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SECTION 2 NOMENCLATURES
SECTION 11 SPECIFICATIONS
SECTION 13 APPENDICES
Contents
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1. INTRODUCTION AND CONTACT PERSONNEL
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1.2. Contact Personnel
The following personnel can be contacted at Transmin Pty Ltd should you require any additional
information regarding the safe operation, performance or maintenance of the rockbreakers:
Please provide the following reference information when making enquiries to ensure a prompt
response:
Transmin
Equipment No. Site Site Equipment No.
Serial No.
Rockbreaker Constancia RB-118 3111-BK-001
HPU Constancia ME-316 3111-LU-002
To enquire about Transmin’s extensive range of bulk materials handling products and services, please
visit our website at www.transmin.com.au or contact our sales offices in Perth or Brisbane for assistance.
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2. NOMENCLATURES
A number of warning icons may be used in this manual. Take note of their definition:
Use caution!
Mandatory isolating machine
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2.1. Glossary of terms:
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3. HEALTH AND SAFETY STATEMENTS
This manual contains instructions for installing, the equipment supplied. It is essential for personnel to
thoroughly read this manual before attempting to operate or carry out any work on the equipment.
This manual must be made accessible for personnel working on or with the equipment and contains
important information regarding safety hazards located on or around the equipment during installation.
Your safety and the safety of those around you depends upon you using care and judgment in the
operation and installation of this equipment
All equipment has limitations. Understand the various characteristics of the machine before starting to
operate. Read the operator's manual and ask questions of your supervisor until you know these
limitations. The following are general safety comments that apply to all equipment. Review them often
as safety reminders:
Be sure you have checked that all controls are in a safe state before starting work.
During operation always check and watch that all machine functions operate normally.
Report any abnormality or damage to your supervisor.
Never under any circumstances put your hands in the chute area to clear material
when in operation. Always use your plant "Tag Out" procedures.
Only qualified electrical personnel should carry out electrical installation, modifications,
repairs and wiring.
Personal protective equipment (i.e.; safety helmet, goggles, safety boots and ear
protection) must be worn when operating or carrying out any repairs per site
requirements
If the system is using hazardous material, know where the nearest safety
shower/emergency eye wash station is and ensure that the route to it is unobstructed.
The location of the Material Safety Data Sheets should be kept in a known secure
location so the appropriate first aid can be administered to injured personnel.
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3.1. Operator Safety
The Rockbreaker and HPU operate as part of a bulk materials handling system, and as such should be
operated as part of the operation and isolation procedures for that system and area of plant.
Covers and guards are fitted to the machine to prevent injury during
operation. The Rockbreaker and HPU should not be operated with the
covers removed for any reason.
Emergency Stops have been installed in the control cabinet or termination box and must be hard wired
back to the MCC to immediately de-energise all corresponding drives.
Any operator using this equipment must be fully trained and aware of the
contents of this manual, in particular all safety features must be reviewed
and understood before attempting to operate the Rockbreaker.
Use safety glasses when operating or carrying out any repairs Always
keep your working area as clean as possible
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3.2. Maintenance Safety
The machine should only be operated in maintenance mode if adjustments are taking place. Hydraulic oil
pressure in tubes/pipes, hoses and fittings can be dangerous, ensure all lines are free of pressure before
disconnecting.
Always carry out maintenance and repairs with qualified and experienced
labour. Do not attempt repairs that are not understood.
IF IN DOUBT ASK.
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3.3. Machine and Operator Safety
Always check that the machine's functions operate normally, report any abnormality or damage to your
supervisor or the relevant department immediately. During this initial check observe any pressure
gauges if fitted and limits and stops on the machine. Ensure that clashes will not occur with any building
or mobile equipment in the area.
The ROCKBREAKER and HPU operate as part of a bulk materials handling system, and as such should
be operated as part of the operation and isolation procedures for that system and area of plant.
Covers and guards are fitted to the machine to prevent injury during operation. The ROCKBREAKER
and HPU should not be operated with the covers removed for any reason.
Emergency Stops have been installed in the control cabinet or termination box and must be hard wired
back to the MCC to immediately de-energise all corresponding drives.
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3.5. Lifting Safety
The Lifting Lugs provided are rated to allow the ROCKBREAKER and HPU
to be lifted in accordance with the lifting diagrams provided.
Incorrect lifting technique will not only result in damage to the product, but also possible injury to the
operator. Always sling the load correctly using any lifting points which may be provided. Never exceed
the S.W.L. which must be marked on all types of lifting gear.
Please refer to the lifting diagram that was supplied with the Rockbreaker (refer to Figure 1 for example)
Due to the complexity of some of these lifts, it is recommended that a lifting study be conducted prior to
completing the major lifts to confirm the required rating of cranage and lifting gear.
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Figure 1 - Lifting diagram (typical)
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4. BASIS OF OPERATION
The Rockbreaker system installed over a primary crusher or grizzly at the mine site. The system
is used to manipulate and break oversize run of mine ore to manageable sizes, suitable for entry
into the primary crusher. The rockbreaker is available 24 hours per day, 365 days per year
The Rockbreaker is made up of a boom system which carries a hydraulic hammer, and is
powered by a Hydraulic Power Unit (HPU) which is a standalone unit connected to the
Rockbreaker by hydraulic, grease and electrical lines.
The control of the standard Rockbreaker system is via a dual joystick radio control transmitter.
The controls for the transmitter provide boom movement, hammer fire, power pack start and
emergency stop functions.
Any operator using this equipment must be fully trained and aware of the contents of this manual,
in particular all safety features must be reviewed and understood before attempting to operate
the Rockbreaker.
It is essential to read the Instructions manual before operating the hammer for the first time.
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4.1. Boom system and hydraulic hammer
4.2.1. Description
The hydraulic power unit (HPU) can be broken down into the following main components:
Oil tank - containing low level and temperature devices and hydraulic oil heater
Control panel - Various levels of cabinet complexity (from full control and starters to
termination only) are supplied, Refer to the specifications for the type of cabinet
supplied. The control panel can contain both, low voltage motor control (415V AC) and
24V DC power. The 415V AC supplies the motor circuit BREAKERs and motor
starters. The 24V DC supplies control devices, PLC (Programmable Logic Controller),
HMI (Human Machine Interface) and operator interfaces. The panel door is interlocked
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with the main isolation switch, preventing the door from opening and thus the live
circuitry being accessible while the switch is on.
Rockbreaker grease lubrication pump (optional). This unit may be mounted on the HPU
or on a stand near the Rockbreaker depending on the location of the HPU.
HMI Panel
The HMI Panel is used to indicate operation of the power pack, alarms, shut-down
conditions and oil temperature.
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5. INSTALLATION AND COMMISSIONING
5.1. Packing and Arrival on Site
The Transmin Rockbreakers and HPUs are supplied workshop tested and pre-assembled as far as
practical and ready for final assembly on site.
The Rockbreakers and HPUs should only be lifted in accordance with the
lifting diagrams provided.
EACH Rockbreaker and HPU is normally packaged into the following major sub-assemblies for transport
to site. However the slew frame assembly, the Jib assembly and the hammer assembly may be shipped
as one assembly depending on the size of the Rockbreaker. Refer to the specific lifting and transport
drawings supplied with the Rockbreaker
HPU
Rockbreaker hammer
Additionally, the following items are removed and supplied loose for assembly on site: (These items are
palletized or crated as required)
Remove all items from the vehicle using the correct lifting equipment discussed previously and ensure
there is a clear flat surface for the rockbreaker to rest.
Upon receipt of the equipment on site check the equipment per the supplied packing list, Check the
equipment over for any obvious signs of transport damage. If in doubt about the quality of quantity of
items, please contact Transmin. .
The packing lists must signed off by site personnel and faxed / emailed back to Transmin as per the
instructions on the Packing Lists within 5 working days of delivery.
If any damage or shortage in supply is found, this must be reported back to Transmin immediately.
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The Rockbreaker and HPU can be stored in an outdoor location. They must rest on an even surface to
stop any twisting of the frames.
Loose items should be stored indoors (with the exception of structural steelwork) and should remain
strapped to pallets or in the crates as delivered. If items are removed from sealed crates they should be
stored in an indoor, secure location.
If rubber components are to be stored outdoors for extended periods, they should be covered by
tarpaulins in order to reduce UV exposure and increase the life of the rubber components.
Where possible, machined surfaces have been wrapped in denso tape for protection, and all other
surfaces have been spray coated with an anti-rust compound. All exposed machined surfaces should be
checked daily for signs of rust. It is important that machined surfaces are coated with an anti-rust
compound regularly during storage. In addition, painted surfaces should be inspected regularly and
paint re-applied as necessary.
Any hydraulic oil tubing/piping and hosing which has free ends has been capped to prevent
contamination. If the caps have fallen off during transport or storage, the tubing/piping and hosing must
be removed and cleaned thoroughly before connecting on site and running.
