFORM ELECTRICAL WORK! INITIAL DREDGE FUNCTIONAL CHECKS 1. Check the hydraulic oil level on the side of the reservoir. Add oil if necessary. Check plumbing for any visible oil leaks. Oil specifications are listed in the maintenance section. 2. Make sure that the electric motor on top of the reservoir is rotating in the proper direction. A reading of 500 to 700 psi on the hydraulic pressure gauge indicates the motor is rotating in the proper direction. 3. Operate each function; slurry pump, travel winch, auger and boom hoist to assure proper operation and direction.
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INSTALLING TRAVERSE CABLE Note: Refer to Drawing 3856, Sheets 1, 2 & 3 in this section when installing the earth anchors, traverse cable, cable tensioners and related rigging components. 1. Layout the cable harness or rigging to suit the waterway configuration for the best operation (traversing and lateral positioning) of the dredge. Normally, this is in alignment with the length of the pond, but if it’s a long pond, it might be better to set the dredge up across the width of the pond. In most installations, the anchors must be moved and the system re-set to completely dredge a pond. 2. Place the anchor plates on the ground sufficiently far back from the edge of the water so that when the system is tensioned, the lateral move or “pullover” cables form a “V” with the traverse cable. Drive a stake into the ground to hold each of them in place. Attach the cable tensioners and install a wire rope through the body of each device and extend the wire ropes to the point of attachment to the triangle. Note: Do not tighten the tensioners until the traverse cable is attached to the triangles at both ends of the pond and the cable is routed through the winch sheaves on-board the dredge. 3. As the traverse cable 3/8” (1 cm) diameter wire rope is unwound from the reel, it must be fed through the snatch blocks on the head and tail frames of the dredge. Do not feed the cable through the traverse winch sheaves until after it is in place across the pond. After the traverse wire is in place across the pond, but not tensioned, feed it through the winch drive sheave and idler sheaves as shown on the next page. 4. Attach the traverse cable to the triangles using two cable clamps (or two clamps at one end and a cable dog with cable and tensioner at the other) at the ends of the pond. 5. Upon tightening the traverse cable, the dredge will move out onto the waterway. It might be necessary to move the cable dog and/or clamps as the dredge is moved to its starting position. Once the cable is pre-tensioned, the traverse winch can be used to position the dredge at the starting location of the first run prior to beginning operations. Traverse Winch Cable Routing Arrows indicate path of travel cable to guide sheaves on head and tail frames.
Loop cable around bottom of drive sheave & over tops of idler sheaves
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EXAMPLE ONLY
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1 4‐ Cable Grip Hoists: Cable Tensiometer 2 Traverse Cable (Do NOT Cut) 5
5
3 Cable Dog: To Grab Cable 4 5‐ 60 foot (18.29 m) Cables (Do NOT Cut) 5 4 sets of Plate Anchors with 4 Stakes
1
1
6 2‐ Cable Clamps 4
4 2 6
2 3
4
1
5
1750 Madison Avenue New Richmond, WI
4
INSTRUCTIONS 1. Hook each grip hoist (1) to a stake in the anchor plate (5). 2. Hook the cables (4) onto the red triangle. TRAVERSE CABLE ADJUSTMENT The traverse cable adjustment is made with the traverse cable (2) and the grip hoists (1).
LWT PIT HOG POND DREDGING SCHEME MANUAL LATERAL MOVE LAYOUT
DATE:
8-19-13 REVISED
4
1
5
DRAWN BY:
J.J.C. CHECKED BY:
DRAWING NUMBER
3858 2 OF 3
ALL DRAWINGS AND INFORMATION ARE THE PROPERTY OF LWT AND ARE NOT TO BE REPRODUCED OR USED WITHOUT WRITTEN PERMISSION FROM LWT, LLC.
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DREDGE FAMILIARIZATION
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SYSTEM FAMILIARIZATION ELECTRICAL CONTROL
2. Electrical Transformer 460 to 120 VAC 3. Phase 3 Power Connect 1. Radio Transceiver
9. 12V Power Supply
4. Fuses
8. Bottom Sense
7. Function Relays
4. Fuses
6. Hydraulic Motor or-On/Off
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5. Slurry Pump VFD
ITEM DESCRIPTION
1. Radio Receiver Receives the radio signals sent from the remote control transmitter. These signals are interpreted into these commands: a. Hoist up and down b. Auger on and off c. Travel forward and reverse d. Pump on and off e. Travel speed increase and decrease f. Dredge on and off 2. Electrical Transformer Transforms 460 VAC to 120 VAC allowing power to the instrumentation. 3. Phase 3 Power Connect Connects or disconnects the main power source. 4. Fuses Avoids electrical spikes in the system. If the current escalates too high the fuses burn out avoiding any potential damage to sensitive components. 5. Slurry Pump VFD Turns the slurry pump on or off. 6. Hydraulic Motor or-On/Off Turns the electrical motor for the hydraulic system on and off. 7. Function Relays Used to open and close the electronic circuit for the functions on the dredge. 8. Bottom Sense Detects when the auger is touching the bottom of the pond so the boom can be adjusted up and down accordingly. 9. 12V Power Supply Transforms 120VAC into 12VDC allowing power to the instrumentation.
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WARNING LIGHTS - Located on the door of the electrical box. 1. Hydraulic Low/Hot Oil Light Indicates when the hydraulic oil level gets too low or gets too hot which will automatically shut off the dredge. This is to prevent any potential damage to the hydraulic system. 2. Slurry Pump Seal Fail Light Indicates when moisture is detected in the electrical motor of the slurry pump which disables the pump to prevent damage. 2. Slurry Pump Seal Fail Light
1. Hydraulic Low/Hot Oil Light
LIGHT TREE The light tree is located on top of the dredge control . The lights indicate when the dredge is running and what functions are in use. Each light indicates a different dredge function. Amber Light = Hydraulic pump motor is running Blue Light = Travel is running White Light = Auger is running Green Light = Pump is running Red Light = Hoist is running
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TRAVEL WINCH
1. Idler Pulleys
2. Travel Sheave
1. Idler Pulleys Guides the travel cable to the travel sheave. 2. Travel Sheave Moves the dredge forward or in reverse. 3. Idler Pulley Grease Zerks Use to grease the idler pulleys which should be greased every shift with high quality EP rated grease. 4. Travel Winch Gear Box Houses the reduction gears that increase the torque of the motor and also allows the dredge to travel within the correct speed limits. 5. Travel Winch Motor Moves the dredge forward or in reverse. 3. Idler Pulley Zerks
4. Travel Winch Gear Box
5. Travel Winch Motor
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FRONT OF DREDGE
2. Bottom Sense Load Cell
1. Boom Hoist Winch
1.
Boom Hoist Winch: Raises and lowers the boom.
2. Bottom Sense Load Cell: Sends signal to the shore control of the cutterhead weight to determine whether it’s on the bottom of the pond, so the cutterhead can be automatically raised or lowered. 3. Travel Guide Pulley: Guides the travel cable to keep the dredge from moving side to side. 4. Travel Proximity Switch: Automatically stops the dredge when it reaches the target stop on either end of the
4. Travel Proximity Switch 3. Travel Guide Pulley
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HYDRAULIC SYSTEM
3. Electric Motor
2. Low Oil/Hot Oil Shutoff Switch
4. Return Filter Housing
1. Hydraulic Oil Tank 5. Oil Level/ Temperature Gauge
1. Hydraulic Tank Houses the hydraulic oil. 2. Low Oil/Hot Oil Shutoff Switch Senses when the oil is too hot or too low. If either of these conditions exist the dredge automatically shuts off and indicator on rear will be lit. 3. Electric Motor Drives the hydraulic pump to provide hydraulic oil flow to the necessary components. 4. Return Filter Housing Houses the return filter that filters the oil that returns to the tank as the oil circulates through the system. 5. Oil Level/Temperature Gauge Used for checking the hydraulic oil level and temperature.
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VALVE BANK 1. Manual Overrides - Red Buttons Used when there is a need to manually actuate the flow control valves. 2. Solenoid Valves Electronically controlled valves used to turn on and off the flow of hydraulic oil. 3. System Pressure Gauge Displays the pressure of the hydraulic system. 4. Travel Speed Flow Control Varies the flow of hydraulic oil to the travel circuit which allows the dredge to go slower or faster; 0-100% speed.
4. Travel Speed Flow Control
1. Manual Overrides
2. Solenoid Valves 3. System Pressure Gauge
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CUTTERHEAD Excavates the material and brings it to the center of the shroud feeding the pump suction pipe. 1. Auger Motor There are two auger motors, one on each side of the cutterhead, which rotate the auger in the forward direction. 2. Auger Shroud Reduces the amount of turbidity caused by the auger head and keeps excessive water from being mixed into the slurry. 3. Auger Teeth Aid in the excavation process and are constructed out of hardened steel and lined with a carbide tip. The teeth are replaceable. 4. Auger This is the main part of the excavation process and conveys the sludge toward the center of the shroud. 2. Auger Shroud 4. Auger 1. Auger Motor
3. Auger Teeth
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C O N TR O L S
33
DREDGE CONTROLS Handheld Remote Control
34
REMOTE CONTROL BUTTON FUNCTIONS 1. Emergency Stop Button—Red button located at bottom of remote control.
Press the Emergency Stop button to shut off power to the dredge in an emergency or when completely shutting down operations—for example, at the end of a shift. If operations are being momentarily suspended, it isn’t necessary to depress this button unless maintenance or repairs of the dredge are forthcoming. Under normal operating conditions, use the individual buttons to shutdown the various functions.
2. Radio Transmitter and Hydraulic Power Unit On and Shift Button – Green button located at top of remote control.
Press the button to energize the radio transmitter and start the motor on the hydraulic power pack. This button must be re-set whenever the Emergency Stop Button has been used to shutdown electrical power.
Bottom Sense is not installed on this dredge and does not perform any functions.
WARNING! The Radio Transmitter Power Button only starts the electric motor on the hydraulic power pack—the Power Disconnect switch must be thrown to shut-off electrical power to the dredge. NOTE: When the Emergency Stop Button is pressed, all functions on the dredge are completely shut down but there is still live power present. The individual buttons must be re-activated to send power to the various functions. 3. Hoist Up/Down Buttons
Pressing and releasing these buttons raises and lowers the boom. Press the “Up” button to raise the boom and press the “Down” button to lower the boom. The boom (and auger-head) remains in the position in which it is placed when the buttons are released when Bottom Sense is not active.
4. Dredge Pump On/Off Button
The Dredge Slurry Pump speed is 1,450 RPM. Press the Slurry Pump button once to “Start” the slurry pump. Press the Slurry Pump button a second time to stop the slurry pump.
NOTE: Turning the slurry pump on/off repeatedly may cause serious damage to the system.
35
5. Dredge Pump Speed Buttons
The dredge pump speed is variable from 0 to 1,450 RPM. With the pump on press and hold the pump “Increase” button to increase the speed. It takes approximately 10 seconds to reach maximum speed; so holding the button for 30 seconds will assure that the pump is at full speed. Of course, a lesser speed can be selected, if desired. Conversely, press and hold the “Decrease” button to reduce the pump speed. Pressing and releasing either of the buttons can select intermediate speeds.
6. Auger On/Off Button
Press the “Auger” button once to start the auger cutter. Press the “Auger” button a second time to stop the auger cutter.
7. Traverse Winch Forward/Reverse Buttons
Press the “Forward” button to traverse in the forward direction. Press the “Reverse” button to traverse in the reverse direction. This button only determines the direction of travel, not the speed. When the dredge is in motion pressing either button will stop the travel.
8. Travel Speed Increase and Decrease Buttons
The “Travel Speed” buttons enable the operator to vary the speed from 0 to 30 feet (9.144m) per minute. Press and hold the “Increase” (INC) button to increase the rate of travel or press and hold the “Decrease” (DEC) button to decrease the rate of travel. If starting at 0, and the button is held for seven seconds, the dredge will be traveling at its maximum rate of speed. While dredging, the likely rate of travel will be in the range of 6 to 10 feet (1.8288 to 3.048 m) per minute. Therefore, press and release the button after only two to three seconds.
9. Bottom Sense On/Off Buttons
Simultaneously press the “Shift” button and Bottom Sense “On” button to activate the Bottom Sense feature of the dredge. Simultaneously press the Shift button and the Bottom Sense Off button once to deactivate the Bottom Sense feature.
36
CONTROLS, GAUGES AND MONITORS ON THE DREDGE 1. Service Entrance Disconnect Switch The Service Entrance Disconnect Switch is located in the NEMA 4 electrical enclosure at the stern (rear) of the dredge. Place the switch in the “On” position to provide electrical power to the on-board motors, radio receiver and hydraulic valve(s). Place the switch in the “Off” position to turn off the electrical power.
DANGER! DISCONNECT THE POWER SUPPLY ON-SHORE AND OBSERVE THAT THE AMBER RUN LIGHT IS NOT FLASHING BEFORE PERFORMING ANY ELECTRICAL WORK ON THE DREDGE! QUALIFIED ELECTRICAL PERSONNEL SHOULD DO WORK ONLY 2. Light Tree Located on top of the dredge control these light will indicate when the dredge is running and what functions are in use. The different colored lights indicate the following: Amber light— hydraulic pump motor is running Blue light— travel is running White light— auger is running Green light— pump is running Red light— hoist is running 3. Moisture Detection Light The red light on the door of the NEMA enclosure at the stern of the dredge illuminates when the Mody Pump Moisture Detection System detects moisture in the motor oil chamber due to the failure of the lower seal and /or breach of the stator housing. 4. Hydraulic Oil Pressure Gauge (On hydraulic control valve block) System and relief pressures are indicated on the gauge. Systems are designed to operate at pressures up to 1,750 psi. If any of the hydraulic functions (auger, winch drive or boom hoist) stall, the relief valve pressure setting of 2,000 psi is indicated. NOTE: The relief valve pressure is set at the factory and should not be adjusted by operating or service personnel in the field. Changes in this setting can affect dredge performance, operational safety and will void the warranty. the factory before making any changes to the hydraulic system. 5. Hydraulic Oil Level Gauge Indicates oil level in reservoir. Fill as required. 6. Hydraulic Oil Temperature Gauge Indicates hydraulic oil temperature in reservoir. Temperature should not exceed 184°F.
37
GENERAL OPERATING TECHNIQUE SETTING THE CONTROLS Refer to the photo on first page of this section for identification and location of the various Radio Transmitter Controls discussed below. The operator should become familiar with the each of the controls and displays and have a basic understanding of each of these before operating the dredge. With the dredge in position near one end (or side) of the pond and ready to commence dredging, perform the following steps to start and complete a typical dredge cycle: 1. Turn on the shore-based power supply to the dredge. NOTE: IN CASE OF AN EMERGENCY, OR WHEN SHUTTING DOWN THE DREDGE, PRESS THE RED EMERGENCY STOP BUTTON ON THE BOTTOM OF THE RADIO TRANSMITTER! 2. Press the Green button at the top of the control to start hydraulic pump motor on the dredge. When hydraulic pump motor is running the amber light is flashing. Dredge is now ready to start all other functions. 3. Press the Boom Hoist “Down” button to lower the boom with the auger-head af fixed to its lower end. Pressing and releasing the button will incrementally lower the boom. If shallow cuts are to be made, the boom should only be lowered a couple of feet below the surface of the liquid. When making successive es in the same cut, the boom (and auger-head) must be lowered another increment at the start of the . The maximum digging depth of the dredge is 15 feet. The dredge should not be operated below this depth. If the pontoons raise slightly out of the water, with the bottom is indicated. To avoid damaging the bottom, raise the boom (and auger-cutter assembly) slightly until it can be observed that the bow (front) of the pontoons dip slightly into the water. This indicates that the auger-cutter is clear of the bottom. NOTE: In very light sludge, it is best to plunge the auger head into the sludge blanket near the bottom of the pond. This will maximize the solids content of the slurry. 4. Press the Pump “ON” button to start the pump. To stop the pump, press the button a second time. 5. If necessary, adjust the slurry pump speed. See the discussion in Section V regarding setting the slurry pump speed. 6. Press the Auger button to start the auger-cutter. To stop the auger-cutter, press the button a second time.
38
DANGER! MAKE CERTAIN ALL PERSONNEL ARE CLEAR OF THE AREA AROUND THE AUGER-HEAD BEFORE STARTING THE AUGER CUTTER! NOTE: It might be necessary to raise or lower the depth of the auger-head as the dredge advances forward if the bottom contour is irregular. If the dredge stops moving forward and the winch is spinning on the travel cable, raise the boom slightly until it begins to move forward again. 7. Set the Travel Winch button in the Forward direction. Jog (press and release) the Travel Speed Increase button until the appropriate rate of travel is obtained – this is normally 6 to 10 feet per minute while dredging. The maximum rate of travel is 30 feet per minute. If the button is pressed and held for 7 seconds, this rate of travel will be achieved. Therefore, jog the button two or three times (or hold for 2 to 3 seconds) and observe the movement of the dredge. If too slow, jog the button again. If too fast, jog the Travel Speed Decrease button to slow it down. 8. Observe the operation of the dredge as it moves forward on the travel cable. If everything goes smoothly no further adjustments will be necessary and the dredge will advance forward until it reaches the opposite end (side) of the pond. At this time, the dredge must be stopped and returned to its starting position in the pond. 9. Press the Slurry Pump button once to stop the pump. Note: Generally, it is necessary to keep the pump running at about half speed to maintain pressure in the floating discharge line so that it stays out of the path of the dredge when it is traveling in reverse. 10. Press the Auger button once to stop the auger cutter. 11. Press the Boom Hoist “UP” button to raise the boom slightly. 12. Press the Travel Winch Reverse button to start the dredge moving in the reverse direction. 13. If the dredge isn’t traveling in reverse at a decent rate of speed, jog the Travel Speed Increase button until it is. Note: It might not be possible to travel in reverse at the maximum rate of speed of 30 feet/minute in some applications. Once the dredge has returned to its starting point, the dredge cycle is complete. 14. Repeat steps 4 through 7 to start another cycle. 15. Turn off all buttons on the radio transmitter at the end of operations. 16. Press the Red (Emergency Stop Button) at the bottom of the radio transmitter to shut-off the electrical power to the hydraulic pump motor. 17. Place the electrical power disconnect on the shore-based power supply in the “OFF” position.
39
DREDGING PRACTICES AND OPERATING HINTS 1. In soft materials (both organic and inorganic) and fluid like sediments, it is often times advantageous to plunge the boom into the material prior to starting the main pump. This minimizes dilution of the slurry and eliminates the pumping of clear fluids. 2. If the auger-cutter is stalled, due to an obstruction preventing its rotation, the auger hydraulic pressure relief valve (located on the reservoir) will be tripped. This can be difficult to detect when the dredge is unmanned and the controls are shore-based. One indication might be if the dredge “fish tails” (moves side to side) Stop the travel winch and try stopping and starting the auger-cutter a few times to see if the obstruction can be cleared. If this procedure is successful, start dredging again. 3. If the auger-cutter is not cleared after stopping and starting, stop the augercutter, slurry pump and travel winch. Raise the boom until the auger-cutter assembly is accessible at the surface of the water. Press the Emergency Stop switch to shut down all functions and place the shore-based electrical disconnect switch in the OFF position. Go out to the dredge and check the auger circuit hydraulic pressure on the gauge located on the reservoir. If the gauge reads zero pressure, use whatever tools and devices are necessary to remove the obstruction from the auger. After removing the obstruction, return to shore, turn the electrical power back on and start the auger-cutter. If the auger head is rotating freely, resume dredging. DANGER! WHENEVER IT IS NECESSARY TO WORK AROUND THE AUGER-HEAD, STOP ALL OF THE FUNCTIONS AND PLACE THE POWER DISCONNECT SWITCH ON THE ELECTRICAL IN THE “OFF” POSITION. NEVER WORK AROUND THE AUGER WHEN THE AMBER LIGHT IS FLASHING! 4. The no-load auger hydraulic circuit pressure is 600 to 700 PSI. In soft materials, there is likely to be only a slight increase in the auger hydraulic circuit pressure when dredging. This pressure can be observed on the pressure gauge mounted on the hydraulic control valve on the power unit. 5. If the material spills over the top or the sides of the auger, slow down the rate of travel or stop travel completely and let the pump and auger continue to operate momentarily. This is most likely to happen when making initial cuts in shallow water.
40
6. If the discharge line is plugging it can normally be cleared by stopping the auger, raising the boom slightly and pumping clear liquid. This is most likely to occur when pumping heavy materials such as sand, through a long pipeline or to an elevated disposal area, or the combination of these conditions. 7. When cutting in shallow water, cutting a shoreline or cutting materials projecting above the water surface, care should be taken to prevent loss of pump prime. The suction inlet must always be submerged below the liquid surface. In extremely shallow water, it may be necessary to make several forward cuts in order to create adequate depth for the machine to float. It takes approximately 16 inches of water to float the machine. 8. At the end of any operational period the auger-head should be raised to its upper limit at or near the surface of the water. 9. The speed of forward travel varies with the type of material being dredged. Optimum operation matches the auger-cutter’s ability to excavate solids at the flow rate of the slurry pump. If the dredge moves into the material too rapidly, the unit may tend to plow material around or over the auger. If material is more densely packed, the unit may tend to "stand on its nose" and begin to dig down into the solids. Either action would result in an uneven . 10. The travel speed will generally be the most commonly used control to optimize production. It is not possible to pump solids at more concentrated rates than they exist in the solids bed. 11. The pump must be in the sludge to move solids. With lighter sludge it is possible to lower the auger head down to the bottom and excavate a large bank of solids that will continually slough down to the pump. With more rigid or heavier solids it is best practice to take solids in layers, with multiple cuts across the waterway, at increasingly lower depths. 12. Heavier solids and more viscous slurries require higher pressure to move the slurry through the pipeline. Dilute slurry to increase flow rate.
41
DIAGNOSING OPERATING PROBLEMS 1. The flow rate at the end of the discharge pipe is less than it has been. Plugging of discharge pipeline. Plugging can generally be found by listening to each pipe t while pumping clear liquid. A hissing noise will be heard at the obstruction. Such obstructions can occur at the main pump discharge elbow, or in the discharge pipe leading to the side of the machine. Consequently, this portion of the discharge piping system should not be overlooked. Plugged pump suction. Obstruction in the impeller. 2. Vibration of the machine and discharge pipe. Obstruction in the pump impeller. 3. Travel cable slipping on winch drive sheave. Travel cable is too loose. Auger-cutter assembly is digging into bottom or it is too deep in material. 4. Loss of pump prime. Cutting too close to liquid surface. Material "viscosity" too thick to flow into the pump. Gas entrapped in material is causing vapor binding. HIGH WINDS 1. High winds can affect the dredge, traverse and anchoring system. To counter the effects of the wind on the system while maintaining operations: 2. Adjust the lateral movement cables as necessary to align the path of the dredge in the pond. Note: Placing stakes at the ends of the pond will provide reference points for locating the ends of the traverse cable on successive cuts. If winds are too intensive to operate the dredge: 1. Move the dredge unit close to shore and tie it off to a suitable anchor. 2. Make sure all electrical cabinets are closed and locked.
42
43
* Refer to Special Functions Section for functionality.
44
Receiver Logic Dredge Emergency Stop Output– The Dredge Emergency Stop Output is on when there is a link with the transmitter and off when the transmitter’s stop button is pressed. If the transmitter goes out of range or the batteries die the Dredge Emergency Stop Output remains on. When the Dredge Emergency Stop Output is off all outputs are shut off. Bottom Sense Output– The Hoist Up/Down outputs are disabled and the Hoist Run Light is enabled whenever the Bottom Sense Output is on. Hoist Up Limit Input– When the Hoist Up Limit Input is off for 250ms, the Hoist Up and Pump outputs are disabled. Forward Travel Limit Input– If the Forward Travel Output is off and the Forward Travel Limit Input is off for 250ms, the Forward Travel Output is disabled. If the Forward Travel Output is on and the Forward Travel Limit Input is off for 250ms, the Forward Travel Output will be set off for 3 seconds then the Reverse Travel Output will be set on. Reverse Travel Limit Input– If the Reverse Travel Output is off and the Reverse Travel Limit Input is off for 250ms the Reverse Travel Output is disabled. If the Reverse Travel Output is on and the Reverse Travel Limit Input is off for 250ms, the Dredge Emergency Stop Output and all other outputs are shut off and will remain off. All outputs will be disabled until the transmitter’s stop button is pressed and the link is reestablished.
45
46
47
48
49
50
51
52
53
HYDRAULICS
54
1 2 3 4 5
1 REF 1 REF REF
PART NUMBER 8000847 8001107 8000819 NONE NONE
6 7 8 9 10 11 12
REF REF 1 1 1 1 REF
NONE NONE 8001081 8000824 8001084 8000826 NONE
Washer, 1|2" Flat, Fender., 316SS Washer, 1|2" Flat, USS Std., Galv. PUMP, HYDRAULIC COMM 1.55CIR COUPLING, 1.375 DRIVE SHAFT COUPLING, DRIVE, .875, .25 KEY INSERT, DRIVE COUPLING 270H Bolt, 3|8-16 UNC x 0.75" Lg., Hex Head, Gr.5, Pltd.
-
13 14
1 1
1105536 1105095
FIITTING, HYD. 6405-20-16 Fitting, F6400-08-16
-
15 16
1 2
-
17 18 19 20 21
1 1 1 REF REF
0007256 8000812 0005572 NONE NONE
TUBE, SUCTION, 8.5" FILTER, HYDRAULIC MOUNT, FILTER, HYD TANK, RUNT Bolt, 3|8-16 UNC x 0.5" Lg., Hex Head, Gr.5, Pltd. Washer, 3|8" Lock, Reg. Pltd.
22 23 24
REF 1 1
NONE 0006113 1105377
Washer, 3|8" Flat, USS Std., 316SS SWITCH, LOW OIL-HI TEMP ASSY 6.6" Fitting, F6801-08
25 26
1 2
8000797 110-1022
GAUGE, OIL LEVEL & TEMP, Zinga #SG-05-A-T Plug, Pipe 3|4"-14 NPT, Black
REV ITEM NO. QTY.
GENERAL NOTES: 1.
ALL DIMENSIONS IN PARENTHESIS ARE FOR REFERENCE ONLY UNLESS NOTED OTHERWISE
2.
BREAK ALL SHARP EDGES, REMOVE ALL BURRS AND SCALE, UNLESS NOTED OTHERWISE.
A -
-
2
ORIENTATE ITEM MOTOR AS SHOWN
9
11
2
10
4
DESCRIPTION MOTOR, ELEC, 10HP W/DRIP MOUNT, MOTOR TO HYD PUMP Bolt, 1|2-13 UNC x 1.75" Lg., Hex Head, Gr.5, Pltd. Washer, 1|2" Lock, Reg. Pltd.
80003218-028 HOSE 08 3000 08FJX-08FJX GATES M3K 1105089 Fitting, F6400-08
23
5 6
5
4
6
16
20
6
18
20
21
22
3
4
18
8
16
3
20
GASKET SILICONE BETWEEN TANK AND MOTOR MOUNT
21
12
16
13
19
14
22
19
GASKET
24 25
15 1
17 25
2
26 1 1
26 24 23
26
55
REV.
ECN#
BY
THIS DRAWING INCLUDES PROPRIETARY DATA WHICH IS TH EXCLUSIVE PROPERTY HYDRAULIC TANK, ASSY OF LIQUID WASTE TECHNOLOGY, LLC NO DISCLOSURE OR REPRODUCTION ALLOWED WITHOUT WRITTEN CONSENT LWT RUNT OF LIQUID WASTE TECHNOLOGY, LLC. THIS PRINT IS NOT TO BE COPIED IN DO NOT SCALE- ALL DIMENSIONS SHOWN WITHOUT WHOLE OR IN PART OR USED DIMENSI0N LINES REFER TO DATUM LINE MARKED "0". DESIGNED RML DETRIMENTALLY TO THE INTEREST OF *ALL DIMENSIONS ARE IN INCHES UNLESS NOTED.* LIQUID WASTE TECHNOLOGY, LLC DRAWN RML *TOLERENCES (UNLESS OTHERWISE SPECIFIED) GENERAL FABRICATION: 1/16" ANGULARITY 0 -30' 2008 ©LIQUID WASTE TECHNOLOGY, LLC MACHINE SURFACE TEXTURE: REVIEWED MACHINE TOLERENCES: SUPERCEDES ACAD .XX .030" APPROVED .XXX .015" DATE APP'D REFERENCE P/N .XXXX .005" YEAR
LIQUID WASTE TECHNOLOGY, LLC 1750MADISON AVENUE NEW RICHMOND, WI (715)246-2888*FAX (715)246-2537
SHEET: 7/9/2008 7/9/2008
1 OF 2
SCALE: EST. WEIGHT:
1:4
SHEET SIZE
D
REV.
589.10
PART NUMBER/ DRAWING NUMBER:
0005841
B
26
2
19
2
18
20
21
22
25
16
24
1
23
2 2
6
5
23
4
18
24 2
26 16
25 1
3
12
8
SIDE OF ITEM 1. REMOVED FOR CLARITY
14 13 15 1
1
17
26 26
56
THIS DRAWING INCLUDES PROPRIETARY DATA WHICH IS TH EXCLUSIVE PROPERTY HYDRAULIC TANK, ASSY OF LIQUID WASTE TECHNOLOGY, LLC NO DISCLOSURE OR REPRODUCTION ALLOWED WITHOUT WRITTEN CONSENT LWT RUNT OF LIQUID WASTE TECHNOLOGY, LLC. THIS PRINT IS NOT TO BE COPIED IN DO NOT SCALE- ALL DIMENSIONS SHOWN WITHOUT WHOLE OR IN PART OR USED DIMENSI0N LINES REFER TO DATUM LINE MARKED "0". DESIGNED RML DETRIMENTALLY TO THE INTEREST OF *ALL DIMENSIONS ARE IN INCHES UNLESS NOTED.* LIQUID WASTE TECHNOLOGY, LLC DRAWN RML *TOLERENCES (UNLESS OTHERWISE SPECIFIED) GENERAL FABRICATION: 1/16" ANGULARITY 0 -30' 2008 ©LIQUID WASTE TECHNOLOGY, LLC MACHINE SURFACE TEXTURE: REVIEWED MACHINE TOLERENCES: SUPERCEDES ACAD .XX .030" APPROVED .XXX .015" REFERENCE P/N .XXXX .005"
LIQUID WASTE TECHNOLOGY, LLC 1750MADISON AVENUE NEW RICHMOND, WI (715)246-2888*FAX (715)246-2537
SHEET: 7/9/2008 7/9/2008
2 OF 2
SCALE: EST. WEIGHT:
1:4
SHEET SIZE
D
REV.
589.10
PART NUMBER/ DRAWING NUMBER:
0005841
B
NOTES: 1. SPEEDS SHOULD BE TOWARD NOMINAL & UPPER RANGE WHEN NEW AND NO LOAD. 2. SPEEDS MAY BE TOWARD LOWER RANGE UNDER LOAD & FACTORED BY .90 WITH AGE.
COMPONENTS ITEM
QTY
PART NO.
1
1
0005841
HYDRAULIC TANK ASSEMBLY, PHE - 60 HZ, FSC VALVE
2
1
0005207-02
HYDRAULIC CUTTER CIRCUIT, PHE - 60 HZ, FSC VALVE
3
1
0005207-03
HYDRAULIC TRAVEL CIRCUIT, PHE - 60 HZ, FSC VALVE
4
1
0005207-04
HYDRAULIC LIFT CIRCUIT, PHE - 60 HZ, FSC VALVE
5
1
0005207-11
HYDRAULIC COMMON CIRCUIT, PHE - 60 HZ, FSC VALVE
DESCRIPTION
3
9.80 CIR GEAR RATIO 5.05 : 1
2 AUGER 6 GPM 60 - 80 RPM
EC1
P
SV1 M
PRESSURE GAUGE 0 - 4000 PSI ON VALVE
TRAVEL WINCH 5 GPM 13 - 20 RPM
S2
1B
P1
7.40 CIR A
1A
S1
G
B
SV2 S2 RV1
2B
FR1 S1
2A SV3
T
S1
3B
A B
T1 S2
7.40 CIR
3A
ELECTRIC MOTOR 1750 RPM 60 HZ
3.36 CIR GEAR RATIO 40 : 1
5
M
COMMON CIRCUIT
4 HOIST WINCH 5 GPM 7 - 9 RPM
HYDRAULIC PUMP 1.55 CIR 11.7 GPM 1500 PSI 1750 RPM HYDRAULIC TANK 30 GALLON 1
-
-
-
-
-
-
-
-
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-
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-
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-
-
-
-
-
-
-
-
-
-
-
-
-
REV.
ECN #
BY
DATE YEAR
APP'D
THIS DRAWING INCLUDES PROPRIETARY DATA WHICH IS THE EXCLUSIVE PROPERTY OF LIQUID WASTE TECHNOLOGY, LLC. NO DISCLOSURE OR REPRODUCTION ALLOWED WITHOUT THE WRITTEN CONSENT OF LIQUID WASTE TECHNOLOGY, LLC. THIS PRINT IS NOT TO BE COPIED IN WHOLE OR IN PART OR USED DETRIMENTALLY TO THE INTEREST OF LIQUID WASTE TECHNOLOGY, LLC. LIQUID WASTE TECHNOLOGY, LLC.
57
SUPERSEDES ACAD
-
REFERENCE P/N
-
LIQUID WASTE TECHNOLOGY, LLC
HYDRAULIC OVERVIEW
1750 MADISON AVENUE NEW RICHMOND, WI (715) 246-2888 * FAX (715) 246-2573
PHE DESIGNED
60 HZ, FSC VALVE THE INFORMATION IN THIS DOCUMENT IS SUBJECT TO CHANGE WITHOUT NOTICE AND SHOULD NOT BE CONSTRUED AS A COMMITMENT BY LIQUID WASTE TECHNOLOGY, LLC.
DRAWN
TAZ
-
SHEET:
SHEET SIZE:
1
OF
1
ADB 9/18/2012 SCALE:
REVIEWED
-
-
APPROVED
-
-
PART NUMBER / DRAWING NUMBER:
0005207
B
COMPONENTS ITEM
QTY
PART NO.
1
2
8000822
2
REF
8000806
FITTINGS
HOSE / TUBE ASSEMBLIES
ITEM
QTY
PART NO.
MOTOR, HYD AUGER 7.4 CIR WHITE
F1
2
1105089
FITTING, HYD. F6400-8-8
VALVE, ASSY 3 BANK HYD RUNT
F2
4
1105151
F3
2
F4
4
DESCRIPTION
ITEM
QTY
PART NO.
H1
2
8003218-076
HOSE 08 3000 08FJX -08FJX
GATES 8M3K
FITTING, HYD. F2403-8-8-SS
H2 *
2
8003218-066
HOSE 08 3000 08FJX -08FJX
GATES 8M3K
1105328
FITTING, HYD. F2703-8-8-8-LN
H3 *
2
8003218-065
HOSE 08 3000 08FJX -08FJX
GATES 8M3K
1105090
FITTING, HYD. F6400-8-10
H4 *
2
8003218-067
HOSE 08 3000 08FJX -08FJX
GATES 8M3K
T1
REF
0006312
DESCRIPTION
DESCRIPTION
TUBE, HYD .5IN ASSY,BOOM 120LG
* THE LENGTH OF THESE HOSES IS DEPENDENT UPON THE LOCATION OF THE TEE FITTING MOUNTED TO THE SLURRY PUMP. THIS LOCATION WILL VARY BASED UPON THE TYPE OF SLURRY PUMP USED CAUSING THESE HOSE LENGTHS TO VARY. 2
1
H4
EC1 P
SV1
M
1B
S2
P1
7.40 CIR
A
G
1A
S1
F3
B H4
SV2 S2 RV1
H1
2B
T1
H2
FR1
H1
T1
H2
2A
S1
AUGER 6 GPM 60 - 80 RPM
F4
F4
H3
SV3 T
S1
3B
A F1
F2
F2
B
T1 7.40 CIR S2
3A
H3
1
NOTES: 1. SPEEDS SHOULD BE TOWARD NOMINAL & UPPER RANGE WHEN NEW AND NO LOAD. 2. SPEEDS MAY BE TOWARD LOWER RANGE UNDER LOAD & FACTORED BY .90 WITH AGE.
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-
-
-
-
-
-
-
-
-
-
-
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-
REV.
ECN #
BY
DATE YEAR
APP'D
THIS DRAWING INCLUDES PROPRIETARY DATA WHICH IS THE EXCLUSIVE PROPERTY OF LIQUID WASTE TECHNOLOGY, LLC. NO DISCLOSURE OR REPRODUCTION ALLOWED WITHOUT THE WRITTEN CONSENT OF LIQUID WASTE TECHNOLOGY, LLC. THIS PRINT IS NOT TO BE COPIED IN WHOLE OR IN PART OR USED DETRIMENTALLY TO THE INTEREST OF LIQUID WASTE TECHNOLOGY, LLC. LIQUID WASTE TECHNOLOGY, LLC.
58
SUPERSEDES ACAD
-
REFERENCE P/N
-
LIQUID WASTE TECHNOLOGY, LLC
HYDRAULIC
1750 MADISON AVENUE NEW RICHMOND, WI (715) 246-2888 * FAX (715) 246-2573
CUTTER CIRCUIT DESIGNED
PHE, 60 HZ, FSC VALVE THE INFORMATION IN THIS DOCUMENT IS SUBJECT TO CHANGE WITHOUT NOTICE AND SHOULD NOT BE CONSTRUED AS A COMMITMENT BY LIQUID WASTE TECHNOLOGY, LLC.
DRAWN
TAZ
-
SHEET:
SHEET SIZE:
1
OF
1
ADB 9/18/2012 SCALE:
REVIEWED
-
-
APPROVED
-
-
PART NUMBER / DRAWING NUMBER:
0005207-02
B
COMPONENTS ITEM
QTY
PART NO.
1
1
8002551
2
REF
8000806
FITTINGS
HOSE / TUBE ASSEMBLIES
ITEM
QTY
PART NO.
DRIVE, TRAVEL, LWT GEARBOX/MTR
F1
2
1105089
FITTING, HYD. F6400-8-8
VALVE, ASSY 3 BANK HYD RUNT
F2
1
1105375
FITTING, HYD. F6801-8-10
F3
1
1104498
FITTING, HYD. 6801-LL-NWO-8-10
DESCRIPTION
DESCRIPTION
ITEM
QTY
PART NO.
H1
2
8003218-099
DESCRIPTION HOSE 08 3000 08FJX -08FJX
TRAVEL WINCH 5 GPM 13 - 20 RPM
2
F2
GATES 8M3K
1
9.80 CIR GEAR RATIO 5.05 : 1
EC1 P
SV1
M
S2
1B
S1
1A
F3
H1
P1
H1 G
SV2
RV1
S2
2B
S1
2A
F1
FR1
SV3 T
S1
3B
S2
3A
T1
NOTES: 1. SPEEDS SHOULD BE TOWARD NOMINAL & UPPER RANGE WHEN NEW AND NO LOAD. 2. SPEEDS MAY BE TOWARD LOWER RANGE UNDER LOAD & FACTORED BY .90 WITH AGE.
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-
-
-
-
-
-
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-
-
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-
REV.
ECN #
BY
DATE YEAR
APP'D
THIS DRAWING INCLUDES PROPRIETARY DATA WHICH IS THE EXCLUSIVE PROPERTY OF LIQUID WASTE TECHNOLOGY, LLC. NO DISCLOSURE OR REPRODUCTION ALLOWED WITHOUT THE WRITTEN CONSENT OF LIQUID WASTE TECHNOLOGY, LLC. THIS PRINT IS NOT TO BE COPIED IN WHOLE OR IN PART OR USED DETRIMENTALLY TO THE INTEREST OF LIQUID WASTE TECHNOLOGY, LLC. LIQUID WASTE TECHNOLOGY, LLC.
59
SUPERSEDES ACAD
-
REFERENCE P/N
-
LIQUID WASTE TECHNOLOGY, LLC
HYDRAULIC
1750 MADISON AVENUE NEW RICHMOND, WI (715) 246-2888 * FAX (715) 246-2573
TRAVEL CIRCUIT DESIGNED
PHE, 60 HZ, FSC VALVE THE INFORMATION IN THIS DOCUMENT IS SUBJECT TO CHANGE WITHOUT NOTICE AND SHOULD NOT BE CONSTRUED AS A COMMITMENT BY LIQUID WASTE TECHNOLOGY, LLC.
DRAWN
TAZ
-
SHEET:
SHEET SIZE:
1
OF
1
ADB 9/18/2012 SCALE:
REVIEWED
-
-
APPROVED
-
-
PART NUMBER / DRAWING NUMBER:
0005207-03
B
COMPONENTS ITEM
QTY
PART NO.