Any grease tubing/piping and hosing which has free ends has been capped to prevent contamination. If
the caps have fallen off during transport or storage, clean grease must be flushed through before
connecting on site and running.
Refer to vendor manuals in section 10 for both short and long term storage of this equipment.
The bearing has a protective coating and can be stored for up to six months in a roofed storage area or
up to twelve months in an enclosed temperature controlled area.
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5.3. Installation Requirements
Before commencing with the installation, clean and inspect all parts upon receipt of equipment for
signs of damage. Parts and quantities must agree with the amounts shown on packing lists.
The procedure to install the Rockbreaker and HPU is generally as follows however the
Installation Contractor should be consulted and requested to review the procedure and modify if
required to suit their work practices and equipment and prepare suitable JSA’s for the hazardous
tasks.
3. If the boom cylinders are not connected to either the boom or slew frame, raise or lower the
end of the boom so the cylinder pins can be fitted.
The slew frame assembly is extremely robust in construction, however of utmost importance is
the correct mounting of the base. Failure to correctly install this will lead to structural damage and
deformation of the slew bearing and will void the slew bearing warranty.
It is recommended that the bolt projections remaining be heavily treated with grease or other protective
coating to ensure that if required in future, the nuts can be removed for major maintenance work to the
boom system assembly.
Ensure the mounting structure is horizontal, flat and clear of any obstructions. Align the holes between
the Rockbreaker base and its mounting and secure with mounting bolts, washers and nuts. Tighten
evenly and progressively with a final torque of M36 grade 8.8 -2300 Nm.
Stage 3 – Mounting of jib assembly (not required if Rockbreaker is shipped as a full assembly)
5. Lift the jib into position using the lifting diagram drawing 600MC0057-02006-DR-ME-0013
and fit the jib pivot pin.
6. Connect all hydraulic, grease and electrical lines between the boom and the jib.
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Figure 4 – 5m Boom System
7. Lift the hammer into position against the hammer mounting and secure with bolts nuts and
washers. Tension bolts to the correct value.
8. Connect all hydraulic and grease lines between the jib assembly and the hammer.
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Figure 6 - Hammer and Hammer Bracket (Typical)
9. The HPU is supplied fully assembled with the connections capped for on-site connection to
the Rockbreaker. Lift the HPU into position using the lifting diagrams provided and secure
with hold down bolts (usually not supplied).
Do not fill with hydraulic oil at this stage, all pipes and hoses must be
fitted and flushed.
10. The HPU is supplied with all instruments, oil cooler motor and oil heater connected to the
control cabinet or terminal box (depending on the specification. Make the electrical
connection from the plant to the control cabinet or termination box. Make the electrical
connection between the HPU and the Rockbreaker.
11. All hydraulic fittings on the Rockbreaker have been capped for transport to ensure
cleanliness. Install any hydraulic hoses that have been detached for transportation.
Hydraulic hoses are required to run from the HPU to the valve bank on the Rockbreaker
and it is essential that these are pre-cleaned prior to connection to the Rockbreaker or HPU.
12. When on site piping/tubing is required to run from one area to another it is essential that a
pipe/tube cleaning system is used to pre-clean prior to connection to the hoses at the
Rockbreaker and HPU. This pre-cleaning is carried out by the engineers during pre-
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commissioning by looping the circuit and bypassing the control valves.
13. The grease lubrication pump may be fitted to the HPU or on its own stand depending on
the distance between Rockbreaker and the HPU. Refer to HPU GA Drawing supplied for this
information.
14. If the grease lubrication pump is supplied separate from the HPU bolt the stand down. If not
proceed to step 15.
15. Install the grease line to the Rockbreaker but do not connect to the Rockbreaker.
17. Purge the grease line by pumping grease through it until there is no sign of air in the
system.
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5.4. Hydraulic System Installation Guidelines
Pipe and tube shall be delivered to the job site with the bores free from scale and corrosion.
All piping and fittings shall comply with AS2671.
Pipe and fittings are to be acid de-scaled and phosphate treated in accordance with AS1627.
Pipe and tube which has been pre-cleaned prior to delivery shall have the ends securely capped at all
times prior to installation to protect against the ingress of dirt.
Care should be taken to ensure that stainless steel materials (where applicable) are not in contact (or
have not been contaminated) with carbon steel during transport and storage
All piping and fittings must be properly protected during storage and installation to prevent corrosion,
damage and deterioration up until commissioning of the system.
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5.4.4. Inspection for Scale and Corrosion
Piping and fittings shall be inspected for scale and corrosion immediately prior to forming and / or
installation. Severely corroded piping must be reported to the client representative and may be rejected
and scrapped.
Pipe and fittings which have not been acid de-scaled and phosphate treated prior to delivery must be
acid de-scaled and phosphate treated in accordance with AS1627 prior to final assembly.
Where the bores of pipe, tube or fittings are found to be contaminated or have signs of corrosion they
shall either be mechanically cleaned or bath pickled and passivated depending upon the extent of the
contamination and its accessibility for cleaning.
Where chemical cleaning is deemed necessary, the procedures for chemical cleaning should be
submitted for review and approval by the client.
NOTE: It should not be necessary to carry out full circulation pickling, neutralisation and passivation on a
new hydraulic pipe installation if all pipe and fittings are pre-cleaned, acid de-scaled and phosphate
treated prior to installation.
After cleaning, piping shall be securely capped or plugged if it is not to be installed immediately.
The Installation Contractor is required to supply all of the necessary tools for the proper installation of the
hydraulic system piping.
5.4.6. General
ALL COMPONENT PORTS ARE TO REMAIN SEALED UNTIL THE SYSTEM PIPING HAS BEEN
FLUSHED TO THE SPECIFIED CONTAMINATION CLASS AND THE PIPING IS READY FOR
CONNECTION TO THE COMPONENTS.
Piping should be designed to discourage its use as a step ladder. External loads should not be imposed
upon piping.
All piping flanges and connections are to be fabricated in such a way that flanges and fittings match
without stress (i.e. all pipe joints are to align squarely and without a need to be sprung into place). Use
of a heating torch is prohibited in realignment (bending) of any piping due to the internal formation of
scale.
Prior to assembly, any coarse contamination (eg weld slag) is to be blown out using compressed air and
a backward facing nozzle.
When welding, an earthing lead is always to be attached to the work piece being welded. This will
provide protection against damage to the motors, pumps and valving.
Piping should be installed so that it is protected from predictable damage and does not restrict access for
adjustments, repairs and replacement of components.
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Flange connections shall be accessible with standard tools without the necessity to disturb or remove
neighbouring pipes, equipment or components.
Piping should be installed so that it does not interfere with operations or walkways.
All piping bends and offsets are to be cold formed in a standard pipe bending machine (i.e. the use of
oxy acetylene heating or cutting torches is not permitted).
Formed bends shall be used wherever possible. Proprietary elbows shall only be used where
specifically noted in the piping drawings and where space restrictions prevent the use of formed bends.
The preferred minimum bending radius for all piping is 5 times the outside diameter of the pipe.
Gauge and bleed connections shall be made using proprietary welded fittings with BSPP internal threads.
Holes made in the pipe shall be drilled and shall have any burrs removed.
Piping should not be used to support any equipment. Where line mounted equipment is unavoidable,
the pipe shall be adequately supported either side of the equipment or the equipment itself shall be
adequately supported.
5.4.10. Hoses
Where it is more economical to install hoses rather than bend and install tube or pipe for short runs.
The hose length is sufficient to prevent sharp flexing and straining of the hose during
equipment operation
They are not subject to torsional loads (axial twisting), ie. Motion is to be preferably in
one plane only
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Hose radii are not to be less than the manufacturer’s specifications and hoses shall be
installed in a manner which does not place bending or twisting strain on the hose ends
and fittings
If the failure of a hose assembly constitutes a whiplash hazard, the hose assembly
shall be restrained or shielded.
CAP / PLUG the hose ends to prevent ingress of dirt or foreign matter
Installation of pipe support clamps shall be carried out concurrently with the laying of the piping. This will
minimise any risk of pipe misalignment problems.
All hydraulic piping is to be adequately supported and clamped to eliminate all visible vibration.
In accordance with AS2671, piping greater than 10mm diameter and up to and including 25mm diameter
should have supports spaced at no greater than 1.5m. Piping greater than 25mm diameter and up to
and including 50mm diameter should have supports spaced at no greater than 2m.
Flanges must be supported by at least one clamp as close as possible to the flange,
but allowing sufficient access to the flange bolts.
Pipe clamps shall incorporate suitable vibration dampening materials suitable for the
environment, e.g. Stauff Heavy Duty clamps or equivalent.
Pipe supports must be securely anchored to building structures either by welding or with the use of
chemset anchors. Anchoring to equipment should only be done with express written approval from the
manufacturer of the equipment and the client.
Supports for hydraulic piping should only be bolted to concrete where there is no suitable steelwork
available.
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5.4.12. Cleaning and Inspection before Assembly
It is important to ensure that each pipe remains plugged until IMMEDIATELY before working on it (eg
cutting, welding, bending, installing etc). Immediately after cutting, remove any burrs ensuring that
debris is removed from the pipe.
Weld penetration projecting into pipe bores should be carefully removed by mechanical means and all
debris thoroughly removed.
WHENEVER THERE IS A SIGNIFICANT GAP BETWEEN TASKS OR AT THE END OF A SHIFT, RE-
PLUG ALL OPENINGS.
Subject to client approval, when socket weld fittings are used it should not be necessary to pickle the
welded assembly afterwards as long as the internal heat affected zone is accessible and is properly
mechanically cleaned.
Where butt welding is permitted, the pipe assembly should be pickled in a specifically designed pickling
reservoir to remove any scale, prior to neutralisation and phosphate treatment in accordance with
AS1627 to provide a hydraulically clean condition prior to final assembly.
Note: All welded pipe assemblies requiring to be pickled may need to be degreased beforehand if they
are covered in an oil film. This will be determined by the surface treatment contractor and the process is
normally carried out in a suitable degreasing tank.
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Dangerous chemicals are used in degreasing, pickling and phosphating
processes. They must be kept in proper, correctly labelled containers
and used strictly in accordance with the manufacturer’s directions.
Transmin recommends that this work is carried out by a specialist
contractor in their own premises.
Pressure Testing
All welded pipe spools should be pressure tested to 1.5 times full system pressure prior to any pickling or
cleaning to ensure that the welding is adequate. Each welded pipe spool pressure test should be
recorded against the relevant pipe spool number as confirmation of a successful test.
Threaded Fittings
Inspect threaded fittings and remove any burrs or metal slivers to prevent them from entering the pipe
bores. Similarly, ensure that any thread sealants (e.g. Teflon tape etc) if permitted, do not enter pipe
bores.
All tubes and hose assemblies should be inspected and pigged in BOTH directions until clean. This
removes most of the larger particles made by cutting of the tubes and hoses and the mounting of fittings.
Mechanical Cleaning
Immediately before installation, confirm the cleanliness of the inside of each pipe and tube visually.
It is recommended that all tube and pipes be cleaned mechanically using ‘pigging’ equipment.
Note: If a welded pipe assembly has been professionally pickled, neutralised and phosphate treated and
properly capped after all welding, additional pigging is not required prior to assembly.
Care should be taken before pigging welded pipes to ensure that any excessive weld protrusions and
any stray welding wires have been mechanically removed. If welding wires or excessive weld protrusion
is discovered, these can usually be removed carefully using a pencil grinder.
When confirmed clean, immediately install them. End protection caps should only be sequentially
removed so that all clean pipes remain fully sealed to avoid ingress of dirt before the interconnecting
pipe is connected.
Ensure that bolted connections are progressively drawn up evenly to avoid distortion of the piping and
hydraulic components.
5.4.14. Labelling
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All piping shall be colour banded and the fluid service labelled in accordance with AS1345. Labels must
be located at a maximum distance apart of 8m and at all branches. Arrows shall indicate the direction of
flow.
If required, the full line number shall be incorporated into the label.
The Contractor is required to supply all of the equipment necessary for the agreed cleaning method,
including installation and removal of temporary circuits and testing equipment.
The Contractor must also supply and dispose of all superfluous fluids used during the cleaning, testing
and flushing procedures if required
5.4.16. Preparation
In preparation for flushing, hydraulic cylinders, directional valves and other items susceptible to damage
should either be replaced with flushing blocks, by-passed by hoses or pipes or completely dismantled.
Any small parts dismantled should be stored in clean plastic bags. All parts should be stored in a clean
area.
In order to flush the isolation system efficiently and in a timely manner, it is recommended that the
following preparation is conducted:
Using a temporary hose connect the PRESSURE AND RETURN hoses at the
rockbreaker valve (i.e. so the rockbreaker valve is by-passed).
Remove any items from the circuit which can not tolerate any contaminants so that
they are not damaged. In their place, temporary bridging hosing or pipe spools should
be fitted which are rated to 330 Bar.
Ensure sufficient trays / buckets are available to collect any spillage of oil when hoses
are disconnected
Ensure facilities are available to clean filter elements and several spare filter elements
are readily available if required.
If oil cleanliness samples are required, have suitable clean sample containers from the
nominated testing laboratory ready for sample collection.
Before filling, all oil bearing parts of the system, in particular oil tanks, filters and pipelines should be
checked for cleanliness.
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A check should also be made that the piping circuit is complete and that all valves fitted are correctly in
the open or closed position according to their function and / or the requirements for the system flushing.
NOTE: Tank covers and air filters should be correctly secured to prevent the infiltration of unfiltered air
into the tank.
Before filling, all oil containers should be cleaned and the oil checked for possible water content. Wipe
away thoroughly any dirt or moisture from around the oil drum bung or plug BEFORE loosening and
emptying.
The system must always be filled through the filling filter installed on the hydraulic power pack reservoir.
IMPORTANT NOTE 1:
Before operating the drive motor, all suction line valves must be in the
operating position.
IMPORTANT NOTE 2
Before start-up it must be certain that the hydraulic pump has been bump
started to confirm it is rotating in the correct direction. (A direction of
rotation arrow should be fitted to assist). This check needs to be
identified as completed on the Pre-Commissioning Checklist Form before
proceeding (See Important Note 3 below).
IMPORTANT NOTE 3
Before operating the system, the Installation and Pre-Commissioning
Checklist Form needs to be completed and signed by the Installation
Contractor and an authorised Client Representative to verify that the
installation has been completed in accordance with Transmin’s
requirements.A copy of this form is included in this manual. DO NOT
PROCEED UNTIL THIS FORM IS SIGNED AND APPROVED.
System flushing is intended to ensure the removal of all weld slag, weld spatter, dirt and any other
foreign materials from the internal surfaces of the piping.
Subject to client requirements, it may be necessary to utilise a specifically designed high flow flushing
unit to carry out flushing of the system.
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It is generally acceptable however to flush the system using the system power pack itself with the
specified filter element and to install additional return filters in the system where required to protective
sensitive equipment from damage due to dirt and foreign particles.
Where a return line filter is fitted to the hydraulic power unit, generally no additional filters are required if
the steps in Section 4.3.1 are followed.
If using a separate flushing rig, flushing is carried out progressively down to the lowest micron filter rating
in the system.
FLUSHING PROCEDURE
For each isolated flushing circuit, the following procedure should be followed:
In the ‘Normal Flow’ direction, run the hydraulic power pack CONTINUOUSLY for 20
minutes to flush the lines
If a separate dedicated flushing rig is being used, the system should be run and flushed
continuously for 20 minutes for each progressive filter rating.
Once the 20 minutes is complete, the filter elements should be checked and cleaned if
necessary. If the filter has collected a large quantity of contamination, flushing should
be repeated for another 20 minutes. Flushing is usually deemed complete when visual
inspection shows no collection of contamination in the filter elements.
IMPORTANT NOTE
During flushing the oil circuit return line MUST ALWAYS REMAIN
COMPLETELY OPEN TO TANK. As a result, full system pressure will not
develop in the lines and this will allow the flow to be reversed in the
system as part of the flushing procedure if this is required.
PRESSURISING THE RETURN LINE FROM THE VALVE TO THE HPU WILL
RESULT IN BURST PIPES AND HOSES.
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IMPORTANT NOTE
It will be necessary to progressively top-up the reservoir during the
flushing procedure until the entire system is filled with oil. ENSURE
THAT THE RESERVOIR LEVEL IS MAINTAINED AT THE CORRECT
OPERATING LEVEL AT ALL TIMES.
Flushing Completion
Upon the completion of flushing, remove any temporary filters, change or clean the filter elements in the
system (as appropriate) and then successively remove bridging pieces from the circuit and immediately
replace the items removed for flushing taking care not to introduce contaminants into the system.
The piping can be connected to the hydraulic cylinders, and the LOP assemblies can be connected to
the piping.
NOTE: Connect each element one at a time and immediately upon removing covers from ports or
blanking plates. Do not leave any piping or hosing disconnected longer than absolutely necessary and
ensure that no water or dirt enters the system as the piping is connected.
Any spilled oil should be immediately cleaned up in accordance with the site environment requirements
and then the oil reservoir should be topped up to the appropriate level.
Once all the removed components are re-installed in the circuit after flushing, and the normal system
filter elements are cleaned and / or replaced, the system should again be run to ensure the entire system
is filled with oil.
NOTE: MONITOR THE HYDRAULIC POWER PACK RESERVOIR LEVEL AT ALL TIMES AS THE
CYLINDERS ARE OPERATED AND TOP UP AS REQUIRED.
All hydraulic cylinders should now be operated to ensure that the entire system of is filled with hydraulic
oil.