1
1
8000846
2
REF
8000806
FITTINGS ITEM
QTY
PART NO.
WINCH, BLOOM 10-AS8-40:1
F1
2
1105089
VALVE, ASSY 3 BANK HYD RUNT
F2
4
F3
2
DESCRIPTION
HOSE / TUBE ASSEMBLIES ITEM
QTY
PART NO.
FITTING, HYD. F6400-8-8
H1
2
8003218-074
HOSE 08 3000 08FJX -08FJX
GATES 8M3K
1105151
FITTING, HYD. F2403-8-8-SS
H2
2
8003218-066
HOSE 08 3000 08FJX -08FJX
GATES 8M3K
1105090
FITTING, HYD. F6400-8-10
T1
REF
0005027
TUBE, HYD .5IN, ASSY, RUNT
DESCRIPTION
DESCRIPTION
2
EC1 P
SV1
M
S2
1B
S1
1A
P1
G
SV2
RV1
S2
2B
S1
2A
FR1
F2
F2
SV3 T
S1
3B
S2
3A
H1
T1
H1
T1
H2
T1 H2
F3
F1
F3
3.36 CIR GEAR RATIO 40 : 1 1 HOIST WINCH 5 GPM 7 - 9 RPM
NOTES: 1. SPEEDS SHOULD BE TOWARD NOMINAL & UPPER RANGE WHEN NEW AND NO LOAD. 2. SPEEDS MAY BE TOWARD LOWER RANGE UNDER LOAD & FACTORED BY .90 WITH AGE.
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-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
REV.
ECN #
BY
DATE YEAR
APP'D
THIS DRAWING INCLUDES PROPRIETARY DATA WHICH IS THE EXCLUSIVE PROPERTY OF LIQUID WASTE TECHNOLOGY, LLC. NO DISCLOSURE OR REPRODUCTION ALLOWED WITHOUT THE WRITTEN CONSENT OF LIQUID WASTE TECHNOLOGY, LLC. THIS PRINT IS NOT TO BE COPIED IN WHOLE OR IN PART OR USED DETRIMENTALLY TO THE INTEREST OF LIQUID WASTE TECHNOLOGY, LLC. LIQUID WASTE TECHNOLOGY, LLC.
60
SUPERSEDES ACAD
-
REFERENCE P/N
-
LIQUID WASTE TECHNOLOGY, LLC
HYDRAULIC
1750 MADISON AVENUE NEW RICHMOND, WI (715) 246-2888 * FAX (715) 246-2573
LADDER LIFT CIRCUIT DESIGNED
PHE, 60 HZ, FSC VALVE THE INFORMATION IN THIS DOCUMENT IS SUBJECT TO CHANGE WITHOUT NOTICE AND SHOULD NOT BE CONSTRUED AS A COMMITMENT BY LIQUID WASTE TECHNOLOGY, LLC.
DRAWN
TAZ
-
SHEET:
SHEET SIZE:
1
OF
1
ADB 9/18/2012 SCALE:
REVIEWED
-
-
APPROVED
-
-
PART NUMBER / DRAWING NUMBER:
0005207-04
B
COMPONENTS ITEM
QTY
PART NO.
1
1
8000806
2
1
8000810
3
REF
4
1
FITTINGS ITEM
QTY
PART NO.
VALVE, ASSY 3 BANK HYD RUNT
F1
1
1105089
VALVE, HYD FLOW CONTROL
F2
2
0005841
TANK, HYDRAULIC, ASSY, RUNT
F3
1
8002636
GAUGE, PRESS. 0-4000 SAE STEM
DESCRIPTION
HOSE / TUBE ASSEMBLIES ITEM
QTY
PART NO.
FITTING, HYD. F6400-8-8
H1
1
8003218-028
HOSE 08 3000 08FJX -08FJX
GATES 8M3K
1105075
FITTING, HYD. F6500-8-8
H2
1
8003218-035
HOSE 08 3000 08FJX -08FJX
GATES 8M3K
1105152
FITTING, HYD. F6400-8-12
DESCRIPTION
DESCRIPTION
2 F1 F2 EC1 P
H1
SV1
M
PRESSURE GAUGE 0 - 4000 PSI ON VALVE
S2
1B
S1
1A
P1
G
4
SV2
RV1
S2
2B
S1
2A
FR1
F3 F2
SV3 T
H2
S1
3B
S2
3A
T1 ELECTRIC MOTOR 1750 RPM 60 HZ
M 1
HYDRAULIC PUMP 1.55 CIR 11.7 GPM 1500 PSI 1750 RPM
HYDRAULIC TANK 30 GALLON 3
NOTES: 1. SPEEDS SHOULD BE TOWARD NOMINAL & UPPER RANGE WHEN NEW AND NO LOAD. 2. SPEEDS MAY BE TOWARD LOWER RANGE UNDER LOAD & FACTORED BY .90 WITH AGE.
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-
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-
REV.
ECN #
BY
DATE YEAR
APP'D
THIS DRAWING INCLUDES PROPRIETARY DATA WHICH IS THE EXCLUSIVE PROPERTY OF LIQUID WASTE TECHNOLOGY, LLC. NO DISCLOSURE OR REPRODUCTION ALLOWED WITHOUT THE WRITTEN CONSENT OF LIQUID WASTE TECHNOLOGY, LLC. THIS PRINT IS NOT TO BE COPIED IN WHOLE OR IN PART OR USED DETRIMENTALLY TO THE INTEREST OF LIQUID WASTE TECHNOLOGY, LLC. LIQUID WASTE TECHNOLOGY, LLC.
61
SUPERSEDES ACAD
-
REFERENCE P/N
-
LIQUID WASTE TECHNOLOGY, LLC
HYDRAULIC
1750 MADISON AVENUE NEW RICHMOND, WI (715) 246-2888 * FAX (715) 246-2573
COMMON CIRCUIT DESIGNED
PHE, 60 HZ, FSC VALVE THE INFORMATION IN THIS DOCUMENT IS SUBJECT TO CHANGE WITHOUT NOTICE AND SHOULD NOT BE CONSTRUED AS A COMMITMENT BY LIQUID WASTE TECHNOLOGY, LLC.
DRAWN
TAZ
-
SHEET:
SHEET SIZE:
1 OF 1
ADB 9/18/2012 SCALE:
REVIEWED
-
-
APPROVED
-
-
PART NUMBER / DRAWING NUMBER:
0005207-11
B
White Hydraulics, Inc. P.O. Box 1127 Hopkinsville, KY 42241 Phone- (270) 885-1110 Fax- (270) 886-8462
PI444200 9/01 Service Instructions For The CE (400/401) Series
FOR USE WITH SEAL KIT 400444200
***USE EXPLODED VIEW ON BACK FOR REFERENCE***
A)
Remove all shaft components from the shaft, (21), (i.e., keys, wire rings, nuts). To aid in reassembly of the motor, make a "V" shaped set of lines from the endcover to the housing using either paint or a marker. With the shaft facing down, secure the motor in a vise by clamping onto the housing, (8). Loosen and remove the seven bolts, (20), holding the motor assembly together. Remove the endcover, (18), from the motor.
B)
Remove the balance plate, (16), rotor set, (15), and the manifold, (14), from the motor. Remove all seals from the components and discard. (Caution - when removing the balance plate, do not allow the three check balls, (17), to fall out from the plate.) (Caution - do not allow the rolls to drop out from the rotor set assembly when removing the assembly from the motor.) Remove the manifold from the motor and lay aside. Remove drive link, (13), from the motor and lay aside. Remove the thrust bearing, (12), from the housing and lay aside. From the front of the housing, gently tap the shaft, (21), upward and remove through the rear of the housing.
C)
Using a slide and hammer type bearing puller, (see Figure 1), remove the rear housing bearing, (11), from the housing. Remove the thrust bearing, (10), and lay aside, remove the thrust washer, (9), and lay aside. Remove the shaft seal, (4), and discard, remove the back-up seal, (3), and discard, remove the metal shim, (2), and discard.
D)
At this point, all parts should be cleaned in an oil-based solvent and dried using compressed air, (for safety, observe all OSHA safety guidelines). All new seals should be lightly coated in clean oil prior to installation.
E)
Place the integral thrust washer/bearing, (10), onto the shaft. The washer side should be against the shoulder of the shaft. Place a thrust washer, (9), onto the shaft on top of the thrust bearing. Coat the shaft seal, (4), with a light coat of oil and install onto the shaft with the lip side down. Place a light coat of oil on the back-up seal, (3), and place over the coat of oil on the metal back-up shim, (2), and place over the back-up seal.
F)
With the pilot of the housing placed down, install the output end of the shaft through the rear bore of the housing.
G)
The rear bearing is now ready to be installed. With the writing side of the bearing facing up, place the bearing, (11), into the housing bore. Using a hand press, the bearing should be pressed into the bore. It is necessary that the bearing be pressed .120 - .130" deep into the bore of the housing to accommodate the width of the thrust bearing.
H)
Install a thrust bearing, (12), on top of the shaft.
I)
Install a lightly oiled body seal, (1), into the seal groove in the housing. Make sure that this seal is in the seal groove and protruding approximately .007" over the top of the housing surface. (Caution - if a bump is felt in the seal remove the seal and make sure that there is no grit on the seal or in the seal groove.)
J)
Install the drive link, (13), into the housing. The proper end of the drive link has a 'hat" machined in the top of the drive link on the 07-16 displacement. The drive link is to be placed in the shaft with the hat facing up on these displacements. The 18 displacements and above have a symmetrical head and either end can be put into the motor. Once the drive link has been installed, the shaft can be seated. This is done by bringing the arbor of the hand press down and putting pressure on the drive link. (Caution - do not use excessive pressure as this could deform the thrust bearing and/or bearing races.)
K)
Place the manifold (14), (seven teardrop hole side down) on the housing. Line the bolt hole notches in the outside diameter of the manifold up with the seven bolt holes in the housing.
L)
Install two oil coated body seals, (5), one on each side, into the seal grooves of the rotor set, (15). Place the deep groove side of the of the rotor set down on the manifold, (14).
M)
Place the balance plate, (16), on top of the rotor set with the check balls, (17), up. If the check balls were removed, install three check balls into the countersunk holes on the balance plate, one ball per hole.
N)
Install an oil coated body seal, (6), into the seal groove of the endcover, (18). Place the endcover onto the motor with the tag holes directly above the housing ports. (Caution - it is very important that the body seal does not fall out of the endcover while being installed. Extra care must be used to insure this doesn't happen.)
O)
Install the seven bolts, (20), into the motor. Pre-torque bolts to 10 ft. lbs. The final torque on the bolts is to be 51.1 + 5.5 ft. lbs.
64
FIGURE 1
CE(400/401) Series Motor Components 1. Housing Seal 2. Metal Back-Up Shim 3. Teflon Back-Up Seal 4. Shaft Seal 5. Body Seals (2) 6. Endcover Seal 7. Front Housing Bearing 8. Housing
9. Thrust Washer 10. Front Thrust Bearing 11. Rear Housing Bearing 12. Thrust Bearing 13. Drive Link 14. Manifold 15. Rotor Assembly 16. Balance Plate 65
17. Steel Balls (3) 18. Endcover 19. I.D. Tag 20. Assembly Bolts (7) 21. Shaft 22. Shaft Key 23. Shaft Nut
BLOOM MANUFACTURING INC. Safety, Warranty, Maintenance & Repair, Installation and Operation Manual Bloom™ Hydraulic Cable Winches 800, 1000, 1100, 1200, 1400 & 1600 Series
Bloom™ Hydraulic Capstan Winches 1000, 1100, 1000V & 1400 Series
All Bloom winches have the model and serial number stamped on the gear case cover. Please take a few minutes to record these numbers for future use. You will need these numbers for ordering parts or gathering service information from the factory: Model#______________________________ # 10-A-S8-40 Serial # 52532 Model Ser #______________________________
Thank you for your purchase of a quality Bloom product ! THIS MANUAL MUST BE KEPT WITH THE WINCH AT ALL TIMES AND NEW WINCH OPERATORS MUST READ AND UNDERSTAND IT. IT REV. 07-2007
Bloom Manufacturing Inc. Winch Division 1443 220th Street Independence, IA 50644
www.bloommfg.com Email: [email protected] 66
800-394-1139 tel 319-827-1139 tel 319-827-1140 fax
Table of Contents 1. General Safety Requirements 2. Warranty 3. Maintenance & Repair ( ) Clean (a) Cl andd IInspectt (b) Oil Change Information (c) Oil Level (d) Recommended Gear Oil (e) Inserts: - Assembly (specific model) - Disassemblyy ((specific p model)) - Parts List (specific model) - Assembly Check Valve Kit - Assembly of Oil Cooled Brake - Replacement of Clutch Handle and Yoke
4. Winch Break In 5. Winch Installation 6. Winch Operation ( ) Cable (a) C bl Considerations C id ti (b) The Importance of a Proper Fleet Angle (c) Wire Rope Anchor & Wrapping (d) Automatic Safety Brakes & Adjustment
Please note that not all of the sections of the Table of Contents apply to each model purchased
Merchandise may not be returned without approval from factory. The customer will be charged for placing the returned goods in salable condition plus a restocking charge of 25%. All returns must be shipped prepaid.
Section 1
General Safety Requirements
THIS SYMBOL MEANS • Attention! • Become Alert! • Your Safety Is Involved SIGNAL WORDS:
2
Take Note! This Safety Alert Symbol Found Throughout This Manual Is Used To Call Your Attention To Instructions Involving Your Personal Safety And The Safety Of Others. Failure To Follow These Instructions Can Result In Injury Or Death.
Note the use of the signal words DANGER, WARNING AND CAUTION with the safety messages. The appropriate signal word for each has been selected using the following guidelines:
• DANGER:
Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations typically for machine components which, for f functional f purposes, cannot be guarded.
• WARNING:
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury, and includes hazards that are exposed when guards are removed. It may also be used to alert against unsafe practice.
• CAUTION:
Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.
Bloom Mfg Inc.
319-827-1139
319-827-1140 fax 67
www.bloommfg.com
CAUTION
WARNING
Failure to Heed The Following Warnings May Result In Serious Injury Or Death
•
Bloom winches are not to be used to lift, hoist, or move people. If your task involves lifting or moving people, you mustt use the th proper equipment, i t nott this thi winch. i h
•
Cable anchors on Bloom winches are not designed to hold the rated load of the winch. You must keep at least five (5) wraps of cable on the drum to ensure that the cable doesn’t come loose. We suggest that the last 5 wraps of cable be painted bright red to serve as a visual warning.
•
Stay clear of suspended loads and of cable under tension. A broken cable or dropped load can cause serious injury or death.
•
No equipment should be installed, operated, or maintained by any person who has not carefully read all contents of this manual. Serious physical injury or property damage can result from failure to read and apply the instructions contained therein. Therefore, we urge you to read all operating instructions and warnings carefully. If any instruction or warning is not clear, or if you feel you need additional information, please Bloom Mfg Inc. This manual should not be understood to prepare you for every possible situation. It is the owner’s and ’s responsibility to determine the pp industry, y trade association, federal, state, and local regulations g suitabilityy of a pproduct for a pparticular use. Applicable should be reviewed.
•
Make sure that all equipment, including the winch and cable, is maintained properly. Pay especially close attention to the clutch, making sure that it fully engages when shifted. Winches equipped with free spooling dog clutch should never be used in a lifting application.
•
Avoid shock loads. This type of load imposes a strain on the winch many times the actual weight of the load and can cause failure of the cable or of the winch. winch
•
Bloom products are sold on the strict understanding that all products selection is the full responsibility of the purchaser.
•
Bloom accepts no liability for the use, misuse or incorrect application of its products.
•
Leather gloves should be used when handling winch cable.
•
Ensure the correct equipment is obtained and installed for the application.
•
Ratings shown in Bloom literature are applicable only to new products.
•
Working load limits shown are the maximum load the product is authorized to under normal environmental conditions. Shock loading and abnormal conditions must be taken into when selecting products.
•
In general, products displayed in Bloom literature are used as parts of a system. As a result, we can only recommend within the working load limits, or other stated limitations, the use of products for this purpose.
•
Working load limits or safety factors for each Bloom product may be affected by wear, misuse or environmental conditions. Regular inspection must be conducted to ensure the equipment continues to meet the published standards. If you have questions not answered in this manual or require additional copies or the manual is damaged, please Bloom Mfg., Inc., 1443 220th Street, Independence, Iowa 50644. This sample manual is based upon general industry considerations and does not take into product or manufacturer specific exposures or needs. This sample manual may not be adopted by a product manufacturer as its manual, but may be used by the manufacturer in the process of developing its own manual, based upon its specific products and operations, after consulting with its advisor. THINK S-A-F-E-T-Y FIRST
Bloom Mfg Inc. 68
319-827-1139
3
Warranty
Section 2
LIMITED NINETY (90) DAY WARRANTY FOR HYDRAULIC CABLE & CAPSTAN WINCHES Effective date January 1, 1999 Bloom Mfg. Inc., Independence, Iowa 50644, provides the following LIMITED NINETY (90) DAY WARRANTY on its product to the purchaser of this product and to any person to whom such product is transferred during the duration of this warranty. The warrantor's obligation shall be limited to repairing or replacing at the factory in Independence, Iowa, any part or parts which shall within the NINETY (90) DAY period hereinafter specified be returned to it with transportation prepaid and which upon examination by Bloom Mfg. Inc. shows to have been defective. This warranty shall not apply if: (a) the product has been altered, repaired or modified outside the warrantor's factory in any way that would adversely affect its operation. (b) the product has been subject to careless or negligent misuse, damage or use of improper oil while in the possession of the purchaser or any person to whom the product was transferred by the purchaser or was installed or operated other than in accordance with the manufacturer's operating instructions. (c) the product was used with accessories not recommended by Bloom Mfg. Inc. or for loads in excess of those listed as rated for the product. (d) in the case of hydraulic motors, Bloom Mfg. Inc. will not accept responsibility and warranty will be subject to manufacturer's warranty. The NINETY (90) DAY LIMITED WARRANTY period shall commence with the date the product is sold to the purchaser by the dealer or if this date cannot be established, the date the product was sold by Bloom Mfg. Inc. to the dealer. THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE ARE LIMITED TO THE DURATION OF THIS WARRANTY - NINETY (90) DAYS - AFTER SAID (90) DAYS, BLOOM MFG. INC. EXPRESSLY DISCLAIMS ANY WARRANTY OR MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. PURPOSE Purchase or other acceptance of the product by the claimant shall be on the condition and agreement that BLOOM MFG. INC. SHALL NOT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL OR CONTINGENT DAMAGE, SECONDARY CHARGES OR LOSS OR EXPENSE RESULTING FROM ANY ALLEGED DEFECT, FAILURE OF ARTICLE TO OPERATE PROPERLY, OR FOR THE NEGLIGENCE OF OTHERS OR DAMAGES OF ANY KIND. Bloom Mfg. Inc. is not responsible for the cost, of removal of product, damages due to removal or any other expenses incurred in shipping the product to or from Bloom Mfg. Inc. or the installation of the repaired or replacement product. The consumer must bear these expenses. To make a claim under this warranty, write directly to Bloom Mfg. Inc., Independence, Iowa 50644, identifying the product and giving its location and follow the company's return instructions which will be provided by the company. Bloom Mfg. Inc. will p or replace p the pproduct,, if found to be defective within the of this warranty, y, within SIXTY make its best efforts to repair (60) DAYS after return of the product to the company. This warranty is exclusive and in lieu of all other warranties whether written, oral or implied (including any warranty of merchantability or fitness for a particular purpose.
4
For Best Results, Only Use Bloom Replacement Parts 69
800-394-1139
Section 3
Maintenance & Repair ƒ Make sure that there is no load on the winch cable and that all of the y hoses have been disconnected before servicingg unit. hydraulic
CAUTION A winch, like other types of machinery, needs to have regular maintenance if it is to perform properly, give lasting service, and provide safe winching. (a) Clean and Inspect: Thoroughly clean all of the parts in a good grade of cleaning solvent; one that is not flammable, not toxic and will not cause skin ki rashes. h If necessary, use rubber bb gloves. l IInspectt allll parts t for f wear, nicks, i k scratches t h andd damage d that th t would ld render them unusable. If a part is questionable, it is better to replace it rather than take a chance on premature failure when the winch is placed back in service. Always replace O-rings and seals, and it is a good idea to use new roll pins as well. Sometimes it is permissible to reuse bearings and bushings...it depends on how much use they have had. The rollers should not exhibit any surface irregularities. If the rollers show any sign of spalling, corrosion, discoloration, material displacement or abnormal wear, the bearings should be replaced. Likewise,, the cage g should be inspected p for unusual wear or deformation,, pparticularlyy the cage g bars. If there is anyy damage that will impair the cage’s ability to separate, retain, and guide the rollers properly, the bearing should be replaced. The thrust washer areas should be free from any surface irregularity that might cause excessive abrasion or friction. If the winch was disassembled only to replace damaged seals after a short period of service, it is not necessary to replace the bearings. Experience and common sense, along with a good inspections, will determine if they can be used again. Always coat O-rings, bearings, bushings and the rubber parts of seals with oil during assembly. Use a light coat of thread sealing compound on pipe fittings and plugs. (b) Oil Change Information: The winch vent/fill and drain plugs are located at the base of the face plate. Oil should be changed every 100 hours of operating time, or every six months, whichever comes first. (c) Oil Level: To check the oil level, remove the level plug. The oil should be level with the bottom of this opening. If more oil is needed, use the recommended gear oil listed below.
OIL CAPACITY CHART
Note: Base mounted position is when h the h worm shaft h f iis below the bronze gear.
Bloom Mfg Inc.
Winch Type
Winch Series
Base Mounted Position*
All Other Mounting Positions
Cable
800 & 1000
1 Pint
2 Pints
1100
1 Pint
2 Pints
1200 w/o brake
2 Pints
3 Pints
1200 w/ brake
3 Pints
4 Pints
1400
4 Pints
6 Pints
1600
4 Pints
6 Pints
1000 & 1100
1 Pints
2 Pints
1100V
2 Pints
2 Pints
1400
4 Pints
6 Pints
Capstan
319-827-1139
319-827-1140 fax 70
www.bloommfg.com
5
(d) Recommended Gear Oil: Use BLOOM ULLTRA-LUBE NO. 601 trans-worm gear oil; available from Bloom in pints or quarts. For emergency situations when BLOOM ULLTRA-LUBE NO. 601 is not immediately available, use Phillips 66 Company SAE grade 80W90 superior multi-purpose gear oil (Phillips 80W90 SMP) meeting API classification GL-5 or equivalent brand. Continuous use of oil other than BLOOM ULLTRA-LUBE NO. 601 or Phillips 80W90 SMP oil may shorten the life of the gears. DO NOT mix BLOOM #601 or Phillips 80W90 SMP with more than 50% of any other kind of oil.
Section 4
CAUTION
Winch Break In • Winches, like any other kind of machinery, require a “break in” to perform well and to maximize their life. • Use extreme care when first spooling cable onto the winch. winch Do not run the winch at high speeds when performing this operation. • Make sure that the cable is unrolled in a line (to prevent kinks) and slowly inhaul the winch to install the cable. • Do not exceed one half rated load or one half rated line speed for the first thirty minutes of operation. This will ensure that the worm and gear have an opportunity to wear in properly. • Periodically, check the gearbox for temperature rises and allow the winch to cool down between pulls.
Winch Installation
Section 5
CAUTION
• Y You mustt make k sure that th t your winch i h iis securely l mounted t d iin order d ffor it tto ffunction ti properly and to ensure safe operation. • The mount must be flat to ensure proper alignment between the gearbox side, the drum, and the clutch. • Winches must never be fastened directly to the frame of a truck. Mounting brackets should be used. y y driven winch,, make sure the hydraulic y system y is clean and that • With a hydraulically all components function properly, especially the relief valve. Winch Series
800
1000
1100
1200
1400
1600
1/2”
1/2”
1/2”
1/2”
1”
1”
Angle Mounts (steel) Length Width Thickness
2-1/2” 2-1/2”” 1/4”
2-1/2” 2-1/2”” 1/4”
2-1/2” 2-1/2”” 1/4”
2-1/2” 2-1/2”” 1/4”
3” 3” 1/2”
3” 3” 1/2”
Capscrews (Hexhead) Size Thread Grade
1/2” 1/2” 13 UNC 13 UNC 5 5
1/2” 13 UNC 5
1/2” 13 UNC 5
57
57
Base Mount (steel) Thickness
HARDWARE REQUIREMENTS
57
Torque / Tightening (foot pounds)
6
THINK S-A-F-E-T-Y FIRST
57
Bloom Mfg Inc. 71
5/8” 5/8” 11 UNC 11 UNC 5 5 112
319-827-1139
112
Winch Operation
Section 6
• To familiarize yourself with the winch, run it for a few minutes to understand the controls and the “feel” of the winch. • Pay particular attention to the controls and how they operate. Make sure you understand which way the winch will rotate when the control lever is moved. • Always make sure that all people are clear of the load and of the cable area before beginning a winching operation. • Ensure that proper protective wear is worn while operating winch. • A broken cable can fly in any direction. • Do not attempt to defeat the relief valve valve. • If you have any doubts about the capability of the winch to lift or move a load, either put a “snatch block” in the line or get a bigger piece of equipment. Winch lifting application: (1) Attach winch cable to load. (2) Make sure no one is in the immediate area of the load or of the cable (3) Begin winching the load slowly, watching carefully to ensure that the load is moving normally. (4) When the load is positioned where you want it, stop the winch.
Winch Series
DRUM CAPACITY (FEET)
Cable Diameter (inches) 3/8 7/16 1/2
3/16
1/4
5/16
S* S8 L L8 XL10 8-13**
--------------------1325
120 260 175 390 840 750
70 160 105 240 550 450
45 105 65 160 340 325
30 75 45 110 250 225
1400
L14
-----
-----
1223
712
1600
L145
-----
-----
1214
842
800 1000, 1100 & 1200
* For series 1000 only ** For series 1000K only
Drum Designation
9/16
5/8
25 55 30 80 170 155
-------------------------
-------------------------
517
409
295
200
662
425
318
303
Consult your local cable supplier for recommendations on the best type of cable and hardware to use in your specific application. (a) Cable Considerations: As the number of layers of cable on a winch increases, the rated lifting capacity of the winch goes down. If you are operating at near the top of the drum flanges, the effective rating of the winch is about half of what it is on the first layer. You should, therefore, only keep as much cable on the winch as you need for your job.
For Best Results, Only Use Bloom Replacement Parts 72
800-394-1139
7
Never use larger or smaller cable on your winch than is recommended for it. The use of larger cable will not allow you to pull larger loads and may, in fact, break easier than the proper size cable. The use of smaller cable may overheat the winch due to the increased running time with more cable. (b) The Importance of a Proper Fleet Angle: Maintaining the proper fleet angle is important to the success of your winching operation, the life of your winch and the life of the cable you are using. The fleet angle can best be described by the following diagram: The fleet angle should be kept as small as possible to ensure proper spooling and to maximize cable and winch life. To promote even cable spooling, keep the fleet angle below three degrees. Never pull directly against the flange of the winch cable drum as this may cause the cable or the winch to break. Adherence to these instructions will ensure better spooling. (c) Wire Rope Anchor & Wrapping: Prepare the end of the wire rope as recommended by the wire rope manufacturer. the free end of the wire rope through the small opening of the cable drum anchor pocket. Lock the cable into the drum by tightening the cable anchor set screw.
Centerline
PROPER FLEET ANGLE
LOAD Cable
Fleet Angle 3 Deg. Max.
Direction To Raise Load Cable
PROPER WRAPPING OF WIRE ROPE
Cable Anchor Set Screw Drum
Drum will turn counter clockwise to spool cable onto drum (d) Automatic Safety Brake: Some Bloom winches are equipped with an automatic hydraulic brakes to hold suspended loads. If your winch is not equipped i d with ith one, it is i intended i t d d for f pulling lli loads l d only. l If you wish i h to t lift andd suspendd loads l d with ith your winch, i h it can be b retrofitted with a brake. Please consult the factory for details. The safety brake is an important feature of your winch and must be maintained properly. There are two types of brakes used on Bloom winches: Adjustable Automatic Safety Brake (Drag) An oil cooled automatic safety brake disengages when a load is lifted and automatically engages when power is removed or the load is lowered. Automatic Hydraulic Fail-Safe Brake (Spring applied hydraulic release) Spring applied hydraulic release brake automatically holds load when hydraulic pressure is released. Double counter balance valve adds additional load holding capability by locking hydraulic oil in motor. Bloom Mfg Inc.
319-827-1139
319-827-1140 fax 73
www.bloommfg.com
8
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75
76
77
Service Manual HY09-SM300/US
Service Manual PGP/PGM315, 330, 350, 365
Effective: April 15, 2002 Supersedes: July 1, 1998
PGP/PGM 300 Series
78
PGP/PGM 300 Series Service Manual HY09-SM300/US
315/330/350/365 Service Manual General Instructions These service instructions will familiarize you with Parker's single and multiple pumps
• their component parts • the relative position of each part • proper methods for assembly or disassembly of the units To facilitate the repair of these units and before any work is done, we suggest that you first read all of the steps used in disassembly and assembly. Dirt is the enemy of any hydraulic system. The first requirement for good maintenance of hydraulic equipment is cleanliness. MAKE SURE YOU DISASSEMBLE AND ASSEMBLE YOUR HYDRAULIC EQUIPMENT IN A CLEAN AREA. The pictures show Model PGP365. Notes in the text cover variations between this unit and the other models. It is important to airblast all parts and wipe them with a clean, lintless cloth before assembly.
Items shaded apply to multiple assemblies only.
USE CAUTION IN GRIPPING ALL PARTS IN THE VISE TO AVOID DAMAGING MACHINED SURFACES.
NOTE: For PGP315 and PGP330 ONLY - Plug 5 required in position A and position B.
A pump must be driven in the direction of rotation for which it was built; otherwise, pressure will blow the shaft seal. Check the exploded view and notes at right for proper direction of rotation.
For PGP350 and PGP365 ONLY - Plug 5 in position B gives clockwise rotation. Plug 5 in position A gives counterclockwise rotation.
Parker's Replacement Parts
PARTS LIST 1. 2. 3. 4. 5. 6. 7. 8. 9.
Snap Ring Outboard Bearing Seal Shaft End Cover Plug Bushings Channel Seal Thrust Plates Integral Drive Shaft and Gear Set 10. Gasket Seal
Parker's replacement parts are of original equipment standards. For assured quality of material and workmanship, and for compatibility in assembly, USE ONLY GENUINE PARTS. Check all replacement parts before installing them to be certain that they were not damaged in shipment.
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11. Dowel Pins (Solid for PGP/PGM 315, 330 and 350. Hollow for PGP/PGM 365 ONLY.) 12. Gear Housing 13. Bearing Carrier 14. Connecting Shaft 15. Matched Gear Set 16. Gear Housing 17. Port End Cover 18. Studs or Cap Screws 19. Washers 20. Nuts
Parker Hannifin Corporation Gear Pump Division Youngstown, OH
PGP/PGM 300 Series Service Manual HY09-SM300/US
Tool List • Arbor press • Awl • 1 1/2" Dia. steel ball • Bearing puller (Owatonna Tool Co. M D - 956 or equivalent) • Bushing remover tool (See A) • Clean, lintless cloths • Deburring tool (an old file with cutting teeth ground off) • Machinist's hammer • Soft hammer • Permatex Aviation Form-A-GasketTM No. 3 non-hardening sealant or equivalent • Medium grit carborundurn stone • Seal removal tool (See B) • Oil and grease • Snap ring pliers • Prick punch • Bushing installation tool (See C) • Scale ( 1/32" or 1/64" graduations) • Small screw driver • Torque wrench • Vise with 6" minimum opening. • Bar for lip seal installation Note: For PGP/PGM315 use 1 5/8" dia. x 2" bar. For PGP/PGM330 use 1 3/4" dia. x 2" bar. For PGP/PGM350 use 2 1/2" dia. x 2" bar For PGP/PGM365 use 2 1/2" dia. x 2" bar. • Special steel sleeve ( see sketch )
Bushing Puller: The bushings in PGP/PGM315, 330, 350 and 365 pumps may be removed from their bores, using blind hole collet-type bushing pullers similar to those manufactured by Owatonna Tool Co. The table below illustrates the modifications necessary to adapt the OTC collets to this task. Equivalent pullers from other suppliers may be modified in similar fashion.
A PGP/PGM 315 PGP/PGM 330 PGP/PGM 350
B
Seal Removal Tool Easily made from an old screw driver. Heat the tip and bend as shown. Grind the tip to fit the notch behind the shaft seal. Special Steel Sleeve The special steel sleeve is used to insert the drive shaft through the lip seal without damage and can be made from bar stock: For the PGP/ PGM315 use a 1 " dia. x 3-1/ 8" bar; for the PGP/PGM330 use a 1-1/8" or 1-1/4" dia. x 4- 5/8" bar; for the PGP/ PGM350 use a 1-3/8" dia. x 4-5/8" bar; for the PGP/ PGM365 use a 1- 1 /2" dia. x 4-5/8" bar. The drawing and chart give details for making this special tool.
C
PGP/PGM 315 PGP/PGM 330 PGP/PGM 350 PGP/PGM 365
PGP/PGM 315
PGP/PGM 330
PGP/PGM 350
PGP/PGM 365
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Parker Hannifin Corporation Gear Pump Division Youngstown, OH
PGP/PGM 300 Series Service Manual HY09-SM300/US
Start Disassembly Here CAUTION: 1. If prying off sections becomes necessary, take extreme care not to mar or damage machined surfaces. Excessive force while prying can result in misalignment and seriously damage parts. 2. If parts are difficult to fit during assembly, tap gently with a soft hammer (never use an iron hammer). 3. Gears are closely matched, therefore they must be kept together as sets when removed from a unit. Handle with care to avoid damage to the journals or teeth. Avoid touching gear journals. 4. Never hammer bushings into bores; use an arbor press.
1) Place the pump in a vise with the drive shaft pointIng down. Caution: DO NOT GRIP ON OR NEAR ANY MACHINED SURFACES DURING ASSEMBLY OR DISASSEMBLY. Match-mark all sections. Be sure to align these marks when reassembling.
2) Use a socket wrench to remove the 4 cap screws on single units or the 4 hex nuts, studs and washers of multiple units.
3) Lift off the port end cover. If prying is necessary, be careful not to damage the machined surfaces. Dowel pins will remain in either the port end cover or the gear housing.
4) Remove the thrust plate. Examine and replace if necessary. See wear guide page 10.
5) Carefully remove the drive and driven gears. Avoid tapping the gear teeth together or against other hardened surfaces. Keep these gears together because they are a matched set. Examine and replace if necessary. (See page 10). Remove the thrust plate from the bearing carrier. Examine and replace if necessary.
6) Lift the gear housing from the bearing carrier. If prying is necessary, take care not to damage machined surfaces. Examine and replace if necessary. (See page 10) For multiple assemblies only
For multiple assemblies only
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Parker Hannifin Corporation Gear Pump Division Youngstown, OH
PGP/PGM 300 Series Service Manual HY09-SM300/US 7) Carefully lift or pry off the bearing carrier to prevent damage to face and edges. Dowel pins will remain in either the bearing carrier or the gear housing. DO NOT REMOVE THEM.
For multiple assemblies only
8) Remove the connecting shaft. Remove the thrust plate. Examine and replace if necessary. (See page 10). Remove the driven gear and the integral gear and drive shaft. Keep these together as they are a matched set. Examine and replace if necessary. (*See page 10). Be careful not to damage the machined surfaces of the gears.
9) Lift or pry off the first section gear housing. Be careful not to damage machined surfaces. Examine and replace if necessary (see page 10).
10) Inspect all bushings for scoring or discoloration and replace if necessary. Use a bushing puller as shown in the tool list to remove bushings (see page 4).
11) If the pump is equipped with an outboard bearing, place the shaft end cover in the vise with the mounting face up. Remove the snap ring with snap ring pliers. If a unit is equipped with a spiral-lock retaining ring, remove with a small screwdriver or awl.
12) Use a bearing puller to remove the outboard bearing.
13) Grip the shaft end cover in a vise with the mounting face down. Remove double lip seal by inserting the special seal removal tool (see Tool List) into the notch between the double lip seal and the shaft end cover. Tap the seal out and discard. Remove and discard all rubber and polymer seals.
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Parker Hannifin Corporation Gear Pump Division Youngstown, OH
PGP/PGM 300 Series Service Manual HY09-SM300/US
Start Assembly Here 1) Stone all machined surfaces with a medium grit carborundurn stone.
2) If the bushings have been removed, deburr the bushing bores with an emery cloth. Rinse parts in a solvent. Air blast all the parts and wipe with a clean, lintless cloth before starting assembly.
3) Grip shaft end cover in vise with mounting face down. Examine plug or plugs* to be sure they're tightly in place. Replacement is necessary only if parts are damaged. Remove with screwdriver.
4) New plugs should be screwed in tightly. Stake the plug with a prick punch at both ends of the screwdriver slot and around edges. Peen the edge of the hole 1/32" to 1/16" with a1-1/2" diameter steel ball. NOTE: If new plug or plugs are being installed, coat threads with LoctiteTM thread sealant.
*PGP/PGM315 and 330 have two plugs in both the shaft end and port end covers. PGP/PGM350 and 365 have one plug on the outlet side of their shaft end and port end covers. 5) Note: Assembly steps 5, 6, 7 & 8 apply to shaft end cover, bearing carrier and portend cover. Any bushings removed from the shaft end cover, portend cover or bearing carrier should be assembled in the drive bores with the groove to the top of unit (12 o'clock). Assemble the bushings in the driven bores with the groove to the bottom of the unit (6 o'clock). The PGP/PGM315 does not have grooved bushings, therefore the bushing seams should be placed at the 12 and 6 o'clock positions.
6) Bushings should be pressed into the bores, one at a time, using the special installation tool and an arbor press. Be sure the that the grooves (or seams) are positioned as stated in Step #5. The bushings must be pressed into the bores flush with the casting face. Be sure to the castings so that they are square and level.
7) Repeat Steps 1 and 2, stone and rinse parts.
8) See that dowel pins are in place in any new castings. Examine all of the dowels. Before inserting, make certain that the hole is clean and free from burrs. Gently start the pin straight into the hole and tap lightly with a soft hammer.
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Parker Hannifin Corporation Gear Pump Division Youngstown, OH
PGP/PGM 300 Series Service Manual HY09-SM300/US 9) Before inserting a new lip seal in the shaft end cover, coat the outer edge of the lip seal and its recess with Permatex Aviation Form-A-Gasket™ No. 3 non-hardening sealant or equivalent. With the metal side of the lip seal up, press it into the mounting flange side of the shaft end cover with an arbor press and bar (see Tool List on page 4). Be careful not to damage the lip of the seal. Press in until flush with the recess. Wipe off excess sealant.
10) If the unit is equipped with an outboard bearing, guide the bearing into its recess in the shaft end cover. This is a light press fit. It may be necessary to lightly tap the bearing into the bore.
11) Install the snap ring in the groove to retain the outboard bearing.
12) Grease the new gasket seals and insert them into the grooves in both sides of all gear housings. Position the first gear housing over the shaft end cover and dowels. Tap it with a soft hammer until it rests tightly against the shaft end cover. Be careful not to pinch the gasket seal. Also be sure that the large rounded core is on the inlet side.
13) Assemble the channel seals into the grooves in the thrust plates with the flat side of the seal facing away from the thrust plate as shown below.
14) Gently slip the thrust plate through the gear housing and into place on the shaft end cover. The channel seal from Step #13 should face the shaft end cover. The relief groove in the plate should face the outlet side of the pump.
Flat Side of Seal
Thrust Plate
15) Slide the driven gear through the housing and into the bushing in the shaft end cover. Coat the steel sleeve tool with grease. Place the lightly-greased drive shaft inside the sleeve and slide both through the shaft end cover with a twisting motion, until the integral gear rests against the thrust plate. Avoid damaging the double lip seal. Remove the steel sleeve. Squirt clean oil over the gears.
8 84
16) Slip the thrust plate with the seal over the gear journals and into the housing bore. The flat side of the seal should face up with the relief groove facing the outlet side. (For single pump assemblies go directly to Step #21).
Parker Hannifin Corporation Gear Pump Division Youngstown, OH
PGP/PGM 300 Series Service Manual HY09-SM300/US
17) Place the bearing carrier onto the journals of the drive and driven gears. Be sure to line up the dowel holes over the dowel pins. When the parts are parallel, squeeze them together or alternately tap over each dowel until the parts are together.