AGAIN, ENSURE THAT THE RESERVOIR LEVEL IS MAINTAINED AT THE CORRECT OPERATING
LEVEL AT ALL TIMES BY TOPPING UP AS REQUIRED.
CAUTION: DO NOT OVER FILL THE HYDRAULIC POWER UNIT. TAKE NOTE OF THE STATUS OF
THE CYLINDERS WHEN ASSESSING OIL LEVELS AS THE HYDRAULIC POWER UNIT LEVEL IS
LARGELY DEPENDENT ON WHICH CYLINDERS ARE OPEN OR CLOSED.
Air in the system will affect the performance of the machine. It can cause jerky movements and bounce
of the rockbreaker boom assembly.
The pipe circuit is fitted with a number of air bleed points to allow air to be bled from the system.
Whilst the system is operating, each of these bleed points should be opened to allow any trapped air to
escape.
Each of the bleed points is fitted with a ball valve and plug. The plug should be removed and a hose
connected to the valve to capture any oil discharged whilst bleeding the lines.
Once each point is bled, the valve should be closed, the drain hose removed and the plug firmly
replaced.
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The rockbreaker is fitted with a number of bleed points to allow for the air to be removed or system
pressure checks. Refer to the IOM for details.
If there are no bleed points on the hydraulic cylinders they can be bled by operating the cylinder to the
end of its stroke and then cracking the hose end fitting at the same end. Then operate the valve very
slowly in the opposite direction until all air is out of the cracked fitting. Secure the fitting
Hydraulic oil and grease pressure within fittings, tubing, and hosing can
be dangerous. Ensure all lines are free of pressure before disconnecting.
With all components installed into the circuit, the system should be brought up to full system pressure
and all connections should be visually checked for signs of leakage.
Pressure should be maintained for at least 10 minutes to ensure that any leaks can be located and
rectified prior to proceeding with the commissioning of the hydraulic power pack and isolation gates.
During commissioning, further inspections for any signs of leaks will be conducted.
5.5. Commissioning
Verification that the system has been installed in accordance with the drawings and this manual is to be
recorded on the Commissioning Records provided at appendix C.
It is a requirement of Transmin’s warranty that prior to use, the Commissioning checks as listed on these
forms are completed in full and signed by an authorized person. When completed, fax or email the final
sheet to Transmin and retain a copy for your own records.
Failure to complete these checks could result in damage to the equipment or injury to personnel.
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6. OPERATING INSTRUCTIONS
6.1. Routine Operator Checks
To ensure that the Rockbreaker and HPU are operating correctly, operators should be instructed to carry
out the following visual checks at start up and during each shift:
Ensure that the oil temperature is at least 10⁰C before attempting to move the
rockbreaker. On HPU start-up the immersion heater will warm the hydraulic oil.
During operation always check and watch that all machine functions operate normally.
Report any abnormality or damage to your supervisor
Check for any unusual noises during operation which may indicated loose fasteners or
inadequate lubrication,
Ensure that all safety guards are securely fitted and are in good condition,
Check for signs of hydraulic oil leaks, BUT DO NOT USE FINGERS,
Check the HPU filters are not indicating the elements need replacing,
Check that the hammer mounting bolts and hydraulic hoses are tight
Any potential problems should be reported immediately to the maintenance supervisor and (if necessary)
the machine stopped and isolated to investigate the problem to avoid damage to the machine or risk of
injury to personnel.
DO NOT USE FINGERS when checking for oil leaks, oil under pressure
can enter the skin and cause poisoning. Get a qualified hydraulics
technician to perform the detailed checks if oil is evident.
30
6.2. Operation of the Rockbreaker
Start the HPU with the radio transmitter. Move the rockbreaker as necessary with the joysticks on the
radio transmitter.
The two joysticks on the radio controller give full proportional control over the boom, jib, hammer and
slew movement of the rockbreaker. That is, the further the joystick is pushed the faster the machine will
react to the function. The joysticks also permit combination of movement, that is slew, boom, jib and
hammer movements can be made at the same time allowing extremely flexible and fast positioning of
the rockbreaker.
Press the “P/PACK START” on the radio transmitter once (battery indicator light starts
blinking).
The pump starts and the rockbreaker can be moved, using the joysticks on the radio
transmitter.
31
6.2.3. HPU shut down
Using the remote radio controller, park the rockbreaker in its dedicated parking position
and press the STOP button on the radio transmitter.
To operate the hammer, press one of the HAMMER buttons on the radio transmitter when the
rockbreaker boom is positioned correctly on a rock.
When operating the hammer, the following guidelines should be followed for optimum use:
Before operating the hammer ensure that the tool is correctly fitted. The hammer
assembly must be positioned firmly down on top of the rock before operating the
hammer switch.
During activation of the hammer switch the operator should listen for the sound of the
blow when the hammer is running. A solid blow indicates that correct rockbreaking
action is occurring. A hollow blow indicates that the hammer is not correctly positioned
and not providing an efficient breaking action. Re-position the hammer on the rock
before operating the hammer switch again.
If these general instructions are followed the life and availability of the
machine will be maintained. The Hammer vendor manual can be found at
appendix G
The HPU control system is fitted into a cabinet and mounted on the HPU frame. It contains switch gear,
safety system, client interface and a PLC unit with HMI.
The PLC unit controls the motors, valves and switch gear of the HPU, based on the status of external
signals, sensors, switches and safety system.
The operator interface is integrated into the panel door and consists of the following components:
HMI Panel. The HMI Panel is used to indicate alarms and navigate through the HPU
functions.
33
The HPU has 3 operation modes which are selected with the selector switch located on the HPU
cabinet:
LOCAL mode
OFF mode
REMOTE mode
The OFF position prevents the HPU from operating. In REMOTE mode, the HPU can be started by an
external source such as the radio controllers. LOCAL mode can be used during maintenance or fault
finding, and individual motors and devices can be started locally to check their operation. Safety
interlocks such as emergency stop buttons will function in both modes.
In LOCAL mode, the motors and heater (if fitted) can be started and stopped individually. LOCAL mode
is available for use as a tool to assist in maintenance, fault finding and commissioning.
To operate in LOCAL mode, the control panel selector switch must be set to the LOCAL position. The
hydraulic pump and cooling fan can then be run individually by selecting the appropriate screen on the
HMI and selecting start from that screen. The motor can then be either stopped from the HMI screen or
by tuning the mode selector switch to OFF.
Any shutdown signal will cause the local start to unlatch. This requires a restart from the HMI once the
cause of the shutdown has been cleared.
When the control panel selector switch is set to the LOCAL position, the remote stop/start control is
locked out. However, all interlocks such as Emergency Stop buttons and thermal overloads remain
operable to prevent the operation of motors where necessary to protect equipment from damage.
When set to REMOTE mode the HPU is started and stopped via the radio transmitter.
When operated in REMOTE mode the cooling fan, oil heater and unloading valve is controlled
automatically by the PLC.
The following interlocks are preventing a REMOTE start or trip the operation of the HPU:
34
6.3.6. HMI Screens
The HMI screen with its function keys is used to show the HPU conditions, warnings and alarms and to
operate the HPU in local mode. The reset function is assigned to a function key as well.
There are 8 screens, to navigate through the first 7 screens, use the function keys F9/F10. Screen 8 can
be accessed via the function keys mentioned on screen 7. To operate the HPU, access alarm pages and
swap between screens, use the function key as noted on each individual screen (see Figure 8)
Screen 1: main.
Line 1: HPU mode information
Line 2: HPU status information
Line 3: oil temperature
35
Screen 4: oil heater control / status
Line 1: oil heater mode information
Line 2: oil heater fan status information
Line 3: start/stop (in local mode)
(shown empty)
Use F1 and F2 to scroll through the list,
F3 to clear the log
36
Screen 8: language selection
Change language between Spanish and
English
37
6.3.7. Shutdown Protection Devices
The following shutdown devices are utilised to protect the hydraulic power unit from damage:
All shutdown devices are arranged for failsafe operation and the associated PLC input must be
energised for the power unit to run.
Release the “Power unit Healthy” dry contact to the Client's Plant Control System (PLC
or DCS (Distributed Control System)).
The RESET button (on HMI screen) will reset all alarms, reset all shutdown devices and reset all output
signals to healthy and reset the emergency stop relay. However, if the shutdown condition has not been
rectified, the shutdown device will re-trip.
The alarm reset button is located on the HMI.
To obtain access and reset any motor circuit BREAKER or thermal overload, the isolation switch must be
turned to the OFF position and the panel door opened.
6.3.8. Alarms
The following alarms are displayed on the HMI panel. These alarms will cause the power unit to shut
down and the Power unit Healthy dry contact to be switched off:
38
The following warnings are displayed on the HMI panel. These warnings will not cause the power unit to
shut down:
All alarms and warnings are reset from the HMI. Pressing RESET will reset all alarms and reset all
output signals to healthy. However, if the alarm condition has not been rectified, the alarm will re-trip.
The Transmin supplied grease and lubrication system is a standard option. If this is not fitted, then the
grease pump inputs are bridged out. For grease pump and injector information refer to appendix F
39
7. MAINTENANCE INSTRUCTIONS
7.1. Introduction
This section details the minimum preventive maintenance required to keep your machine in a safe and
serviceable condition. Careful performance of this maintenance will ensure long machine life.
The maintenance schedule lists the maintenance items with their recommended intervals. The intervals
are based on standard operating conditions and an average eight-hour operating day or approximately
2000 operating hours per year. Under no circumstances should the recommended intervals be
exceeded. When operating under extreme weather conditions and/or higher operating rates, the intervals
should be reduced accordingly.
CAUTION: ENSURE that all motors are switched off and isolated and
that pressure is released before attempting to service hydraulic
components and piping
Refer to the Maintenance Schedule at appendix C for the Maintenance Schedule Matrix
The lubrication grease pump (optional) may be mounted on the HPU or its own stand depending on the
distance of the HPU to the Rockbreaker or site requirements. It operates independent of when the HPU
to ensure there is always grease at the necessary points when the Rockbreaker is required to operate. It
is factory set to the correct frequency. Both the frequency and the quantity are adjustable to suit the
particular application. However, these settings should not be changed unless in consultation with
Transmin. Refer to appendix F for vendor manuals for the grease pump and injectors.
40
Figure 9 - Lincoln Grease Pump and Reservoir
41
7.4. Hydraulic power unit and Rockbreaker hydraulics
Refer to the lubrication schedule in appendix E to ensure the correct selection of oils and lubricants.
Transmin recommend that the oil be tested by a specialist organization to determine if the oil cleanliness
and properties are satisfactory. This way the oil is only changed when necessary. The frequency of the
testing depends on the site conditions and duty cycle of the Rockbreaker.
The maintenance schedule at appendix C details the frequency of oil changes and top-ups.
42
7.4.2. Filtration
The maintenance schedule in appendix C sets the frequency of maintenance tasks. As a guide the filters
should be replaced in accordance with Table 1
Description Frequency
Pressure Filter First Change 50 hrs after commissioning
7.4.3. Lubrication
Regular and correct lubrication is essential to ensure correct and reliable operation of the Rockbreaker. It
is extremely important that the lubrication schedules in appendix E are followed to avoid cross
contamination of incorrect oil. Should conditions vary during the life of the Rockbreaker, please contact
Transmin for a review of the lubricants that are recommended.
43
7.5. Hydraulic valves
To service, repair or replace the hydraulic valves, please contact Transmin Service.
Before replacement, ensure that all motors are switched off and isolated
and that pressure is released before attempting to service hydraulic
components and piping
7.6.1. Transport
This large diameter bearing (see Figure 11) requires careful handling. It should be transported and
stored in the horizontal position; if it must be transported vertically, it will require cross bracing. Impact
loads, particularly in a radial direction, must be avoided.
7.6.2. Storage
The bearing has a protective coating and can be stored for up to six months in a roofed storage area or
up to twelve months in an enclosed temperature controlled area.
7.6.3. Installation
The bearing support surface must be absolutely flat. The upper and lower ring must make perfect
contact and this must be checked using a levelling instrument or a feeler gauge. If the out-of-flatness
exceeds 0.2 mm the contact surfaces may require re-machining.
44
7.6.4. Assembly procedure
Clean bearing taking care not to allow any solvent to penetrate into the bearings.
The soft spot on outer race, identified by an ‘S’ stamped on top of a tooth, is to be
located at the left hand side of the machine. The soft spot on the inner race, identified
by an ‘S’ stamped on the plug, is to be located 180° opposite.
Fit bearing to slew base first. Locating dowels, 4 off, must be used to correctly locate
the bearing to the to the slew base. These dowels must remain in position until all
remaining capscrews have been torqued to their final setting.
Fit all capscrews to holes and fit plain nut to every 6th capscrew using 3/4” drive rattle
gun to tighten sequentially crosswise.
Fit cone lock nuts using Loctite 262 and tightening using pneumatic nut runner to
correct setting, tightening sequentially crosswise.
Fit and purge slew bearing grease lines prior to final assembly of mounting face to slew
bearing (check all hoses are labeled and lengths recorded).
Using locating dowels position bearing onto fixed base, these are to remain in position
until all other capscrews have been torqued to their final setting.
Fit all capscrews to holes and fit plain nut to every 6th capscrew using 3/4” drive rattle
gun to tighten sequentially crosswise.
Fit cone lock nuts using Loctite 262 and torquing using pneumatic nut runner to correct
setting, tightening sequentially crosswise to their final setting of 1395 Nm.
Gear teeth - At the point of maximum deviation of the pitch circle three teeth are marked in green. This
allows the satisfactory adjustment of the backlash. Refer to instructions on setting the backlash. After the
final tightening of the bearing capscrews the bearing gear should be checked around the entire
circumference.
7.6.5. Lubrication
The first re-lubrication of the raceway must be carried out immediately after installation.
The raceway should be lubricated with grease such as Shell Superplant M or equivalent. The bearing
must be liberally greased so that a collar of fresh grease forms at the gaps and seals around the whole
circumference. The bearing should be rotated during re-lubrication. The gear teeth should be manually
lubricated with Moluballoy - open gear heavy or equivalent.
45
7.6.6. Wear measurement
For assessing the condition of a bearing, it is recommended that its normal wear rate is determined. The
wear present in the raceway system shows itself by a change in the axial motion of the bearing. The first
measurement should be performed when the equipment is put into operation in order to obtain a base
value for subsequent repeat measurements.
The measuring points should be marked around the circumference, in four places 90° apart, while the
boom is kept in a specified position. Measurements are taken, as close to the bearing as possible,
between the underside of the bearing and the underside of the slewing frame. Slew the boom to the next
position and repeat the measurement procedure. When all positions have been measured, record the
base values.
The measurements should be repeated at regular periods, every six months is recommended, under
identical conditions to the base values. The difference between the values measured represents the
wear that has occurred. Once the wear reaches 0.6 mm it is recommended that the bearing be rotated
by unbolting the bearing and rotating the lower ring to even out the wear. When the wear reaches 2.0
mm it is recommended that the bearing be replaced
If the bearing is to be re-positioned, the unhardened zone (soft spot) must be positioned outside the
main area of load.
46
7.7. Slew gearbox
To remove the gearbox first mark both the gearbox flange and slew frame with a line so that the gearbox
can be reinstalled in the same position.
The gearbox shaft is eccentric to the gearbox flange spigot so that the
correct backlash of the pinion to slew bearing can be achieved. If
reinstalling the same box and pinion make sure the gearbox is installed in
the same position and then check the backlash.
If a new gearbox and or pinion are installed the backlash must be set
Disconnect the hydraulic hoses at the motor ports and plug both the ports and the hoses. Remove the
bolts holding the gearbox to the slew frame.
Refitting the gearbox is the reverse of removal EXCEPT THAT THE BACKLASH BETWEEN THE
PINION AND SLEW BEARING MUST BE CORRECTLY SET.
The gear teeth on the slew bearing are marked in green on three (3) teeth that have the maximum
deviation from the pitch circle. Rotate the Rockbreaker carefully until these teeth are central in the bore
for the gearbox.
Thoroughly clean the faces of the slew bearing teeth and the pinion teeth. Fit the gearbox and pinion into
the bore and make sure the flange and spigot are fully seated, do not fit the gearbox retaining bolts at
this time.
Through the opening in the bottom of the slew frame (remove the cover if this has not already been done)
check the backlash between the pinion and bearing teeth.
If the backlash is not within specification rotate the gearbox assembly until the specification is achieved.
Fit the retaining bolts and recheck the backlash for the entire working slew range. When the backlash is
correct fit the gearbox retaining bolts with Loctite 243 and tension to M16 grade 8.8 – 190 Nm.
Coat the pinion with Moluballoy 777-2 open gear heavy duty grease and refit the cover to the bottom of
the slew frame.
47
7.7.2. Slew Pinion
The gearbox(s) on Rockbreaker Series 100, 130 and 160 are fitted with a removable pinion.
To remove the pinion from the gearbox. Remove the 3 bolts holding the pinion retaining cap. If the same
pinion is to be fitted to the same gearbox, mark both the pinion and shaft so they can be reassembled in
the same place. This prolongs the spline life. Slide the pinion from the splines on the gearbox shaft.
To refit the pinion, or fit a new pinion. Grease the gearbox splines with general purpose grease. Slide the
pinion onto the gearbox splines, refit the retaining cap and tighten the retaining bolts to a torque of M14
grade 8.8 - 122Nm.
The gearbox shaft is eccentric to the gearbox flange spigot so that the
correct backlash of the pinion to slew bearing can be achieved. If
reinstalling the same box and pinion make sure the gearbox is installed in
the same position and then check the backlash.
If a new pinion is installed the backlash must be set as stated in the slew
gearbox section.