18) Insert the connecting shaft into the spline of the drive gear. Position and place the second gear housing on the bearing carrier as outlined in Step #12.
19) Place the thrust plate in the gear housing per Step #14. Insert the drive and driven gears of the second section in their respective bearings. Make certain the gears are in with the thrust plate face. Place the port end cover plate in the housing per Step #16.
20) Check the plug or plugs in the port end cover to be sure that they are tight. Follow the procedure outlined in Step #4 for new plugs.
For multiple assemblies only
For multiple assemblies only
For multiple assemblies only
22) Thread the fasteners into the shaft end cover and tighten alternately or cross corner. Rotate the drive shaft with a 6" wrench to check for binding. If there is no internal binding, torque diagonally opposed fasteners to 200 ft. lbs. (2400 in. lbs.); 141 ft. lbs. (1700 in. lbs.) for PGP/ PGM315 models; 450 ft. lbs. (5400 in lbs.) for PGP/ PGM365.
21) Place the port end cover over the gear journals. Align the dowels with the holes in the mating casting. Being careful not to pinch the gasket-seal, tap the port end cover lightly in the center between bearing bores to engage the dowels and to move parts together in the final seating.
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Parker Hannifin Corporation Gear Pump Division Youngstown, OH
PGP/PGM 300 Series Service Manual HY09-SM300/US
Guideline for acceptable wear Gear Housings
Dowel Pins
Wear in excess of .007" cut-out necessitates replacement of the gear housing. Place a straight-edge across bore. If you can slip a .007 feeler gage under the straight-edge in the cut-out area, replace the gear housing.
If either the dowel or dowel hole is damaged, the dowel or machined casting, or both, must be replaced. If more than reasonable force is required to seat dowels, the cause may be poorly deburred or dirty parts; cocking of the dowel in the hole or improper pin-to-hole fit.
Pressure pushes the gears against the housing on the low pressure side. As the hubs and bushings wear, the cut-out becomes more pronounced. Excessive cut-outin a short period of time indicates excessive pressure or oil contamination. If the relief valve settings are within prescribed limits, check for shock pressures or tampering. When the cut-out is moderate, 007" or less, the gear housing is in good condition and may be reused.
Bushings If gears are replaced, bushings must be replaced. Bushings should fit into the bore with a heavy press fit. Seals and Gaskets Replace all rubber and polymer seals, including all "0" rings, thrust plate channel seals, shaft seal and gasket seals.
Gears Any scoring on gear hubs necessitates replacement. Scoring, grooving, or burring of the outside diameter of the teeth requires replacement. Nicking, grooving, or fretting of teeth surfaces also necessitates replacement.
Plugs Examine the plugs in the shaft end and port end cover to make sure that they are in the proper position and tight. The PGP/PGM315 and PGP/PGM330 should have two plugs in both the shaft end and port end in tandem units only. The PGP/PGM350 and PGP/PGM365 have one plug in their shaft and port ends high pressure side only.
Drive Shafts Replace if there is any wear detectable by touch in the seal area or at the drive coupling. The maximum allowable wear is .002". Wear in the shaft seal area indicates oil contamination. Wear or damage to splines, keys, or keyways necessitates replacement. Thrust Plates The thrust plates seal the gear section at the sides of the gears. Wear here will allow internal slippage, that is, oil will by within the pump. A maximum of .002" wear is allowable. Replace thrust plates if they are scored, eroded or pitted. Check center of thrust plates where the gears mesh. Erosion here indicates oil contamination. Pitted thrust plates indicate cavitation or oil aeration. Discolored thrust plates indicate overheating, likely due to insufficient oil.
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Parker Hannifin Corporation Gear Pump Division Youngstown, OH
PGP/PGM 300 Series Service Manual HY09-SM300/US
Lubrication and Oil Recommendations General Recommendations:
All parts, with the exception of the outboard bearing, are lubricated by the hydraulic oil in the circuit. Particular attention must be paid to keep clean oil in the circuit system. Whenever there is a pump or motor failure, and there is reason to feel that metal particles may be in the system, the oil must be drained, the entire system flushed clean and any filter screens thoroughly cleaned or replaced. New oil should be supplied for the entire system. Oil suitable and recommended for use in circuits involving Parker's pumps and motors should meet the following specifications:
A good-quality hydraulic oil conforming to the characteristics listed above is essential to the satisfactory performance and long life of any hydraulic system. The oil should be changed on regular schedules in accordance with the manufacturer's recommendations, and the system periodically flushed. The oil temperature in the reservoir must not exceed 200° F., (93.3° C.) with a maximum temperature of 180° F. (82.2° C.) recommended. Higher temperatures will result in rapid oil deterioration.
Viscosity: • 50 SSU minimum @ operating temperature 7500 SSU maximum @ starting temperature
Reservoir capacity should equal in gallons the pump output in gpm or the total gpm of all pumps, where there is more than one in the system.
• 150 to 225 SSU @ 100° F. (37.8°C.) (generally) 44 to 48 SSU @ 210° F. (98.9° C.) (generally)
Oil poured into the reservoir should through a 100-mesh screen. Pour only clean oil from clean containers into the reservoir. A 100-mesh screen may be used in the suction line leading to the pump. A suction filter should be of sufficient size to handle twice the pump capacity. It must be cleaned and checked regularly to avoid damage due to contamination and cavitation.
Approximate SSU @
Normal Temperatures: O° F. (-1 8° C.) to 100° F. (37.8° C.) Ambient 100° F. (37.8° C.) to 180° F. (82.2° C.) System. Be sure your oil is recommended for the temperatures you expect to encounter.
Viscosity Index: 90 minimum Aniline Point: 175 minimum Recommended Additives: Foam depressant, rust and oxidation inhibitors. Filtration: 10 micron recommended for maximum pump life.
Cold Weather Operation: Oils for use in cold weather should have a viscosity not exceeding 7500 SSU at the minimum start-up temperature. A pour point of at least 20° F. below start-up temperature is recommended. Start-up procedures should allow for a gradual warm-up until the oil reaches a reasonably fluid state.
Other Desirable Characteristics: • Stability of physical and chemical characteristics. • High demulsibility (low emulsibility) for separation of water, air and contaminants. • Resistant to the formation of gums, sludges, acids, tars and varnishes. • High lubricity and film strength.
Continued on the following page.
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Parker Hannifin Corporation Gear Pump Division Youngstown, OH
PGP/PGM 300 Series Service Manual HY09-SM300/US Continued from the previous page
Recommended Start-up Procedure For New or Rebuilt Pump
The Use of Other Fluids:
Before installing a new or rebuilt pump, back off the main relief valve until the spring tension on the adjusting screw is relieved. This will avoid the possibility of immediate damage to the replacement unit in the event that the relief valve setting had been increased beyond the recommended operating pressure, prior to removing the old unit.
• Automatic Transmission Fluid (ATF): In general, ATF performance is satisfactory; however these fluids are sometimes too expensive for normal use in hydraulic systems. • Diesel Fuel or Kerosene (Coal Oil): Though sometimes used as dilutants for cold weather operations, they are not recommended, as they are not sufficiently refined.
Before connecting any lines to the pump, fill all ports with clean oil to provide initial lubrication. This is particularly important if the unit is located above the oil reservoir.
• Fire Resistant Fluids: DO NOT USE ANY FIRE RESISTANT FLUIDS OR NON-PETROLEUM OILS WITHOUT CONSULTING OUR TECHNICAL SERVICE DEPARTMENT.
After connecting the lines and mounting the replacement unit, operate the pump at least two minutes at no load and at low rpm (400 min.) During this break-in period, the unit should run free and not develop an excessive amount of heat. If the unit operates properly, speed and pressure can then be increased to normal operating settings.
• These suggestions are intended as a guide only. OBTAIN YOUR FINAL FLUID RECOMMENDATIONS FROM YOUR FLUID SUPPLIER.
Reset the main relief valve to its proper setting while the pump is running at maximum operating engine (motor) speed for the vehicle.
ALWAYS USE AN ACCURATE GAUGE WHEN ADJUSTING THE RELIEF VALVE PRESSURE SETTING.
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Parker Hannifin Corporation Gear Pump Division Youngstown, OH
PGP/PGM 300 Series Service Manual HY09-SM300/US
Recommended Test Procedure Many repairmen measure the output at normal operating speed and at zero pressure, then again at 1000 psi (or the operating pressure of the equipment) and allow a volume decrease approximating the listing below. It is a suggested reference only which makes allowance for reused parts.
Make certain that there is an adequate supply of oil for the pump; at least one gallon of oiI for each gpm of pump capacity. If one section of a tandem pump is being tested, make sure that all other sections not being tested are adequately supplied with oil. If any of the other sections run dry, or if plugs are left in ports, serious and permanent damage will result.
At test speeds other than 1800 rpm, gpm delivery will vary almost proportionately, but the same (drop-off) figures should be used.
The oil should be a good quality hydraulic oil rated at 150 SSU at 100° F., with the oil temperature held at 120° F. plus or minus 50° F. (Test procedures are described in detail in SAE handbooks; see Hydraulic Power Pump Test Procedure, SAE J745c.)
Be sure to run the pump in the direction for which it was designed and built. Driving the pump in the wrong direction will build up pressure behind the shaft seal, damaging it and necessitating replacement. After completing testing procedures, the pump is ready for installation and immediate duty operation on equipment. Again, it must be ed that to prevent seizure, hot oil must not be fed into a cold pump.
The feed line must be of adequate size with no more than 5" mercury vacuum adjacent to the pump inlet. As a rule, the feed line must provide a feed flow velocity not in excess of 8 feet per second. Feeding hot oil into a cold pump may cause the pump to seize. Jog the pump by momentarily starting and stopping repeatedly the driving engine or motor to gradually equalize pump and oil temperatures. Run the pump at least two minutes at no load and moderate speed (not over 1500 rpm). If the pump becomes excessively hot, shut down immediately and locate the problem source. Gradually increase pressure on pump, in 500 psi increments until the desired test pressure has been reached. This should take about five minutes. Delivery should run close to rated catalog performance figures, which are averaged from testing several pumps. A 5% lower reading may be used as a rated minimum if new or relatively new parts have been used. When rebuilding the pump with parts from the original pump, which, while worn, appear satisfactory for reuse, a 10% or 15% lower reading may be permitted, depending on the performance expected from the equipment. One's own experience will prove the best guide here.
13 89
Parker Hannifin Corporation Gear Pump Division Youngstown, OH
PGP/PGM 300 Series Service Manual HY09-SM300/US Offer of Sale The items described in this document and other documents or descriptions provided by Parker Hannifin Corporation, its subsidiaries and its authorized distributors are hereby offered for sale at prices to be established by Parker Hannifin Corporation, its subsidiaries and its authorized distributors. This offer and its acceptance by any customer ("Buyer") shall be governed by all of the following and Conditions. Buyer’s order for any such items, when communicated to Parker Hannifin Corporation, its subsidiary or an authorized distributor ("Seller") verbally or in writing, shall constitute acceptance of this offer. items sold hereunder, even if such apparatus has been specially converted or adapted for such manufacture and notwithstanding any charges paid by Buyer. Unless otherwise agreed, Seller shall have the right to alter, discard or otherwise dispose of any special tooling or other property in its sole discretion at any time. 8. Buyer’s Property: Any designs, tools, patterns, materials, drawings, confidential information or equipment furnished by Buyer or any other items which become Buyer’s property, may be considered obsolete and may be destroyed by Seller after two (2) consecutive years have elapsed without Buyer placing an order for the items which are manufactured using such property, Seller shall not be responsible for any loss or damage to such property while it is in Seller’s possession or control. 9. Taxes: Unless otherwise indicated on the face hereof, all prices and charges are exclusive of excise, sales, use, property, occupational or like taxes which may be imposed by any taxing authority upon the manufacture, sale or delivery of the items sold hereunder. If any such taxes must be paid by Seller or if Seller is liable for the collection of such tax, the amount thereof shall be in addition to the amounts for the items sold. Buyer agrees to pay all such taxes or to reimburse Seller therefore upon receipt of its invoice. If Buyer claims exemption from any sales, use or other tax imposed by any taxing authority, Buyer shall save Seller harmless from and against any such tax, together with any interest or penalties thereon which may be assessed if the items are held to be taxable. 10. Indemnity For Infringement of Intellectual Property Rights: Seller shall have no liability for infringement of any patents, trademarks, copyrights, trade dress, trade secrets or similar rights except as provided in this Part 10. Seller will defend and indemnify Buyer against allegations of infringement of U.S. Patents, U.S. Trademarks, copyrights, trade dress and trade secrets (hereinafter ‘Intellectual Property Rights’). Seller will defend at its expense and will pay the cost of any settlement or damages awarded in an action brought against Buyer based on an allegation that an item sold pursuant to this contract infringes the Intellectual Property Rights of a third party. Seller’s obligation to defend and indemnify Buyer is contingent on Buyer notifying Seller within ten (10) days after Buyer becomes aware of such allegations of infringement, and Seller having sole control over the defense of any allegations or actions including all negotiations for settlement or compromise. If an item sold hereunder is subject to a claim that it infringes the Intellectual Property Rights of a third party, Seller may, at its sole expense and option, procure for Buyer the right to continue using said item, replace or modify said item so as to make it noninfringing, or offer to accept return of said item and return the purchase price less a reasonable allowance for depreciation. Notwithstanding the foregoing, Seller shall have no liability for claims of infringement based on information provided by Buyer, or directed to items delivered hereunder for which the designs are specified in whole or part by Buyer, or infringements resulting from the modification, combination or use in a system of any item sold hereunder. The foregoing provisions of this Part 10 shall constitute Seller’s sole and exclusive liability and Buyer’s sole and exclusive remedy for infringement of Intellectual Property Rights. If a claim is based on information provided by Buyer or if the design for an item delivered hereunder is specified in whole or in part by Buyer, Buyer shall defend and indemnify Seller for all costs, expenses or judgments resulting from any claim that such item infringes any patent, trademark, copyright, trade dress, trade secret or any similar right. 11. Force Majeure: Seller does not assume the risk of and shall not be liable for delay or failure to perform any of Seller’s obligations by reason of circumstances beyond the reasonable control of Seller (hereinafter ‘Events of Force Majeure’). Events of Force Majeure shall include without limitation, accidents, acts of God, strikes or labor disputes, acts, laws, rules or regulations of any government or government agency, fires, floods, delays or failures in delivery of carriers or suppliers, shortages of materials and any other cause beyond Seller’s control. 12. Entire Agreement/Governing Law: The and conditions set forth herein, together with any amendments, modifications and any different or conditions expressly accepted by Seller in writing, shall constitute the entire Agreement concerning the items sold, and there are no oral or other representations or agreements which pertain thereto. This Agreement shall be governed in all respects by the law of the State of Ohio. No actions arising out of the sale of the items sold hereunder or this Agreement may be brought by either party more than two (2) years after the cause of action accrues. 9/91-P
1. and Conditions of Sale: All descriptions, quotations, proposals, offers, acknowledgments, acceptances and sales of Seller’s products are subject to and shall be governed exclusively by the and conditions stated herein. Buyer’s acceptance of any offer to sell is limited to these and conditions. Any or conditions in addition to, or inconsistent with those stated herein, proposed by Buyer in any acceptance of an offer by Seller, are hereby objected to. No such additional, different or inconsistent and conditions shall become part of the contract between Buyer and Seller unless expressly accepted in writing by Seller. Seller’s acceptance of any offer to purchase by Buyer is expressly conditional upon Buyer’s assent to all the and conditions stated herein, including any in addition to, or inconsistent with those contained in Buyer’s offer, Acceptance of Seller’s products shall in all events constitute such assent. 2. Payment: Payment shall be made by Buyer net 30 days from the date of delivery of the items purchased hereunder. Amounts not timely paid shall bear interest at the maximum rate permitted by law for each month or portion thereof that the Buyer is late in making payment. Any claims by Buyer for omissions or shortages in a shipment shall be waived unless Seller receives notice thereof within 30 days after Buyer’s receipt of the shipment. 3. Delivery: Unless otherwise provided on the face hereof, delivery shall be made F.O.B. Seller’s plant. Regardless of the method of delivery, however, risk of loss shall to Buyer upon Seller’s delivery to a carrier. Any delivery dates shown are approximate only and Seller shall have no liability for any delays in delivery. 4. Warranty: Seller warrants that the items sold hereunder shall be free from defects in material or workmanship for a period of 18 months from date of shipment from Parker Hannifin Corporation. THIS WARRANTY COMPRISES THE SOLE AND ENTIRE WARRANTY PERTAINING TO ITEMS PROVIDED HEREUNDER. SELLER MAKES NO OTHER WARRANTY, GUARANTEE, OR REPRESENTATION OF ANY KIND WHATSOEVER. ALL OTHER WARRANTIES, INCLUDING BUT NOT LIMITED TO, MERCHANTABILITY AND FITNESS FOR PURPOSE, WHETHER EXPRESS, IMPLIED, OR ARISING BY OPERATION OF LAW, TRADE USAGE, OR COURSE OF DEALING ARE HEREBY DISCLAIMED. NOTWITHSTANDING THE FOREGOING, THERE ARE NO WARRANTIES WHATSOEVER ON ITEMS BUILT OR ACQUIRED WHOLLY OR PARTIALLY, TO BUYER’S DESIGNS OR SPECIFICATIONS. 5. Limitation Of Remedy: SELLER’S LIABILITY ARISING FROM OR IN ANY WAY CONNECTED WITH THE ITEMS SOLD OR THIS CONTRACT SHALL BE LIMITED EXCLUSIVELY TO REPAIR OR REPLACEMENT OF THE ITEMS SOLD OR REFUND OF THE PURCHASE PRICE PAID BY BUYER, AT SELLER’S SOLE OPTION. IN NO EVENT SHALL SELLER BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY KIND OR NATURE WHATSOEVER, INCLUDING BUT NOT LIMITED TO LOST PROFITS ARISING FROM OR IN ANY WAY CONNECTED WITH THIS AGREEMENT OR ITEMS SOLD HEREUNDER, WHETHER ALLEGED TO ARISE FROM BREACH OF CONTRACT, EXPRESS OR IMPLIED WARRANTY, OR IN TORT, INCLUDING WITHOUT LIMITATION, NEGLIGENCE, FAILURE TO WARN OR STRICT LIABILITY. 6. Changes, Reschedules and Cancellations: Buyer may request to modify the designs or specifications for the items sold hereunder as well as the quantities and delivery dates thereof, or may request to cancel all or part of this order, however, no such requested modification or cancellation shall become part of the contract between Buyer and Seller unless accepted by Seller in a written amendment to this Agreement. Acceptance of any such requested modification or cancellation shall be at Seller’s discretion, and shall be upon such and conditions as Seller may require. 7. Special Tooling: A tooling charge may be imposed for any special tooling, including without limitation, dies, fixtures, molds and patterns, acquired to manufacture items sold pursuant to this contract. Such special tooling shall be and remain Seller’s property notwithstanding payment of any charges by Buyer. In no event will Buyer acquire any interest in apparatus belonging to Seller which is utilized in the manufacture of the
14 90
Parker Hannifin Corporation Gear Pump Division Youngstown, OH
Power Wheel® Service Manual Model 6 Single Reduction Wheel Drives
AUBURN, INDIANA 46706-3499 U.S.A.
PHONE: (219) 925-3200 FAX: (219) 925-4725 3 1 2 4 5 6 7
8
11
7 12 13 17
14 16
18 9 10 15
19
24 20
21 22
25
23
26 27 29
30
28
31
OPTIONAL 91
ITEM NO.
DESCRIPTION*
NO. USED IN ASS’Y.
ITEM NO.
DESCRIPTION*
NO. USED IN ASS’Y.
1
Coupling
1
17
Ring Gear
1
2
Input Shaft
1
18
Carrier Assembly
1
3
Spindle
1
19
Sun Gear
1
4
Boot Seal 604401
1
20
Retaining Ring
1
5
Oil Seal 14-00-044-010
1
21
Thrust Washer
1
6
Bearing Cone 04-01-101-35
1
22
Disengage Plunger
1
7
Bearing Cup 04-01-102-12
2
23
1
8
Wheel Bolt
9
“O” Ring 614101 Aluminum Cover 10-00-141-113 Cast Iron Cover 614101
24 Hex Head Bolt (Grade 8)
6-12
Large Cover Aluminum Cover 14-02-039-004 Cast Iron Cover 603915
1
9 10
Flat Washer 14-00-047-002
6-12
25
Hex Head Bolt
8
11
Hub
1
26
Magnetic Plug 14-00-052-002
1
12
Bearing Cone 04-01-101-17
1
27
Disengage Cover 14-02-039-005
1
13
Retaining Ring Kit 14-02-410-003
1
28
Hex Head Bolt 618305
2
14
Retaining Ring 613912
2
29
Quick Disconnect Gasket
1
15
Washer 14-02-193-002
2
30
Quick Disconnect Assembly
1
16
Disengage Spring 14-02-156-001
1
31
Hex Head Bolt
2
* Auburn Gear with part number and order code of drive to obtain the appropriate parts list. Refer to parts list for the specific part numbers and quantities.
Model 6 Power Wheel® Service Kits Part No.
Description
Included Items
14-02-410-003 641008** 641017**
Retaining Ring Kit Bearing and Seal Kit Seal Kit
13 (7 Retaining Rings) 5, 6, 7, 12, 13 and 23 5, 13 and 23
** Indicates kit also includes a tube of sealant, part number 604101. MH422 - 0397
Power Wheel® is a ed trademark of Auburn Gear 92
IDENTIFICATION IMPORTANT: All Power Wheel units and kits are shipped with a nameplate that includes the Auburn Gear part number and order code as shown.
Power Wheel® Example:
ORDER CODE: 6WB13156C PART NO.: 6000236 SERIAL NO.: 143434
AUBURN, IN U.S.A.
In addition to the nameplate, Power Wheel drives are stamped with an identification number which appears on the cover or hub flange as shown. Example:
6000236-A-4-9
When ordering parts, the information included on the nameplate or the stamped identification number is necessary to accurately identify the drive and obtain the correct replacement parts. Once this information has been obtained, Auburn Gear for the appropriate parts list.
DISASSEMBLY OF POWER WHEEL STEP 1
STEP 7
Slide the coupling (1) from splines on input shaft (2).
Remove the input shaft (2) from spindle (3). Remove the retaining rings (14), washers (15), and disengage spring (16) from input shaft (2) only if replacement is required.
STEP 2 Position the assembly upright on face of spindle (3).
STEP 8
STEP 3
Remove the 6 or 12 bolts (9) and washers (10) from hub (11) and remove ring gear (17). It may be necessary to strike ring gear (17) with a rubber mallet to loosen from hub (11).
Remove the disengage cover (27) if necessary. STEP 4 Remove bolts (25) and the large cover (24) from the unit. The thrust washer (21) and the disengage plunger (22) usually remain attached to the large cover (24) when it is removed. Remove thrust washer (21), disengage plunger (22) and “O” ring (23) from the large cover (24). STEP 5 Remove sun gear (19) and thrust washer (20), used in aluminum cover units only, from end of input shaft (2). STEP 6 Remove the carrier assembly (18).
STEP 9 Remove the retaining ring (13) from in front of the bearing cone (12) and lift hub (11) from spindle (3). If bearings are not a loose fit, it may be necessary to press spindle (3) from hub (11). NOTE: Use a retaining ring expander tool to remove retaining ring (13). STEP 10 Remove the oil seals (4) and (5) and bearing cones (6 & 12) from hub (11). Inspect bearing cups (7) in position and remove only if replacement is required.
ASSEMBLY OF POWER WHEEL STEP 1
STEP 5
Press new bearing cups (7) in each side of the hub (11). It is recommended that bearing cups (7) and cones (6 & 12) be replaced in sets.
Assemble a retaining ring (14) in groove opposite pilot end of input shaft (2). Assemble a washer (15), spring (16), a second washer (15), and a second retaining ring (14) in the middle grooves of input shaft (2). Some shafts have a shoulder and require only one retaining ring (14).
STEP 2 Assemble bearing cone (6) into cup (7) at seal end of hub (11) and press a new seal (5) into hub (11). Install boot seal (4) on hub (11) if unit is so equipped.
STEP 6 Assemble the splined end of the input shaft (2) down into spindle (3).
STEP 3
STEP 7
Position spindle (3) upright on bench. Lubricate lips of seals (4 & 5) and lower hub (11) onto spindle (3). Hub (11) should be centered as it is lowered over spindle (3) to prevent seal damage.
Assemble the carrier assembly (18) to spindle (3) at splines.
STEP 4 Assemble bearing cone (12) over spindle (3) and into bearing cup (7). If bearings (6, 7, &12), hub (11) or spindle (3) is replaced, a new retaining ring (13) is required for proper bearing setting. Do not re-use snap ring after it has been installed and removed from unit. Select the thickest retaining ring (13) that can be assembled into the ring groove of the splined end of spindle (3) above bearing cone (12). Bearing should have from .000 – .006 inches of end play when proper retaining ring (13) is installed.
STEP 8 Clean mating surfaces and apply a bead of silicone sealant to face of hub (11) that mates with ring gear (17). {See instructions on sealant package.} Hub (11) is attached to ring gear (17) with 6 or 12 3/8-24 grade 8 hex head cap screws (9) and flat washers (10). Torque cap screws to 52 – 60 lb. ft. (70 – 81 Nm). STEP 9 Assemble sun gear (19) over input shaft (2). Rotate sun gear (19) to align input shaft (2) to gear splines and gear teeth in carrier assembly (18).
2 93
STEP 10
STEP 13
For units with the aluminum cover (24) assemble the small thrust washer (20) over input shaft (2) and against shoulder of input shaft (2).
Assemble the disengage cover (27) with dimpled center protruding out if wheel is to be used to drive the vehicle. Assemble and torque the two 5/16-18 x 1/2 inch bolts (28). Torque bolts to 10 – 20 lb. ft. (13 – 27 Nm).
STEP 11 For units with the aluminum cover (24), lubricate “O” ring (23) and assemble in groove of the disengage plunger (22). Assemble disengage plunger (22) over end of input shaft (2) and against thrust washer (20). For units with cast iron cover (24), lubricate “O” ring (23) and assemble in groove inside cover hole, push plunger (22) into cover with pointed end facing inside of unit.
STEP 14 Invert the Power Wheel assembly and assemble the coupling (1), with counterbore out, to the input shaft (2). STEP 15
STEP 12
After motor is assembled to drive or drive is sealed at spindle, fill with lubricant to proper level and replace all plugs.
Assemble the thrust washer (21) with tangs engaged with cover (24). NOTE: A small amount of grease applied to the back side of thrust washer (21) will hold washer in place. Apply a bead of silicone sealant to end of face of ring gear (17). Assemble cover (24) aligning holes of cover and ring gear. Assemble the eight 5/16-18 x 1 inch hex head bolts (25). Torque bolts to 20 – 25 lb. ft. (27 – 34 Nm).
NOTE: When installing a hydraulic motor to the Power Wheel drive it is necessary to place an “O” ring or gasket (not supplied by Auburn Gear) between the motor and the planetary drive. “O” ring sizes: SAE A 2-042, SAE B 2-155, SAE C 2-159.
CARRIER ASSEMBLIES It is recommended that the carrier assembly (18) be replaced in its entirety to protect the integrity of the Power Wheel drive.
LUBRICATION RECOMMENDATIONS IMPORTANT: POWER WHEEL PLANETARY DRIVES ARE SHIPPED WITHOUT LUBRICANT AND MUST BE FILLED TO THE PROPER LEVEL PRIOR TO START UP. Observe lubrication recommendations given by the original equipment manufacturer. When specific recommendations are not available, use mild extreme pressure lubricant API-GL-5, No. 80 or 90 when filling the Power Wheel under normal temperature ranges between 0 - 120°F (-18 to 49°C). Power Wheel is to be half full of oil when unit is mounted level and horizontal. Use drain and fill plugs located in cover and ring gear. Oil is to be changed after first 50 hours of operation with subsequent changes every 1000 hours or yearly, which ever comes first. If unit is to be operated vertically, if ambient conditions are outside the specified range, or if the oil temperature exceeds 200°F (93°C) Auburn Gear for oil and level recommendations.
TOWING VEHICLE CAUTION: The Power Wheel will not normally be damaged by towing; however, the hydraulic drive components may be damaged unless the Power Wheel is disengaged from the drive motor. Road speeds in excess of 25 MPH should be avoided unless clearly specified to be permissible by the equipment manufacturer.
TO DISENGAGE POWER WHEEL CAUTION: For units equipped with the standard spring disconnect, assemble the disengage cover (27) with the dimpled center protruding inward. For units equipped with the optional quick disconnect, push in center plunger of disconnect.
STORAGE A protective film is applied to the Power Wheel at the factory to prevent rust during shipment. Additional protection may be required if the Power Wheel is to be stored for an extended period of time.
SEALING COMPOUND Silastic RTV732 sealer and General Electric Silimate RTV No. 1473 or RTV No. 1503 are currently recommended for sealing gasket surfaces. Sealant should be applied in a continuous bead, which should be centered on the surface to be sealed but should move to the inside of the hole at each bolt hole location. For service requirements order Auburn Gear part number 604101.
SPECIFICATIONS Maximum intermittent output torque ................................................................................................................................................. 22,000 lb. in. (2,485 Nm) Maximum input speed ....................................................................................................................................................................................... 3,500 RPM Oil capacity ................................................................................................................................................................................................... 25 oz (738 ml) 94 3
ELECTRICAL
95
96
97
98
Adjustable Frequency AC Drive for Fan & Pump Applications FRN 2.xx
Manual
www.abpowerflex.com
99
Chapter 4
Troubleshooting Chapter 4 provides information to guide you in troubleshooting the PowerFlex 400 drive. Included is a listing and description of drive faults (with possible solutions, when applicable). For information on… Drive Status Faults
See page… For information on… 4-1 Fault Descriptions 4-1 Common Symptoms and Corrective Actions
See page… 4-3 4-5
Drive Status The condition or state of your drive is constantly monitored. Any changes will be indicated through the integral keypad.
LED Indications See page 2-3 for information on drive status indicators and controls.
Faults A fault is a condition that stops the drive. There are two fault types. Type Fault Description ➀ Auto-Reset/Run When this type of fault occurs, and A163 [Auto Rstrt Tries] is set to a value greater than “0,” a -configurable timer, A164 [Auto Rstrt Delay], begins. When the timer reaches zero, the drive attempts to automatically reset the fault. If the condition that caused the fault is no longer present, the fault will be reset and the drive will be restarted. ➁ Non-Resetable This type of fault may require drive or motor repair, or is caused by wiring or programing errors. The cause of the fault must be corrected before the fault can be cleared.
100
4-2
Troubleshooting
Fault Indication Condition Drive is indicating a fault. The integral keypad provides visual notification of a fault condition by displaying the following. • Flashing fault number • Flashing fault indicator Press the Escape key to regain control of the integral keypad.
Manually Clearing Faults Step Key(s) 1. Press Esc to acknowledge the fault. The fault information will be removed so that you can use the integral keypad. Access b007 [Fault 1 Code] to view the most recent fault information. 2. Address the condition that caused the fault. The cause must be corrected before the fault can be cleared. See Table 4.A. 3. After corrective action has been taken, clear the fault by one of these methods. • Press Stop if P037 [Stop Mode] is set to a value between “0” and “3”. • Cycle drive power. • Set A197 [Fault Clear] to “1” or “2”. • Cycle digital input if T051-T054 [Digital Inx Sel] is set to option 10 “Clear Fault”.
Automatically Clearing Faults Option / Step Clear a Type 1 fault and restart the drive. 1. Set A163 [Auto Rstrt Tries] to a value other than “0”. 2. Set A164 [Auto Rstrt Delay] to a value other than “0”. Clear an OverVoltage, UnderVoltage or Heatsink OvrTmp fault without restarting the drive. 1. Set A163 [Auto Rstrt Tries] to a value other than “0”. 2. Set A164 [Auto Rstrt Delay] to “0”.
Auto Restart (Reset/Run) The Auto Restart feature allows the drive to automatically perform a fault reset followed by a start attempt without or application intervention. This allows remote or “unattended” operation. Only certain faults are allowed to be reset. Certain faults (Type 2) that indicate possible drive component malfunction are not resettable. Caution should be used when enabling this feature, since the drive will attempt to issue its own start command based on selected programming.
101
Troubleshooting
4-3
Fault Descriptions Type(1)
Table 4.A Fault Types, Descriptions and Actions
No. F2
Fault Auxiliary Input
F3
Power Loss
➁
F4
UnderVoltage
➀
F5
OverVoltage
➀
F6
Motor Stalled
➀
F7
Motor Overload
➀
F8
Heatsink OvrTmp
➀
F12
HW OverCurrent
➁
F13
Ground Fault
➁
F15
Load Loss
➀
F29
Anaput Loss
➀
(1)
➀
Description Auxiliary input interlock is open.
Action 1. Check remote wiring. 2. communications programming for intentional fault. DC bus voltage remained below 1. Monitor the incoming AC line for 85% of nominal. low voltage or line power interruption. 2. Check input fuses. DC bus voltage fell below the Monitor the incoming AC line for low minimum value. voltage or line power interruption. DC bus voltage exceeded Monitor the AC line for high line maximum value. voltage or transient conditions. Bus overvoltage can also be caused by motor regeneration. Extend the decel time or install dynamic brake option. Drive is unable to accelerate Increase P039 - A147 [Accel Time x] motor. or reduce load so drive output current does not exceed the current set by parameter A179 [Current Limit 1]. Internal electronic overload trip. 1. An excessive motor load exists. Reduce load so drive output current does not exceed the current set by parameter P033 [Motor OL Current]. 2. A170 [Boost Select] setting Heatsink temperature exceeds a 1. Check for blocked or dirty heat predefined value. sink fins. that ambient temperature has not exceeded 45°C (113°F) for IP 30/NEMA 1/UL Type 1 installations or 50°C (122°F) for IP20/Open type installations. 2. Check fan. The drive output current has Check programming. Check for exceeded the hardware current excess load, improper A170 [Boost Select] setting, DC brake volts set limit. too high or other causes of excess current. A current path to earth ground Check the motor and external wiring has been detected at one or to the drive output terminals for a more of the drive output grounded condition. terminals. Check for load loss (i.e., a broken Output current has dropped below the level set in A184 [Load belt). Loss Level]. An anaput is configured to 1. Check parameters. fault on signal loss. A signal loss 2. Check for broken/loose has occurred. connections at inputs. Configure with T072 [Ana Loss].
See page 4-1 for a description of fault types. 102
Troubleshooting Type(1)
4-4
No. F33
Fault Auto Rstrt Tries
F38 F39 F40
Phase U to Gnd Phase V to Gnd Phase W to Gnd
➁
F41 F42 F43
Phase UV Short Phase UW Short Phase VW Short
➁
F48
Params Defaulted
F63
SW OverCurrent
➀
F64
Drive Overload
➁
F70
Power Unit
➁
F71
Net Loss
F81
Comm Loss
➁
F94
Function Loss
➁
F100 Parameter Checksum
➁
➁
Description Drive unsuccessfully attempted to reset a fault and resume running for the programmed number of A163 [Auto Rstrt Tries]. A phase to ground fault has been detected between the drive and motor in this phase.
Action Correct the cause of the fault and manually clear.
1. Check the wiring between the drive and motor. 2. Check motor for grounded phase. 3. Replace drive if fault cannot be cleared. Excessive current has been 1. Check the motor and drive output detected between these two terminal wiring for a shorted output terminals. condition. 2. Replace drive if fault cannot be cleared. The drive was commanded to 1. Clear the fault or cycle power to write default values to EEPROM. the drive. 2. Program the drive parameters as needed. Programmed A183 [SW Current Check load requirements and A183 Trip] has been exceeded. [SW Current Trip] setting. Drive rating of 150% for 1 minute Reduce load or extend Accel Time. or 200% for 3 seconds has been exceeded. Failure has been detected in the 1. Cycle power. drive power section. 2. Replace drive if fault cannot be cleared. The communication network has 1. Cycle power. faulted. 2. Check communications cabling. 3. Check network adapter setting. 4. Check external network status. RS485 (DSI) port stopped 1. Check RS485 wiring connection. communicating. 2. Check if a communications adapter or HIM was disconnected. 3. Increase C106 [Comm Loss Time] to an appropriate time for application. 4. Change C105 [Comm Loss Action] to a value other than “0” (fault), if appropriate for the application. P036 [Start Source] is set to Close input to terminal 01 and setting 6. The input to terminal 01 re-start the drive. has been opened. The checksum read from the Set P041 [Reset To Defalts] to option board does not match the 1 “Reset Defaults”. checksum calculated.
103
No. Fault F122 I/O Board Fail
(1)
Type(1)
Troubleshooting
➁
4-5
Description Action Failure has been detected in the 1. Cycle power. drive control and I/O section. 2. Replace drive if fault cannot be cleared.
See page 4-1 for a description of fault types.
Common Symptoms and Corrective Actions Motor does not Start. Cause(s) No output voltage to the motor.
Indication None
Drive is Faulted
Flashing red status light
104
Corrective Action Check the power circuit. • Check the supply voltage. • Check all fuses and disconnects. Check the motor. • that the motor is connected properly. Check the control input signals. • that a Start signal is present. If 2-Wire control is used, that either the Run Forward or Run Reverse signal is active, but not both. • that I/O Terminal 01 is active. • that P036 [Start Source] matches your configuration. • that A166 [Reverse Disable] is not prohibiting movement. Clear fault. • Press Stop • Cycle power • Set A197 [Fault Clear] to option 1 “Clear Faults”. • Cycle digital input if T051 - T054 [Digital Inx Sel] is set to option 7 “Clear Fault”.
4-6
Troubleshooting Drive does not Start from Start or Run Inputs wired to the terminal block.
Cause(s) Drive is Faulted
Indication Flashing red status light
Incorrect programming. None • P036 [Start Source] is set to option 0 “Keypad” or option 5 “RS485 (DSI) Port”. • T051 - T054 [Digital Inx Sel] is set to option 5 “Local” and the input is active. None Incorrect input wiring. See 1-20 for wiring examples. • 2 wire control requires Run Forward, Run Reverse or Jog input. • 3 wire control requires Start and Stop inputs • Stop input is always required. Incorrect Sink/Source DIP switch None setting.
Corrective Action Clear fault. • Press Stop • Cycle power • Set A197 [Fault Clear] to option 1 “Clear Faults”. • Cycle digital input if T051 - T054 [Digital Inx Sel] is set to option 7 “Clear Fault”. Check parameter settings.
Wire inputs correctly and/or install jumper.
Set switch to match wiring scheme.
Drive does not Start from Integral Keypad. Cause(s) Indication Corrective Action Integral keypad is not enabled. Green LED above Start key is • Set parameter P036 [Start not illuminated. Source] to option 0 “Keypad”. • Set parameter T051 - T054 [Digital Inx Sel] to option 5 “Local” and activate the input. I/O Terminal 01 “Stop” input is None Wire inputs correctly and/or install not present. jumper.
105
Troubleshooting
4-7
Drive does not respond to changes in speed command. Cause(s) No value is coming from the source of the command.
Indication The drive “Run” indicator is lit and output is 0 Hz.
Incorrect reference source is being selected via remote device or digital inputs.
None
Corrective Action • Check d301 [Control Source] for correct source. • If the source is an anaput, check wiring and use a meter to check for presence of signal. • Check b002 [Commanded Freq] to correct command. • Check d301 [Control Source] for correct source. • Check d302 [Contrl In Status] to see if inputs are selecting an alternate source. settings for T051 - T054 [Digital Inx Sel]. • Check P038 [Speed Reference] for the source of the speed reference. Reprogram as necessary. • Review the Speed Reference Control chart on page 1-24.
Motor and/or drive will not accelerate to commanded speed. Cause(s) Indication Acceleration time is excessive. None
Corrective Action Reprogram P039 [Accel Time 1] or A147 [Accel Time 2]. Compare b003 [Output Current] with A179 [Current Limit 1]. Remove excess load or reprogram P039 [Accel Time 1] or A147 [Accel Time 2]. Check for improper A170 [Boost Select] setting. b002 [Commanded Freq]. Check d301 [Control Source] for the proper Speed Command. Check P035 [Maximum Freq] to insure that speed is not limited by programming.
Excess load or short None acceleration times force the drive into current limit, slowing or stopping acceleration.
Speed command source or value is not as expected.
None
Programming is preventing the None drive output from exceeding limiting values.
106
4-8
Troubleshooting Motor operation is unstable.
Cause(s) Motor data was incorrectly entered.
Indication None
Corrective Action 1. Correctly enter motor nameplate data into P031, P032 and P033. 2. Enable A194 [Compensation]. 3. Use A170 [Boost Select] to reduce boost level.