When the backlash is correct, coat the pinion with Moluballoy 777-2 open gear heavy duty grease and
refit the cover to the bottom of the slew frame.
If the pump motor requires replacement or repairs, please contact the Transmin Service Department.
Ensure that all motors are switched off and isolated and that pressure is
released before attempting to service hydraulic components and piping.
7.7.4. Hammer
To replace the hammer, refer to the Vendor manual in appendix G. For service or replacement of
the hammer and/or hammer parts, please contact the Transmin Service Department.
Ensure that all motors are switched off and isolated and that pressure is
released before attempting to service hydraulic components and piping
48
7.7.5. Pump motor
If the pump motor requires replacement or repairs, please contact the Transmin Service Department.
If the oil cooler motor requires replacement or repairs, please contact the Transmin Service Department.
If the hydraulic pump requires replacement or repairs, please contact the Transmin Service Department.
Ensure that all motors are switched off and isolated and before attempting
to replace the hydraulic components and piping
If the cooling pump requires replacement or repairs, please contact the Transmin Service Department.
Ensure that all motors are switched off and isolated and before attempting
to replace the hydraulic components and piping
49
7.7.9. Grease Lubrication pump and injectors
To service or repair the grease lubrication pump or injectors, refer to the Vendor manual appendix F.
Pump and Injector settings should not be changed unless Transmin is consulted first. Transmin must
assess the necessity and site conditions to warrant the change.
This Rockbreaker is fitted with the Transmin QUICK UNLOCK system of taper bushes at all pivot and
cylinder pins. The system allows for easy removal of the pins for inspection or replacement.
7.8.1. Removal
To remove the pivot pin proceed as follows: (see Figure 13)
Remove the three locking screws and disc-lock washers from both sides of the pivot
pin
Replace the screws into the jacking position and screw in evenly thus prising the taper
bush out. Repeat the operation on the other side until the pivot pin is released
7.8.2. Assembly
Firstly, the assembly should be carried out by ensuring that the pin is located centrally and that the holes
in the taper bush align with the corresponding holes in the pin. The tapered surface of the pin and bush
should be lightly sprayed with CRC 5.56, DWF or equivalent. The bush retaining screws should be
treated with an anti-seize compound. The taper bushes should then be tapped lightly into place ensuring
that they protrude equally from each boss and the measured depth from the outside of the bush to the
pin is the same on each side. Once this set-up is correct, the following tightening procedure should be
adhered to:
Having fitted a pair of disc-lock washers to each locking screw (ensuring teeth are
inter-locking together), snug tighten all screws on both sides (lightly tapping the bush if
necessary) ensuring that pin and taper bushes sit evenly each side.
50
Torque all M12 locking screws alternately to 100Nm (It is important to torque screws
evenly on both sides of the pin, checking the pin depth regularly to ensure even
tightening), then alternately to 120Nm. Finally tighten all screws to 135Nm
Torque all M16 locking screws alternately to 100Nm (It is important to torque screws
evenly on both sides of the pin, checking the pin depth regularly to ensure even
tightening), then alternately to 200Nm. Finally tighten all screws to 270Nm
51
7.9. Pivot & cylinder pin removal and replacement tooling (optional extra)
Tooling is available for easy removal of the pivot pins for maintenance or replacement (see Figure 14).
For the purchase of this item, please contact the Transmin Service Department.
7.9.1. Removal
Ensure there is adequate support around the pivot pin to be removed. After the taper bushes have been
removed as described in the previous section, an adapter is attached to the pivot pin using the existing
taper bush bolts.
The adapter used must be the same diameter as the pivot pin to be
removed.
The threaded rod assembly is then fed through the ram and puller and
screwed fully into the adapter. The hand pump is then activated to pull
the pivot pin out.
7.9.2. Assembly
Assembly is exactly the same as the above procedure with the pivot pin being pulled in from the opposite
side. Ensure the pin is pulled through enough to be positioned centrally about the pivot.
52
53
8. WARRANTY STATEMENT
Goods supplied by TRANSMIN and warranted for a period of 18 months after delivery or 12 months from
commencement of operation, whichever is sooner.
Any goods in storage shall be inspected at 6 monthly intervals, by Transmin, to maintain the warranty
period. Any additional requirements for storage stipulated by Transmin shall be maintained for the
duration of storage.
Transmin warrants that if any defect in any workmanship manufactured by the Transmin becomes
apparent and is reported to the Company in writing within Defects Liability Period of twelve (12) months
from Load Commissioning then Transmin will either (at the their sole discretion) replace the defective
part repair the defect.
(i) The warranty shall not cover any defect or damage which may be caused or partly
caused by or arise through:
a) Failure on the part of the Customer to properly install or maintain the Equipment;
or
b) Failure on the part of the Customer to follow any instructions or guidelines
provided by Transmin; or
c) Any use of the Equipment otherwise than for the original intended application for
which the Equipment has been specifically designed, including modifications to the
Equipment or changes in operation which have not been specifically approved by
Transmin in writing; or
d) The continued use of any Equipment after any defect becomes apparent or would
have become apparent to a reasonably prudent operator or user; or
e) Ingress of tramp or extraneous material; or
f) Fair wear and tear, any accident, or act of God.
(ii) The warranty shall cease and Transmin shall thereafter in no circumstances be liable
under the terms of the warranty if the workmanship is repaired, altered or overhauled
without Transmin’s approval in writing.
(iii) The Customer shall afford Transmin an opportunity to inspect the Equipment within a
reasonable time following delivery if the Customer believes the Equipment is defective in
any way.
(iv) The defective part is promptly returned to the Transmin’s designated service centre.
Expenses incurred in transport of Goods or travel by personnel to or from the installation
site to the Transmin approved repair workshop will be to Customer’s expense.
(v) Any defective part replaced will become Transmin’s property and the repaired or new
part will be delivered to the Customer’s site via means selected by Transmin.
54
(vi) In respect of all claims Transmin shall not be liable to compensate the Customer for
any delay in either replacing or repairing the workmanship/Goods or in properly assessing
the Customer’s claim.
(vii) Where Transmin elects to replace faulty parts, this warranty covers the supply of the
replacement parts only and does not cover the change over costs of replacement parts.
(viii) Transmin does not provide any warranty with regard to any Customer specified or
supplied Equipment or materials unless specifically approved in writing and will endeavor
to have the supplier provide any warranties on these Goods direct to the Customer.
(ix) Warranties will be conditional upon carrying out the site pre-commissioning inspection
and commissioning in accordance with Transmin’s requirements as detailed in the IOM
manuals as a minimum, and the timely submission of properly completed forms to
Transmin prior to any warranty claims.
Any goods replaced or repaired shall from the date of making good be under warranty for the
period of 12 months.
8.3. Exceptions
The warranties given by TRANSMIN herein to the extent permitted by State and Federal law do
not cover:
(a) Failure not reported to TRANSMIN within the warranty period specified here in.
(c) Failures due to operation, either intentional or otherwise, above or below rated capacities
or in an otherwise improper manner.
(d) Products which have in any way been tampered with or altered by anyone other than an
authorised representative of TRANSMIN.
55
9. SPARE PARTS
9.1. Ordering information
To order spare parts please quote the following information to help us provide prompt responses
to your Spare Parts enquiries.
Reference should be made to the recommended Spare Parts List at appendix B when ordering
parts.
It is strongly recommended that the recommended spare parts are held on site and maintained in
good condition in stores at all times during the operation of this plant. A number of these items
are long lead components, which could lead to significant down time if required in the event of
failure.
Equipment serial number - Refer the front of this manual or the nameplate affixed to
the equipment.
56
10. PARTS LISTS
1 R601192 SLEW 1
2 R600071 GEARBOX & MOTOR 1
3 R600801 130 SERIES 5m BOOM 1
4 R600702 130 SERIES 5m JIB 1
5 R600319 130 SERIES BR3288 HAMMER BRACKET 1
6 R600766 BOOM CYLINDER 1
7 R600077 JIB CYLINDER 1
8 R600600 HAMMER CYLINDEER 1
9 R600625 HAMMER BR3288 1
10 R601221 LOCKING VALVE KIT, BOOM 1
11 R601222 LOCKING KIT, JIB 1
57
58
SLEW BASE ASSEMBLY – 130 SERIES
59
60
61
GEARBOX & MOTOR – 130 SERIES
62
63
5m BOOM ARRANGEMENT
64
65
5m JIB ARRANGEMENT
66
67
130 SERIES HAMMER BRACKET BR3288 HAMMER
68
HYDRAULIC POWER UNIT (HPU) HP1100S
69
42 R600251 FILTER, PRESSURE 1
43 49374-03 AUTOMATIC LUBRICATION PANEL 1
44 R507652 INLINE CHECK VALVE 1
45 R601207 GASKET, RETURN FILTER 1
46 R601206 SPACER PLATE, RETURN FILTER 1
47 R601226 SPACER BRACKET 1
48 R601238 PRESSURE PIPE, FILTER INLET 1
49 R601239 PRESSURE PIPE, PUMP OUTLET 1
50 43246 TEST COUPLING 1
51 THREADED ADAPTOR 1
70
71
72
130SERIES Rockbreaker REMOTE RADIO CONTROL
1 R504016/01 Battery 2
2 R507736/01 Bellows - Joystick 2
3 R507736/03 Carry Belt - Hip 1
74
75
11. SPECIFICATIONS
Transmin’s Scope of Supply for the Rockbreaker System comprises the following:
One (1) 110kW non-submerged power pack c/w control panel (derated to 97 kW)
Transmin supply a wide range of Rockbreaker and HPU configurations, listed below is a summary of the
technical specifications of the Transmin Rockbreaker and HPU for this contract.