Drive will not reverse motor direction. Cause(s) Indication Digital input is not selected for None reversing control.
Digital input is incorrectly wired. Motor wiring is improperly phased for reverse. Reverse is disabled.
None
Corrective Action Check T051 - T054 [Digital Inx Sel] and P036 [Start Source]. Choose correct input and program for reversing mode. Check input wiring. (See page 1-18)
None
Switch two motor leads.
None
Check A166 [Reverse Disable].
Drive does not power up. Cause(s) No input power to drive.
Indication None
Jumper between Power Terminals P2 and P1 not installed and/or DC Bus Inductor not connected.
None
Corrective Action Check the power circuit. • Check the supply voltage. • Check all fuses and disconnects. Install jumper or connect DC Bus Inductor.
107
SLURRY PUMP
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
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128
RECEIVING AND HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2, 3 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4, 5 THERMAL PROTECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 6 MOISTURE DETECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 7 LEAD COLOR CODING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
STANDARD REPLACEMENT SEAL CROSS REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
STANDARD REPLACEMENT O" RING CROSS REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
STANDARD REPLACEMENT SNAP RING CROSS REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
* ) #&%(*$* ** *) $)*(+* %$) )*+ / * &()%$$" $)*"" $ $ %&(* $ * ) '+ &#$* *%(%+"/ %( )*(* $ & *) $)*(+* %$) %( +*+( (($
#%*%() )& $ * ) $)*(+* %$ %%! ( " )* %( &&" * %$ $ ")) (%+&) $ .&"%) %$1&(%% $, (%$#$*) "" (& () %*( *$ " (%$$*) $ %+*( )" (&"#$* )"" &(%(# / $ +*%( 0 " $ )(, " */ $/ %*( (& () &(%(# / * +)*%#( %( $%$1" $ )(, " * ) $*) * " )* $ $ #%*%( -(($*/
©Copyright Reliance Electric Industrial Company, 1996. Revisions to this manual require Hazardous Approval Engineering and/or UL approval. ®Reliance and DutyMaster are ed trademarks of Reliance Electric Industrial Company
0 129
RECEIVING AND HANDLING ACCEPTANCE #*-*0"#'4 $).+ / /#$. ,0$+( )/ !* +/$)" .#$+( )/ !-*( /# /-).+*-//$*) *(+)4 ! )4 *! /# "**. '' !*- $) /# $'' *! '$)" *- 3+- .. - $+/ - (" */# ,0)/$/4 $. .#*-/ * )*/ +/ /# ( 0)/$' /# !- $"#/ *- 3+- .. " )/ (& . ) ++-*+-$/ )*//$*) *) 4*0- !- $"#/ $'' *- 3+- .. - $+/ ! )4 *) ' '*.. *- (" $. $.*1 - '/ - )*/$!4 4*0- !- $"#/ *- 3+- .. " )/ / *) ) - ,0 ./ #$( /* (& ) $).+ /$*) 2$'' ..$./ 4*0 $) *'' /$)" '$(. !*- '*.. *- (" $) .#$+( )/ #*2 1 - /#$. 2$''$)") .. *) *0- +-/ * . )*/ - (*1 /# /-).+*-//$*) *(+)4. - .+*).$$'$/4 $) - $(0-.$)" 4*0 !*- *'' /$*) *! '$(. *- - +' ( )/ *! (/ -$' '$(. !*- '*.. *- (" $) .#$+( )/ (0./ )*/ 0/ !-*( /# '$) ' /-$ $)1*$ )*- .#*0' +4( )/ *! /# '$) ' /-$ $)1*$ 2$/## ' 2$/$)" %0./( )/ *! .0# '$(. . /# --$ - "0-)/ . .! '$1 -4 ! *).$ -' (" #. ) $)0-- ) /# .$/0/$*) $. 0-" )/ *)// /# ) - ./ '$) ' /-$ ' . !!$ !*- ..$./) ' . & + 2-$// ) - *- *! '' .0# *((0)$/$*). UNPACKING ! !$'$/$ . !*- /# .# '/ - *! ,0$+( )/ - )*/ 1$'' - +& (*/*- ) ./*- .#!/ *2) 0)/$' - 4 !*- 0. !/ - 0)+&$)" ) $).+ /$)" /* . /#/ '' +-/. #1 ) - $1 $) "** *)$/$*) /0-) /# (*/*- .#!/ 4 #) /* .0- /#/ /# - )* *./-0/$*). /* !- -*//$*) # (*/*- .#*0' # & !*- *$' ' &. !/ $)" - (*1 !-*( /# -/ ! +*.$/$1 $)$/$*) *! ) *$' ' & $. !*0) -*0) /# .#!/ . ' *- -$1 ) -& / )*/$!4 /# ) - ./ '$) ' /-$ ' . !!$ APPLICATION
- ,0$- 4 *) '' (*/*-. ) '-" '$./ '.. -*0+. ) # . 1$ . - )*/ - *")$5 4 !*- (*/*-. ' .. /#) 0/ - $)'0 4 '$) !*- $/$*)' (*/*- +-*/ /$*) Motors less than 1 HP are supplied with a cautionary label and are suitable on applications where vapor or gas ignition temperatures exceed 280°C. These motors are listed for Class I, Group D only. Reliance Electric stocks common ratings through 100 HP continuous duty submerged in liquid, 15 minutes duty in air at nameplate horsepower. Designs through 250 HP and special continuous in air ratings are also available. (Continuous in Air Designs have a 1.0 Service Factor.) *-(''4 /# - - !*0- *)$/$*). 0-$)" 2#$# .0( -.$' . 2" +0(+ (4 *+ -/ $) ". . *- 1+*-. # ) /# 2 / 2 '' $. $)" 2/ - # ) /# +0(+ (*/*- .. ('4 $. $)" '*2 - *2) /# "0$ -$'. # !'*2 !-*( /# +0(+ $. ) 0-$)" /# $)./''/$*) +-* .. /* $).0- /#/ .*'$. - ' - !-*( /# $.#-" !')" - /* $).0- +-*+ . /$)" # ) '*26' 1 ' 0/*!! *)/-*'. !$' # ) '*26' 1 ' . ).*-. - +*.$/$*) / /# *//*( *! /# +0(+ .. ('4
CONTINUOUS OPERATION GASES OR VAPORS It is the driven equipment manufacturer's responsibility to insure this motor product is properly applied.
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131
When removing impeller warm slightly with a torch and pry impeller off evenly with either small pry bars or a wheel puller. When the submersible pump motor leaves the factory it is ready for installation. No adjustment, venting or oil filling is required. For THREE PHASE motors the only connection to the motor lead cable is the power supply. For SINGLE PHASE motors the motor lead cable and power supply must be properly connected at the Control Box. Motor will operate successfully with frequency not more than 5% and voltage not more than 10% above or below nameplate data. Performance within this range will not necessarily be the same as the established performance at exact rated voltage and frequency. All submersible pump motors will operate in either direction of rotation. To reverse direction of a THREE PHASE motor, interchange any two motor leads at the starter. To reverse direction of rotation of a SINGLE PHASE motor the proper connections must be made in the motor connection chamber; refer to the W/D's supplied in the motor connection chamber and Control Box. Lifting eyes are supplied for purpose of installation and servicing. ' &'* +) %'*'( $ $ ) !'( $#!*#&" % &) Normal care should be exercised to prevent mechaniĆ cal damage to the seal, the frame and the insulated cable.
Surface temperature of motor enclosure may reach temperatures which can cause discomfort or injury to personnel acciĆ dentally coming into with hot surĆ faces. (When installing, protection should be provided by to protect against accidental with hot surface) . On initial start up the motor and pump should be checked for proper rotation prior to final application. The unit is designed to protect all power connecĆ tions against moisture. All Reliance Submersible Pump Motors have a lead connection chamber. - THREE PHASE dual voltage motors have 9 motor leads and SINGLE PHASE dual voltage motors have 8 motor leads in this chamber. All Submersible Pump Motors have 2 thermal proĆ tector leads and 2 moisture sensing probe leads in this chamber. Leads are tagged for easy identification. A conĆ nection diagram is provided in the lead chamber. Motors can be connected for either high or low voltages. (Some motor ratings are built as single voltage units and as such are not reconnectable). The motor lead cable assembly for all Submersible Pump Motors has 3 marked power leads plus two ground leads, two thermal leads and two moisture sensing probe leads in standard cable lengths of 25 feet. Leads are brought through an epoxy sealed conĆ nector providing a mechanically strong water tight seal. The cap and cable assembly are available from Reliance Electric as a replacement part asĆ sembly. When replacing the lead wire cap, care should be taken not to nick or damage the O" ring seal. Replace any damaged or nicked O" rings. ,
LIFT MOTOR ONLY USING BOTH ATTACHMENT POINTS. EYENUTS & EYEBOLTS MUST BE SEATED & IN LINE AS SHOWN BELOW. PREFERRED METHOD - USE SPREADER BAR.
4
692.FF
45° MAX.
3 132
With proper application and installation of monitoring devices, periodic inspection of motor seals is not required. Should a malfunction occur the motor has been equipped with a moisture detection system and thermal protection which will provide advance warning of impending failure allowing the to plan a maintenance program before failure occurs. 1. Reliance Submersible Motors utilize an explosionĆproof Class I, Groups C and D, tandem seal design, with an oil chamber separate from the winding area.
6. When replacement cable assembly is required, order from Reliance Electric Industrial Co. using motor identification number. U/L listed motors must be returned to an authorized Reliance Electric Service Facility for repairs other than to replace the outer seal. (See note on Table of Content page.) To inspect the outer seal proceed as follows: 1. Remove outer snap ring (3), replace as needed.
2. Wound Stators - Reliance Submersible MoĆ tors utilize a wound stator which has been pressed into the frame. The stator insulation system has been designed for the temperaĆ ture and electrical rating involved. If the motor failure is analyzed to encom a winding failure, return the motor to an authorized ReĆ liance Electric Service Shop. 3. Encapsulated Lead Connector Assembly The lead connector assembly has been especially encapsulated to insure integrity of the motor. The connector can be removed from the motor in order to reconnect leads. Should the lead connector assembly be damaged or the integrity of the encapsulation be in question, it is required that a replaceĆ ment lead connector assembly be ordered from Reliance Electric Company.
MOTOR MAY CONTAIN GAS UNDER PRESSURE DUE TO HIGH TEMPERATURES FROM OPERATION WITHOUT BEING SUBMERGED. DISASSEMBLY MAY CAUSE BODILY INJURY. FOR ASSISTANCE A RELIANCE OFFICE. 4. Hardware - All hardware is stainless steel and should be replaced with the same type. 5. If the Conduit Connection is used, a corrosion resistant conduit such as stainless steel is recommended.
2. Remove rotating outer seal (4), replace as needed. 3. Approved lubricating and insulating oil shall meet Reliance approved source sheet 4824Ć 18ĆAF. Manufacturer's materials currently meeting this specification are as follows:
ITEM
MANUFACTURER
MANUFACTURER'S IDENTIFICATION OF MATERIAL
1
Sun Oil Company
Sun Fleet Regular SAE 10W
2
Standard Oil Co.
Sohio 62 SAE 10W
3
Shell Oil Company
Rotella 10 SAE 10W
After assembly, run motor in shaft down position for 30 seconds minimum to one minute maximum to allow seals to seat; then check for oil leakage. In some cases, a slight oil mist will appear around the seal. Wipe clean after test.
Before painting motor, cover exposed seal. Remove any paper, tape, etc., from seal area before crating motor. These motors can be shipped in shaft up or shaft down position. Care must be taken that exposed seal is not damaged during shipment. Carton must protect exposed seal from dirt, dust and damage.
4 133
1. Loosen four bolts, securing lead cable connector (1), two complete turns.
CABLE CONNECTOR
2. Attempt to break the cable connector seal thus relieving gas pressure within the motor. If gas pressure is not relieved loosen the bolts another turn and try again. Continue this process until the pressure is relieved and/or the cap is removed. Be extremely careful until the cable connector assembly is removed. MOISTURE SENSORS (2)
3. Remove cable connector and reconnect to desired voltage as shown on connection diagram inside the cable connector.
OUTER SEAL
OUTER SNAP RING
The cable connector assembly may be removed to reconnect the leads without negating the U/L listing or the warranty.
4. Insulate connectors with 4824Ć13ĆAU heat shrinkable plastic. If the 4824Ć13ĆAU shrinkĆ able plastic is not available, tape may be used, but it should be an oil resistant type. Enough wraps should be used to insure the buildup will be sufficient to prevent the connector from breaking through the insulation. The following procedure should be employed: Five layers of plastic elecĆ trical tape followed by two layers electrical grade woven adhesive tape, such as Mystik 7020 or 3M #27, for oil and abrasion resistance. 5. Place O" ring over fit and coat fit with Chevron SRI grease (not excessive).
MOTOR MAY CONTAIN GAS UNDER PRESSURE DUE TO HIGH TEMPERATURES FROM OPERATION WITHOUT BEING SUBMERGED. DISASSEMBLY MAY CAUSE BODILY INJURY. FOR ASSISTANCE A RELIANCE OFFICE.
6. Place cable connector back on motor, install four bolts, and tighten.
Thermostat leads marked P1 & P2 must be conĆ nected in series with the stop button of the 3Ćwire pilot circuit of the magnetic motor controller, so that the thermostat will open the circuit before dangerous temperatures are reached.
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5 134
Alternating Current
Thermostats are automatic reset for use in a normally closed circuit where the thermostat is connected in series with the holding coil of the magnetic starter. Thermostats provide Over Temperature Protection 2" in accordance with NEMA MG 1Ć12.53. When the motor is so marked locked rotor protection is not provided by the winding over temperature protector. It is suggested that over current protection be used in the motor starter to insure locked rotor protection. !
Volts
Continuous Amperes
Inrush Amperes
110Ć120
3.0
30
220Ć240
1.5
15
440Ć480
0.75
7.5
550Ć600
0.6
6.0 STARTER
P1
AĆC LINE
P2
WARNING
(2)
STOP
MOTOR CONTROLLER MAY HAVE AUTOMATIC OR MANUAL OVERLOAD RESET. DISCONNECT ALL POWER LEADS TO MOTOR WHEN PERFORMING ANY WORK ON MOTOR OR DRIVEN EQUIPMENT.
(1)
L1 L2 L3 AĆC LINE
START
T1 T2 T3
GRD
P2 MOTOR P1
A MANUAL, MOMENTARY START SWITCH IS REQUIRED TO PREVENT AUTOMATIC RESTART OF MOTOR WHEN THERMOSTAT RESETS.
P1 & P2 Normally Closed Thermostat Leads (normally open thermostats are not acceptable to UL) (1) Starter Holding Coil (2) Holding Coil s - N.O.
THERMOSTATS
FIGURE 2 TYPICAL THERMAL PROTECTOR WIRING DIAGRAM
If current through the thermostat will exceed the values listed in Figure 2 an intermediate control circuit relay must be used to reduce the current or the thermostat will not work properly.
MOISTURE DETECTION SYSTEM MOISTURE SENSING PROBES !
IMPORTANT
Reliance Submersible Pump Motors are equipped with moisture detection devices. Failure to properly connect or utilize this system voids motor warranty. Moisture sensing probes, leads marked W1, and W2, must be used in conjunction with an induction relay. This device will detect moisture entering the oil chamber due to failure of the outer seal and, when properly connected to a
warning device, will provide notification of needed maintenance. Integrity of system requires periodic test. CONTROLS AND SIGNAL DEVICES A control and signal device (not supplied by Reliance) must be installed at the job site to complete the moisture detection system. Compatible controls are available from: Charles F. Warrick Co., Normandy Court, Royal Oak, Michigan 48073, (810) 549Ć4900.
6 135
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136
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Normally open load s close and normally closed load s open when the sensor probes detect the influx of moisture within the motor.
#
A normally closed pushbutton and neon indicating lamp are provided as means of checking the moisture sensing components.
#
When the pushbutton is depressed, the indicating lamp will be illuminated to indicate (A) power is supplied to the control, (B) the control is operative, and (C) wiring to the moisture sensing probes in the motor is intact. This procedure should be performed periodically to confirm integrity of circuit.
!
#
! The signal device may be audible (bell, buzzer, horn or siren) or visible (incandescent or neon lamp) or both - a signal device of your choice may be obtained from your local electrical supply house.
"
#
#
It is recommended that upon indication (by warnĆ ing light, etc.,) of outer seal failure that the motor be removed from the installation and the oil and outer seal be replaced as soon as possible.
"
"
WIRING BY WARRICK WIRING BY OTHERS CONTROL ENCLOSURE
If reconditioning is not performed within a 30 day period it is recommended that the inner seal be thoroughly inspected and replaced if required.
#"
When ordering parts or reporting trouble give Sales Office complete Nameplate Data.
Power Cable Control Cable
"
Polyphase
T1
T2
T3
Ċ
Ground
Single Phase
T1
T4
TA
Ċ
Ground
All
P1
P2
W1
W2
Ground
8 137
MAINTENANCE
138
MAINTENANCE PROCEDURES GENERAL MAINTENANCE SCHEDULE SAFETY NOTES: ! LOCK OUT ALL ELECTRICAL POWER BEFORE SERVICING !
Avoid wetting electrical components Bleed off all hydraulic pressure before working on the hydraulic system Keep all safety guards in place Follow all other plant safety steps Keep loose clothing away from moving parts
DAILY TASKS:
Inspect hydraulic reservoir oil level (look for evidence of fluid leaks). Check hydraulic oil temperature after dredge has been operating for at least ½ hour (maximum temperature is 184 F). Check area around auger motor shafts (power off) and clean out as required. Check boom hoist winch cable for wear and cable clamps for tightness. Inspect traverse pulleys for wear. Check lock collar set screws for tightness. Grease idler sheaves (one or two strokes as required). Grease travel guide pulleys. Check for vibration indicating slurry pump or hydraulic system problems. Check for loose fasteners, worn parts or misalignment.
NOTE: Check hydraulic fluid level in sight glass with boom up and power unit off WEEKLY TASKS:
Grease boom trunnions (pivot points) two to three strokes Inspect boom hoist winch bolts for tightness. Inspect hydraulic system for leaks. Check hydraulic filter – clean or replace as necessary. Inspect traverse winch idler sheaves - grease, as required Inspect auger motors and taper locks for wear - using a pry bar, check for movement. Check auger motor seals for leakage (raise head and look for oil around the seal) Inspect slurry pump bearings for wear* – using a pry bar, through suction or discharge, apply a load to the pump impeller and check for movement.
Note: This check might not be practical for some pump installations. Therefore, perform this check if problems in the slurry pump are apparent.
139
Check traverse winch bolts in mounting bracket for tightness. Check auger motor bolts for tightness. Check auger-cutter teeth (if part of assembly) for wear and bolt for tightness. Check cable clamps and fittings.
MONTHLY TASKS
Check traverse gear reducer lubricant level and condition. If Low: Add Oil If Dirty: Change Oil **See Oil and Lubricant specifications below Check boom hoist winch lubricant level and condition. If Low: Add Oil If Dirty: Change Oil **See Oil and Lubricant specifications below Inspect hydraulic lines and hoses for wear and/or leaks.
BIANNUAL TASKS (1000 HOURS)
Change travel winch gear reducer oil. Fill to level plug (capacity is approximately 17 ounces) **See oil specification below. Change boom hoist gearbox oil. Fill to level plug. **See oil specification below. Clean hydraulic system and check air breather cap – clean if necessary. Replace hydraulic return-line filter. Check electric motors (slurry pump and hydraulic drive), slurry pump and the various system components for vibration and wear. Inspect mounts for loose or missing fasteners-tighten or replace as required.
ANNUALLY
Clean off and wash down dredge. Replace or repair all parts of dredge. Repeat any of the above checks and/or inspections appropriate at this interval and perform the necessary maintenance or service as required. OIL AND LUBRICANT SPECIFICATIONS
**OIL SPECIFICATIONS Hydraulic oil for this system should meet the following requirements:
Hydraulic oil: ISO 46 Winch: 80W-90 Gear Oil. Must be EP-rated. Traverse Gear Reducer Lubricant: Pennzoil Synthetic Gear Oil - SAE 75W - 140 Alternate must meet API - GL - 5 specs and be EP - rated.
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Grease Fittings
Oil Drain Plug (In 6 o’clock position)
Oil Level Check & Fill Plug
Photo 10-2 – Travel Winch Idler Sheave Grease Points & Oil Check, Fill & Drain Plugs Hydraulic Motor
Oil Drain Plug
Photo 10-3 - Typical Boom Hoist Winch – Oil Check, Fill & Drain Plugs Oil Level Check & Fill Plug
Auger-Cutter Hydraulic Drive Motor Photo 10-4 - Typical Auger-Cutter Hydraulic Drive Motor 4 141
SPECIFIC EQUIPMENT & COMPONENTS MAINTENANCE SCHEDULE
AUGER SYSTEM
DAILY Clean area around motor shaft (See safety warning below).
WEEKLY Inspect auger out-board bearing for wear. Inspect auger-bearing bolts for tightness Inspect auger cutter blades bolts for tightness Inspect hydraulic hoses and fittings for leaks and wear Inspect hose system for leakage or wear Inspect power cord and control cable (if part of system).
ANNUALLY Replace worn cutter blades Replace hydraulic motor seal and shaft if badly worn or leaking Replace all other worn parts Clean off and wash down dredge. Replace or repair all parts of dredge.
SLURRY PUMP
DAILY Check Boom Hoist winch cable for wear and cable clamp U-bolts for tightness
WEEKLY Check pillow block bearings for wear Grease drive shaft bearings every four hours
BI-ANNUALLY Check other parts for wear
DANGER! Turn Off Electric Power Before Servicing
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TRAVERSE WINCH DRIVE SYSTEM
DAILY Inspect traverse drive pulley for wear Grease idler sheave shafts (one or two strokes as required) Check lock collar set screws for tightness. Grease guide pulley front and rear
WEEKLY Inspect travel cable for wear and cable clamps for tightness. Inspect travel winch bracket bolts for tightness. Inspect travel winch snatch blocks for wear and hardware for tightness.
MONTHLY Check travel winch gear reducer oil level. If low, fill with oil per the specifications listed above.
ANNUALLY Replace travel winch gearbox oil. See recommended oil specifications below. Check drive sheave and idler sheaves for wear and proper alignment. Check for loose hardware items. Check snatch blocks or guide sheaves on head and tail frames for wear. DANGER! Turn off electric power to dredge before servicing. Follow all other plants safety steps. Keep all safety guards in place.
BOOM HOIST WINCH
DAILY Check lift cable for wear Check cable clamps and hardware for tightness
WEEKLY Check lift winch bolts for tightness Check lift cable and clamps for wear
MONTHLY Check winch gear reducer oil. If low, add oil per recommended lubricant
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OTHER COMPONENTS
DAILY Check for evidence of hydraulic oil leaks in motor or hoses
WEEKLY Inspect hydraulic motor and hoses for leakage or wear Inspect power cord and control cable (if part of system)
MONTHLY Inspect all pins Grease boom trunnion (pivot) bearings Wash down dredge as required Check discharge hose gaskets for leakage – replace as required
STORAGE AND WINTER PREPARATION To store for any length of time LWT recommends that the pump volute and discharge plumbing should be drained of liquid. Any hydraulic oil, which is contaminated with water, should be drained and replaced. Floats should be checked for any water infiltration. Any that have accumulated water should be drained and patched. Any flat hose type hose should be well flushed, rolled and stored off the ground away from direct sunlight, excessive hot or cold temperatures and rodents. In climates where freezing weather is likely to occur, the unit should be removed from the pond and stored. If water cannot be entirely removed from the volute, antifreeze should be added at the mix ratio stated by the manufacturer for the anticipated low temperature. REMOVAL FROM STORAGE 1. Check all lubricant oil levels – hydraulic reservoir, winch gear reducer, boom hoist gearbox and slurry pump drive (bearing assembly or electric motor) 2. Check for the presence of water in all oils due to condensation 3. Start unit and run hydraulic system for a minimum of one-half hour 4. Check each hydraulic or electrical function for proper operation 5. Again, check fluid levels and quality of oil 6. Make any final repairs or adjustments to the various systems
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Preventive Maintenance Schedule Dredge operator is responsible for performing all maintenance at each interval without exception. Failure to comply with maintenance will cause component failure and possible warranty termination. If you are uncertain on how to maintain any component, an LWT representative. Hourly Intervals
Daily
Weekly
Monthly Bi-Annually OR AS NEEDED
Annually
Auger System Clean area around motor shaft and inspect for leaks Inspect auger mounting bolts for tightness Inspect auger cutter blade bolts for tightness Inspect hydraulic hoses and fittings for leaks and wear Check auger for stuck debris Replace worn cutter blades Replace hydraulic motor seal and shaft if badly worn or leaking
X X X X
X X X
Slurry Pump Ensure intake is free of clogs or debris
X
Check for motor power cable damage Check other parts for wear
X X
Traverse Winch Drive System Inspect traverse drive pulley for wear Grease idler sheave shafts one or two strokes as required Check lock collar set screws for tightness Grease snatch block pulley(s) Inspect travel cable for wear and cable clamps for tightness Inspect travel winch bracket bolts for tightness Inspect travel winch snatch blocks for wear and hardware for tightness Check travel winch gear reducer oil level Replace travel winch gearbox oil Check drive sheave and idler sheaves for wear and proper alignment
X X X X X X X X X X
Check for loose hardware items
X
Hoist System Inspect hoist cable for wear and cable clamps for tightness
X
Check hoist winch gearbox fluid Check lift winch bolts for tightness Ensure hoist winch operates in correct direction
X X X
PHE/070313 145
Preventive Maintenance Schedule (continued) Daily
Hourly Intervals
Weekly
Monthly Bi-Annually OR AS NEEDED
Annually
Other Components Check for evidence of hydraulic oil leaks in motor and hoses Inspect power cord and control cable Inspect all pins Check discharge hose gaskets for leakage; replace as required Inspect hydraulic reservoir oil level in sight glass Check hydraulic oil temperature after dredge has been operating for at least 30 minutes (Max Temp: 184° F) Check area around auger motor shafts with power off and clean out as required Check for vibration indicating slurry pump or hydraulic system problems Grease boom trunnion (pivot) bearings Check hydraulic filter, clean and replace as necessary Inspect slurry pump bearing for wear Check auger motor bolts for tightness Check cable clamps and fittings Check boom hoist winch lubricant level and condition Change winch gear reducer oil (Max Capacity:17 oz.) Change boom hoist gearbox oil Clean hydraulic system and check air breather cap Replace hydraulic return-line filter Check electric motors for vibration and wear Inspect mounts for loose or missing fasteners, tighten or replace as required Clean off and wash down dredge Reapply anti-foulant to required parts (Min: 4 mils wet, 2.5 mils dry)
X X X X X X X X X X X X X X X X X X X X X X
Cable/Rail System (when used) Check tensiometer reading to ensure proper cable tension, if applicable Check cable clamps and hardware for tightness Grease closed loop sheaves Grease tension cable sheaves Grease all fittings on trolley Inspect cable for damage or wear Inspect and grease closed loop, tension winches, and tensiometers when used
X X X X
X X X
PHE/070313 146
ASSEMBLY/DISASSEMBLY OF AUGER MOTOR DRIVES
Photo 10-5 - Typical Auger Assembly – Taper Lock Bushing Being Inserted into Auger
Splined Taper Lock Bushing
Install & Tighten 2 Set Screws Photo 10-6 - Typical Auger Assembly – Splined Taper Lock Bushing
5 147
DISASSEMBLY/ASSEMBLY OF TRAVERSE WINCH
Shaft set screw
2 each 1” washers
Gear Reducer Shaft
Bearing shaft (1” x 6 ¾”) Photo 10-7 - Typical Traverse Winch Assembly - Drive Sheave and Idler Sheaves Removed 7 5/8” Dia. Sheave
Bearing insert 2 each 1” washers
Photo 10-8 - Typical Traverse Idler Sheave Assembly
6 148
1” lock collar
2 ¼” lock collar
Photo 10-8 - Typical Traverse Winch Assembly – Drive Sheave Removed
Grease Fittings
2 ¼” Lock Collar
Photo 10-9 - Typical Traverse Winch Sheave Assembly NOTE: Tighten all lock collars securely to the shafts. 7 149
Serial Number: R2014‐107‐13‐1027 LWT, LLC 1750 Madison Avenue, New Richmond, WI 54017 WWW.LWTPITHOG.COM
+715‐246‐2888
OFFLOADING THE DREDGE Equipment Needed 4 Cable Slings – Rated at 10 tons 4 Shackles – Rated at 5 tons each 2 50-ft Guide Ropes – For guiding the dredge to prevent dredge from turning while being lifted. Crane (with crew) – An appropriately-sized crane to lift and place the dredge in the water from the closest stable location. Consult with a crane company to determine the size of crane needed. Rigging When unloading the dredge, be sure ONLY authorized personnel are present. Steps: 1. Position crane in a safe and stable area close to the basin. 2. Rig the cable slings and shackles on the lifting lugs of the dredge. 3. Attach the guide ropes at the front and back of the dredge. Have two authorized personnel at these ropes. Their job is to rotate and position the dredge. 4. Attach the slings to the crane. Utilizing proper lifting practices (per rigger) lift the dredge off the truck. This is a picture of an LWT PHE 20HP. All LWT PHE dredges have similar lifting points.
Lifting Points
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Operation and Maintenance Manual This manual should be considered a permanent part of this equipment. It should stay with the dredge while being operated to provide the operator important operating, safety and maintenance information. In the event this dredge is sold, this manual should be given to the new owner to provide them with necessary information for operation and maintenance. For additional copies of this manual, please : Liquid Waste Technology, LLC Attn: Parts & Service Department 1750 Madison Avenue New Richmond, WI 54017 Ph: (715) 246-2888 Fax: (715) 246-2573 All information, illustrations, and specifications in this manual are based upon the latest product information available at the time of printing. LWT reserves the right to make changes at any time without notice.
O & M Manual should remain with the dredge at all times!
2
SAFETY INFORMATION
1
SAFETY PROCEDURES Good safety procedures and practices should be observed at all times to avoid personal injury and lost time due to accidents. We recommend that a safety program with rules governing the assembly, operation and maintenance of the equipment be established and enforced for the benefit of all personnel. The importance of observing and maintaining good safety practices cannot be overemphasized. Appropriate rules and regulations governing the work site should be observed. National, Provincial, State and Industrial laws and applicable regulations should be observed. Safety Symbol This safety alert symbol indicates important safety messages in this manual. When you see this symbol, followed by “DANGER” or “WARNING”, be alert to the possibility of personal injury and carefully read the message that follows. Whenever the word “CAUTION” appears, follow the recommended procedure to avoid injury to personnel and damaging the equipment. Any message preceded by the word “NOTE” is an advisory to emphasize the content of the statement.
WARNING! SHUT OFF ELECTRICAL POWER TO THE DREDGE BEFORE PERFORMING ANY ON-BOARD MAINTENANCE TO ANY OF THE ELECTRICAL, HYDRAULIC OR MECHANICAL SYSTEMS! TURN OFF ELECTRICAL POWER ON-SHORE AND PLACE THE DISCONNECT SWITCH IN THE “DOWN” POSITION ON THE NEMA ENCLOSURE AT THE STERN OF THE DREDGE. THE AMBER INDICATOR LIGHT MUST NOT BE ILLUMINATED WHEN MAINTENANCE IS BEING PERFORMED!
Safety Practices The following safety practices are recommended as minimums to be in effect at all times during dredging operations: 1. Shut down electrical power before performing maintenance or repairs on board the dredge that could result in personal injury due to sudden or unexpected movement(s). 2
CAUTION! Personnel should wear life jackets and hard hats when in the workboat or on board the dredge. WARNING! Always disconnect the ECU before performing any welding on the MudCat. Failure to do so may result in serious injury or death. 2. Before starting the dredge, check to make sure personnel are clear of all machinery that rotates or moves when the dredge is running. 3. Do not operate machinery with safety guards removed. 4. Never attempt to remove an object from the auger cutter or the submersible pump when they are stalled and the hydraulic system is under pressure. 5. Keep the machinery surfaces clean and free of oil or other slippery substance. 6. Check all cables for wear and cable clamps for tightness at least on a weekly schedule. Operating Parameters The following precautions should be observed when operating the dredge: 1. The dredges should not be operated in open or unprotected waterways when the wind velocity exceeds 20 miles per hour. 2. The dredge should not be operated on any waterway when waves exceed 1.5 feet. DANGER! Personnel should not be on board the dredge during electrical storms. Typical Safety Decals and Labels To avoid serious personal injury, observe the various safety decals on the dredge and comply with the message(s). EXAMPLE:
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SPECIFICATIONS
4
SPECIFICATIONS LWT Pit Hog “RUNT” Model RCLPES 40HP with VFD Electric Radio Controlled Dredge
Physical: Flotation –Two cylindrical pontoons, 28” Dia. x 20’-0” O.A.L x 10 gauge steel. Transportation Length - 24’-7 3/8” Transport Width - 8’-2 1/2” with auger motors removed Transportation Height – 6’-1/4” Operational Weight – 5,800 Lbs Maximum Digging Depth - 14’ Operational Draft - 16” Power: 460 VAC, 3 Phases, 60 Hz Electric Power Slurry Pump Electric Motor - 40 Hp Hydraulic System Electric Motor – 10 Hp
Dredge Controls: Radio Remote – Hand Held Transmitter (1000 feet max) Slurry Pump On/Off and Speed Control (VFD) Auger On /Off Travel Forward/Off/Reverse and Speed Control Boom Hoist Up/Down – Upward Elevation Limit Switch Multi-Color Light Tree – Colored Light for each function
Slurry Pump: Hayward Gordon XR4-11-S Pump w/ Submersible Motor Centrifugal, Solids handling Impeller Basic Construction – Super Ni-Hard ASTM A532 Pump Speed – 1750 RPM Suction Diameter – 6 Inches Discharge Diameter – 4 Inches Impeller Diameter, inches - 8.50” Sphere size, inches (max) 4”
Design -Capacity: For 40HP - 900 GPM @ 50 ft head (water)
Auger Head: Auger with Shroud - Welded Steel Construction Helix – 10” Dia. X 9” pitch – 3/8” Thick Flighting Speed 60 RPM Torque 3,400 In.-Lbs. Length, Overall - 8’-2 ½” Cutter Knives – 7 Left Hand and 7 Right Hand
Propulsion: Treble Sheave Hydraulic Winch w/ 3/8” Diameter Wire Rope Hydraulic Motor with Planetary Gear Reducer Drive Traverse Speed Variable from 0 to 30 FPM Hydraulics: Three Circuits – Auger-Cutter, Traverse Winch and Hoist Winch Flow Controls – 3-Position, 4-Way Directional Control Valves w/ Electronic Flow Control for Winch Speed Hydraulic Pump Output @1,750 RPM - 8 GPM Hydraulic Relief Pressure - 1,500 PSI (124 Bar) Hydraulic Reservoir Capacity – 30 US Gallons High Oil Temperature and Low Oil Level Shutdown Switch in Reservoir
Coating System: All weldments shall be sand blasted and given an epoxy powder prime coat followed by a polyester powder top coat for a total coating thickness of 5 mils minimum. Electric motors, hydraulic components etc. are installed as received with coatings applied by the original equipment manufacturer.
Liquid Waste Technology is an innovative leader in the design and manufacture of sludge handling equipment including Auger Dredges, Lagoon Pumpers, Submersible Chopper Pumps, Prop Agitators and Subsurface Land disposal Systems. Call 1-800-2431406, and e-mail at [email protected] or for more information, on the internet at www.lwtpithog.com Rclpes40hp
Rev: 11/21/08 5
GENERAL INFORMATION
6
SERVICE POLICY The service and of LWT equipment in the field is one of our top priorities. We maintain an inventory of most of the replacement parts for our equipment. Whenever possible, we will fill parts orders as quickly as possible.
PARTS The Parts and Service Department’s normal operating hours are 8:00 AM to 4:00 PM (Central Standard Time or GMT -6), Monday through Friday. To place an order for parts, : •
Parts Department at 715-243-2132, toll free 800-243-1406 or via email: [email protected].
To insure we provide assistance specific to your equipment, please provide the following information when ing LWT: Equipment Model
Serial Number
RCLP 40HP
R2014-107-13-1027
If you wish to return an item purchased through the Parts Department, you must have a Return Authorization Number which will be assigned by the LWT Parts Department. A restocking fee may be charged on the returned parts based upon the reason for return. SERVICE For operational questions, troubleshooting assistance, or to schedule on-site service, : •
Customer Service at 715-243-2159, toll free 800-243-1406 or via email: [email protected].
Field service is available at a flat daily rate plus expenses for travel, lodging and meals.
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LIMITED WARRANTY Liquid Waste Technology, LLC; hereinafter referred to as “LWT”, warrants equipment of its manufacture to be free from defects in material and workmanship for a period of one (1) year from the date of startup or twelve (12) months from the date of shipment, whichever occurs first. This limited warranty is effective only if the equipment has been installed and maintained in accordance with LWT’s instructions for the use and service for which it was designed, and is used as directed. This limited warranty does not extend to any condition arising from neglect, misuse, or abnormal use in any manner; or caused by an accident or force majeure; or from failure to properly maintain or service the product or regularly to inspect it; or where it has been modified in any way so as to affect its stability or reliability; or it has been altered or improperly repaired by someone other than LWT or its designee. Due to the widely varying conditions under which LWT products are used or installed, LWT offers no warranty, expressed or implied, as to the length of service life of equipment or parts. This warranty does not extend to such wear parts as, but not limited to, seals, slurry pump wet end components, bearings, tires, or any damages caused by any failure of such parts. Neither does this warranty extend to damages from corrosion due to extremes of either high or low pH, or from other chemical or electrolytic reaction caused by contents in the waters where the equipment is used. Equipment and accessories not manufactured by LWT, which are incorporated into any LWT equipment, are warranted only to the extent of the original manufacturer’s warranty or guarantee. As a condition of this warranty, the customer shall, promptly upon its determination of intent to make any claim against LWT, arising under this warranty, so notify LWT, in writing, specifically describing the part alleged to be defective; and further, upon request from LWT, shall ship such part to LWT, prepaid, as directed by LWT, for inspection by LWT. LWT may, at its discretion, send an authorized service representative, with transportation and expenses prepaid, to the customer’s site to perform such inspection. LWT’s sole obligation under this warranty, upon determination that such defectiveness did in fact exist within the period provided, shall be limited to, at LWT’s expense, either repairing or replacing such defective part. IN NO EVENT SHALL LWT BE LIABLE HEREINUNDER FOR LOSS OR CONSEQUENTIAL DAMAGES OF ANY KIND OR CHARACTER CAUSED BY DEFECTIVE PARTS OR OTHER CHARGES INCURRED BY THE CUSTOMER FOR BREACH OF ANY WARRANTY OR IN THE REPLACEMENT OR REPAIR OF DEFECTIVE PARTS. THIS WARRANTY IS LWT’S SOLE WARRANTY EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED OR STATUATORY IN ORIGIN, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR LIABILITIES ON THE PART OF LWT, AND NO REPRESENTATIVE OF LWT HAS THE AUTHORITY TO CHANGE THE OF THIS WARRANTY IN ANY MANNER WHATSOEVER, AND NO ASSISTANCE BY LWT OR ITS REPRESENTATIVES IN THE REPAIR OR OPERATION OF THE PRODUCTS COVERED BY THIS WARRANTY SHALL CONSTITUTE A WAIVER OF THIS WARRANTY, NOR SHALL SUCH ASSISTANCE EXTEND OR REVIVE IT.
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ACCEPTANCE OF EQUIPMENT Equipment Model
Dredge Serial Number
RCLP 40HP
R2014-107-13-1027
Please initial items reviewed. CUSTOMER
LWT
1. Dredge Appearance
__________
__________
2. Dredge Maintenance
__________
__________
3. Dredge Functions
__________
__________
4. Dredge Operations & Safety
__________
__________
5. Warranty Policy
__________
__________
At completion of the above, Liquid Waste Technology, LLC certifies that all equipment has been reviewed with the representatives of ____________________________________ and is found to be totally satisfactory to all involved parties. Customer Signature: _________________________________________
Date:________________
Print Name: _________________________________________ Email: _________________________________________ Phone: _________________________________________ Address: ________________________________________________________________ Shipping Address: ________________________________________________________________ LWT Signature: _________________________________________
Date:_________________
Print Name: _________________________________________
Liquid Waste Technology, LLC 1750 Madison Avenue New Richmond WI 54017 Phone: (715)246-2888 Fax: (715)246-2573 Email: [email protected] Web: www.lwtpithog.com REV 0412
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OPERATION OVERVIEW
10
OVERVIEW OF DREDGE OPERATION
The LWT Model 40HP RCLPES, an electrically-powered, remotely-controlled, auger dredge is designed to remove sediments from the bottom of natural waterways or man-made such as waste treatment ponds and settling lagoons. Solids that have settled or accumulated within these holding facilities are excavated and transported as slurry through a hose and/or piping system to a remote location. Steel pontoons provide the necessary flotation to the on-board machinery and equipment in the waterway. Principal features include the auger-head, submersible pump, boom, boom hoist, traverse winch, electrical and hydraulic system. The auger-head and the submersible pump are essential for effective solids removal. The boom hoist vertically positions the auger and submersible pump in the sediment while the traversing winch propels the machine forward and backward along a wire rope cable anchored at both ends. This proven design provides one of the most cost-effective means of hydraulically dredging sediments on the market today. Prior to operation of the dredge, an anchored cable harness is established for positioning and propelling the unit in the waterway. Generally, the harness is comprised of two lateral cables located on opposite ends (or sides) of the pond with a traverse cable stretched between them. The traverse cable is threaded through the treble sheave winch and fairlead (cable guide) near the bow and through the lead block (guide sheave) on the tail frame of the dredge. After pre-tensioning the cable to remove the slack, the traverse winch propels the unit in both the forward and reverse directions. After floating discharge hose and/or pipe are connected to the dredge, it is ready to operate. Generally, solids are excavated while traversing forward only. All dredge functions are remotely controlled from shore using a hand-held radio transmitter. A series of push buttons on the transmitter enables the operator to start and stop all on-board equipment. These functions include Dredge Pump “On” or “Off,” Dredge Pump Speed, Auger-Cutter “On” or “Off,” Boom Hoist “Down” or “Up,” Traverse Winch “Forward” or “Reverse,” and Traverse Winch Speed.
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At the starting point, near one end (or side) of the pond, the operator turns on the electrical power to the dredge, lowers the boom, turns the auger on, turns the slurry pump on and increases the speed, sets the travel control forward and adjusts the speed to the desired rate of travel. The dredge travels forward until it reaches the other end (side) of the pond or the operator stops it. At this point, operator raises the head to a position above the material and reduces the slurry pump to approximately one-half speed. NOTE: This keeps the hose pressurized and out of the path of the dredge during the reverse operating cycle. The operator then sets the travel switch in reverse and “dead-heads” the dredge back to the starting point. The traverse speed can be increased during this cycle to save time. Once the far end of the pond is reached, the control settings, including the digging depth or depth of cut, pump “on” and/or speed and traverse speed must be set before starting a new dredging cycle. When all of the bottom sediments have been excavated in a given area, the dredge is laterally repositioned and operations are resumed. This procedure is repeated as many times as necessary until the entire waterway has been cleaned.
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GENERAL OPERATING TECHNIQUE The function and/or operation of the dredge controls and displays are discussed in the Dredge Familiarization and Controls sections. The operator should become familiar with each of the controls and displays, and have a basic understanding of each of these before operating the dredge. With the dredge in position near one end or side of the pond and ready to commence dredging, perform the following steps to start and complete a typical dredge cycle. 1. Check all switches on the handheld radio transmitter to determine that all controls are in the OFF positions. 2. Turn on the shore-based power supply to the dredge. NOTE:
In case of an emergency or when shutting down the dredge, press the red EMERGENCY STOP button on the top left of the radio transmitter.
3. Release the Emergency Stop button on handheld and turn the handheld power switch to ON. Once the handheld transmitter has completed its start-up procedure, turn the power switch to start and release. This will link the transmitter to the receiver. When a link is established, the hydraulic power unit will turn on along with the flashing amber light on the light stack, located on the top of the dredge electrical enclosure. 4. Press the Boom Hoist DOWN switch to lower the boom and auger head. Pressing and releasing the switch will incrementally lower the boom. If shallow cuts are to be made, the boom should only be lowered a couple of feet below the surface of the liquid. When making successive es in the same cut, the boom and auger head must be lowered another increment at the start of the until the maximum digging depth of the dredge is reached. The dredge should not be operated below the maximum depth stated in the specifications. If the pontoons rise slightly out of the water, with the bottom is indicated. To avoid damaging the bottom, raise the boom and auger head assembly slightly until it can be observed that the bow (front) of the pontoons dip slightly into the water. This indicates that the auger is clear of the bottom. NOTE:
In very light sludge, it is best to plunge the auger head into the sludge blanket near the bottom of the pond. This will maximize the solids content of the slurry.
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5. Press the pump ON switch to start the pump. To stop the pump, press the switch a second time. 6. If the dredge is equipped with a VFD, adjust the slurry pump speed as necessary. 7. Press the auger switch to start the auger. To stop the auger, press the switch a second time. MAKE CERTAIN ALL PERSONNEL ARE CLEAR OF THE AREA AROUND THE AUGER HEAD BEFORE STARTING THE AUGER CUTTER. 8. Set the travel winch switch in the FORWARD direction. Jog (press and release) the travel speed increase switch until the appropriate rate of travel is obtained – this is normally 6 to 10 feet per minute while dredging. The maximum rate of travel is 30 feet per minute. If the switch is pressed and held for 7 seconds, this rate of travel will be achieved. Therefore, jog the switch two or three times (or hold for 2 to 3 seconds) and observe the movement of the dredge. If too slow, jog the switch again. If too fast, jog the travel speed decrease switch to slow it down. 9. Observe the operation of the dredge as it moves forward on the travel cable. If everything goes smoothly, no further adjustments will be necessary and the dredge will advance until it reaches the opposite end or side of the pond. At this time the dredge must be stopped and returned to its starting position in the pond. To STOP the dredge, press Travel Forward again. NOTE:
It might be necessary to raise or lower the depth of the auger as the dredge advances if the bottom contour is irregular. If the dredge stops moving forward as indicated by fish-tailing or the stern raising out of the water, raise the boom slightly until it begins to move forward again.
10. Press the slurry pump switch once to stop the pump. NOTE:
If the dredge is equipped with a VFD, it is generally necessary to keep the pump running at about half speed to maintain pressure in the floating discharge line so that it stays out of the path of the dredge when it is traveling in reverse.
11. Press the auger switch once to stop the auger. 12. Press the boom hoist UP switch to raise the boom slightly. 13. Press the travel winch reverse switch to start the dredge moving in the reverse direction.
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NOTE:
It might not be possible to travel in reverse at the maximum rate of speed of 30 feet/minute in some applications. Once the dredge has returned to its starting point, the dredge cycle is complete. Adjust the reverse travel speed so the dredge is moving back as quickly as possible but make sure to reduce speed as you get near the rear stopping point.
14. Repeat steps 3 through 5 to start another cycle. 15. Press the red EMERGENCY STOP button on the top left side of the radio transmitter to shut off the dredge. 16. Place the electrical power disconnect on the shore-based power supply in the OFF position.
DREDGING PRACTICES AND OPERATING HINTS 1. In soft material, both organic and inorganic, and fluid-like sediments, it is oftentimes advantageous to plunge the boom into the material prior to starting the main pump. This minimizes dilution of the slurry and eliminates the pumping of clear fluids. 2. If the auger cutter is stalled due to an obstruction preventing its rotation, the auger hydraulic pressure relief valve, located on the reservoir, will be tripped. This can be difficult to detect when the dredge is unmanned and the controls are shore-based. One indication might be if the dredge fish-tails (moves side to side) or if the dredge starts rising out of the water. Stop the travel winch and try stopping and starting the auger cutter a few times to see if the obstruction can be cleared. If this procedure is successful, start dredging again. 3. If the auger cutter is not cleared after stopping and starting, stop the auger cutter, slurry pump and travel winch. Raise the boom until the auger cutter assembly is accessible at the surface of the water. Press the Emergency Stop switch to shut down all functions and place the shore-based electrical disconnect switch in the OFF position. Go out to the dredge and check the auger circuit hydraulic pressure on the gauge located on the reservoir. If the gauge reads zero pressure, use whatever tools and devices necessary to remove the obstruction from the auger. After removing the obstruction, return to shore, turn the electrical power back on and start the auger cutter. If the auger head is rotating freely, resume dredging. WHENEVER IT IS NECESSARY TO WORK AROUND THE AUGER HEAD, STOP ALL OF THE FUNCTIONS AND PLACE THE POWER DISCONNECT SWITCH ON THE ELECTRICAL IN THE “OFF” POSITION. NEVER WORK AROUND THE AUGER WHEN THE AMBER LIGHT IS FLASHING!
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4. The no-load auger hydraulic circuit pressure is 600 to 700 PSI. In soft materials, there is likely to be only a slight increase in the auger hydraulic circuit pressure when dredging. This pressure can be observed on the pressure gauge mounted on the hydraulic control valve on the power unit. 5. If the material spills over the top or the sides of the auger, slow down the rate of travel or stop travel completely and let the pump and auger continue to operate momentarily. This is most likely to happen when making initial cuts in shallow water. 6. If the discharge line is plugging, it can normally be cleared by stopping the auger, raising the boom slightly and pumping clear liquid. This is most likely to occur when pumping heavy materials such as sand through a long pipeline or to an elevated disposal area, or a combination of these conditions. 7. When cutting in shallow water, cutting a shoreline or cutting materials projecting above the water surface, care should be taken to prevent loss of pump prime. The suction inlet must always be submerged below the liquid surface. In extremely shallow water, it may be necessary to make several forward cuts in order to create adequate depth for the machine to float. It takes approximately 16 inches of water to float the machine. 8. At the end of any operational period the auger head should be raised to its upper limit at or near the surface of the water and water pumped to clear the line. This will also prevent freshly cut areas from collapsing and trapping the auger head. 9. The speed of forward travel varies with the type of material being dredged. Optimum operation matches the auger cutter’s ability to excavate solids at the flow rate of the slurry pump. If the dredge moves into the material too rapidly, the unit may tend to plow materials around or over the auger. If material is more densely packed, the unit may tend to “stand on its nose” and begin to dig down into the solids. Either action would result in an uneven . 10. The travel speed will generally be the most commonly used control to optimize production. It is not possible to pump solids at more concentrated rates than they exist in the solids bed. 11. The pump must be in the sludge to move solids. With lighter sludge it is possible to lower the auger head down to the bottom and excavate a large bank of solids that will continually slough down to the pump. With more rigid or heavier solids it is best practice to take solids in layers with multiple cuts across the waterway at increasingly lower depths. 12. Heavier solids and more viscous slurries require higher pressure to move the slurry through the pipeline. Dilute slurry to increase flow rate.
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DIAGNOSING OPERATING PROBLEMS 1. The flow rate at the end of the discharge pipe is less than it has been. a. Plugging of discharge pipeline. b. Plugging can generally be found by listening to each pipe t while pumping clear liquid. A hissing noise will be heard at the obstruction. Such obstructions can occur at the main pump discharge elbow or in the discharge pipe leading to the side of the machine. Consequently this portion of the discharge piping system should not be overlooked. c. Plugged pump suction. d. Obstruction in the impeller. 2. Vibration of the machine and discharge pipe. a. Obstruction in the pump impeller. 3. Travel cable slipping on winch drive sheave. a. Travel cable is too loose. b. Auger cutter assembly is digging into bottom or it is too deep in material. 4. Loss of pump prime. a. Cutting too close to liquid surface. b. Material viscosity is too thick to flow into the pump. c. Gas entrapped in material is causing vapor binding. HIGH WINDS High winds can affect the dredge, traverse and anchoring system. To counter the effects of the wind on the system while maintaining operations, adjust the lateral movement cables as necessary to align the path of the dredge in the pond. NOTE:
Placing stakes at the ends of the pond will provide reference points for locating the ends of the traverse cable on successive cuts.
If winds are too intensive to operate the dredge, move the dredge unit close to shore and tie it off to a suitable anchor. Check that all electrical cabinets are closed and locked.
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SETUP AND RIGGING
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DREDGE SET-UP, RIGGING & HOSE ASSEMBLY OFF-LOADING THE DREDGE 1. During preparation for launching into the pond, the dredge, floating hose and power cable should be unloaded on the bank close to the starting location. The gussets at the base of the head and tail frames have holes for this purpose. Use a crane of adequate size to handle a 5,800-pound (2630.84 kg) weight at the swing radius required to place the dredge in the pond. Once the dredge and accessories are off-loaded, the preparations prior to launching into the pond can commence. 2. The Status Indicator Signaling Light on the NEMA electrical enclosure is normally removed in preparation for shipping. Install this light on top of the electrical enclosure at the stern of the dredge and connect the wires, (use the plug-in electrical connectors, if provided). 3. Check and tighten all bolted connections that might have loosened during shipment. 4. Wire the 4-conductor power cable and the control cable between the shore based power supply and the NEMA electrical enclosure at the stern (rear) of the dredge in accordance with the electric schematic supplied in this manual. Perform the initial functional tests listed below.
DANGER! ONLY QUALIFIED PERSONNEL SHOULD PERFORM ELECTRICAL WORK! INITIAL DREDGE FUNCTIONAL CHECKS 1. Check the hydraulic oil level on the side of the reservoir. Add oil if necessary. Check plumbing for any visible oil leaks. Oil specifications are listed in the maintenance section. 2. Make sure that the electric motor on top of the reservoir is rotating in the proper direction. A reading of 500 to 700 psi on the hydraulic pressure gauge indicates the motor is rotating in the proper direction. 3. Operate each function; slurry pump, travel winch, auger and boom hoist to assure proper operation and direction.
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INSTALLING TRAVERSE CABLE Note: Refer to Drawing 3856, Sheets 1, 2 & 3 in this section when installing the earth anchors, traverse cable, cable tensioners and related rigging components. 1. Layout the cable harness or rigging to suit the waterway configuration for the best operation (traversing and lateral positioning) of the dredge. Normally, this is in alignment with the length of the pond, but if it’s a long pond, it might be better to set the dredge up across the width of the pond. In most installations, the anchors must be moved and the system re-set to completely dredge a pond. 2. Place the anchor plates on the ground sufficiently far back from the edge of the water so that when the system is tensioned, the lateral move or “pullover” cables form a “V” with the traverse cable. Drive a stake into the ground to hold each of them in place. Attach the cable tensioners and install a wire rope through the body of each device and extend the wire ropes to the point of attachment to the triangle. Note: Do not tighten the tensioners until the traverse cable is attached to the triangles at both ends of the pond and the cable is routed through the winch sheaves on-board the dredge. 3. As the traverse cable 3/8” (1 cm) diameter wire rope is unwound from the reel, it must be fed through the snatch blocks on the head and tail frames of the dredge. Do not feed the cable through the traverse winch sheaves until after it is in place across the pond. After the traverse wire is in place across the pond, but not tensioned, feed it through the winch drive sheave and idler sheaves as shown on the next page. 4. Attach the traverse cable to the triangles using two cable clamps (or two clamps at one end and a cable dog with cable and tensioner at the other) at the ends of the pond. 5. Upon tightening the traverse cable, the dredge will move out onto the waterway. It might be necessary to move the cable dog and/or clamps as the dredge is moved to its starting position. Once the cable is pre-tensioned, the traverse winch can be used to position the dredge at the starting location of the first run prior to beginning operations. Traverse Winch Cable Routing Arrows indicate path of travel cable to guide sheaves on head and tail frames.
Loop cable around bottom of drive sheave & over tops of idler sheaves
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EXAMPLE ONLY
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1 4‐ Cable Grip Hoists: Cable Tensiometer 2 Traverse Cable (Do NOT Cut) 5
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3 Cable Dog: To Grab Cable 4 5‐ 60 foot (18.29 m) Cables (Do NOT Cut) 5 4 sets of Plate Anchors with 4 Stakes
1
1
6 2‐ Cable Clamps 4
4 2 6
2 3
4
1
5
1750 Madison Avenue New Richmond, WI
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INSTRUCTIONS 1. Hook each grip hoist (1) to a stake in the anchor plate (5). 2. Hook the cables (4) onto the red triangle. TRAVERSE CABLE ADJUSTMENT The traverse cable adjustment is made with the traverse cable (2) and the grip hoists (1).
LWT PIT HOG POND DREDGING SCHEME MANUAL LATERAL MOVE LAYOUT
DATE:
8-19-13 REVISED
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1
5
DRAWN BY:
J.J.C. CHECKED BY:
DRAWING NUMBER
3858 2 OF 3
ALL DRAWINGS AND INFORMATION ARE THE PROPERTY OF LWT AND ARE NOT TO BE REPRODUCED OR USED WITHOUT WRITTEN PERMISSION FROM LWT, LLC.
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DREDGE FAMILIARIZATION
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SYSTEM FAMILIARIZATION ELECTRICAL CONTROL
2. Electrical Transformer 460 to 120 VAC 3. Phase 3 Power Connect 1. Radio Transceiver
9. 12V Power Supply
4. Fuses
8. Bottom Sense
7. Function Relays
4. Fuses
6. Hydraulic Motor or-On/Off
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5. Slurry Pump VFD
ITEM DESCRIPTION
1. Radio Receiver Receives the radio signals sent from the remote control transmitter. These signals are interpreted into these commands: a. Hoist up and down b. Auger on and off c. Travel forward and reverse d. Pump on and off e. Travel speed increase and decrease f. Dredge on and off 2. Electrical Transformer Transforms 460 VAC to 120 VAC allowing power to the instrumentation. 3. Phase 3 Power Connect Connects or disconnects the main power source. 4. Fuses Avoids electrical spikes in the system. If the current escalates too high the fuses burn out avoiding any potential damage to sensitive components. 5. Slurry Pump VFD Turns the slurry pump on or off. 6. Hydraulic Motor or-On/Off Turns the electrical motor for the hydraulic system on and off. 7. Function Relays Used to open and close the electronic circuit for the functions on the dredge. 8. Bottom Sense Detects when the auger is touching the bottom of the pond so the boom can be adjusted up and down accordingly. 9. 12V Power Supply Transforms 120VAC into 12VDC allowing power to the instrumentation.
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WARNING LIGHTS - Located on the door of the electrical box. 1. Hydraulic Low/Hot Oil Light Indicates when the hydraulic oil level gets too low or gets too hot which will automatically shut off the dredge. This is to prevent any potential damage to the hydraulic system. 2. Slurry Pump Seal Fail Light Indicates when moisture is detected in the electrical motor of the slurry pump which disables the pump to prevent damage. 2. Slurry Pump Seal Fail Light
1. Hydraulic Low/Hot Oil Light
LIGHT TREE The light tree is located on top of the dredge control . The lights indicate when the dredge is running and what functions are in use. Each light indicates a different dredge function. Amber Light = Hydraulic pump motor is running Blue Light = Travel is running White Light = Auger is running Green Light = Pump is running Red Light = Hoist is running
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TRAVEL WINCH
1. Idler Pulleys
2. Travel Sheave
1. Idler Pulleys Guides the travel cable to the travel sheave. 2. Travel Sheave Moves the dredge forward or in reverse. 3. Idler Pulley Grease Zerks Use to grease the idler pulleys which should be greased every shift with high quality EP rated grease. 4. Travel Winch Gear Box Houses the reduction gears that increase the torque of the motor and also allows the dredge to travel within the correct speed limits. 5. Travel Winch Motor Moves the dredge forward or in reverse. 3. Idler Pulley Zerks
4. Travel Winch Gear Box
5. Travel Winch Motor
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FRONT OF DREDGE
2. Bottom Sense Load Cell
1. Boom Hoist Winch
1.
Boom Hoist Winch: Raises and lowers the boom.
2. Bottom Sense Load Cell: Sends signal to the shore control of the cutterhead weight to determine whether it’s on the bottom of the pond, so the cutterhead can be automatically raised or lowered. 3. Travel Guide Pulley: Guides the travel cable to keep the dredge from moving side to side. 4. Travel Proximity Switch: Automatically stops the dredge when it reaches the target stop on either end of the
4. Travel Proximity Switch 3. Travel Guide Pulley
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HYDRAULIC SYSTEM
3. Electric Motor
2. Low Oil/Hot Oil Shutoff Switch
4. Return Filter Housing
1. Hydraulic Oil Tank 5. Oil Level/ Temperature Gauge
1. Hydraulic Tank Houses the hydraulic oil. 2. Low Oil/Hot Oil Shutoff Switch Senses when the oil is too hot or too low. If either of these conditions exist the dredge automatically shuts off and indicator on rear will be lit. 3. Electric Motor Drives the hydraulic pump to provide hydraulic oil flow to the necessary components. 4. Return Filter Housing Houses the return filter that filters the oil that returns to the tank as the oil circulates through the system. 5. Oil Level/Temperature Gauge Used for checking the hydraulic oil level and temperature.
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VALVE BANK 1. Manual Overrides - Red Buttons Used when there is a need to manually actuate the flow control valves. 2. Solenoid Valves Electronically controlled valves used to turn on and off the flow of hydraulic oil. 3. System Pressure Gauge Displays the pressure of the hydraulic system. 4. Travel Speed Flow Control Varies the flow of hydraulic oil to the travel circuit which allows the dredge to go slower or faster; 0-100% speed.
4. Travel Speed Flow Control
1. Manual Overrides
2. Solenoid Valves 3. System Pressure Gauge
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CUTTERHEAD Excavates the material and brings it to the center of the shroud feeding the pump suction pipe. 1. Auger Motor There are two auger motors, one on each side of the cutterhead, which rotate the auger in the forward direction. 2. Auger Shroud Reduces the amount of turbidity caused by the auger head and keeps excessive water from being mixed into the slurry. 3. Auger Teeth Aid in the excavation process and are constructed out of hardened steel and lined with a carbide tip. The teeth are replaceable. 4. Auger This is the main part of the excavation process and conveys the sludge toward the center of the shroud. 2. Auger Shroud 4. Auger 1. Auger Motor
3. Auger Teeth
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C O N TR O L S
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DREDGE CONTROLS Handheld Remote Control
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REMOTE CONTROL BUTTON FUNCTIONS 1. Emergency Stop Button—Red button located at bottom of remote control.
Press the Emergency Stop button to shut off power to the dredge in an emergency or when completely shutting down operations—for example, at the end of a shift. If operations are being momentarily suspended, it isn’t necessary to depress this button unless maintenance or repairs of the dredge are forthcoming. Under normal operating conditions, use the individual buttons to shutdown the various functions.
2. Radio Transmitter and Hydraulic Power Unit On and Shift Button – Green button located at top of remote control.
Press the button to energize the radio transmitter and start the motor on the hydraulic power pack. This button must be re-set whenever the Emergency Stop Button has been used to shutdown electrical power.
Bottom Sense is not installed on this dredge and does not perform any functions.
WARNING! The Radio Transmitter Power Button only starts the electric motor on the hydraulic power pack—the Power Disconnect switch must be thrown to shut-off electrical power to the dredge. NOTE: When the Emergency Stop Button is pressed, all functions on the dredge are completely shut down but there is still live power present. The individual buttons must be re-activated to send power to the various functions. 3. Hoist Up/Down Buttons
Pressing and releasing these buttons raises and lowers the boom. Press the “Up” button to raise the boom and press the “Down” button to lower the boom. The boom (and auger-head) remains in the position in which it is placed when the buttons are released when Bottom Sense is not active.
4. Dredge Pump On/Off Button
The Dredge Slurry Pump speed is 1,450 RPM. Press the Slurry Pump button once to “Start” the slurry pump. Press the Slurry Pump button a second time to stop the slurry pump.
NOTE: Turning the slurry pump on/off repeatedly may cause serious damage to the system.
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5. Dredge Pump Speed Buttons
The dredge pump speed is variable from 0 to 1,450 RPM. With the pump on press and hold the pump “Increase” button to increase the speed. It takes approximately 10 seconds to reach maximum speed; so holding the button for 30 seconds will assure that the pump is at full speed. Of course, a lesser speed can be selected, if desired. Conversely, press and hold the “Decrease” button to reduce the pump speed. Pressing and releasing either of the buttons can select intermediate speeds.
6. Auger On/Off Button
Press the “Auger” button once to start the auger cutter. Press the “Auger” button a second time to stop the auger cutter.
7. Traverse Winch Forward/Reverse Buttons
Press the “Forward” button to traverse in the forward direction. Press the “Reverse” button to traverse in the reverse direction. This button only determines the direction of travel, not the speed. When the dredge is in motion pressing either button will stop the travel.
8. Travel Speed Increase and Decrease Buttons
The “Travel Speed” buttons enable the operator to vary the speed from 0 to 30 feet (9.144m) per minute. Press and hold the “Increase” (INC) button to increase the rate of travel or press and hold the “Decrease” (DEC) button to decrease the rate of travel. If starting at 0, and the button is held for seven seconds, the dredge will be traveling at its maximum rate of speed. While dredging, the likely rate of travel will be in the range of 6 to 10 feet (1.8288 to 3.048 m) per minute. Therefore, press and release the button after only two to three seconds.
9. Bottom Sense On/Off Buttons
Simultaneously press the “Shift” button and Bottom Sense “On” button to activate the Bottom Sense feature of the dredge. Simultaneously press the Shift button and the Bottom Sense Off button once to deactivate the Bottom Sense feature.
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CONTROLS, GAUGES AND MONITORS ON THE DREDGE 1. Service Entrance Disconnect Switch The Service Entrance Disconnect Switch is located in the NEMA 4 electrical enclosure at the stern (rear) of the dredge. Place the switch in the “On” position to provide electrical power to the on-board motors, radio receiver and hydraulic valve(s). Place the switch in the “Off” position to turn off the electrical power.
DANGER! DISCONNECT THE POWER SUPPLY ON-SHORE AND OBSERVE THAT THE AMBER RUN LIGHT IS NOT FLASHING BEFORE PERFORMING ANY ELECTRICAL WORK ON THE DREDGE! QUALIFIED ELECTRICAL PERSONNEL SHOULD DO WORK ONLY 2. Light Tree Located on top of the dredge control these light will indicate when the dredge is running and what functions are in use. The different colored lights indicate the following: Amber light— hydraulic pump motor is running Blue light— travel is running White light— auger is running Green light— pump is running Red light— hoist is running 3. Moisture Detection Light The red light on the door of the NEMA enclosure at the stern of the dredge illuminates when the Mody Pump Moisture Detection System detects moisture in the motor oil chamber due to the failure of the lower seal and /or breach of the stator housing. 4. Hydraulic Oil Pressure Gauge (On hydraulic control valve block) System and relief pressures are indicated on the gauge. Systems are designed to operate at pressures up to 1,750 psi. If any of the hydraulic functions (auger, winch drive or boom hoist) stall, the relief valve pressure setting of 2,000 psi is indicated. NOTE: The relief valve pressure is set at the factory and should not be adjusted by operating or service personnel in the field. Changes in this setting can affect dredge performance, operational safety and will void the warranty. the factory before making any changes to the hydraulic system. 5. Hydraulic Oil Level Gauge Indicates oil level in reservoir. Fill as required. 6. Hydraulic Oil Temperature Gauge Indicates hydraulic oil temperature in reservoir. Temperature should not exceed 184°F.
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GENERAL OPERATING TECHNIQUE SETTING THE CONTROLS Refer to the photo on first page of this section for identification and location of the various Radio Transmitter Controls discussed below. The operator should become familiar with the each of the controls and displays and have a basic understanding of each of these before operating the dredge. With the dredge in position near one end (or side) of the pond and ready to commence dredging, perform the following steps to start and complete a typical dredge cycle: 1. Turn on the shore-based power supply to the dredge. NOTE: IN CASE OF AN EMERGENCY, OR WHEN SHUTTING DOWN THE DREDGE, PRESS THE RED EMERGENCY STOP BUTTON ON THE BOTTOM OF THE RADIO TRANSMITTER! 2. Press the Green button at the top of the control to start hydraulic pump motor on the dredge. When hydraulic pump motor is running the amber light is flashing. Dredge is now ready to start all other functions. 3. Press the Boom Hoist “Down” button to lower the boom with the auger-head af fixed to its lower end. Pressing and releasing the button will incrementally lower the boom. If shallow cuts are to be made, the boom should only be lowered a couple of feet below the surface of the liquid. When making successive es in the same cut, the boom (and auger-head) must be lowered another increment at the start of the . The maximum digging depth of the dredge is 15 feet. The dredge should not be operated below this depth. If the pontoons raise slightly out of the water, with the bottom is indicated. To avoid damaging the bottom, raise the boom (and auger-cutter assembly) slightly until it can be observed that the bow (front) of the pontoons dip slightly into the water. This indicates that the auger-cutter is clear of the bottom. NOTE: In very light sludge, it is best to plunge the auger head into the sludge blanket near the bottom of the pond. This will maximize the solids content of the slurry. 4. Press the Pump “ON” button to start the pump. To stop the pump, press the button a second time. 5. If necessary, adjust the slurry pump speed. See the discussion in Section V regarding setting the slurry pump speed. 6. Press the Auger button to start the auger-cutter. To stop the auger-cutter, press the button a second time.
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DANGER! MAKE CERTAIN ALL PERSONNEL ARE CLEAR OF THE AREA AROUND THE AUGER-HEAD BEFORE STARTING THE AUGER CUTTER! NOTE: It might be necessary to raise or lower the depth of the auger-head as the dredge advances forward if the bottom contour is irregular. If the dredge stops moving forward and the winch is spinning on the travel cable, raise the boom slightly until it begins to move forward again. 7. Set the Travel Winch button in the Forward direction. Jog (press and release) the Travel Speed Increase button until the appropriate rate of travel is obtained – this is normally 6 to 10 feet per minute while dredging. The maximum rate of travel is 30 feet per minute. If the button is pressed and held for 7 seconds, this rate of travel will be achieved. Therefore, jog the button two or three times (or hold for 2 to 3 seconds) and observe the movement of the dredge. If too slow, jog the button again. If too fast, jog the Travel Speed Decrease button to slow it down. 8. Observe the operation of the dredge as it moves forward on the travel cable. If everything goes smoothly no further adjustments will be necessary and the dredge will advance forward until it reaches the opposite end (side) of the pond. At this time, the dredge must be stopped and returned to its starting position in the pond. 9. Press the Slurry Pump button once to stop the pump. Note: Generally, it is necessary to keep the pump running at about half speed to maintain pressure in the floating discharge line so that it stays out of the path of the dredge when it is traveling in reverse. 10. Press the Auger button once to stop the auger cutter. 11. Press the Boom Hoist “UP” button to raise the boom slightly. 12. Press the Travel Winch Reverse button to start the dredge moving in the reverse direction. 13. If the dredge isn’t traveling in reverse at a decent rate of speed, jog the Travel Speed Increase button until it is. Note: It might not be possible to travel in reverse at the maximum rate of speed of 30 feet/minute in some applications. Once the dredge has returned to its starting point, the dredge cycle is complete. 14. Repeat steps 4 through 7 to start another cycle. 15. Turn off all buttons on the radio transmitter at the end of operations. 16. Press the Red (Emergency Stop Button) at the bottom of the radio transmitter to shut-off the electrical power to the hydraulic pump motor. 17. Place the electrical power disconnect on the shore-based power supply in the “OFF” position.
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DREDGING PRACTICES AND OPERATING HINTS 1. In soft materials (both organic and inorganic) and fluid like sediments, it is often times advantageous to plunge the boom into the material prior to starting the main pump. This minimizes dilution of the slurry and eliminates the pumping of clear fluids. 2. If the auger-cutter is stalled, due to an obstruction preventing its rotation, the auger hydraulic pressure relief valve (located on the reservoir) will be tripped. This can be difficult to detect when the dredge is unmanned and the controls are shore-based. One indication might be if the dredge “fish tails” (moves side to side) Stop the travel winch and try stopping and starting the auger-cutter a few times to see if the obstruction can be cleared. If this procedure is successful, start dredging again. 3. If the auger-cutter is not cleared after stopping and starting, stop the augercutter, slurry pump and travel winch. Raise the boom until the auger-cutter assembly is accessible at the surface of the water. Press the Emergency Stop switch to shut down all functions and place the shore-based electrical disconnect switch in the OFF position. Go out to the dredge and check the auger circuit hydraulic pressure on the gauge located on the reservoir. If the gauge reads zero pressure, use whatever tools and devices are necessary to remove the obstruction from the auger. After removing the obstruction, return to shore, turn the electrical power back on and start the auger-cutter. If the auger head is rotating freely, resume dredging. DANGER! WHENEVER IT IS NECESSARY TO WORK AROUND THE AUGER-HEAD, STOP ALL OF THE FUNCTIONS AND PLACE THE POWER DISCONNECT SWITCH ON THE ELECTRICAL IN THE “OFF” POSITION. NEVER WORK AROUND THE AUGER WHEN THE AMBER LIGHT IS FLASHING! 4. The no-load auger hydraulic circuit pressure is 600 to 700 PSI. In soft materials, there is likely to be only a slight increase in the auger hydraulic circuit pressure when dredging. This pressure can be observed on the pressure gauge mounted on the hydraulic control valve on the power unit. 5. If the material spills over the top or the sides of the auger, slow down the rate of travel or stop travel completely and let the pump and auger continue to operate momentarily. This is most likely to happen when making initial cuts in shallow water.
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6. If the discharge line is plugging it can normally be cleared by stopping the auger, raising the boom slightly and pumping clear liquid. This is most likely to occur when pumping heavy materials such as sand, through a long pipeline or to an elevated disposal area, or the combination of these conditions. 7. When cutting in shallow water, cutting a shoreline or cutting materials projecting above the water surface, care should be taken to prevent loss of pump prime. The suction inlet must always be submerged below the liquid surface. In extremely shallow water, it may be necessary to make several forward cuts in order to create adequate depth for the machine to float. It takes approximately 16 inches of water to float the machine. 8. At the end of any operational period the auger-head should be raised to its upper limit at or near the surface of the water. 9. The speed of forward travel varies with the type of material being dredged. Optimum operation matches the auger-cutter’s ability to excavate solids at the flow rate of the slurry pump. If the dredge moves into the material too rapidly, the unit may tend to plow material around or over the auger. If material is more densely packed, the unit may tend to "stand on its nose" and begin to dig down into the solids. Either action would result in an uneven . 10. The travel speed will generally be the most commonly used control to optimize production. It is not possible to pump solids at more concentrated rates than they exist in the solids bed. 11. The pump must be in the sludge to move solids. With lighter sludge it is possible to lower the auger head down to the bottom and excavate a large bank of solids that will continually slough down to the pump. With more rigid or heavier solids it is best practice to take solids in layers, with multiple cuts across the waterway, at increasingly lower depths. 12. Heavier solids and more viscous slurries require higher pressure to move the slurry through the pipeline. Dilute slurry to increase flow rate.
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DIAGNOSING OPERATING PROBLEMS 1. The flow rate at the end of the discharge pipe is less than it has been. Plugging of discharge pipeline. Plugging can generally be found by listening to each pipe t while pumping clear liquid. A hissing noise will be heard at the obstruction. Such obstructions can occur at the main pump discharge elbow, or in the discharge pipe leading to the side of the machine. Consequently, this portion of the discharge piping system should not be overlooked. Plugged pump suction. Obstruction in the impeller. 2. Vibration of the machine and discharge pipe. Obstruction in the pump impeller. 3. Travel cable slipping on winch drive sheave. Travel cable is too loose. Auger-cutter assembly is digging into bottom or it is too deep in material. 4. Loss of pump prime. Cutting too close to liquid surface. Material "viscosity" too thick to flow into the pump. Gas entrapped in material is causing vapor binding. HIGH WINDS 1. High winds can affect the dredge, traverse and anchoring system. To counter the effects of the wind on the system while maintaining operations: 2. Adjust the lateral movement cables as necessary to align the path of the dredge in the pond. Note: Placing stakes at the ends of the pond will provide reference points for locating the ends of the traverse cable on successive cuts. If winds are too intensive to operate the dredge: 1. Move the dredge unit close to shore and tie it off to a suitable anchor. 2. Make sure all electrical cabinets are closed and locked.
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* Refer to Special Functions Section for functionality.
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Receiver Logic Dredge Emergency Stop Output– The Dredge Emergency Stop Output is on when there is a link with the transmitter and off when the transmitter’s stop button is pressed. If the transmitter goes out of range or the batteries die the Dredge Emergency Stop Output remains on. When the Dredge Emergency Stop Output is off all outputs are shut off. Bottom Sense Output– The Hoist Up/Down outputs are disabled and the Hoist Run Light is enabled whenever the Bottom Sense Output is on. Hoist Up Limit Input– When the Hoist Up Limit Input is off for 250ms, the Hoist Up and Pump outputs are disabled. Forward Travel Limit Input– If the Forward Travel Output is off and the Forward Travel Limit Input is off for 250ms, the Forward Travel Output is disabled. If the Forward Travel Output is on and the Forward Travel Limit Input is off for 250ms, the Forward Travel Output will be set off for 3 seconds then the Reverse Travel Output will be set on. Reverse Travel Limit Input– If the Reverse Travel Output is off and the Reverse Travel Limit Input is off for 250ms the Reverse Travel Output is disabled. If the Reverse Travel Output is on and the Reverse Travel Limit Input is off for 250ms, the Dredge Emergency Stop Output and all other outputs are shut off and will remain off. All outputs will be disabled until the transmitter’s stop button is pressed and the link is reestablished.
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48
49
50
51
52
53
HYDRAULICS
54
1 2 3 4 5
1 REF 1 REF REF
PART NUMBER 8000847 8001107 8000819 NONE NONE
6 7 8 9 10 11 12
REF REF 1 1 1 1 REF
NONE NONE 8001081 8000824 8001084 8000826 NONE
Washer, 1|2" Flat, Fender., 316SS Washer, 1|2" Flat, USS Std., Galv. PUMP, HYDRAULIC COMM 1.55CIR COUPLING, 1.375 DRIVE SHAFT COUPLING, DRIVE, .875, .25 KEY INSERT, DRIVE COUPLING 270H Bolt, 3|8-16 UNC x 0.75" Lg., Hex Head, Gr.5, Pltd.
-
13 14
1 1
1105536 1105095
FIITTING, HYD. 6405-20-16 Fitting, F6400-08-16
-
15 16
1 2
-
17 18 19 20 21
1 1 1 REF REF
0007256 8000812 0005572 NONE NONE
TUBE, SUCTION, 8.5" FILTER, HYDRAULIC MOUNT, FILTER, HYD TANK, RUNT Bolt, 3|8-16 UNC x 0.5" Lg., Hex Head, Gr.5, Pltd. Washer, 3|8" Lock, Reg. Pltd.
22 23 24
REF 1 1
NONE 0006113 1105377
Washer, 3|8" Flat, USS Std., 316SS SWITCH, LOW OIL-HI TEMP ASSY 6.6" Fitting, F6801-08
25 26
1 2
8000797 110-1022
GAUGE, OIL LEVEL & TEMP, Zinga #SG-05-A-T Plug, Pipe 3|4"-14 NPT, Black
REV ITEM NO. QTY.
GENERAL NOTES: 1.
ALL DIMENSIONS IN PARENTHESIS ARE FOR REFERENCE ONLY UNLESS NOTED OTHERWISE
2.
BREAK ALL SHARP EDGES, REMOVE ALL BURRS AND SCALE, UNLESS NOTED OTHERWISE.
A -
-
2
ORIENTATE ITEM MOTOR AS SHOWN
9
11
2
10
4
DESCRIPTION MOTOR, ELEC, 10HP W/DRIP MOUNT, MOTOR TO HYD PUMP Bolt, 1|2-13 UNC x 1.75" Lg., Hex Head, Gr.5, Pltd. Washer, 1|2" Lock, Reg. Pltd.
80003218-028 HOSE 08 3000 08FJX-08FJX GATES M3K 1105089 Fitting, F6400-08
23
5 6
5
4
6
16
20
6
18
20
21
22
3
4
18
8
16
3
20
GASKET SILICONE BETWEEN TANK AND MOTOR MOUNT
21
12
16
13
19
14
22
19
GASKET
24 25
15 1
17 25
2
26 1 1
26 24 23
26
55
REV.