Please refer to the comprehensive Spare Parts List in the appendices section for a full list of
recommended spare parts.
Rockbreaker
Options / Variations
Faster Slew : NA
Automation : NA
76
Colour : Golden Yellow Y14
Hoses : Duffield
Pressure & Return Line Filters : Yes, standard with visual blocked filter
indication and switches. Stauff Filters.
77
Filling Point : Parker
Filter Magnet : No
Power unit Start / Stop Operation : By Transmin with PLC Allen-Bradley 1763
Additional Requirements : No
78
12. REFERENCE DOCUMENTS & DRAWINGS
Client Document Transmin Doc
Document Title
Reference Reference
49243 R600191 Boom Mounting and Loading Details
79
DRAWING No. REVISION
GENERAL NOTES:
49374-SH1 1 260
1. ALL LETTERING TO BE ENGRAVED BOLD.
5 250 CRS
TYP.
TYP. TYP. 2. ALL LETTERING TO BE COLOUR BLACK
5
0
45
TYP. 3-LINES
12 TEXT
70
ROCKBREAKER NAMEPLATE
90
190 CRS
TYP.
200
ITEM PART No DRG REF QTY DESCRIPTION REMARKS
110
1 49374-01 49374 1 1.6SHT 260x200 316 S/S 125
140
155
TYP. 5-LINES
170
7 TEXT
185
1:1
350
TYP.
5 170 CRS 170 CRS
TYP. TYP. TYP.
5
0
HPU NAMEPLATE
12 TEXT
45
12 TEXT
TYP.
70
ITEM PART No DRG REF QTY DESCRIPTION REMARKS
170 CRS
TYP.
2 49374-02 49374 1 1.6SHT 350x180 316 S/S
180
90
105
120
TYP. 5-LINES
135
7 TEXT
150
165
1:1
AUSENCO PROJECT No:
2172-0020
TOLERANCES TO AS 1100 UNO 35 DENNINUP WAY DRAWN: DB CHK'D: DH
MALAGA. W.A. 6090 DATE: 19/06/2012 DATE: 19/06/2012
NOM DIM MACHINED OTHER PH. (08)9249 5755 APP'D: DH SCALE:
0.5 - 6 ±0.1 ±0.3 THIRD ANGLE AUSTRALIAN ENGINEERING WORLDWIDE FX. (08)9249 6116 DATE: 19/06/2012 1:1 UNO
1 18/04/2013 RK AS BUILTS DH
>6 - 30 ±0.2 ±0.5 COPYRIGHT © CLIENT: HUDBAY PERU
JOB NUMBER TM4215
0
B
18/04/2013
27/06/2012
RK
DB
ISSUED FOR CONSTRUCTION
UPDATED TO CLIENT MARK UPS
DH
DH
>30 - 120
>120 - 315
±0.3
±0.5
±0.8
±1.2
THIS DRAWING IS THE PROPERTY OF
TRANSMIN PTY LTD FOR WHICH WE
RESERVE ALL RIGHTS INCLUDING THOSE
PROJECT: CONSTANCIA PROJECT
SHEET 1 OF 2
A1
>315 - 1000 ±0.8 ±2.0
RELATING TO PATENTS OR REGISTERED
DESIGNS. IT MUST NOT BE REPRODUCED
ROCKBREAKER DRAWING No. REVISION
A 19/06/2012 DB ISSUED FOR REVIEW DH >1000 - 2000 ±1.2 ±3.0 OR USED OTHERWISE OR MADE EQUIPMENT NAMEPLATES & LABELS
REFERENCE DRAWINGS REV DATE BY DESCRIPTION APP'D REV DATE BY DESCRIPTION APP'D >2000 - 4000 ±2.0 ±4.0
AVAILABLE TO ANY THIRD PARTY
WITHOUT PRIOR PERMISSION IN WRITING. DETAILS 49374-SH1 1
DRAWING No. REVISION
110
55
AUTO LUBRICATION LABEL TEXT CRS
TYP.
8
12 TEXT
ITEM PART No DRG REF QTY DESCRIPTION REMARKS
TYP.
34 CRS
3 49374-03 49374 1 1.6SHT 110x50 316 S/S
50
TYP.
4
1:1 6 SLOT
TYP.
8 94
TYP. SLOT CRS
160
ELECTRICAL CONTROL 80
TYP.
TEXT CRS
8
PANEL LABEL
12 TEXT
TYP.
34 CRS
50
ITEM PART No DRG REF QTY DESCRIPTION REMARKS
TYP.
4
4 49374-04 49374 1 1.6SHT 160x50 316 S/S
1:1 6 SLOT
TYP.
8 144
TYP. SLOT CRS
110
55
TYP.
TEXT CRS
8
RADIO RECEIVER LABEL
12 TEXT
TYP.
34 CRS
50
TYP.
ITEM PART No DRG REF QTY DESCRIPTION REMARKS
4
5 49374-05 49374 1 1.6SHT 110x50 316 S/S
1:1 6 SLOT
TYP.
8 94
TYP. SLOT CRS
49401 1
ITEM PART No DRG REF QTY DESCRIPTION REMARKS ITEM PART No DRG REF QTY DESCRIPTION REMARKS
10 49374-01 49374 1 ROCKBREAKER BOOM SYSTEM - NAME PLATE 40 49374-02 49374 1 NAMEPLATE - HYDRAULIC POWERUNIT
20 49374-04 49374 1 ELECTRICAL CONTROL PANEL LABEL 50 49374-03 49374 1 AUTOMATIC LUBRICATION LABEL
30 49374-05 49374 1 RADIO RECEIVER LABEL
40
10
50
20
A. Troubleshooting Guide
B. Spare Parts Lists
C. Commissioning Records
D. Maintenance Schedule
E. Lubrication Schedule
F. Lincoln Grease pump and injectors
G. Sandvik Hydraulic hammer
81
A. Troubleshooting Guide
The following sections are intended to provide a guide to help identify problem areas.
In most instances, simple common sense will provide the location and cause of the problem.
However, in some cases, other causes such as low voltage supply and blocked hydraulic
filters may not be easily recognised and cause problems similar to those caused by other
conditions. Please contact Transmin engineers should you have any problems regarding
this issue.
The Stauff ‘Mini Mess’ test points fitted throughout the hydraulic system are a powerful tool for
troubleshooting and setting up the machine to effect its best performance and life. The following
section shows the location of the points and the results that should be obtained if the system is
operating correctly.
82
CHART 1 - FAULTY OPERATION
REMEDIES 1.
Fluid
may be too cold or should be changed to clean fluid of correct viscosity.
3. Recondition or replace.
4. Lubricate.
6. Fluid level too low - Fill reservoir to proper level - (* all return lines that enter oil reservoir must
terminate below fluid level)