ECN#
BY
THIS DRAWING INCLUDES PROPRIETARY DATA WHICH IS TH EXCLUSIVE PROPERTY HYDRAULIC TANK, ASSY OF LIQUID WASTE TECHNOLOGY, LLC NO DISCLOSURE OR REPRODUCTION ALLOWED WITHOUT WRITTEN CONSENT LWT RUNT OF LIQUID WASTE TECHNOLOGY, LLC. THIS PRINT IS NOT TO BE COPIED IN DO NOT SCALE- ALL DIMENSIONS SHOWN WITHOUT WHOLE OR IN PART OR USED DIMENSI0N LINES REFER TO DATUM LINE MARKED "0". DESIGNED RML DETRIMENTALLY TO THE INTEREST OF *ALL DIMENSIONS ARE IN INCHES UNLESS NOTED.* LIQUID WASTE TECHNOLOGY, LLC DRAWN RML *TOLERENCES (UNLESS OTHERWISE SPECIFIED) GENERAL FABRICATION: 1/16" ANGULARITY 0 -30' 2008 ©LIQUID WASTE TECHNOLOGY, LLC MACHINE SURFACE TEXTURE: REVIEWED MACHINE TOLERENCES: SUPERCEDES ACAD .XX .030" APPROVED .XXX .015" DATE APP'D REFERENCE P/N .XXXX .005" YEAR
LIQUID WASTE TECHNOLOGY, LLC 1750MADISON AVENUE NEW RICHMOND, WI (715)246-2888*FAX (715)246-2537
SHEET: 7/9/2008 7/9/2008
1 OF 2
SCALE: EST. WEIGHT:
1:4
SHEET SIZE
D
REV.
589.10
PART NUMBER/ DRAWING NUMBER:
0005841
B
26
2
19
2
18
20
21
22
25
16
24
1
23
2 2
6
5
23
4
18
24 2
26 16
25 1
3
12
8
SIDE OF ITEM 1. REMOVED FOR CLARITY
14 13 15 1
1
17
26 26
56
THIS DRAWING INCLUDES PROPRIETARY DATA WHICH IS TH EXCLUSIVE PROPERTY HYDRAULIC TANK, ASSY OF LIQUID WASTE TECHNOLOGY, LLC NO DISCLOSURE OR REPRODUCTION ALLOWED WITHOUT WRITTEN CONSENT LWT RUNT OF LIQUID WASTE TECHNOLOGY, LLC. THIS PRINT IS NOT TO BE COPIED IN DO NOT SCALE- ALL DIMENSIONS SHOWN WITHOUT WHOLE OR IN PART OR USED DIMENSI0N LINES REFER TO DATUM LINE MARKED "0". DESIGNED RML DETRIMENTALLY TO THE INTEREST OF *ALL DIMENSIONS ARE IN INCHES UNLESS NOTED.* LIQUID WASTE TECHNOLOGY, LLC DRAWN RML *TOLERENCES (UNLESS OTHERWISE SPECIFIED) GENERAL FABRICATION: 1/16" ANGULARITY 0 -30' 2008 ©LIQUID WASTE TECHNOLOGY, LLC MACHINE SURFACE TEXTURE: REVIEWED MACHINE TOLERENCES: SUPERCEDES ACAD .XX .030" APPROVED .XXX .015" REFERENCE P/N .XXXX .005"
LIQUID WASTE TECHNOLOGY, LLC 1750MADISON AVENUE NEW RICHMOND, WI (715)246-2888*FAX (715)246-2537
SHEET: 7/9/2008 7/9/2008
2 OF 2
SCALE: EST. WEIGHT:
1:4
SHEET SIZE
D
REV.
589.10
PART NUMBER/ DRAWING NUMBER:
0005841
B
NOTES: 1. SPEEDS SHOULD BE TOWARD NOMINAL & UPPER RANGE WHEN NEW AND NO LOAD. 2. SPEEDS MAY BE TOWARD LOWER RANGE UNDER LOAD & FACTORED BY .90 WITH AGE.
COMPONENTS ITEM
QTY
PART NO.
1
1
0005841
HYDRAULIC TANK ASSEMBLY, PHE - 60 HZ, FSC VALVE
2
1
0005207-02
HYDRAULIC CUTTER CIRCUIT, PHE - 60 HZ, FSC VALVE
3
1
0005207-03
HYDRAULIC TRAVEL CIRCUIT, PHE - 60 HZ, FSC VALVE
4
1
0005207-04
HYDRAULIC LIFT CIRCUIT, PHE - 60 HZ, FSC VALVE
5
1
0005207-11
HYDRAULIC COMMON CIRCUIT, PHE - 60 HZ, FSC VALVE
DESCRIPTION
3
9.80 CIR GEAR RATIO 5.05 : 1
2 AUGER 6 GPM 60 - 80 RPM
EC1
P
SV1 M
PRESSURE GAUGE 0 - 4000 PSI ON VALVE
TRAVEL WINCH 5 GPM 13 - 20 RPM
S2
1B
P1
7.40 CIR A
1A
S1
G
B
SV2 S2 RV1
2B
FR1 S1
2A SV3
T
S1
3B
A B
T1 S2
7.40 CIR
3A
ELECTRIC MOTOR 1750 RPM 60 HZ
3.36 CIR GEAR RATIO 40 : 1
5
M
COMMON CIRCUIT
4 HOIST WINCH 5 GPM 7 - 9 RPM
HYDRAULIC PUMP 1.55 CIR 11.7 GPM 1500 PSI 1750 RPM HYDRAULIC TANK 30 GALLON 1
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
REV.
ECN #
BY
DATE YEAR
APP'D
THIS DRAWING INCLUDES PROPRIETARY DATA WHICH IS THE EXCLUSIVE PROPERTY OF LIQUID WASTE TECHNOLOGY, LLC. NO DISCLOSURE OR REPRODUCTION ALLOWED WITHOUT THE WRITTEN CONSENT OF LIQUID WASTE TECHNOLOGY, LLC. THIS PRINT IS NOT TO BE COPIED IN WHOLE OR IN PART OR USED DETRIMENTALLY TO THE INTEREST OF LIQUID WASTE TECHNOLOGY, LLC. LIQUID WASTE TECHNOLOGY, LLC.
57
SUPERSEDES ACAD
-
REFERENCE P/N
-
LIQUID WASTE TECHNOLOGY, LLC
HYDRAULIC OVERVIEW
1750 MADISON AVENUE NEW RICHMOND, WI (715) 246-2888 * FAX (715) 246-2573
PHE DESIGNED
60 HZ, FSC VALVE THE INFORMATION IN THIS DOCUMENT IS SUBJECT TO CHANGE WITHOUT NOTICE AND SHOULD NOT BE CONSTRUED AS A COMMITMENT BY LIQUID WASTE TECHNOLOGY, LLC.
DRAWN
TAZ
-
SHEET:
SHEET SIZE:
1
OF
1
ADB 9/18/2012 SCALE:
REVIEWED
-
-
APPROVED
-
-
PART NUMBER / DRAWING NUMBER:
0005207
B
COMPONENTS ITEM
QTY
PART NO.
1
2
8000822
2
REF
8000806
FITTINGS
HOSE / TUBE ASSEMBLIES
ITEM
QTY
PART NO.
MOTOR, HYD AUGER 7.4 CIR WHITE
F1
2
1105089
FITTING, HYD. F6400-8-8
VALVE, ASSY 3 BANK HYD RUNT
F2
4
1105151
F3
2
F4
4
DESCRIPTION
ITEM
QTY
PART NO.
H1
2
8003218-076
HOSE 08 3000 08FJX -08FJX
GATES 8M3K
FITTING, HYD. F2403-8-8-SS
H2 *
2
8003218-066
HOSE 08 3000 08FJX -08FJX
GATES 8M3K
1105328
FITTING, HYD. F2703-8-8-8-LN
H3 *
2
8003218-065
HOSE 08 3000 08FJX -08FJX
GATES 8M3K
1105090
FITTING, HYD. F6400-8-10
H4 *
2
8003218-067
HOSE 08 3000 08FJX -08FJX
GATES 8M3K
T1
REF
0006312
DESCRIPTION
DESCRIPTION
TUBE, HYD .5IN ASSY,BOOM 120LG
* THE LENGTH OF THESE HOSES IS DEPENDENT UPON THE LOCATION OF THE TEE FITTING MOUNTED TO THE SLURRY PUMP. THIS LOCATION WILL VARY BASED UPON THE TYPE OF SLURRY PUMP USED CAUSING THESE HOSE LENGTHS TO VARY. 2
1
H4
EC1 P
SV1
M
1B
S2
P1
7.40 CIR
A
G
1A
S1
F3
B H4
SV2 S2 RV1
H1
2B
T1
H2
FR1
H1
T1
H2
2A
S1
AUGER 6 GPM 60 - 80 RPM
F4
F4
H3
SV3 T
S1
3B
A F1
F2
F2
B
T1 7.40 CIR S2
3A
H3
1
NOTES: 1. SPEEDS SHOULD BE TOWARD NOMINAL & UPPER RANGE WHEN NEW AND NO LOAD. 2. SPEEDS MAY BE TOWARD LOWER RANGE UNDER LOAD & FACTORED BY .90 WITH AGE.
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
REV.
ECN #
BY
DATE YEAR
APP'D
THIS DRAWING INCLUDES PROPRIETARY DATA WHICH IS THE EXCLUSIVE PROPERTY OF LIQUID WASTE TECHNOLOGY, LLC. NO DISCLOSURE OR REPRODUCTION ALLOWED WITHOUT THE WRITTEN CONSENT OF LIQUID WASTE TECHNOLOGY, LLC. THIS PRINT IS NOT TO BE COPIED IN WHOLE OR IN PART OR USED DETRIMENTALLY TO THE INTEREST OF LIQUID WASTE TECHNOLOGY, LLC. LIQUID WASTE TECHNOLOGY, LLC.
58
SUPERSEDES ACAD
-
REFERENCE P/N
-
LIQUID WASTE TECHNOLOGY, LLC
HYDRAULIC
1750 MADISON AVENUE NEW RICHMOND, WI (715) 246-2888 * FAX (715) 246-2573
CUTTER CIRCUIT DESIGNED
PHE, 60 HZ, FSC VALVE THE INFORMATION IN THIS DOCUMENT IS SUBJECT TO CHANGE WITHOUT NOTICE AND SHOULD NOT BE CONSTRUED AS A COMMITMENT BY LIQUID WASTE TECHNOLOGY, LLC.
DRAWN
TAZ
-
SHEET:
SHEET SIZE:
1
OF
1
ADB 9/18/2012 SCALE:
REVIEWED
-
-
APPROVED
-
-
PART NUMBER / DRAWING NUMBER:
0005207-02
B
COMPONENTS ITEM
QTY
PART NO.
1
1
8002551
2
REF
8000806
FITTINGS
HOSE / TUBE ASSEMBLIES
ITEM
QTY
PART NO.
DRIVE, TRAVEL, LWT GEARBOX/MTR
F1
2
1105089
FITTING, HYD. F6400-8-8
VALVE, ASSY 3 BANK HYD RUNT
F2
1
1105375
FITTING, HYD. F6801-8-10
F3
1
1104498
FITTING, HYD. 6801-LL-NWO-8-10
DESCRIPTION
DESCRIPTION
ITEM
QTY
PART NO.
H1
2
8003218-099
DESCRIPTION HOSE 08 3000 08FJX -08FJX
TRAVEL WINCH 5 GPM 13 - 20 RPM
2
F2
GATES 8M3K
1
9.80 CIR GEAR RATIO 5.05 : 1
EC1 P
SV1
M
S2
1B
S1
1A
F3
H1
P1
H1 G
SV2
RV1
S2
2B
S1
2A
F1
FR1
SV3 T
S1
3B
S2
3A
T1
NOTES: 1. SPEEDS SHOULD BE TOWARD NOMINAL & UPPER RANGE WHEN NEW AND NO LOAD. 2. SPEEDS MAY BE TOWARD LOWER RANGE UNDER LOAD & FACTORED BY .90 WITH AGE.
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
REV.
ECN #
BY
DATE YEAR
APP'D
THIS DRAWING INCLUDES PROPRIETARY DATA WHICH IS THE EXCLUSIVE PROPERTY OF LIQUID WASTE TECHNOLOGY, LLC. NO DISCLOSURE OR REPRODUCTION ALLOWED WITHOUT THE WRITTEN CONSENT OF LIQUID WASTE TECHNOLOGY, LLC. THIS PRINT IS NOT TO BE COPIED IN WHOLE OR IN PART OR USED DETRIMENTALLY TO THE INTEREST OF LIQUID WASTE TECHNOLOGY, LLC. LIQUID WASTE TECHNOLOGY, LLC.
59
SUPERSEDES ACAD
-
REFERENCE P/N
-
LIQUID WASTE TECHNOLOGY, LLC
HYDRAULIC
1750 MADISON AVENUE NEW RICHMOND, WI (715) 246-2888 * FAX (715) 246-2573
TRAVEL CIRCUIT DESIGNED
PHE, 60 HZ, FSC VALVE THE INFORMATION IN THIS DOCUMENT IS SUBJECT TO CHANGE WITHOUT NOTICE AND SHOULD NOT BE CONSTRUED AS A COMMITMENT BY LIQUID WASTE TECHNOLOGY, LLC.
DRAWN
TAZ
-
SHEET:
SHEET SIZE:
1
OF
1
ADB 9/18/2012 SCALE:
REVIEWED
-
-
APPROVED
-
-
PART NUMBER / DRAWING NUMBER:
0005207-03
B
COMPONENTS ITEM
QTY
PART NO.
1
1
8000846
2
REF
8000806
FITTINGS ITEM
QTY
PART NO.
WINCH, BLOOM 10-AS8-40:1
F1
2
1105089
VALVE, ASSY 3 BANK HYD RUNT
F2
4
F3
2
DESCRIPTION
HOSE / TUBE ASSEMBLIES ITEM
QTY
PART NO.
FITTING, HYD. F6400-8-8
H1
2
8003218-074
HOSE 08 3000 08FJX -08FJX
GATES 8M3K
1105151
FITTING, HYD. F2403-8-8-SS
H2
2
8003218-066
HOSE 08 3000 08FJX -08FJX
GATES 8M3K
1105090
FITTING, HYD. F6400-8-10
T1
REF
0005027
TUBE, HYD .5IN, ASSY, RUNT
DESCRIPTION
DESCRIPTION
2
EC1 P
SV1
M
S2
1B
S1
1A
P1
G
SV2
RV1
S2
2B
S1
2A
FR1
F2
F2
SV3 T
S1
3B
S2
3A
H1
T1
H1
T1
H2
T1 H2
F3
F1
F3
3.36 CIR GEAR RATIO 40 : 1 1 HOIST WINCH 5 GPM 7 - 9 RPM
NOTES: 1. SPEEDS SHOULD BE TOWARD NOMINAL & UPPER RANGE WHEN NEW AND NO LOAD. 2. SPEEDS MAY BE TOWARD LOWER RANGE UNDER LOAD & FACTORED BY .90 WITH AGE.
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
REV.
ECN #
BY
DATE YEAR
APP'D
THIS DRAWING INCLUDES PROPRIETARY DATA WHICH IS THE EXCLUSIVE PROPERTY OF LIQUID WASTE TECHNOLOGY, LLC. NO DISCLOSURE OR REPRODUCTION ALLOWED WITHOUT THE WRITTEN CONSENT OF LIQUID WASTE TECHNOLOGY, LLC. THIS PRINT IS NOT TO BE COPIED IN WHOLE OR IN PART OR USED DETRIMENTALLY TO THE INTEREST OF LIQUID WASTE TECHNOLOGY, LLC. LIQUID WASTE TECHNOLOGY, LLC.
60
SUPERSEDES ACAD
-
REFERENCE P/N
-
LIQUID WASTE TECHNOLOGY, LLC
HYDRAULIC
1750 MADISON AVENUE NEW RICHMOND, WI (715) 246-2888 * FAX (715) 246-2573
LADDER LIFT CIRCUIT DESIGNED
PHE, 60 HZ, FSC VALVE THE INFORMATION IN THIS DOCUMENT IS SUBJECT TO CHANGE WITHOUT NOTICE AND SHOULD NOT BE CONSTRUED AS A COMMITMENT BY LIQUID WASTE TECHNOLOGY, LLC.
DRAWN
TAZ
-
SHEET:
SHEET SIZE:
1
OF
1
ADB 9/18/2012 SCALE:
REVIEWED
-
-
APPROVED
-
-
PART NUMBER / DRAWING NUMBER:
0005207-04
B
COMPONENTS ITEM
QTY
PART NO.
1
1
8000806
2
1
8000810
3
REF
4
1
FITTINGS ITEM
QTY
PART NO.
VALVE, ASSY 3 BANK HYD RUNT
F1
1
1105089
VALVE, HYD FLOW CONTROL
F2
2
0005841
TANK, HYDRAULIC, ASSY, RUNT
F3
1
8002636
GAUGE, PRESS. 0-4000 SAE STEM
DESCRIPTION
HOSE / TUBE ASSEMBLIES ITEM
QTY
PART NO.
FITTING, HYD. F6400-8-8
H1
1
8003218-028
HOSE 08 3000 08FJX -08FJX
GATES 8M3K
1105075
FITTING, HYD. F6500-8-8
H2
1
8003218-035
HOSE 08 3000 08FJX -08FJX
GATES 8M3K
1105152
FITTING, HYD. F6400-8-12
DESCRIPTION
DESCRIPTION
2 F1 F2 EC1 P
H1
SV1
M
PRESSURE GAUGE 0 - 4000 PSI ON VALVE
S2
1B
S1
1A
P1
G
4
SV2
RV1
S2
2B
S1
2A
FR1
F3 F2
SV3 T
H2
S1
3B
S2
3A
T1 ELECTRIC MOTOR 1750 RPM 60 HZ
M 1
HYDRAULIC PUMP 1.55 CIR 11.7 GPM 1500 PSI 1750 RPM
HYDRAULIC TANK 30 GALLON 3
NOTES: 1. SPEEDS SHOULD BE TOWARD NOMINAL & UPPER RANGE WHEN NEW AND NO LOAD. 2. SPEEDS MAY BE TOWARD LOWER RANGE UNDER LOAD & FACTORED BY .90 WITH AGE.
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
REV.
ECN #
BY
DATE YEAR
APP'D
THIS DRAWING INCLUDES PROPRIETARY DATA WHICH IS THE EXCLUSIVE PROPERTY OF LIQUID WASTE TECHNOLOGY, LLC. NO DISCLOSURE OR REPRODUCTION ALLOWED WITHOUT THE WRITTEN CONSENT OF LIQUID WASTE TECHNOLOGY, LLC. THIS PRINT IS NOT TO BE COPIED IN WHOLE OR IN PART OR USED DETRIMENTALLY TO THE INTEREST OF LIQUID WASTE TECHNOLOGY, LLC. LIQUID WASTE TECHNOLOGY, LLC.
61
SUPERSEDES ACAD
-
REFERENCE P/N
-
LIQUID WASTE TECHNOLOGY, LLC
HYDRAULIC
1750 MADISON AVENUE NEW RICHMOND, WI (715) 246-2888 * FAX (715) 246-2573
COMMON CIRCUIT DESIGNED
PHE, 60 HZ, FSC VALVE THE INFORMATION IN THIS DOCUMENT IS SUBJECT TO CHANGE WITHOUT NOTICE AND SHOULD NOT BE CONSTRUED AS A COMMITMENT BY LIQUID WASTE TECHNOLOGY, LLC.
DRAWN
TAZ
-
SHEET:
SHEET SIZE:
1 OF 1
ADB 9/18/2012 SCALE:
REVIEWED
-
-
APPROVED
-
-
PART NUMBER / DRAWING NUMBER:
0005207-11
B
White Hydraulics, Inc. P.O. Box 1127 Hopkinsville, KY 42241 Phone- (270) 885-1110 Fax- (270) 886-8462
PI444200 9/01 Service Instructions For The CE (400/401) Series
FOR USE WITH SEAL KIT 400444200
***USE EXPLODED VIEW ON BACK FOR REFERENCE***
A)
Remove all shaft components from the shaft, (21), (i.e., keys, wire rings, nuts). To aid in reassembly of the motor, make a "V" shaped set of lines from the endcover to the housing using either paint or a marker. With the shaft facing down, secure the motor in a vise by clamping onto the housing, (8). Loosen and remove the seven bolts, (20), holding the motor assembly together. Remove the endcover, (18), from the motor.
B)
Remove the balance plate, (16), rotor set, (15), and the manifold, (14), from the motor. Remove all seals from the components and discard. (Caution - when removing the balance plate, do not allow the three check balls, (17), to fall out from the plate.) (Caution - do not allow the rolls to drop out from the rotor set assembly when removing the assembly from the motor.) Remove the manifold from the motor and lay aside. Remove drive link, (13), from the motor and lay aside. Remove the thrust bearing, (12), from the housing and lay aside. From the front of the housing, gently tap the shaft, (21), upward and remove through the rear of the housing.
C)
Using a slide and hammer type bearing puller, (see Figure 1), remove the rear housing bearing, (11), from the housing. Remove the thrust bearing, (10), and lay aside, remove the thrust washer, (9), and lay aside. Remove the shaft seal, (4), and discard, remove the back-up seal, (3), and discard, remove the metal shim, (2), and discard.
D)
At this point, all parts should be cleaned in an oil-based solvent and dried using compressed air, (for safety, observe all OSHA safety guidelines). All new seals should be lightly coated in clean oil prior to installation.
E)
Place the integral thrust washer/bearing, (10), onto the shaft. The washer side should be against the shoulder of the shaft. Place a thrust washer, (9), onto the shaft on top of the thrust bearing. Coat the shaft seal, (4), with a light coat of oil and install onto the shaft with the lip side down. Place a light coat of oil on the back-up seal, (3), and place over the coat of oil on the metal back-up shim, (2), and place over the back-up seal.
F)
With the pilot of the housing placed down, install the output end of the shaft through the rear bore of the housing.
G)
The rear bearing is now ready to be installed. With the writing side of the bearing facing up, place the bearing, (11), into the housing bore. Using a hand press, the bearing should be pressed into the bore. It is necessary that the bearing be pressed .120 - .130" deep into the bore of the housing to accommodate the width of the thrust bearing.
H)
Install a thrust bearing, (12), on top of the shaft.
I)
Install a lightly oiled body seal, (1), into the seal groove in the housing. Make sure that this seal is in the seal groove and protruding approximately .007" over the top of the housing surface. (Caution - if a bump is felt in the seal remove the seal and make sure that there is no grit on the seal or in the seal groove.)
J)
Install the drive link, (13), into the housing. The proper end of the drive link has a 'hat" machined in the top of the drive link on the 07-16 displacement. The drive link is to be placed in the shaft with the hat facing up on these displacements. The 18 displacements and above have a symmetrical head and either end can be put into the motor. Once the drive link has been installed, the shaft can be seated. This is done by bringing the arbor of the hand press down and putting pressure on the drive link. (Caution - do not use excessive pressure as this could deform the thrust bearing and/or bearing races.)
K)
Place the manifold (14), (seven teardrop hole side down) on the housing. Line the bolt hole notches in the outside diameter of the manifold up with the seven bolt holes in the housing.
L)
Install two oil coated body seals, (5), one on each side, into the seal grooves of the rotor set, (15). Place the deep groove side of the of the rotor set down on the manifold, (14).
M)
Place the balance plate, (16), on top of the rotor set with the check balls, (17), up. If the check balls were removed, install three check balls into the countersunk holes on the balance plate, one ball per hole.
N)
Install an oil coated body seal, (6), into the seal groove of the endcover, (18). Place the endcover onto the motor with the tag holes directly above the housing ports. (Caution - it is very important that the body seal does not fall out of the endcover while being installed. Extra care must be used to insure this doesn't happen.)
O)
Install the seven bolts, (20), into the motor. Pre-torque bolts to 10 ft. lbs. The final torque on the bolts is to be 51.1 + 5.5 ft. lbs.
64
FIGURE 1
CE(400/401) Series Motor Components 1. Housing Seal 2. Metal Back-Up Shim 3. Teflon Back-Up Seal 4. Shaft Seal 5. Body Seals (2) 6. Endcover Seal 7. Front Housing Bearing 8. Housing
9. Thrust Washer 10. Front Thrust Bearing 11. Rear Housing Bearing 12. Thrust Bearing 13. Drive Link 14. Manifold 15. Rotor Assembly 16. Balance Plate 65
17. Steel Balls (3) 18. Endcover 19. I.D. Tag 20. Assembly Bolts (7) 21. Shaft 22. Shaft Key 23. Shaft Nut
BLOOM MANUFACTURING INC. Safety, Warranty, Maintenance & Repair, Installation and Operation Manual Bloom™ Hydraulic Cable Winches 800, 1000, 1100, 1200, 1400 & 1600 Series
Bloom™ Hydraulic Capstan Winches 1000, 1100, 1000V & 1400 Series
All Bloom winches have the model and serial number stamped on the gear case cover. Please take a few minutes to record these numbers for future use. You will need these numbers for ordering parts or gathering service information from the factory: Model#______________________________ # 10-A-S8-40 Serial # 52532 Model Ser #______________________________
Thank you for your purchase of a quality Bloom product ! THIS MANUAL MUST BE KEPT WITH THE WINCH AT ALL TIMES AND NEW WINCH OPERATORS MUST READ AND UNDERSTAND IT. IT REV. 07-2007
Bloom Manufacturing Inc. Winch Division 1443 220th Street Independence, IA 50644
www.bloommfg.com Email: [email protected] 66
800-394-1139 tel 319-827-1139 tel 319-827-1140 fax
Table of Contents 1. General Safety Requirements 2. Warranty 3. Maintenance & Repair ( ) Clean (a) Cl andd IInspectt (b) Oil Change Information (c) Oil Level (d) Recommended Gear Oil (e) Inserts: - Assembly (specific model) - Disassemblyy ((specific p model)) - Parts List (specific model) - Assembly Check Valve Kit - Assembly of Oil Cooled Brake - Replacement of Clutch Handle and Yoke
4. Winch Break In 5. Winch Installation 6. Winch Operation ( ) Cable (a) C bl Considerations C id ti (b) The Importance of a Proper Fleet Angle (c) Wire Rope Anchor & Wrapping (d) Automatic Safety Brakes & Adjustment
Please note that not all of the sections of the Table of Contents apply to each model purchased
Merchandise may not be returned without approval from factory. The customer will be charged for placing the returned goods in salable condition plus a restocking charge of 25%. All returns must be shipped prepaid.
Section 1
General Safety Requirements
THIS SYMBOL MEANS • Attention! • Become Alert! • Your Safety Is Involved SIGNAL WORDS:
2
Take Note! This Safety Alert Symbol Found Throughout This Manual Is Used To Call Your Attention To Instructions Involving Your Personal Safety And The Safety Of Others. Failure To Follow These Instructions Can Result In Injury Or Death.
Note the use of the signal words DANGER, WARNING AND CAUTION with the safety messages. The appropriate signal word for each has been selected using the following guidelines:
• DANGER:
Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations typically for machine components which, for f functional f purposes, cannot be guarded.
• WARNING:
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury, and includes hazards that are exposed when guards are removed. It may also be used to alert against unsafe practice.
• CAUTION:
Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.
Bloom Mfg Inc.
319-827-1139
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www.bloommfg.com
CAUTION
WARNING
Failure to Heed The Following Warnings May Result In Serious Injury Or Death
•
Bloom winches are not to be used to lift, hoist, or move people. If your task involves lifting or moving people, you mustt use the th proper equipment, i t nott this thi winch. i h
•
Cable anchors on Bloom winches are not designed to hold the rated load of the winch. You must keep at least five (5) wraps of cable on the drum to ensure that the cable doesn’t come loose. We suggest that the last 5 wraps of cable be painted bright red to serve as a visual warning.
•
Stay clear of suspended loads and of cable under tension. A broken cable or dropped load can cause serious injury or death.
•
No equipment should be installed, operated, or maintained by any person who has not carefully read all contents of this manual. Serious physical injury or property damage can result from failure to read and apply the instructions contained therein. Therefore, we urge you to read all operating instructions and warnings carefully. If any instruction or warning is not clear, or if you feel you need additional information, please Bloom Mfg Inc. This manual should not be understood to prepare you for every possible situation. It is the owner’s and ’s responsibility to determine the pp industry, y trade association, federal, state, and local regulations g suitabilityy of a pproduct for a pparticular use. Applicable should be reviewed.
•
Make sure that all equipment, including the winch and cable, is maintained properly. Pay especially close attention to the clutch, making sure that it fully engages when shifted. Winches equipped with free spooling dog clutch should never be used in a lifting application.
•
Avoid shock loads. This type of load imposes a strain on the winch many times the actual weight of the load and can cause failure of the cable or of the winch. winch
•
Bloom products are sold on the strict understanding that all products selection is the full responsibility of the purchaser.
•
Bloom accepts no liability for the use, misuse or incorrect application of its products.
•
Leather gloves should be used when handling winch cable.
•
Ensure the correct equipment is obtained and installed for the application.
•
Ratings shown in Bloom literature are applicable only to new products.
•
Working load limits shown are the maximum load the product is authorized to under normal environmental conditions. Shock loading and abnormal conditions must be taken into when selecting products.
•
In general, products displayed in Bloom literature are used as parts of a system. As a result, we can only recommend within the working load limits, or other stated limitations, the use of products for this purpose.
•
Working load limits or safety factors for each Bloom product may be affected by wear, misuse or environmental conditions. Regular inspection must be conducted to ensure the equipment continues to meet the published standards. If you have questions not answered in this manual or require additional copies or the manual is damaged, please Bloom Mfg., Inc., 1443 220th Street, Independence, Iowa 50644. This sample manual is based upon general industry considerations and does not take into product or manufacturer specific exposures or needs. This sample manual may not be adopted by a product manufacturer as its manual, but may be used by the manufacturer in the process of developing its own manual, based upon its specific products and operations, after consulting with its advisor. THINK S-A-F-E-T-Y FIRST
Bloom Mfg Inc. 68
319-827-1139
3
Warranty
Section 2
LIMITED NINETY (90) DAY WARRANTY FOR HYDRAULIC CABLE & CAPSTAN WINCHES Effective date January 1, 1999 Bloom Mfg. Inc., Independence, Iowa 50644, provides the following LIMITED NINETY (90) DAY WARRANTY on its product to the purchaser of this product and to any person to whom such product is transferred during the duration of this warranty. The warrantor's obligation shall be limited to repairing or replacing at the factory in Independence, Iowa, any part or parts which shall within the NINETY (90) DAY period hereinafter specified be returned to it with transportation prepaid and which upon examination by Bloom Mfg. Inc. shows to have been defective. This warranty shall not apply if: (a) the product has been altered, repaired or modified outside the warrantor's factory in any way that would adversely affect its operation. (b) the product has been subject to careless or negligent misuse, damage or use of improper oil while in the possession of the purchaser or any person to whom the product was transferred by the purchaser or was installed or operated other than in accordance with the manufacturer's operating instructions. (c) the product was used with accessories not recommended by Bloom Mfg. Inc. or for loads in excess of those listed as rated for the product. (d) in the case of hydraulic motors, Bloom Mfg. Inc. will not accept responsibility and warranty will be subject to manufacturer's warranty. The NINETY (90) DAY LIMITED WARRANTY period shall commence with the date the product is sold to the purchaser by the dealer or if this date cannot be established, the date the product was sold by Bloom Mfg. Inc. to the dealer. THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE ARE LIMITED TO THE DURATION OF THIS WARRANTY - NINETY (90) DAYS - AFTER SAID (90) DAYS, BLOOM MFG. INC. EXPRESSLY DISCLAIMS ANY WARRANTY OR MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. PURPOSE Purchase or other acceptance of the product by the claimant shall be on the condition and agreement that BLOOM MFG. INC. SHALL NOT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL OR CONTINGENT DAMAGE, SECONDARY CHARGES OR LOSS OR EXPENSE RESULTING FROM ANY ALLEGED DEFECT, FAILURE OF ARTICLE TO OPERATE PROPERLY, OR FOR THE NEGLIGENCE OF OTHERS OR DAMAGES OF ANY KIND. Bloom Mfg. Inc. is not responsible for the cost, of removal of product, damages due to removal or any other expenses incurred in shipping the product to or from Bloom Mfg. Inc. or the installation of the repaired or replacement product. The consumer must bear these expenses. To make a claim under this warranty, write directly to Bloom Mfg. Inc., Independence, Iowa 50644, identifying the product and giving its location and follow the company's return instructions which will be provided by the company. Bloom Mfg. Inc. will p or replace p the pproduct,, if found to be defective within the of this warranty, y, within SIXTY make its best efforts to repair (60) DAYS after return of the product to the company. This warranty is exclusive and in lieu of all other warranties whether written, oral or implied (including any warranty of merchantability or fitness for a particular purpose.
4
For Best Results, Only Use Bloom Replacement Parts 69
800-394-1139
Section 3
Maintenance & Repair ƒ Make sure that there is no load on the winch cable and that all of the y hoses have been disconnected before servicingg unit. hydraulic
CAUTION A winch, like other types of machinery, needs to have regular maintenance if it is to perform properly, give lasting service, and provide safe winching. (a) Clean and Inspect: Thoroughly clean all of the parts in a good grade of cleaning solvent; one that is not flammable, not toxic and will not cause skin ki rashes. h If necessary, use rubber bb gloves. l IInspectt allll parts t for f wear, nicks, i k scratches t h andd damage d that th t would ld render them unusable. If a part is questionable, it is better to replace it rather than take a chance on premature failure when the winch is placed back in service. Always replace O-rings and seals, and it is a good idea to use new roll pins as well. Sometimes it is permissible to reuse bearings and bushings...it depends on how much use they have had. The rollers should not exhibit any surface irregularities. If the rollers show any sign of spalling, corrosion, discoloration, material displacement or abnormal wear, the bearings should be replaced. Likewise,, the cage g should be inspected p for unusual wear or deformation,, pparticularlyy the cage g bars. If there is anyy damage that will impair the cage’s ability to separate, retain, and guide the rollers properly, the bearing should be replaced. The thrust washer areas should be free from any surface irregularity that might cause excessive abrasion or friction. If the winch was disassembled only to replace damaged seals after a short period of service, it is not necessary to replace the bearings. Experience and common sense, along with a good inspections, will determine if they can be used again. Always coat O-rings, bearings, bushings and the rubber parts of seals with oil during assembly. Use a light coat of thread sealing compound on pipe fittings and plugs. (b) Oil Change Information: The winch vent/fill and drain plugs are located at the base of the face plate. Oil should be changed every 100 hours of operating time, or every six months, whichever comes first. (c) Oil Level: To check the oil level, remove the level plug. The oil should be level with the bottom of this opening. If more oil is needed, use the recommended gear oil listed below.
OIL CAPACITY CHART
Note: Base mounted position is when h the h worm shaft h f iis below the bronze gear.
Bloom Mfg Inc.
Winch Type
Winch Series
Base Mounted Position*
All Other Mounting Positions
Cable
800 & 1000
1 Pint
2 Pints
1100
1 Pint
2 Pints
1200 w/o brake
2 Pints
3 Pints
1200 w/ brake
3 Pints
4 Pints
1400
4 Pints
6 Pints
1600
4 Pints
6 Pints
1000 & 1100
1 Pints
2 Pints
1100V
2 Pints
2 Pints
1400
4 Pints
6 Pints
Capstan
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5
(d) Recommended Gear Oil: Use BLOOM ULLTRA-LUBE NO. 601 trans-worm gear oil; available from Bloom in pints or quarts. For emergency situations when BLOOM ULLTRA-LUBE NO. 601 is not immediately available, use Phillips 66 Company SAE grade 80W90 superior multi-purpose gear oil (Phillips 80W90 SMP) meeting API classification GL-5 or equivalent brand. Continuous use of oil other than BLOOM ULLTRA-LUBE NO. 601 or Phillips 80W90 SMP oil may shorten the life of the gears. DO NOT mix BLOOM #601 or Phillips 80W90 SMP with more than 50% of any other kind of oil.
Section 4
CAUTION
Winch Break In • Winches, like any other kind of machinery, require a “break in” to perform well and to maximize their life. • Use extreme care when first spooling cable onto the winch. winch Do not run the winch at high speeds when performing this operation. • Make sure that the cable is unrolled in a line (to prevent kinks) and slowly inhaul the winch to install the cable. • Do not exceed one half rated load or one half rated line speed for the first thirty minutes of operation. This will ensure that the worm and gear have an opportunity to wear in properly. • Periodically, check the gearbox for temperature rises and allow the winch to cool down between pulls.
Winch Installation
Section 5
CAUTION
• Y You mustt make k sure that th t your winch i h iis securely l mounted t d iin order d ffor it tto ffunction ti properly and to ensure safe operation. • The mount must be flat to ensure proper alignment between the gearbox side, the drum, and the clutch. • Winches must never be fastened directly to the frame of a truck. Mounting brackets should be used. y y driven winch,, make sure the hydraulic y system y is clean and that • With a hydraulically all components function properly, especially the relief valve. Winch Series
800
1000
1100
1200
1400
1600
1/2”
1/2”
1/2”
1/2”
1”
1”
Angle Mounts (steel) Length Width Thickness
2-1/2” 2-1/2”” 1/4”
2-1/2” 2-1/2”” 1/4”
2-1/2” 2-1/2”” 1/4”
2-1/2” 2-1/2”” 1/4”
3” 3” 1/2”
3” 3” 1/2”
Capscrews (Hexhead) Size Thread Grade
1/2” 1/2” 13 UNC 13 UNC 5 5
1/2” 13 UNC 5
1/2” 13 UNC 5
57
57
Base Mount (steel) Thickness
HARDWARE REQUIREMENTS
57
Torque / Tightening (foot pounds)
6
THINK S-A-F-E-T-Y FIRST
57
Bloom Mfg Inc. 71
5/8” 5/8” 11 UNC 11 UNC 5 5 112
319-827-1139
112
Winch Operation
Section 6
• To familiarize yourself with the winch, run it for a few minutes to understand the controls and the “feel” of the winch. • Pay particular attention to the controls and how they operate. Make sure you understand which way the winch will rotate when the control lever is moved. • Always make sure that all people are clear of the load and of the cable area before beginning a winching operation. • Ensure that proper protective wear is worn while operating winch. • A broken cable can fly in any direction. • Do not attempt to defeat the relief valve valve. • If you have any doubts about the capability of the winch to lift or move a load, either put a “snatch block” in the line or get a bigger piece of equipment. Winch lifting application: (1) Attach winch cable to load. (2) Make sure no one is in the immediate area of the load or of the cable (3) Begin winching the load slowly, watching carefully to ensure that the load is moving normally. (4) When the load is positioned where you want it, stop the winch.
Winch Series
DRUM CAPACITY (FEET)
Cable Diameter (inches) 3/8 7/16 1/2
3/16
1/4
5/16
S* S8 L L8 XL10 8-13**
--------------------1325
120 260 175 390 840 750
70 160 105 240 550 450
45 105 65 160 340 325
30 75 45 110 250 225
1400
L14
-----
-----
1223
712
1600
L145
-----
-----
1214
842
800 1000, 1100 & 1200
* For series 1000 only ** For series 1000K only
Drum Designation
9/16
5/8
25 55 30 80 170 155
-------------------------
-------------------------
517
409
295
200
662
425
318
303
Consult your local cable supplier for recommendations on the best type of cable and hardware to use in your specific application. (a) Cable Considerations: As the number of layers of cable on a winch increases, the rated lifting capacity of the winch goes down. If you are operating at near the top of the drum flanges, the effective rating of the winch is about half of what it is on the first layer. You should, therefore, only keep as much cable on the winch as you need for your job.
For Best Results, Only Use Bloom Replacement Parts 72
800-394-1139
7
Never use larger or smaller cable on your winch than is recommended for it. The use of larger cable will not allow you to pull larger loads and may, in fact, break easier than the proper size cable. The use of smaller cable may overheat the winch due to the increased running time with more cable. (b) The Importance of a Proper Fleet Angle: Maintaining the proper fleet angle is important to the success of your winching operation, the life of your winch and the life of the cable you are using. The fleet angle can best be described by the following diagram: The fleet angle should be kept as small as possible to ensure proper spooling and to maximize cable and winch life. To promote even cable spooling, keep the fleet angle below three degrees. Never pull directly against the flange of the winch cable drum as this may cause the cable or the winch to break. Adherence to these instructions will ensure better spooling. (c) Wire Rope Anchor & Wrapping: Prepare the end of the wire rope as recommended by the wire rope manufacturer. the free end of the wire rope through the small opening of the cable drum anchor pocket. Lock the cable into the drum by tightening the cable anchor set screw.
Centerline
PROPER FLEET ANGLE
LOAD Cable
Fleet Angle 3 Deg. Max.
Direction To Raise Load Cable
PROPER WRAPPING OF WIRE ROPE
Cable Anchor Set Screw Drum
Drum will turn counter clockwise to spool cable onto drum (d) Automatic Safety Brake: Some Bloom winches are equipped with an automatic hydraulic brakes to hold suspended loads. If your winch is not equipped i d with ith one, it is i intended i t d d for f pulling lli loads l d only. l If you wish i h to t lift andd suspendd loads l d with ith your winch, i h it can be b retrofitted with a brake. Please consult the factory for details. The safety brake is an important feature of your winch and must be maintained properly. There are two types of brakes used on Bloom winches: Adjustable Automatic Safety Brake (Drag) An oil cooled automatic safety brake disengages when a load is lifted and automatically engages when power is removed or the load is lowered. Automatic Hydraulic Fail-Safe Brake (Spring applied hydraulic release) Spring applied hydraulic release brake automatically holds load when hydraulic pressure is released. Double counter balance valve adds additional load holding capability by locking hydraulic oil in motor. Bloom Mfg Inc.
319-827-1139
319-827-1140 fax 73
www.bloommfg.com
8
74
75
76
77
Service Manual HY09-SM300/US
Service Manual PGP/PGM315, 330, 350, 365
Effective: April 15, 2002 Supersedes: July 1, 1998
PGP/PGM 300 Series
78
PGP/PGM 300 Series Service Manual HY09-SM300/US
315/330/350/365 Service Manual General Instructions These service instructions will familiarize you with Parker's single and multiple pumps
• their component parts • the relative position of each part • proper methods for assembly or disassembly of the units To facilitate the repair of these units and before any work is done, we suggest that you first read all of the steps used in disassembly and assembly. Dirt is the enemy of any hydraulic system. The first requirement for good maintenance of hydraulic equipment is cleanliness. MAKE SURE YOU DISASSEMBLE AND ASSEMBLE YOUR HYDRAULIC EQUIPMENT IN A CLEAN AREA. The pictures show Model PGP365. Notes in the text cover variations between this unit and the other models. It is important to airblast all parts and wipe them with a clean, lintless cloth before assembly.
Items shaded apply to multiple assemblies only.
USE CAUTION IN GRIPPING ALL PARTS IN THE VISE TO AVOID DAMAGING MACHINED SURFACES.
NOTE: For PGP315 and PGP330 ONLY - Plug 5 required in position A and position B.
A pump must be driven in the direction of rotation for which it was built; otherwise, pressure will blow the shaft seal. Check the exploded view and notes at right for proper direction of rotation.
For PGP350 and PGP365 ONLY - Plug 5 in position B gives clockwise rotation. Plug 5 in position A gives counterclockwise rotation.
Parker's Replacement Parts
PARTS LIST 1. 2. 3. 4. 5. 6. 7. 8. 9.
Snap Ring Outboard Bearing Seal Shaft End Cover Plug Bushings Channel Seal Thrust Plates Integral Drive Shaft and Gear Set 10. Gasket Seal
Parker's replacement parts are of original equipment standards. For assured quality of material and workmanship, and for compatibility in assembly, USE ONLY GENUINE PARTS. Check all replacement parts before installing them to be certain that they were not damaged in shipment.
3 79
11. Dowel Pins (Solid for PGP/PGM 315, 330 and 350. Hollow for PGP/PGM 365 ONLY.) 12. Gear Housing 13. Bearing Carrier 14. Connecting Shaft 15. Matched Gear Set 16. Gear Housing 17. Port End Cover 18. Studs or Cap Screws 19. Washers 20. Nuts
Parker Hannifin Corporation Gear Pump Division Youngstown, OH
PGP/PGM 300 Series Service Manual HY09-SM300/US
Tool List • Arbor press • Awl • 1 1/2" Dia. steel ball • Bearing puller (Owatonna Tool Co. M D - 956 or equivalent) • Bushing remover tool (See A) • Clean, lintless cloths • Deburring tool (an old file with cutting teeth ground off) • Machinist's hammer • Soft hammer • Permatex Aviation Form-A-GasketTM No. 3 non-hardening sealant or equivalent • Medium grit carborundurn stone • Seal removal tool (See B) • Oil and grease • Snap ring pliers • Prick punch • Bushing installation tool (See C) • Scale ( 1/32" or 1/64" graduations) • Small screw driver • Torque wrench • Vise with 6" minimum opening. • Bar for lip seal installation Note: For PGP/PGM315 use 1 5/8" dia. x 2" bar. For PGP/PGM330 use 1 3/4" dia. x 2" bar. For PGP/PGM350 use 2 1/2" dia. x 2" bar For PGP/PGM365 use 2 1/2" dia. x 2" bar. • Special steel sleeve ( see sketch )
Bushing Puller: The bushings in PGP/PGM315, 330, 350 and 365 pumps may be removed from their bores, using blind hole collet-type bushing pullers similar to those manufactured by Owatonna Tool Co. The table below illustrates the modifications necessary to adapt the OTC collets to this task. Equivalent pullers from other suppliers may be modified in similar fashion.
A PGP/PGM 315 PGP/PGM 330 PGP/PGM 350
B
Seal Removal Tool Easily made from an old screw driver. Heat the tip and bend as shown. Grind the tip to fit the notch behind the shaft seal. Special Steel Sleeve The special steel sleeve is used to insert the drive shaft through the lip seal without damage and can be made from bar stock: For the PGP/ PGM315 use a 1 " dia. x 3-1/ 8" bar; for the PGP/PGM330 use a 1-1/8" or 1-1/4" dia. x 4- 5/8" bar; for the PGP/ PGM350 use a 1-3/8" dia. x 4-5/8" bar; for the PGP/ PGM365 use a 1- 1 /2" dia. x 4-5/8" bar. The drawing and chart give details for making this special tool.
C
PGP/PGM 315 PGP/PGM 330 PGP/PGM 350 PGP/PGM 365
PGP/PGM 315
PGP/PGM 330
PGP/PGM 350
PGP/PGM 365
4 80
Parker Hannifin Corporation Gear Pump Division Youngstown, OH
PGP/PGM 300 Series Service Manual HY09-SM300/US
Start Disassembly Here CAUTION: 1. If prying off sections becomes necessary, take extreme care not to mar or damage machined surfaces. Excessive force while prying can result in misalignment and seriously damage parts. 2. If parts are difficult to fit during assembly, tap gently with a soft hammer (never use an iron hammer). 3. Gears are closely matched, therefore they must be kept together as sets when removed from a unit. Handle with care to avoid damage to the journals or teeth. Avoid touching gear journals. 4. Never hammer bushings into bores; use an arbor press.
1) Place the pump in a vise with the drive shaft pointIng down. Caution: DO NOT GRIP ON OR NEAR ANY MACHINED SURFACES DURING ASSEMBLY OR DISASSEMBLY. Match-mark all sections. Be sure to align these marks when reassembling.
2) Use a socket wrench to remove the 4 cap screws on single units or the 4 hex nuts, studs and washers of multiple units.
3) Lift off the port end cover. If prying is necessary, be careful not to damage the machined surfaces. Dowel pins will remain in either the port end cover or the gear housing.
4) Remove the thrust plate. Examine and replace if necessary. See wear guide page 10.
5) Carefully remove the drive and driven gears. Avoid tapping the gear teeth together or against other hardened surfaces. Keep these gears together because they are a matched set. Examine and replace if necessary. (See page 10). Remove the thrust plate from the bearing carrier. Examine and replace if necessary.
6) Lift the gear housing from the bearing carrier. If prying is necessary, take care not to damage machined surfaces. Examine and replace if necessary. (See page 10) For multiple assemblies only
For multiple assemblies only
5 81
Parker Hannifin Corporation Gear Pump Division Youngstown, OH
PGP/PGM 300 Series Service Manual HY09-SM300/US 7) Carefully lift or pry off the bearing carrier to prevent damage to face and edges. Dowel pins will remain in either the bearing carrier or the gear housing. DO NOT REMOVE THEM.
For multiple assemblies only
8) Remove the connecting shaft. Remove the thrust plate. Examine and replace if necessary. (See page 10). Remove the driven gear and the integral gear and drive shaft. Keep these together as they are a matched set. Examine and replace if necessary. (*See page 10). Be careful not to damage the machined surfaces of the gears.
9) Lift or pry off the first section gear housing. Be careful not to damage machined surfaces. Examine and replace if necessary (see page 10).
10) Inspect all bushings for scoring or discoloration and replace if necessary. Use a bushing puller as shown in the tool list to remove bushings (see page 4).
11) If the pump is equipped with an outboard bearing, place the shaft end cover in the vise with the mounting face up. Remove the snap ring with snap ring pliers. If a unit is equipped with a spiral-lock retaining ring, remove with a small screwdriver or awl.
12) Use a bearing puller to remove the outboard bearing.
13) Grip the shaft end cover in a vise with the mounting face down. Remove double lip seal by inserting the special seal removal tool (see Tool List) into the notch between the double lip seal and the shaft end cover. Tap the seal out and discard. Remove and discard all rubber and polymer seals.
6 82
Parker Hannifin Corporation Gear Pump Division Youngstown, OH
PGP/PGM 300 Series Service Manual HY09-SM300/US
Start Assembly Here 1) Stone all machined surfaces with a medium grit carborundurn stone.
2) If the bushings have been removed, deburr the bushing bores with an emery cloth. Rinse parts in a solvent. Air blast all the parts and wipe with a clean, lintless cloth before starting assembly.
3) Grip shaft end cover in vise with mounting face down. Examine plug or plugs* to be sure they're tightly in place. Replacement is necessary only if parts are damaged. Remove with screwdriver.
4) New plugs should be screwed in tightly. Stake the plug with a prick punch at both ends of the screwdriver slot and around edges. Peen the edge of the hole 1/32" to 1/16" with a1-1/2" diameter steel ball. NOTE: If new plug or plugs are being installed, coat threads with LoctiteTM thread sealant.
*PGP/PGM315 and 330 have two plugs in both the shaft end and port end covers. PGP/PGM350 and 365 have one plug on the outlet side of their shaft end and port end covers. 5) Note: Assembly steps 5, 6, 7 & 8 apply to shaft end cover, bearing carrier and portend cover. Any bushings removed from the shaft end cover, portend cover or bearing carrier should be assembled in the drive bores with the groove to the top of unit (12 o'clock). Assemble the bushings in the driven bores with the groove to the bottom of the unit (6 o'clock). The PGP/PGM315 does not have grooved bushings, therefore the bushing seams should be placed at the 12 and 6 o'clock positions.
6) Bushings should be pressed into the bores, one at a time, using the special installation tool and an arbor press. Be sure the that the grooves (or seams) are positioned as stated in Step #5. The bushings must be pressed into the bores flush with the casting face. Be sure to the castings so that they are square and level.
7) Repeat Steps 1 and 2, stone and rinse parts.
8) See that dowel pins are in place in any new castings. Examine all of the dowels. Before inserting, make certain that the hole is clean and free from burrs. Gently start the pin straight into the hole and tap lightly with a soft hammer.
7 83
Parker Hannifin Corporation Gear Pump Division Youngstown, OH
PGP/PGM 300 Series Service Manual HY09-SM300/US 9) Before inserting a new lip seal in the shaft end cover, coat the outer edge of the lip seal and its recess with Permatex Aviation Form-A-Gasket™ No. 3 non-hardening sealant or equivalent. With the metal side of the lip seal up, press it into the mounting flange side of the shaft end cover with an arbor press and bar (see Tool List on page 4). Be careful not to damage the lip of the seal. Press in until flush with the recess. Wipe off excess sealant.
10) If the unit is equipped with an outboard bearing, guide the bearing into its recess in the shaft end cover. This is a light press fit. It may be necessary to lightly tap the bearing into the bore.
11) Install the snap ring in the groove to retain the outboard bearing.
12) Grease the new gasket seals and insert them into the grooves in both sides of all gear housings. Position the first gear housing over the shaft end cover and dowels. Tap it with a soft hammer until it rests tightly against the shaft end cover. Be careful not to pinch the gasket seal. Also be sure that the large rounded core is on the inlet side.
13) Assemble the channel seals into the grooves in the thrust plates with the flat side of the seal facing away from the thrust plate as shown below.
14) Gently slip the thrust plate through the gear housing and into place on the shaft end cover. The channel seal from Step #13 should face the shaft end cover. The relief groove in the plate should face the outlet side of the pump.
Flat Side of Seal
Thrust Plate
15) Slide the driven gear through the housing and into the bushing in the shaft end cover. Coat the steel sleeve tool with grease. Place the lightly-greased drive shaft inside the sleeve and slide both through the shaft end cover with a twisting motion, until the integral gear rests against the thrust plate. Avoid damaging the double lip seal. Remove the steel sleeve. Squirt clean oil over the gears.
8 84
16) Slip the thrust plate with the seal over the gear journals and into the housing bore. The flat side of the seal should face up with the relief groove facing the outlet side. (For single pump assemblies go directly to Step #21).
Parker Hannifin Corporation Gear Pump Division Youngstown, OH
PGP/PGM 300 Series Service Manual HY09-SM300/US
17) Place the bearing carrier onto the journals of the drive and driven gears. Be sure to line up the dowel holes over the dowel pins. When the parts are parallel, squeeze them together or alternately tap over each dowel until the parts are together.
18) Insert the connecting shaft into the spline of the drive gear. Position and place the second gear housing on the bearing carrier as outlined in Step #12.
19) Place the thrust plate in the gear housing per Step #14. Insert the drive and driven gears of the second section in their respective bearings. Make certain the gears are in with the thrust plate face. Place the port end cover plate in the housing per Step #16.
20) Check the plug or plugs in the port end cover to be sure that they are tight. Follow the procedure outlined in Step #4 for new plugs.
For multiple assemblies only
For multiple assemblies only
For multiple assemblies only
22) Thread the fasteners into the shaft end cover and tighten alternately or cross corner. Rotate the drive shaft with a 6" wrench to check for binding. If there is no internal binding, torque diagonally opposed fasteners to 200 ft. lbs. (2400 in. lbs.); 141 ft. lbs. (1700 in. lbs.) for PGP/ PGM315 models; 450 ft. lbs. (5400 in lbs.) for PGP/ PGM365.
21) Place the port end cover over the gear journals. Align the dowels with the holes in the mating casting. Being careful not to pinch the gasket-seal, tap the port end cover lightly in the center between bearing bores to engage the dowels and to move parts together in the final seating.
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Parker Hannifin Corporation Gear Pump Division Youngstown, OH
PGP/PGM 300 Series Service Manual HY09-SM300/US
Guideline for acceptable wear Gear Housings
Dowel Pins
Wear in excess of .007" cut-out necessitates replacement of the gear housing. Place a straight-edge across bore. If you can slip a .007 feeler gage under the straight-edge in the cut-out area, replace the gear housing.
If either the dowel or dowel hole is damaged, the dowel or machined casting, or both, must be replaced. If more than reasonable force is required to seat dowels, the cause may be poorly deburred or dirty parts; cocking of the dowel in the hole or improper pin-to-hole fit.
Pressure pushes the gears against the housing on the low pressure side. As the hubs and bushings wear, the cut-out becomes more pronounced. Excessive cut-outin a short period of time indicates excessive pressure or oil contamination. If the relief valve settings are within prescribed limits, check for shock pressures or tampering. When the cut-out is moderate, 007" or less, the gear housing is in good condition and may be reused.
Bushings If gears are replaced, bushings must be replaced. Bushings should fit into the bore with a heavy press fit. Seals and Gaskets Replace all rubber and polymer seals, including all "0" rings, thrust plate channel seals, shaft seal and gasket seals.
Gears Any scoring on gear hubs necessitates replacement. Scoring, grooving, or burring of the outside diameter of the teeth requires replacement. Nicking, grooving, or fretting of teeth surfaces also necessitates replacement.
Plugs Examine the plugs in the shaft end and port end cover to make sure that they are in the proper position and tight. The PGP/PGM315 and PGP/PGM330 should have two plugs in both the shaft end and port end in tandem units only. The PGP/PGM350 and PGP/PGM365 have one plug in their shaft and port ends high pressure side only.
Drive Shafts Replace if there is any wear detectable by touch in the seal area or at the drive coupling. The maximum allowable wear is .002". Wear in the shaft seal area indicates oil contamination. Wear or damage to splines, keys, or keyways necessitates replacement. Thrust Plates The thrust plates seal the gear section at the sides of the gears. Wear here will allow internal slippage, that is, oil will by within the pump. A maximum of .002" wear is allowable. Replace thrust plates if they are scored, eroded or pitted. Check center of thrust plates where the gears mesh. Erosion here indicates oil contamination. Pitted thrust plates indicate cavitation or oil aeration. Discolored thrust plates indicate overheating, likely due to insufficient oil.
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Parker Hannifin Corporation Gear Pump Division Youngstown, OH
PGP/PGM 300 Series Service Manual HY09-SM300/US
Lubrication and Oil Recommendations General Recommendations:
All parts, with the exception of the outboard bearing, are lubricated by the hydraulic oil in the circuit. Particular attention must be paid to keep clean oil in the circuit system. Whenever there is a pump or motor failure, and there is reason to feel that metal particles may be in the system, the oil must be drained, the entire system flushed clean and any filter screens thoroughly cleaned or replaced. New oil should be supplied for the entire system. Oil suitable and recommended for use in circuits involving Parker's pumps and motors should meet the following specifications:
A good-quality hydraulic oil conforming to the characteristics listed above is essential to the satisfactory performance and long life of any hydraulic system. The oil should be changed on regular schedules in accordance with the manufacturer's recommendations, and the system periodically flushed. The oil temperature in the reservoir must not exceed 200° F., (93.3° C.) with a maximum temperature of 180° F. (82.2° C.) recommended. Higher temperatures will result in rapid oil deterioration.
Viscosity: • 50 SSU minimum @ operating temperature 7500 SSU maximum @ starting temperature
Reservoir capacity should equal in gallons the pump output in gpm or the total gpm of all pumps, where there is more than one in the system.
• 150 to 225 SSU @ 100° F. (37.8°C.) (generally) 44 to 48 SSU @ 210° F. (98.9° C.) (generally)
Oil poured into the reservoir should through a 100-mesh screen. Pour only clean oil from clean containers into the reservoir. A 100-mesh screen may be used in the suction line leading to the pump. A suction filter should be of sufficient size to handle twice the pump capacity. It must be cleaned and checked regularly to avoid damage due to contamination and cavitation.
Approximate SSU @
Normal Temperatures: O° F. (-1 8° C.) to 100° F. (37.8° C.) Ambient 100° F. (37.8° C.) to 180° F. (82.2° C.) System. Be sure your oil is recommended for the temperatures you expect to encounter.
Viscosity Index: 90 minimum Aniline Point: 175 minimum Recommended Additives: Foam depressant, rust and oxidation inhibitors. Filtration: 10 micron recommended for maximum pump life.
Cold Weather Operation: Oils for use in cold weather should have a viscosity not exceeding 7500 SSU at the minimum start-up temperature. A pour point of at least 20° F. below start-up temperature is recommended. Start-up procedures should allow for a gradual warm-up until the oil reaches a reasonably fluid state.
Other Desirable Characteristics: • Stability of physical and chemical characteristics. • High demulsibility (low emulsibility) for separation of water, air and contaminants. • Resistant to the formation of gums, sludges, acids, tars and varnishes. • High lubricity and film strength.
Continued on the following page.
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Parker Hannifin Corporation Gear Pump Division Youngstown, OH
PGP/PGM 300 Series Service Manual HY09-SM300/US Continued from the previous page
Recommended Start-up Procedure For New or Rebuilt Pump
The Use of Other Fluids:
Before installing a new or rebuilt pump, back off the main relief valve until the spring tension on the adjusting screw is relieved. This will avoid the possibility of immediate damage to the replacement unit in the event that the relief valve setting had been increased beyond the recommended operating pressure, prior to removing the old unit.
• Automatic Transmission Fluid (ATF): In general, ATF performance is satisfactory; however these fluids are sometimes too expensive for normal use in hydraulic systems. • Diesel Fuel or Kerosene (Coal Oil): Though sometimes used as dilutants for cold weather operations, they are not recommended, as they are not sufficiently refined.
Before connecting any lines to the pump, fill all ports with clean oil to provide initial lubrication. This is particularly important if the unit is located above the oil reservoir.
• Fire Resistant Fluids: DO NOT USE ANY FIRE RESISTANT FLUIDS OR NON-PETROLEUM OILS WITHOUT CONSULTING OUR TECHNICAL SERVICE DEPARTMENT.
After connecting the lines and mounting the replacement unit, operate the pump at least two minutes at no load and at low rpm (400 min.) During this break-in period, the unit should run free and not develop an excessive amount of heat. If the unit operates properly, speed and pressure can then be increased to normal operating settings.
• These suggestions are intended as a guide only. OBTAIN YOUR FINAL FLUID RECOMMENDATIONS FROM YOUR FLUID SUPPLIER.
Reset the main relief valve to its proper setting while the pump is running at maximum operating engine (motor) speed for the vehicle.
ALWAYS USE AN ACCURATE GAUGE WHEN ADJUSTING THE RELIEF VALVE PRESSURE SETTING.
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Parker Hannifin Corporation Gear Pump Division Youngstown, OH
PGP/PGM 300 Series Service Manual HY09-SM300/US
Recommended Test Procedure Many repairmen measure the output at normal operating speed and at zero pressure, then again at 1000 psi (or the operating pressure of the equipment) and allow a volume decrease approximating the listing below. It is a suggested reference only which makes allowance for reused parts.
Make certain that there is an adequate supply of oil for the pump; at least one gallon of oiI for each gpm of pump capacity. If one section of a tandem pump is being tested, make sure that all other sections not being tested are adequately supplied with oil. If any of the other sections run dry, or if plugs are left in ports, serious and permanent damage will result.
At test speeds other than 1800 rpm, gpm delivery will vary almost proportionately, but the same (drop-off) figures should be used.
The oil should be a good quality hydraulic oil rated at 150 SSU at 100° F., with the oil temperature held at 120° F. plus or minus 50° F. (Test procedures are described in detail in SAE handbooks; see Hydraulic Power Pump Test Procedure, SAE J745c.)
Be sure to run the pump in the direction for which it was designed and built. Driving the pump in the wrong direction will build up pressure behind the shaft seal, damaging it and necessitating replacement. After completing testing procedures, the pump is ready for installation and immediate duty operation on equipment. Again, it must be ed that to prevent seizure, hot oil must not be fed into a cold pump.
The feed line must be of adequate size with no more than 5" mercury vacuum adjacent to the pump inlet. As a rule, the feed line must provide a feed flow velocity not in excess of 8 feet per second. Feeding hot oil into a cold pump may cause the pump to seize. Jog the pump by momentarily starting and stopping repeatedly the driving engine or motor to gradually equalize pump and oil temperatures. Run the pump at least two minutes at no load and moderate speed (not over 1500 rpm). If the pump becomes excessively hot, shut down immediately and locate the problem source. Gradually increase pressure on pump, in 500 psi increments until the desired test pressure has been reached. This should take about five minutes. Delivery should run close to rated catalog performance figures, which are averaged from testing several pumps. A 5% lower reading may be used as a rated minimum if new or relatively new parts have been used. When rebuilding the pump with parts from the original pump, which, while worn, appear satisfactory for reuse, a 10% or 15% lower reading may be permitted, depending on the performance expected from the equipment. One's own experience will prove the best guide here.
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Parker Hannifin Corporation Gear Pump Division Youngstown, OH
PGP/PGM 300 Series Service Manual HY09-SM300/US Offer of Sale The items described in this document and other documents or descriptions provided by Parker Hannifin Corporation, its subsidiaries and its authorized distributors are hereby offered for sale at prices to be established by Parker Hannifin Corporation, its subsidiaries and its authorized distributors. This offer and its acceptance by any customer ("Buyer") shall be governed by all of the following and Conditions. Buyer’s order for any such items, when communicated to Parker Hannifin Corporation, its subsidiary or an authorized distributor ("Seller") verbally or in writing, shall constitute acceptance of this offer. items sold hereunder, even if such apparatus has been specially converted or adapted for such manufacture and notwithstanding any charges paid by Buyer. Unless otherwise agreed, Seller shall have the right to alter, discard or otherwise dispose of any special tooling or other property in its sole discretion at any time. 8. Buyer’s Property: Any designs, tools, patterns, materials, drawings, confidential information or equipment furnished by Buyer or any other items which become Buyer’s property, may be considered obsolete and may be destroyed by Seller after two (2) consecutive years have elapsed without Buyer placing an order for the items which are manufactured using such property, Seller shall not be responsible for any loss or damage to such property while it is in Seller’s possession or control. 9. Taxes: Unless otherwise indicated on the face hereof, all prices and charges are exclusive of excise, sales, use, property, occupational or like taxes which may be imposed by any taxing authority upon the manufacture, sale or delivery of the items sold hereunder. If any such taxes must be paid by Seller or if Seller is liable for the collection of such tax, the amount thereof shall be in addition to the amounts for the items sold. Buyer agrees to pay all such taxes or to reimburse Seller therefore upon receipt of its invoice. If Buyer claims exemption from any sales, use or other tax imposed by any taxing authority, Buyer shall save Seller harmless from and against any such tax, together with any interest or penalties thereon which may be assessed if the items are held to be taxable. 10. Indemnity For Infringement of Intellectual Property Rights: Seller shall have no liability for infringement of any patents, trademarks, copyrights, trade dress, trade secrets or similar rights except as provided in this Part 10. Seller will defend and indemnify Buyer against allegations of infringement of U.S. Patents, U.S. Trademarks, copyrights, trade dress and trade secrets (hereinafter ‘Intellectual Property Rights’). Seller will defend at its expense and will pay the cost of any settlement or damages awarded in an action brought against Buyer based on an allegation that an item sold pursuant to this contract infringes the Intellectual Property Rights of a third party. Seller’s obligation to defend and indemnify Buyer is contingent on Buyer notifying Seller within ten (10) days after Buyer becomes aware of such allegations of infringement, and Seller having sole control over the defense of any allegations or actions including all negotiations for settlement or compromise. If an item sold hereunder is subject to a claim that it infringes the Intellectual Property Rights of a third party, Seller may, at its sole expense and option, procure for Buyer the right to continue using said item, replace or modify said item so as to make it noninfringing, or offer to accept return of said item and return the purchase price less a reasonable allowance for depreciation. Notwithstanding the foregoing, Seller shall have no liability for claims of infringement based on information provided by Buyer, or directed to items delivered hereunder for which the designs are specified in whole or part by Buyer, or infringements resulting from the modification, combination or use in a system of any item sold hereunder. The foregoing provisions of this Part 10 shall constitute Seller’s sole and exclusive liability and Buyer’s sole and exclusive remedy for infringement of Intellectual Property Rights. If a claim is based on information provided by Buyer or if the design for an item delivered hereunder is specified in whole or in part by Buyer, Buyer shall defend and indemnify Seller for all costs, expenses or judgments resulting from any claim that such item infringes any patent, trademark, copyright, trade dress, trade secret or any similar right. 11. Force Majeure: Seller does not assume the risk of and shall not be liable for delay or failure to perform any of Seller’s obligations by reason of circumstances beyond the reasonable control of Seller (hereinafter ‘Events of Force Majeure’). Events of Force Majeure shall include without limitation, accidents, acts of God, strikes or labor disputes, acts, laws, rules or regulations of any government or government agency, fires, floods, delays or failures in delivery of carriers or suppliers, shortages of materials and any other cause beyond Seller’s control. 12. Entire Agreement/Governing Law: The and conditions set forth herein, together with any amendments, modifications and any different or conditions expressly accepted by Seller in writing, shall constitute the entire Agreement concerning the items sold, and there are no oral or other representations or agreements which pertain thereto. This Agreement shall be governed in all respects by the law of the State of Ohio. No actions arising out of the sale of the items sold hereunder or this Agreement may be brought by either party more than two (2) years after the cause of action accrues. 9/91-P
1. and Conditions of Sale: All descriptions, quotations, proposals, offers, acknowledgments, acceptances and sales of Seller’s products are subject to and shall be governed exclusively by the and conditions stated herein. Buyer’s acceptance of any offer to sell is limited to these and conditions. Any or conditions in addition to, or inconsistent with those stated herein, proposed by Buyer in any acceptance of an offer by Seller, are hereby objected to. No such additional, different or inconsistent and conditions shall become part of the contract between Buyer and Seller unless expressly accepted in writing by Seller. Seller’s acceptance of any offer to purchase by Buyer is expressly conditional upon Buyer’s assent to all the and conditions stated herein, including any in addition to, or inconsistent with those contained in Buyer’s offer, Acceptance of Seller’s products shall in all events constitute such assent. 2. Payment: Payment shall be made by Buyer net 30 days from the date of delivery of the items purchased hereunder. Amounts not timely paid shall bear interest at the maximum rate permitted by law for each month or portion thereof that the Buyer is late in making payment. Any claims by Buyer for omissions or shortages in a shipment shall be waived unless Seller receives notice thereof within 30 days after Buyer’s receipt of the shipment. 3. Delivery: Unless otherwise provided on the face hereof, delivery shall be made F.O.B. Seller’s plant. Regardless of the method of delivery, however, risk of loss shall to Buyer upon Seller’s delivery to a carrier. Any delivery dates shown are approximate only and Seller shall have no liability for any delays in delivery. 4. Warranty: Seller warrants that the items sold hereunder shall be free from defects in material or workmanship for a period of 18 months from date of shipment from Parker Hannifin Corporation. THIS WARRANTY COMPRISES THE SOLE AND ENTIRE WARRANTY PERTAINING TO ITEMS PROVIDED HEREUNDER. SELLER MAKES NO OTHER WARRANTY, GUARANTEE, OR REPRESENTATION OF ANY KIND WHATSOEVER. ALL OTHER WARRANTIES, INCLUDING BUT NOT LIMITED TO, MERCHANTABILITY AND FITNESS FOR PURPOSE, WHETHER EXPRESS, IMPLIED, OR ARISING BY OPERATION OF LAW, TRADE USAGE, OR COURSE OF DEALING ARE HEREBY DISCLAIMED. NOTWITHSTANDING THE FOREGOING, THERE ARE NO WARRANTIES WHATSOEVER ON ITEMS BUILT OR ACQUIRED WHOLLY OR PARTIALLY, TO BUYER’S DESIGNS OR SPECIFICATIONS. 5. Limitation Of Remedy: SELLER’S LIABILITY ARISING FROM OR IN ANY WAY CONNECTED WITH THE ITEMS SOLD OR THIS CONTRACT SHALL BE LIMITED EXCLUSIVELY TO REPAIR OR REPLACEMENT OF THE ITEMS SOLD OR REFUND OF THE PURCHASE PRICE PAID BY BUYER, AT SELLER’S SOLE OPTION. IN NO EVENT SHALL SELLER BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY KIND OR NATURE WHATSOEVER, INCLUDING BUT NOT LIMITED TO LOST PROFITS ARISING FROM OR IN ANY WAY CONNECTED WITH THIS AGREEMENT OR ITEMS SOLD HEREUNDER, WHETHER ALLEGED TO ARISE FROM BREACH OF CONTRACT, EXPRESS OR IMPLIED WARRANTY, OR IN TORT, INCLUDING WITHOUT LIMITATION, NEGLIGENCE, FAILURE TO WARN OR STRICT LIABILITY. 6. Changes, Reschedules and Cancellations: Buyer may request to modify the designs or specifications for the items sold hereunder as well as the quantities and delivery dates thereof, or may request to cancel all or part of this order, however, no such requested modification or cancellation shall become part of the contract between Buyer and Seller unless accepted by Seller in a written amendment to this Agreement. Acceptance of any such requested modification or cancellation shall be at Seller’s discretion, and shall be upon such and conditions as Seller may require. 7. Special Tooling: A tooling charge may be imposed for any special tooling, including without limitation, dies, fixtures, molds and patterns, acquired to manufacture items sold pursuant to this contract. Such special tooling shall be and remain Seller’s property notwithstanding payment of any charges by Buyer. In no event will Buyer acquire any interest in apparatus belonging to Seller which is utilized in the manufacture of the
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Parker Hannifin Corporation Gear Pump Division Youngstown, OH
Power Wheel® Service Manual Model 6 Single Reduction Wheel Drives
AUBURN, INDIANA 46706-3499 U.S.A.
PHONE: (219) 925-3200 FAX: (219) 925-4725 3 1 2 4 5 6 7
8
11
7 12 13 17
14 16
18 9 10 15
19
24 20
21 22
25
23
26 27 29
30
28
31
OPTIONAL 91
ITEM NO.
DESCRIPTION*
NO. USED IN ASS’Y.
ITEM NO.
DESCRIPTION*
NO. USED IN ASS’Y.
1
Coupling
1
17
Ring Gear
1
2
Input Shaft
1
18
Carrier Assembly
1
3
Spindle
1
19
Sun Gear
1
4
Boot Seal 604401
1
20
Retaining Ring
1
5
Oil Seal 14-00-044-010
1
21
Thrust Washer
1
6
Bearing Cone 04-01-101-35
1
22
Disengage Plunger
1
7
Bearing Cup 04-01-102-12
2
23
1
8
Wheel Bolt
9
“O” Ring 614101 Aluminum Cover 10-00-141-113 Cast Iron Cover 614101
24 Hex Head Bolt (Grade 8)
6-12
Large Cover Aluminum Cover 14-02-039-004 Cast Iron Cover 603915
1
9 10
Flat Washer 14-00-047-002
6-12
25
Hex Head Bolt
8
11
Hub
1
26
Magnetic Plug 14-00-052-002
1
12
Bearing Cone 04-01-101-17
1
27
Disengage Cover 14-02-039-005
1
13
Retaining Ring Kit 14-02-410-003
1
28
Hex Head Bolt 618305
2
14
Retaining Ring 613912
2
29
Quick Disconnect Gasket
1
15
Washer 14-02-193-002
2
30
Quick Disconnect Assembly
1
16
Disengage Spring 14-02-156-001
1
31
Hex Head Bolt
2
* Auburn Gear with part number and order code of drive to obtain the appropriate parts list. Refer to parts list for the specific part numbers and quantities.
Model 6 Power Wheel® Service Kits Part No.
Description
Included Items
14-02-410-003 641008** 641017**
Retaining Ring Kit Bearing and Seal Kit Seal Kit
13 (7 Retaining Rings) 5, 6, 7, 12, 13 and 23 5, 13 and 23
** Indicates kit also includes a tube of sealant, part number 604101. MH422 - 0397
Power Wheel® is a ed trademark of Auburn Gear 92
IDENTIFICATION IMPORTANT: All Power Wheel units and kits are shipped with a nameplate that includes the Auburn Gear part number and order code as shown.
Power Wheel® Example:
ORDER CODE: 6WB13156C PART NO.: 6000236 SERIAL NO.: 143434
AUBURN, IN U.S.A.
In addition to the nameplate, Power Wheel drives are stamped with an identification number which appears on the cover or hub flange as shown. Example:
6000236-A-4-9
When ordering parts, the information included on the nameplate or the stamped identification number is necessary to accurately identify the drive and obtain the correct replacement parts. Once this information has been obtained, Auburn Gear for the appropriate parts list.
DISASSEMBLY OF POWER WHEEL STEP 1
STEP 7
Slide the coupling (1) from splines on input shaft (2).
Remove the input shaft (2) from spindle (3). Remove the retaining rings (14), washers (15), and disengage spring (16) from input shaft (2) only if replacement is required.
STEP 2 Position the assembly upright on face of spindle (3).
STEP 8
STEP 3
Remove the 6 or 12 bolts (9) and washers (10) from hub (11) and remove ring gear (17). It may be necessary to strike ring gear (17) with a rubber mallet to loosen from hub (11).
Remove the disengage cover (27) if necessary. STEP 4 Remove bolts (25) and the large cover (24) from the unit. The thrust washer (21) and the disengage plunger (22) usually remain attached to the large cover (24) when it is removed. Remove thrust washer (21), disengage plunger (22) and “O” ring (23) from the large cover (24). STEP 5 Remove sun gear (19) and thrust washer (20), used in aluminum cover units only, from end of input shaft (2). STEP 6 Remove the carrier assembly (18).
STEP 9 Remove the retaining ring (13) from in front of the bearing cone (12) and lift hub (11) from spindle (3). If bearings are not a loose fit, it may be necessary to press spindle (3) from hub (11). NOTE: Use a retaining ring expander tool to remove retaining ring (13). STEP 10 Remove the oil seals (4) and (5) and bearing cones (6 & 12) from hub (11). Inspect bearing cups (7) in position and remove only if replacement is required.
ASSEMBLY OF POWER WHEEL STEP 1
STEP 5
Press new bearing cups (7) in each side of the hub (11). It is recommended that bearing cups (7) and cones (6 & 12) be replaced in sets.
Assemble a retaining ring (14) in groove opposite pilot end of input shaft (2). Assemble a washer (15), spring (16), a second washer (15), and a second retaining ring (14) in the middle grooves of input shaft (2). Some shafts have a shoulder and require only one retaining ring (14).
STEP 2 Assemble bearing cone (6) into cup (7) at seal end of hub (11) and press a new seal (5) into hub (11). Install boot seal (4) on hub (11) if unit is so equipped.
STEP 6 Assemble the splined end of the input shaft (2) down into spindle (3).
STEP 3
STEP 7
Position spindle (3) upright on bench. Lubricate lips of seals (4 & 5) and lower hub (11) onto spindle (3). Hub (11) should be centered as it is lowered over spindle (3) to prevent seal damage.
Assemble the carrier assembly (18) to spindle (3) at splines.
STEP 4 Assemble bearing cone (12) over spindle (3) and into bearing cup (7). If bearings (6, 7, &12), hub (11) or spindle (3) is replaced, a new retaining ring (13) is required for proper bearing setting. Do not re-use snap ring after it has been installed and removed from unit. Select the thickest retaining ring (13) that can be assembled into the ring groove of the splined end of spindle (3) above bearing cone (12). Bearing should have from .000 – .006 inches of end play when proper retaining ring (13) is installed.
STEP 8 Clean mating surfaces and apply a bead of silicone sealant to face of hub (11) that mates with ring gear (17). {See instructions on sealant package.} Hub (11) is attached to ring gear (17) with 6 or 12 3/8-24 grade 8 hex head cap screws (9) and flat washers (10). Torque cap screws to 52 – 60 lb. ft. (70 – 81 Nm). STEP 9 Assemble sun gear (19) over input shaft (2). Rotate sun gear (19) to align input shaft (2) to gear splines and gear teeth in carrier assembly (18).
2 93
STEP 10
STEP 13
For units with the aluminum cover (24) assemble the small thrust washer (20) over input shaft (2) and against shoulder of input shaft (2).
Assemble the disengage cover (27) with dimpled center protruding out if wheel is to be used to drive the vehicle. Assemble and torque the two 5/16-18 x 1/2 inch bolts (28). Torque bolts to 10 – 20 lb. ft. (13 – 27 Nm).
STEP 11 For units with the aluminum cover (24), lubricate “O” ring (23) and assemble in groove of the disengage plunger (22). Assemble disengage plunger (22) over end of input shaft (2) and against thrust washer (20). For units with cast iron cover (24), lubricate “O” ring (23) and assemble in groove inside cover hole, push plunger (22) into cover with pointed end facing inside of unit.
STEP 14 Invert the Power Wheel assembly and assemble the coupling (1), with counterbore out, to the input shaft (2). STEP 15
STEP 12
After motor is assembled to drive or drive is sealed at spindle, fill with lubricant to proper level and replace all plugs.
Assemble the thrust washer (21) with tangs engaged with cover (24). NOTE: A small amount of grease applied to the back side of thrust washer (21) will hold washer in place. Apply a bead of silicone sealant to end of face of ring gear (17). Assemble cover (24) aligning holes of cover and ring gear. Assemble the eight 5/16-18 x 1 inch hex head bolts (25). Torque bolts to 20 – 25 lb. ft. (27 – 34 Nm).
NOTE: When installing a hydraulic motor to the Power Wheel drive it is necessary to place an “O” ring or gasket (not supplied by Auburn Gear) between the motor and the planetary drive. “O” ring sizes: SAE A 2-042, SAE B 2-155, SAE C 2-159.
CARRIER ASSEMBLIES It is recommended that the carrier assembly (18) be replaced in its entirety to protect the integrity of the Power Wheel drive.
LUBRICATION RECOMMENDATIONS IMPORTANT: POWER WHEEL PLANETARY DRIVES ARE SHIPPED WITHOUT LUBRICANT AND MUST BE FILLED TO THE PROPER LEVEL PRIOR TO START UP. Observe lubrication recommendations given by the original equipment manufacturer. When specific recommendations are not available, use mild extreme pressure lubricant API-GL-5, No. 80 or 90 when filling the Power Wheel under normal temperature ranges between 0 - 120°F (-18 to 49°C). Power Wheel is to be half full of oil when unit is mounted level and horizontal. Use drain and fill plugs located in cover and ring gear. Oil is to be changed after first 50 hours of operation with subsequent changes every 1000 hours or yearly, which ever comes first. If unit is to be operated vertically, if ambient conditions are outside the specified range, or if the oil temperature exceeds 200°F (93°C) Auburn Gear for oil and level recommendations.
TOWING VEHICLE CAUTION: The Power Wheel will not normally be damaged by towing; however, the hydraulic drive components may be damaged unless the Power Wheel is disengaged from the drive motor. Road speeds in excess of 25 MPH should be avoided unless clearly specified to be permissible by the equipment manufacturer.
TO DISENGAGE POWER WHEEL CAUTION: For units equipped with the standard spring disconnect, assemble the disengage cover (27) with the dimpled center protruding inward. For units equipped with the optional quick disconnect, push in center plunger of disconnect.
STORAGE A protective film is applied to the Power Wheel at the factory to prevent rust during shipment. Additional protection may be required if the Power Wheel is to be stored for an extended period of time.
SEALING COMPOUND Silastic RTV732 sealer and General Electric Silimate RTV No. 1473 or RTV No. 1503 are currently recommended for sealing gasket surfaces. Sealant should be applied in a continuous bead, which should be centered on the surface to be sealed but should move to the inside of the hole at each bolt hole location. For service requirements order Auburn Gear part number 604101.
SPECIFICATIONS Maximum intermittent output torque ................................................................................................................................................. 22,000 lb. in. (2,485 Nm) Maximum input speed ....................................................................................................................................................................................... 3,500 RPM Oil capacity ................................................................................................................................................................................................... 25 oz (738 ml) 94 3
ELECTRICAL
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Adjustable Frequency AC Drive for Fan & Pump Applications FRN 2.xx
Manual
www.abpowerflex.com
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Chapter 4
Troubleshooting Chapter 4 provides information to guide you in troubleshooting the PowerFlex 400 drive. Included is a listing and description of drive faults (with possible solutions, when applicable). For information on… Drive Status Faults
See page… For information on… 4-1 Fault Descriptions 4-1 Common Symptoms and Corrective Actions
See page… 4-3 4-5
Drive Status The condition or state of your drive is constantly monitored. Any changes will be indicated through the integral keypad.
LED Indications See page 2-3 for information on drive status indicators and controls.
Faults A fault is a condition that stops the drive. There are two fault types. Type Fault Description ➀ Auto-Reset/Run When this type of fault occurs, and A163 [Auto Rstrt Tries] is set to a value greater than “0,” a -configurable timer, A164 [Auto Rstrt Delay], begins. When the timer reaches zero, the drive attempts to automatically reset the fault. If the condition that caused the fault is no longer present, the fault will be reset and the drive will be restarted. ➁ Non-Resetable This type of fault may require drive or motor repair, or is caused by wiring or programing errors. The cause of the fault must be corrected before the fault can be cleared.
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4-2
Troubleshooting
Fault Indication Condition Drive is indicating a fault. The integral keypad provides visual notification of a fault condition by displaying the following. • Flashing fault number • Flashing fault indicator Press the Escape key to regain control of the integral keypad.
Manually Clearing Faults Step Key(s) 1. Press Esc to acknowledge the fault. The fault information will be removed so that you can use the integral keypad. Access b007 [Fault 1 Code] to view the most recent fault information. 2. Address the condition that caused the fault. The cause must be corrected before the fault can be cleared. See Table 4.A. 3. After corrective action has been taken, clear the fault by one of these methods. • Press Stop if P037 [Stop Mode] is set to a value between “0” and “3”. • Cycle drive power. • Set A197 [Fault Clear] to “1” or “2”. • Cycle digital input if T051-T054 [Digital Inx Sel] is set to option 10 “Clear Fault”.
Automatically Clearing Faults Option / Step Clear a Type 1 fault and restart the drive. 1. Set A163 [Auto Rstrt Tries] to a value other than “0”. 2. Set A164 [Auto Rstrt Delay] to a value other than “0”. Clear an OverVoltage, UnderVoltage or Heatsink OvrTmp fault without restarting the drive. 1. Set A163 [Auto Rstrt Tries] to a value other than “0”. 2. Set A164 [Auto Rstrt Delay] to “0”.
Auto Restart (Reset/Run) The Auto Restart feature allows the drive to automatically perform a fault reset followed by a start attempt without or application intervention. This allows remote or “unattended” operation. Only certain faults are allowed to be reset. Certain faults (Type 2) that indicate possible drive component malfunction are not resettable. Caution should be used when enabling this feature, since the drive will attempt to issue its own start command based on selected programming.
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Troubleshooting
4-3
Fault Descriptions Type(1)
Table 4.A Fault Types, Descriptions and Actions
No. F2
Fault Auxiliary Input
F3
Power Loss
➁
F4
UnderVoltage
➀
F5
OverVoltage
➀
F6
Motor Stalled
➀
F7
Motor Overload
➀
F8
Heatsink OvrTmp
➀
F12
HW OverCurrent
➁
F13
Ground Fault
➁
F15
Load Loss
➀
F29
Anaput Loss
➀
(1)
➀
Description Auxiliary input interlock is open.
Action 1. Check remote wiring. 2. communications programming for intentional fault. DC bus voltage remained below 1. Monitor the incoming AC line for 85% of nominal. low voltage or line power interruption. 2. Check input fuses. DC bus voltage fell below the Monitor the incoming AC line for low minimum value. voltage or line power interruption. DC bus voltage exceeded Monitor the AC line for high line maximum value. voltage or transient conditions. Bus overvoltage can also be caused by motor regeneration. Extend the decel time or install dynamic brake option. Drive is unable to accelerate Increase P039 - A147 [Accel Time x] motor. or reduce load so drive output current does not exceed the current set by parameter A179 [Current Limit 1]. Internal electronic overload trip. 1. An excessive motor load exists. Reduce load so drive output current does not exceed the current set by parameter P033 [Motor OL Current]. 2. A170 [Boost Select] setting Heatsink temperature exceeds a 1. Check for blocked or dirty heat predefined value. sink fins. that ambient temperature has not exceeded 45°C (113°F) for IP 30/NEMA 1/UL Type 1 installations or 50°C (122°F) for IP20/Open type installations. 2. Check fan. The drive output current has Check programming. Check for exceeded the hardware current excess load, improper A170 [Boost Select] setting, DC brake volts set limit. too high or other causes of excess current. A current path to earth ground Check the motor and external wiring has been detected at one or to the drive output terminals for a more of the drive output grounded condition. terminals. Check for load loss (i.e., a broken Output current has dropped below the level set in A184 [Load belt). Loss Level]. An anaput is configured to 1. Check parameters. fault on signal loss. A signal loss 2. Check for broken/loose has occurred. connections at inputs. Configure with T072 [Ana Loss].
See page 4-1 for a description of fault types. 102
Troubleshooting Type(1)
4-4
No. F33
Fault Auto Rstrt Tries
F38 F39 F40
Phase U to Gnd Phase V to Gnd Phase W to Gnd
➁
F41 F42 F43
Phase UV Short Phase UW Short Phase VW Short
➁
F48
Params Defaulted
F63
SW OverCurrent
➀
F64
Drive Overload
➁
F70
Power Unit
➁
F71
Net Loss
F81
Comm Loss
➁
F94
Function Loss
➁
F100 Parameter Checksum
➁
➁
Description Drive unsuccessfully attempted to reset a fault and resume running for the programmed number of A163 [Auto Rstrt Tries]. A phase to ground fault has been detected between the drive and motor in this phase.
Action Correct the cause of the fault and manually clear.
1. Check the wiring between the drive and motor. 2. Check motor for grounded phase. 3. Replace drive if fault cannot be cleared. Excessive current has been 1. Check the motor and drive output detected between these two terminal wiring for a shorted output terminals. condition. 2. Replace drive if fault cannot be cleared. The drive was commanded to 1. Clear the fault or cycle power to write default values to EEPROM. the drive. 2. Program the drive parameters as needed. Programmed A183 [SW Current Check load requirements and A183 Trip] has been exceeded. [SW Current Trip] setting. Drive rating of 150% for 1 minute Reduce load or extend Accel Time. or 200% for 3 seconds has been exceeded. Failure has been detected in the 1. Cycle power. drive power section. 2. Replace drive if fault cannot be cleared. The communication network has 1. Cycle power. faulted. 2. Check communications cabling. 3. Check network adapter setting. 4. Check external network status. RS485 (DSI) port stopped 1. Check RS485 wiring connection. communicating. 2. Check if a communications adapter or HIM was disconnected. 3. Increase C106 [Comm Loss Time] to an appropriate time for application. 4. Change C105 [Comm Loss Action] to a value other than “0” (fault), if appropriate for the application. P036 [Start Source] is set to Close input to terminal 01 and setting 6. The input to terminal 01 re-start the drive. has been opened. The checksum read from the Set P041 [Reset To Defalts] to option board does not match the 1 “Reset Defaults”. checksum calculated.
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No. Fault F122 I/O Board Fail
(1)
Type(1)
Troubleshooting
➁
4-5
Description Action Failure has been detected in the 1. Cycle power. drive control and I/O section. 2. Replace drive if fault cannot be cleared.
See page 4-1 for a description of fault types.
Common Symptoms and Corrective Actions Motor does not Start. Cause(s) No output voltage to the motor.
Indication None
Drive is Faulted
Flashing red status light
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Corrective Action Check the power circuit. • Check the supply voltage. • Check all fuses and disconnects. Check the motor. • that the motor is connected properly. Check the control input signals. • that a Start signal is present. If 2-Wire control is used, that either the Run Forward or Run Reverse signal is active, but not both. • that I/O Terminal 01 is active. • that P036 [Start Source] matches your configuration. • that A166 [Reverse Disable] is not prohibiting movement. Clear fault. • Press Stop • Cycle power • Set A197 [Fault Clear] to option 1 “Clear Faults”. • Cycle digital input if T051 - T054 [Digital Inx Sel] is set to option 7 “Clear Fault”.
4-6
Troubleshooting Drive does not Start from Start or Run Inputs wired to the terminal block.
Cause(s) Drive is Faulted
Indication Flashing red status light
Incorrect programming. None • P036 [Start Source] is set to option 0 “Keypad” or option 5 “RS485 (DSI) Port”. • T051 - T054 [Digital Inx Sel] is set to option 5 “Local” and the input is active. None Incorrect input wiring. See 1-20 for wiring examples. • 2 wire control requires Run Forward, Run Reverse or Jog input. • 3 wire control requires Start and Stop inputs • Stop input is always required. Incorrect Sink/Source DIP switch None setting.
Corrective Action Clear fault. • Press Stop • Cycle power • Set A197 [Fault Clear] to option 1 “Clear Faults”. • Cycle digital input if T051 - T054 [Digital Inx Sel] is set to option 7 “Clear Fault”. Check parameter settings.
Wire inputs correctly and/or install jumper.
Set switch to match wiring scheme.
Drive does not Start from Integral Keypad. Cause(s) Indication Corrective Action Integral keypad is not enabled. Green LED above Start key is • Set parameter P036 [Start not illuminated. Source] to option 0 “Keypad”. • Set parameter T051 - T054 [Digital Inx Sel] to option 5 “Local” and activate the input. I/O Terminal 01 “Stop” input is None Wire inputs correctly and/or install not present. jumper.
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Troubleshooting
4-7
Drive does not respond to changes in speed command. Cause(s) No value is coming from the source of the command.
Indication The drive “Run” indicator is lit and output is 0 Hz.
Incorrect reference source is being selected via remote device or digital inputs.
None
Corrective Action • Check d301 [Control Source] for correct source. • If the source is an anaput, check wiring and use a meter to check for presence of signal. • Check b002 [Commanded Freq] to correct command. • Check d301 [Control Source] for correct source. • Check d302 [Contrl In Status] to see if inputs are selecting an alternate source. settings for T051 - T054 [Digital Inx Sel]. • Check P038 [Speed Reference] for the source of the speed reference. Reprogram as necessary. • Review the Speed Reference Control chart on page 1-24.
Motor and/or drive will not accelerate to commanded speed. Cause(s) Indication Acceleration time is excessive. None
Corrective Action Reprogram P039 [Accel Time 1] or A147 [Accel Time 2]. Compare b003 [Output Current] with A179 [Current Limit 1]. Remove excess load or reprogram P039 [Accel Time 1] or A147 [Accel Time 2]. Check for improper A170 [Boost Select] setting. b002 [Commanded Freq]. Check d301 [Control Source] for the proper Speed Command. Check P035 [Maximum Freq] to insure that speed is not limited by programming.
Excess load or short None acceleration times force the drive into current limit, slowing or stopping acceleration.
Speed command source or value is not as expected.
None
Programming is preventing the None drive output from exceeding limiting values.
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4-8
Troubleshooting Motor operation is unstable.
Cause(s) Motor data was incorrectly entered.
Indication None
Corrective Action 1. Correctly enter motor nameplate data into P031, P032 and P033. 2. Enable A194 [Compensation]. 3. Use A170 [Boost Select] to reduce boost level.
Drive will not reverse motor direction. Cause(s) Indication Digital input is not selected for None reversing control.
Digital input is incorrectly wired. Motor wiring is improperly phased for reverse. Reverse is disabled.
None
Corrective Action Check T051 - T054 [Digital Inx Sel] and P036 [Start Source]. Choose correct input and program for reversing mode. Check input wiring. (See page 1-18)
None
Switch two motor leads.
None
Check A166 [Reverse Disable].
Drive does not power up. Cause(s) No input power to drive.
Indication None
Jumper between Power Terminals P2 and P1 not installed and/or DC Bus Inductor not connected.
None
Corrective Action Check the power circuit. • Check the supply voltage. • Check all fuses and disconnects. Install jumper or connect DC Bus Inductor.
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SLURRY PUMP
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RECEIVING AND HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2, 3 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4, 5 THERMAL PROTECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 6 MOISTURE DETECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 7 LEAD COLOR CODING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
STANDARD REPLACEMENT SEAL CROSS REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
STANDARD REPLACEMENT O" RING CROSS REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
STANDARD REPLACEMENT SNAP RING CROSS REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
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©Copyright Reliance Electric Industrial Company, 1996. Revisions to this manual require Hazardous Approval Engineering and/or UL approval. ®Reliance and DutyMaster are ed trademarks of Reliance Electric Industrial Company
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RECEIVING AND HANDLING ACCEPTANCE #*-*0"#'4 $).+ / /#$. ,0$+( )/ !* +/$)" .#$+( )/ !-*( /# /-).+*-//$*) *(+)4 ! )4 *! /# "**. '' !*- $) /# $'' *! '$)" *- 3+- .. - $+/ - (" */# ,0)/$/4 $. .#*-/ * )*/ +/ /# ( 0)/$' /# !- $"#/ *- 3+- .. " )/ (& . ) ++-*+-$/ )*//$*) *) 4*0- !- $"#/ $'' *- 3+- .. - $+/ ! )4 *) ' '*.. *- (" $. $.*1 - '/ - )*/$!4 4*0- !- $"#/ *- 3+- .. " )/ / *) ) - ,0 ./ #$( /* (& ) $).+ /$*) 2$'' ..$./ 4*0 $) *'' /$)" '$(. !*- '*.. *- (" $) .#$+( )/ #*2 1 - /#$. 2$''$)") .. *) *0- +-/ * . )*/ - (*1 /# /-).+*-//$*) *(+)4. - .+*).$$'$/4 $) - $(0-.$)" 4*0 !*- *'' /$*) *! '$(. *- - +' ( )/ *! (/ -$' '$(. !*- '*.. *- (" $) .#$+( )/ (0./ )*/ 0/ !-*( /# '$) ' /-$ $)1*$ )*- .#*0' +4( )/ *! /# '$) ' /-$ $)1*$ 2$/## ' 2$/$)" %0./( )/ *! .0# '$(. . /# --$ - "0-)/ . .! '$1 -4 ! *).$ -' (" #. ) $)0-- ) /# .$/0/$*) $. 0-" )/ *)// /# ) - ./ '$) ' /-$ ' . !!$ !*- ..$./) ' . & + 2-$// ) - *- *! '' .0# *((0)$/$*). UNPACKING ! !$'$/$ . !*- /# .# '/ - *! ,0$+( )/ - )*/ 1$'' - +& (*/*- ) ./*- .#!/ *2) 0)/$' - 4 !*- 0. !/ - 0)+&$)" ) $).+ /$)" /* . /#/ '' +-/. #1 ) - $1 $) "** *)$/$*) /0-) /# (*/*- .#!/ 4 #) /* .0- /#/ /# - )* *./-0/$*). /* !- -*//$*) # (*/*- .#*0' # & !*- *$' ' &. !/ $)" - (*1 !-*( /# -/ ! +*.$/$1 $)$/$*) *! ) *$' ' & $. !*0) -*0) /# .#!/ . ' *- -$1 ) -& / )*/$!4 /# ) - ./ '$) ' /-$ ' . !!$ APPLICATION
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CONTINUOUS OPERATION GASES OR VAPORS It is the driven equipment manufacturer's responsibility to insure this motor product is properly applied.
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131
When removing impeller warm slightly with a torch and pry impeller off evenly with either small pry bars or a wheel puller. When the submersible pump motor leaves the factory it is ready for installation. No adjustment, venting or oil filling is required. For THREE PHASE motors the only connection to the motor lead cable is the power supply. For SINGLE PHASE motors the motor lead cable and power supply must be properly connected at the Control Box. Motor will operate successfully with frequency not more than 5% and voltage not more than 10% above or below nameplate data. Performance within this range will not necessarily be the same as the established performance at exact rated voltage and frequency. All submersible pump motors will operate in either direction of rotation. To reverse direction of a THREE PHASE motor, interchange any two motor leads at the starter. To reverse direction of rotation of a SINGLE PHASE motor the proper connections must be made in the motor connection chamber; refer to the W/D's supplied in the motor connection chamber and Control Box. Lifting eyes are supplied for purpose of installation and servicing. ' &'* +) %'*'( $ $ ) !'( $#!*#&" % &) Normal care should be exercised to prevent mechaniĆ cal damage to the seal, the frame and the insulated cable.
Surface temperature of motor enclosure may reach temperatures which can cause discomfort or injury to personnel acciĆ dentally coming into with hot surĆ faces. (When installing, protection should be provided by to protect against accidental with hot surface) . On initial start up the motor and pump should be checked for proper rotation prior to final application. The unit is designed to protect all power connecĆ tions against moisture. All Reliance Submersible Pump Motors have a lead connection chamber. - THREE PHASE dual voltage motors have 9 motor leads and SINGLE PHASE dual voltage motors have 8 motor leads in this chamber. All Submersible Pump Motors have 2 thermal proĆ tector leads and 2 moisture sensing probe leads in this chamber. Leads are tagged for easy identification. A conĆ nection diagram is provided in the lead chamber. Motors can be connected for either high or low voltages. (Some motor ratings are built as single voltage units and as such are not reconnectable). The motor lead cable assembly for all Submersible Pump Motors has 3 marked power leads plus two ground leads, two thermal leads and two moisture sensing probe leads in standard cable lengths of 25 feet. Leads are brought through an epoxy sealed conĆ nector providing a mechanically strong water tight seal. The cap and cable assembly are available from Reliance Electric as a replacement part asĆ sembly. When replacing the lead wire cap, care should be taken not to nick or damage the O" ring seal. Replace any damaged or nicked O" rings. ,
LIFT MOTOR ONLY USING BOTH ATTACHMENT POINTS. EYENUTS & EYEBOLTS MUST BE SEATED & IN LINE AS SHOWN BELOW. PREFERRED METHOD - USE SPREADER BAR.
4
692.FF
45° MAX.
3 132
With proper application and installation of monitoring devices, periodic inspection of motor seals is not required. Should a malfunction occur the motor has been equipped with a moisture detection system and thermal protection which will provide advance warning of impending failure allowing the to plan a maintenance program before failure occurs. 1. Reliance Submersible Motors utilize an explosionĆproof Class I, Groups C and D, tandem seal design, with an oil chamber separate from the winding area.
6. When replacement cable assembly is required, order from Reliance Electric Industrial Co. using motor identification number. U/L listed motors must be returned to an authorized Reliance Electric Service Facility for repairs other than to replace the outer seal. (See note on Table of Content page.) To inspect the outer seal proceed as follows: 1. Remove outer snap ring (3), replace as needed.
2. Wound Stators - Reliance Submersible MoĆ tors utilize a wound stator which has been pressed into the frame. The stator insulation system has been designed for the temperaĆ ture and electrical rating involved. If the motor failure is analyzed to encom a winding failure, return the motor to an authorized ReĆ liance Electric Service Shop. 3. Encapsulated Lead Connector Assembly The lead connector assembly has been especially encapsulated to insure integrity of the motor. The connector can be removed from the motor in order to reconnect leads. Should the lead connector assembly be damaged or the integrity of the encapsulation be in question, it is required that a replaceĆ ment lead connector assembly be ordered from Reliance Electric Company.
MOTOR MAY CONTAIN GAS UNDER PRESSURE DUE TO HIGH TEMPERATURES FROM OPERATION WITHOUT BEING SUBMERGED. DISASSEMBLY MAY CAUSE BODILY INJURY. FOR ASSISTANCE A RELIANCE OFFICE. 4. Hardware - All hardware is stainless steel and should be replaced with the same type. 5. If the Conduit Connection is used, a corrosion resistant conduit such as stainless steel is recommended.
2. Remove rotating outer seal (4), replace as needed. 3. Approved lubricating and insulating oil shall meet Reliance approved source sheet 4824Ć 18ĆAF. Manufacturer's materials currently meeting this specification are as follows:
ITEM
MANUFACTURER
MANUFACTURER'S IDENTIFICATION OF MATERIAL
1
Sun Oil Company
Sun Fleet Regular SAE 10W
2
Standard Oil Co.
Sohio 62 SAE 10W
3
Shell Oil Company
Rotella 10 SAE 10W
After assembly, run motor in shaft down position for 30 seconds minimum to one minute maximum to allow seals to seat; then check for oil leakage. In some cases, a slight oil mist will appear around the seal. Wipe clean after test.
Before painting motor, cover exposed seal. Remove any paper, tape, etc., from seal area before crating motor. These motors can be shipped in shaft up or shaft down position. Care must be taken that exposed seal is not damaged during shipment. Carton must protect exposed seal from dirt, dust and damage.
4 133
1. Loosen four bolts, securing lead cable connector (1), two complete turns.
CABLE CONNECTOR
2. Attempt to break the cable connector seal thus relieving gas pressure within the motor. If gas pressure is not relieved loosen the bolts another turn and try again. Continue this process until the pressure is relieved and/or the cap is removed. Be extremely careful until the cable connector assembly is removed. MOISTURE SENSORS (2)
3. Remove cable connector and reconnect to desired voltage as shown on connection diagram inside the cable connector.
OUTER SEAL
OUTER SNAP RING
The cable connector assembly may be removed to reconnect the leads without negating the U/L listing or the warranty.
4. Insulate connectors with 4824Ć13ĆAU heat shrinkable plastic. If the 4824Ć13ĆAU shrinkĆ able plastic is not available, tape may be used, but it should be an oil resistant type. Enough wraps should be used to insure the buildup will be sufficient to prevent the connector from breaking through the insulation. The following procedure should be employed: Five layers of plastic elecĆ trical tape followed by two layers electrical grade woven adhesive tape, such as Mystik 7020 or 3M #27, for oil and abrasion resistance. 5. Place O" ring over fit and coat fit with Chevron SRI grease (not excessive).
MOTOR MAY CONTAIN GAS UNDER PRESSURE DUE TO HIGH TEMPERATURES FROM OPERATION WITHOUT BEING SUBMERGED. DISASSEMBLY MAY CAUSE BODILY INJURY. FOR ASSISTANCE A RELIANCE OFFICE.
6. Place cable connector back on motor, install four bolts, and tighten.
Thermostat leads marked P1 & P2 must be conĆ nected in series with the stop button of the 3Ćwire pilot circuit of the magnetic motor controller, so that the thermostat will open the circuit before dangerous temperatures are reached.
'$% '" !&!$% $ #'"" )& &$ "$!&&! (% '$ &! "$!"$* ! & !$ '&+ &% %*%& (!% !&!$ )$$ &*
5 134
Alternating Current
Thermostats are automatic reset for use in a normally closed circuit where the thermostat is connected in series with the holding coil of the magnetic starter. Thermostats provide Over Temperature Protection 2" in accordance with NEMA MG 1Ć12.53. When the motor is so marked locked rotor protection is not provided by the winding over temperature protector. It is suggested that over current protection be used in the motor starter to insure locked rotor protection. !
Volts
Continuous Amperes
Inrush Amperes
110Ć120
3.0
30
220Ć240
1.5
15
440Ć480
0.75
7.5
550Ć600
0.6
6.0 STARTER
P1
AĆC LINE
P2
WARNING
(2)
STOP
MOTOR CONTROLLER MAY HAVE AUTOMATIC OR MANUAL OVERLOAD RESET. DISCONNECT ALL POWER LEADS TO MOTOR WHEN PERFORMING ANY WORK ON MOTOR OR DRIVEN EQUIPMENT.
(1)
L1 L2 L3 AĆC LINE
START
T1 T2 T3
GRD
P2 MOTOR P1
A MANUAL, MOMENTARY START SWITCH IS REQUIRED TO PREVENT AUTOMATIC RESTART OF MOTOR WHEN THERMOSTAT RESETS.
P1 & P2 Normally Closed Thermostat Leads (normally open thermostats are not acceptable to UL) (1) Starter Holding Coil (2) Holding Coil s - N.O.
THERMOSTATS
FIGURE 2 TYPICAL THERMAL PROTECTOR WIRING DIAGRAM
If current through the thermostat will exceed the values listed in Figure 2 an intermediate control circuit relay must be used to reduce the current or the thermostat will not work properly.
MOISTURE DETECTION SYSTEM MOISTURE SENSING PROBES !
IMPORTANT
Reliance Submersible Pump Motors are equipped with moisture detection devices. Failure to properly connect or utilize this system voids motor warranty. Moisture sensing probes, leads marked W1, and W2, must be used in conjunction with an induction relay. This device will detect moisture entering the oil chamber due to failure of the outer seal and, when properly connected to a
warning device, will provide notification of needed maintenance. Integrity of system requires periodic test. CONTROLS AND SIGNAL DEVICES A control and signal device (not supplied by Reliance) must be installed at the job site to complete the moisture detection system. Compatible controls are available from: Charles F. Warrick Co., Normandy Court, Royal Oak, Michigan 48073, (810) 549Ć4900.
6 135
"& .'$, + * &'%"&$ .$-+ & %0 &0/!* *'% &'%"&$ %"&-+ ,' &'%"&$ ($-+
$$ ,0(
2 '&,*'$+ * "&,"" 0 +("" '%('&&, &-%* /!"! '$$'/+ ,! '*%,
2 /!* ,! + * *($ 0&-%*+ & $,,*+ "&",". ' ,! 2 +-(($0 $"& .'$, & *)-&0 '&,, '&" -*,"'& & &$'+-* ! '&,*'$ !+ , $$ '& ,! *" !, !& +" ' ,! ,*%"&$ $'# & ","'& ! &$'+ '&,*'$ !+ &',!* , $$ '& ,! '-,+" ' ,! &$'+-* '.* '-&, ,! '&,*'$ '& .*,"$ +-* /",! ,! ,*&+'*%* '& ,! $, !& +" & '%($"+! $$ "&", /"*"& *%"&$+ '& ,! '&,*'$ *&-%* & * "& ,! +% *$,". ('+","'& + ,! ,*%"&$+ +!'/& '& ,! /"*"& " *%
136
*%"&$ ("* 2 %-+, '&,"&-'-+$0 &* "1 *'% & 2 +-(($0 $"& ' $,*"$ !*,*2 "+,"+ +!'/& '& ,! , $$ '&,,+ %-+, /"* "&,' ,! $,*"$ $' "*-",+ ' ,! /*&"& ."+ + *)-"* ! '&,, -+ '* $' -,0 %-+, /"* "& +*"+ /",! ,! $' & ,!, +*"+ *&! "*-", '&&, *'++ ('/* +'-* '%(,"$ /",! ,! $' "*"& %-+, (*'." *'% ,! %'"+,-* ,,'* +&+'* (*' $+ ' ,! %','* +" &, & ,' ,*%"&$+ & ' ,!
2 '&,*'$ '&,*'$ $+ +!'-$ &', "&+,$$ "& ,! +% '&-", + ('/* $+ &- .'$, & -+ $+ %'"+,-* +" &$+
Normally open load s close and normally closed load s open when the sensor probes detect the influx of moisture within the motor.
#
A normally closed pushbutton and neon indicating lamp are provided as means of checking the moisture sensing components.
#
When the pushbutton is depressed, the indicating lamp will be illuminated to indicate (A) power is supplied to the control, (B) the control is operative, and (C) wiring to the moisture sensing probes in the motor is intact. This procedure should be performed periodically to confirm integrity of circuit.
!
#
! The signal device may be audible (bell, buzzer, horn or siren) or visible (incandescent or neon lamp) or both - a signal device of your choice may be obtained from your local electrical supply house.
"
#
#
It is recommended that upon indication (by warnĆ ing light, etc.,) of outer seal failure that the motor be removed from the installation and the oil and outer seal be replaced as soon as possible.
"
"
WIRING BY WARRICK WIRING BY OTHERS CONTROL ENCLOSURE
If reconditioning is not performed within a 30 day period it is recommended that the inner seal be thoroughly inspected and replaced if required.
#"
When ordering parts or reporting trouble give Sales Office complete Nameplate Data.
Power Cable Control Cable
"
Polyphase
T1
T2
T3
Ċ
Ground
Single Phase
T1
T4
TA
Ċ
Ground
All
P1
P2
W1
W2
Ground
8 137
MAINTENANCE
138
MAINTENANCE PROCEDURES GENERAL MAINTENANCE SCHEDULE SAFETY NOTES: ! LOCK OUT ALL ELECTRICAL POWER BEFORE SERVICING !
Avoid wetting electrical components Bleed off all hydraulic pressure before working on the hydraulic system Keep all safety guards in place Follow all other plant safety steps Keep loose clothing away from moving parts
DAILY TASKS:
Inspect hydraulic reservoir oil level (look for evidence of fluid leaks). Check hydraulic oil temperature after dredge has been operating for at least ½ hour (maximum temperature is 184 F). Check area around auger motor shafts (power off) and clean out as required. Check boom hoist winch cable for wear and cable clamps for tightness. Inspect traverse pulleys for wear. Check lock collar set screws for tightness. Grease idler sheaves (one or two strokes as required). Grease travel guide pulleys. Check for vibration indicating slurry pump or hydraulic system problems. Check for loose fasteners, worn parts or misalignment.
NOTE: Check hydraulic fluid level in sight glass with boom up and power unit off WEEKLY TASKS:
Grease boom trunnions (pivot points) two to three strokes Inspect boom hoist winch bolts for tightness. Inspect hydraulic system for leaks. Check hydraulic filter – clean or replace as necessary. Inspect traverse winch idler sheaves - grease, as required Inspect auger motors and taper locks for wear - using a pry bar, check for movement. Check auger motor seals for leakage (raise head and look for oil around the seal) Inspect slurry pump bearings for wear* – using a pry bar, through suction or discharge, apply a load to the pump impeller and check for movement.
Note: This check might not be practical for some pump installations. Therefore, perform this check if problems in the slurry pump are apparent.
139
Check traverse winch bolts in mounting bracket for tightness. Check auger motor bolts for tightness. Check auger-cutter teeth (if part of assembly) for wear and bolt for tightness. Check cable clamps and fittings.
MONTHLY TASKS
Check traverse gear reducer lubricant level and condition. If Low: Add Oil If Dirty: Change Oil **See Oil and Lubricant specifications below Check boom hoist winch lubricant level and condition. If Low: Add Oil If Dirty: Change Oil **See Oil and Lubricant specifications below Inspect hydraulic lines and hoses for wear and/or leaks.
BIANNUAL TASKS (1000 HOURS)
Change travel winch gear reducer oil. Fill to level plug (capacity is approximately 17 ounces) **See oil specification below. Change boom hoist gearbox oil. Fill to level plug. **See oil specification below. Clean hydraulic system and check air breather cap – clean if necessary. Replace hydraulic return-line filter. Check electric motors (slurry pump and hydraulic drive), slurry pump and the various system components for vibration and wear. Inspect mounts for loose or missing fasteners-tighten or replace as required.
ANNUALLY
Clean off and wash down dredge. Replace or repair all parts of dredge. Repeat any of the above checks and/or inspections appropriate at this interval and perform the necessary maintenance or service as required. OIL AND LUBRICANT SPECIFICATIONS
**OIL SPECIFICATIONS Hydraulic oil for this system should meet the following requirements:
Hydraulic oil: ISO 46 Winch: 80W-90 Gear Oil. Must be EP-rated. Traverse Gear Reducer Lubricant: Pennzoil Synthetic Gear Oil - SAE 75W - 140 Alternate must meet API - GL - 5 specs and be EP - rated.
140
Grease Fittings
Oil Drain Plug (In 6 o’clock position)
Oil Level Check & Fill Plug
Photo 10-2 – Travel Winch Idler Sheave Grease Points & Oil Check, Fill & Drain Plugs Hydraulic Motor
Oil Drain Plug
Photo 10-3 - Typical Boom Hoist Winch – Oil Check, Fill & Drain Plugs Oil Level Check & Fill Plug
Auger-Cutter Hydraulic Drive Motor Photo 10-4 - Typical Auger-Cutter Hydraulic Drive Motor 4 141
SPECIFIC EQUIPMENT & COMPONENTS MAINTENANCE SCHEDULE
AUGER SYSTEM
DAILY Clean area around motor shaft (See safety warning below).
WEEKLY Inspect auger out-board bearing for wear. Inspect auger-bearing bolts for tightness Inspect auger cutter blades bolts for tightness Inspect hydraulic hoses and fittings for leaks and wear Inspect hose system for leakage or wear Inspect power cord and control cable (if part of system).
ANNUALLY Replace worn cutter blades Replace hydraulic motor seal and shaft if badly worn or leaking Replace all other worn parts Clean off and wash down dredge. Replace or repair all parts of dredge.
SLURRY PUMP
DAILY Check Boom Hoist winch cable for wear and cable clamp U-bolts for tightness
WEEKLY Check pillow block bearings for wear Grease drive shaft bearings every four hours
BI-ANNUALLY Check other parts for wear
DANGER! Turn Off Electric Power Before Servicing
142
TRAVERSE WINCH DRIVE SYSTEM
DAILY Inspect traverse drive pulley for wear Grease idler sheave shafts (one or two strokes as required) Check lock collar set screws for tightness. Grease guide pulley front and rear
WEEKLY Inspect travel cable for wear and cable clamps for tightness. Inspect travel winch bracket bolts for tightness. Inspect travel winch snatch blocks for wear and hardware for tightness.
MONTHLY Check travel winch gear reducer oil level. If low, fill with oil per the specifications listed above.
ANNUALLY Replace travel winch gearbox oil. See recommended oil specifications below. Check drive sheave and idler sheaves for wear and proper alignment. Check for loose hardware items. Check snatch blocks or guide sheaves on head and tail frames for wear. DANGER! Turn off electric power to dredge before servicing. Follow all other plants safety steps. Keep all safety guards in place.
BOOM HOIST WINCH
DAILY Check lift cable for wear Check cable clamps and hardware for tightness
WEEKLY Check lift winch bolts for tightness Check lift cable and clamps for wear
MONTHLY Check winch gear reducer oil. If low, add oil per recommended lubricant
143
OTHER COMPONENTS
DAILY Check for evidence of hydraulic oil leaks in motor or hoses
WEEKLY Inspect hydraulic motor and hoses for leakage or wear Inspect power cord and control cable (if part of system)
MONTHLY Inspect all pins Grease boom trunnion (pivot) bearings Wash down dredge as required Check discharge hose gaskets for leakage – replace as required
STORAGE AND WINTER PREPARATION To store for any length of time LWT recommends that the pump volute and discharge plumbing should be drained of liquid. Any hydraulic oil, which is contaminated with water, should be drained and replaced. Floats should be checked for any water infiltration. Any that have accumulated water should be drained and patched. Any flat hose type hose should be well flushed, rolled and stored off the ground away from direct sunlight, excessive hot or cold temperatures and rodents. In climates where freezing weather is likely to occur, the unit should be removed from the pond and stored. If water cannot be entirely removed from the volute, antifreeze should be added at the mix ratio stated by the manufacturer for the anticipated low temperature. REMOVAL FROM STORAGE 1. Check all lubricant oil levels – hydraulic reservoir, winch gear reducer, boom hoist gearbox and slurry pump drive (bearing assembly or electric motor) 2. Check for the presence of water in all oils due to condensation 3. Start unit and run hydraulic system for a minimum of one-half hour 4. Check each hydraulic or electrical function for proper operation 5. Again, check fluid levels and quality of oil 6. Make any final repairs or adjustments to the various systems
144
Preventive Maintenance Schedule Dredge operator is responsible for performing all maintenance at each interval without exception. Failure to comply with maintenance will cause component failure and possible warranty termination. If you are uncertain on how to maintain any component, an LWT representative. Hourly Intervals
Daily
Weekly
Monthly Bi-Annually OR AS NEEDED
Annually
Auger System Clean area around motor shaft and inspect for leaks Inspect auger mounting bolts for tightness Inspect auger cutter blade bolts for tightness Inspect hydraulic hoses and fittings for leaks and wear Check auger for stuck debris Replace worn cutter blades Replace hydraulic motor seal and shaft if badly worn or leaking
X X X X
X X X
Slurry Pump Ensure intake is free of clogs or debris
X
Check for motor power cable damage Check other parts for wear
X X
Traverse Winch Drive System Inspect traverse drive pulley for wear Grease idler sheave shafts one or two strokes as required Check lock collar set screws for tightness Grease snatch block pulley(s) Inspect travel cable for wear and cable clamps for tightness Inspect travel winch bracket bolts for tightness Inspect travel winch snatch blocks for wear and hardware for tightness Check travel winch gear reducer oil level Replace travel winch gearbox oil Check drive sheave and idler sheaves for wear and proper alignment
X X X X X X X X X X
Check for loose hardware items
X
Hoist System Inspect hoist cable for wear and cable clamps for tightness
X
Check hoist winch gearbox fluid Check lift winch bolts for tightness Ensure hoist winch operates in correct direction
X X X
PHE/070313 145
Preventive Maintenance Schedule (continued) Daily
Hourly Intervals
Weekly
Monthly Bi-Annually OR AS NEEDED
Annually
Other Components Check for evidence of hydraulic oil leaks in motor and hoses Inspect power cord and control cable Inspect all pins Check discharge hose gaskets for leakage; replace as required Inspect hydraulic reservoir oil level in sight glass Check hydraulic oil temperature after dredge has been operating for at least 30 minutes (Max Temp: 184° F) Check area around auger motor shafts with power off and clean out as required Check for vibration indicating slurry pump or hydraulic system problems Grease boom trunnion (pivot) bearings Check hydraulic filter, clean and replace as necessary Inspect slurry pump bearing for wear Check auger motor bolts for tightness Check cable clamps and fittings Check boom hoist winch lubricant level and condition Change winch gear reducer oil (Max Capacity:17 oz.) Change boom hoist gearbox oil Clean hydraulic system and check air breather cap Replace hydraulic return-line filter Check electric motors for vibration and wear Inspect mounts for loose or missing fasteners, tighten or replace as required Clean off and wash down dredge Reapply anti-foulant to required parts (Min: 4 mils wet, 2.5 mils dry)
X X X X X X X X X X X X X X X X X X X X X X
Cable/Rail System (when used) Check tensiometer reading to ensure proper cable tension, if applicable Check cable clamps and hardware for tightness Grease closed loop sheaves Grease tension cable sheaves Grease all fittings on trolley Inspect cable for damage or wear Inspect and grease closed loop, tension winches, and tensiometers when used
X X X X
X X X
PHE/070313 146
ASSEMBLY/DISASSEMBLY OF AUGER MOTOR DRIVES
Photo 10-5 - Typical Auger Assembly – Taper Lock Bushing Being Inserted into Auger
Splined Taper Lock Bushing
Install & Tighten 2 Set Screws Photo 10-6 - Typical Auger Assembly – Splined Taper Lock Bushing
5 147
DISASSEMBLY/ASSEMBLY OF TRAVERSE WINCH
Shaft set screw
2 each 1” washers
Gear Reducer Shaft
Bearing shaft (1” x 6 ¾”) Photo 10-7 - Typical Traverse Winch Assembly - Drive Sheave and Idler Sheaves Removed 7 5/8” Dia. Sheave
Bearing insert 2 each 1” washers
Photo 10-8 - Typical Traverse Idler Sheave Assembly
6 148
1” lock collar
2 ¼” lock collar
Photo 10-8 - Typical Traverse Winch Assembly – Drive Sheave Removed
Grease Fittings
2 ¼” Lock Collar
Photo 10-9 - Typical Traverse Winch Sheave Assembly NOTE: Tighten all lock collars securely to the shafts. 7 149
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