83
CHART 2 - EXCESSIVE NOISE
PUMP NOISY ELECTRIC MOTOR NOISY RELEIF VALVE NOISY
A Cavitation A Motor worn or damaged A Setting too close to
Remedy 1 & 2 Remedy 5 operating pressure or to
another relief valve
setting
Remedy 4
B Coupling misaligned B Coupling misaligned B Worn poppet and seat
Remedy 3 & 5 Remedy 3 & 5 Remedy 5
C Air in fluid
Remedy 2
D Pump worn or damaged
Remedy 5
REMEDIES
3. Align unit to within ± 0.1mm parallel alignment and check condition of seals and bearings.
5. Recondition.
84
CHART 3 - EXCESSIVE HEAT
PUMP HEATED ELECTRIC MOTOR FLUID HEATED
HEATED
A Air in fluid A Motor worn or damaged A System pressure too
Remedy 2 Remedy 4 & 6 high
Remedy 1 & 5
B Excessive load B Excessive load B Relief valve or valves
Remedy 3 Remedy 3 constantly blowing
Remedy 4
C Cavitation C Fluid dirty or low level
Remedy 1 Remedy 5
D Fluid heated D Incorrect fluid viscosity
Remedy 1 Remedy 5
E Pump worn or damaged E Faulty fluid cooling
Remedy 4 system
Remedy 4
F Worn Pump, valve,
motor, cylinder or other
component
Remedy 4
REMEDIES
Fill reservoir
Install clean filters
Clean clogged inlet line
Clean air breather
Change system fluid
3. Align unit to within ± 0.1mm parallel alignment and check condition of seals and bearings.
85
Replace or recondition
86
CHART 4 - INCORRECT PRESSURE
NO PRESSURE LOW PRESSURE ERRATIC EXCESSIVE
PRESSURE PRESSURE
A No flow A Pressure relief A Air in fluid A Relief valve
Remedy 1, 2, valve blowing Remedy 2 maladjusted
3&5 Remedy 1, 2 & 4 Remedy 4
B Excessive B Worn relief B Worn or
external leakage valve damaged relief
Remedy 2 & 5 Remedy 5 valve
Remedy 5
C Relief valve stuck C Contamination
open in system
Remedy 5 Remedy 1
D Worn pump or
cylinder
Remedy 5
REMEDIES
4. Adjust pressure.
5. Recondition or replace.
87
CHART 5 - INCORRECT FLOW
NO FLOW LOW FLOW EXCESSIVE FLOW
A Pump not receiving fluid A Flow control set too low A Flow control set too high
Remedy 1 or failed to open Remedy 4
Remedy 4
B Pump drive coupling B Relief or unloading
sheared valve set too low
Remedy 3 Remedy 4 & 5
C Pump drive motor turning C External leak in system
in the wrong direction Remedy 2
Remedy 7
D Directional control set in D Worn Pump, valve,
wrong position motor, cylinder or other
Remedy 6 component
Remedy 5
E Entire flow passing over
relief valve
Remedy 4
F Unloading valve failed to
close
Remedy 4, 5 & 8
G Damaged pump
Remedy 3
REMEDIES
1. Any or all of the following:
3. Check for damaged pump or pump drive, replace and align coupling.
5. Overhaul or replace.
7. Reverse rotation.
88
B. Spare Parts Lists
89
OPERATING AND COMMISSIONING SPARES
130 SERIES TRANSMIN ROCKBREAKER BOOM – 12 MONTHS OPERATION
PLEASE NOTE :- All prices quoted are Ex-works Transmin`s factory, Malaga Western Australia.
All prices quoted remain valid until 30th December 2012– ( GST not included )
90
ON SITE INSURANCE SPARES FOR
130 SERIES TRANSMIN ROCKBREAKER BOOM
91
19 Setscrew – M12 R508209 42 $ 10.00 $ 420.00
20 Setscrew – M16 R600208 12 $ 12.00 $ 144.00
PLEASE NOTE :- All prices quoted are Ex-works Transmin`s factory, Malaga Western Australia.
All prices quoted remain valid until 30th December 2012 – ( GST not included )
92
ON SITE INSURANCE SPARES FOR
130 SERIES TRANSMIN ROCKBREAKER BOOM
PLEASE NOTE :- All prices quoted are Ex-works Transmin`s factory, Malaga Western Australia.
All prices quoted remain valid until 30th December 2012 – ( GST not included )
93
RECOMMENDED ON SITE SPARES FOR
SANDVIK BR3288-020 HAMMER
PLEASE NOTE: - All prices quoted are Ex-works Transmin’s factory, Malaga, Western Australia
All prices quoted remain valid until 30th December 2012 - (GST Not Included)
94
COMMISSIONING SPARES
110KW ROCKBREAKER POWERPACK
PLEASE NOTE: - All prices quoted are Ex-works Transmin’s factory, Malaga, Western Australia
All prices quoted remain valid until 30th December 2012 - (GST Not Included)
95
OPERATING SPARES - 12 MONTHS OPERATION
RADIO CONTROL SYSTEM
PLEASE NOTE: - All prices quoted are Ex-works Transmin’s factory, Malaga, Western Australia
All prices quoted remain valid until 30th December 2012 - (GST Not Included)
96
RECOMMENDED ON SITE TOOLING FOR
130 SERIES TRANSMIN ROCKBREAKER
PLEASE NOTE: - All prices quoted are Ex-works Transmin`s factory, Malaga Western Australia.
97
All prices quoted remain valid until 30Th December 2012 – (GST Not Included)
98
C. Commissioning Records
99
-1-
A) NAMEPLATE CHECK
Hydraulic Pump Design Flow Rate: 240 litres per minute (Variable)
Manufacturer: TECO
J:\JOBFOLDERS\TM4200-4299\TM4215 HUDBAY PERU AUSENCO (CONSTANCIA PROJECT) Rockbreaker\3 VDDR Documentation\3.22 Commissioning record
(COM)\COMMISSIONING RECORD (HYDRAULIC SYSTEM).doc
-2-
All interconnecting hydraulic hosing, tube / pipe between hydraulic power pack has been installed
correctly. : ____________________
All site run piping, hosing and fittings is as per design drawings, registers and installation procedures
followed. : ____________________
All fitting flange connection bolts are fitted and tightened. : ____________________
Isolation valves from power pack have been opened and locked in position. Ref to site rep for site specific
isolation lock requirements. : ____________________
Correct Hydraulic oil grade used as per Transmin specifications. Note if different to Transmin
specifications Transmin must approve the oil in writing. : SHELL TELLUS S2 M 32
Correct Grease grade used as per Transmin specifications. Note if different to Transmin specifications
Transmin must approve the grease in writing. : SHELL ALBIDA HDX2
Purge air from load sensing line from power pack test point. : ____________________
Purge air from load sensing line from control valve test point. : ____________________
J:\JOBFOLDERS\TM4200-4299\TM4215 HUDBAY PERU AUSENCO (CONSTANCIA PROJECT) Rockbreaker\3 VDDR Documentation\3.22 Commissioning record
(COM)\COMMISSIONING RECORD (HYDRAULIC SYSTEM).doc
-3-
Check Motors Rotate Freely by Hand YES / NO (If NO, do not proceed)
All motors should be bump started to confirmation that direction of rotation is in accordance with labels.
Direction of Rotations checks are to be recorded below:
Required Direction of Rotation Confirmed (YES / NO)
Motor NOTE: Directions are when viewed from Non-Drive end of motor
Pump CLOCKWISE
Cooler Fan motor (if COUNTER CLOCKWISE
fitted)
Cooler fan blades are concaved when viewed from fan motor Non drive end . IE pull air through matrix
and blow past cooler fan motor (if fitted) : ______________
J:\JOBFOLDERS\TM4200-4299\TM4215 HUDBAY PERU AUSENCO (CONSTANCIA PROJECT) Rockbreaker\3 VDDR Documentation\3.22 Commissioning record
(COM)\COMMISSIONING RECORD (HYDRAULIC SYSTEM).doc
-1-
A) NAMEPLATE CHECK
Rockbreaker Boom Assembly : RB-118 Transmin Serial Number
: 3111-BK-001 Client Equipment Number
B) PRE-START CHECK
What is rockbreaker base being attached to? : STEEL / CONCRETE
STEEL STRUCTURE
Slew bearing soft spot is stamped. : YES / NO / NA
Confirm hold down bolts have all been torque to spec: YES / NO (If NOT, do not proceed)
CONCRETE FOOTING
Confirm grout spacers have been fitted and levelled. : YES / NO (If NOT, do not proceed)
Confirm non shrink grout has fully cured. : YES / NO (If NOT, do not proceed)
Confirm M36 grade 8.8 slew base hold down studs have all been torque to spec: YES / NO (If NOT,
do not proceed)
J:\JOBFOLDERS\TM4200-4299\TM4215 HUDBAY PERU AUSENCO (CONSTANCIA PROJECT) Rockbreaker\3 VDDR Documentation\3.22 Commissioning record
(COM)\COMMISSIONING RECORD (ROCKBREAKER BOOM).docx
-2-
ALL ROCKBREAKERS
Confirm jib assembly has been correctly installed to the boom. Cap bolts torque correctly as per
specification, hydraulic hoses, grease hoses and electrical connections correct.: YES / NO (If NOT,
do not proceed)
Confirm hammer bolts have all been torque to spec : YES / NO (If NOT, do not proceed)
All hydraulic cylinders in good condition. (INSPECT ROD AND BARREL FOR SIGNS OF IMPACT)
: YES / NO (If NOT, do not proceed)
Slew Proximity Sensors (optional) : Installed and Secure – Electrical Installation Approved
Control System Sensors (optional) : Installed and Secure – Electrical Installation Approved
Guarding – Motors, fans, inspection cover on pump bell housing & pinion guard.
: Installed, Secure and confirmed as adequate
All personnel cleared and safety procedures put in place including area bunting as required.
: YES / NO (If NOT, do not proceed)
Status of other works not hindering commissioning. : YES / NO (If NOT, do not proceed)
J:\JOBFOLDERS\TM4200-4299\TM4215 HUDBAY PERU AUSENCO (CONSTANCIA PROJECT) Rockbreaker\3 VDDR Documentation\3.22 Commissioning record
(COM)\COMMISSIONING RECORD (ROCKBREAKER BOOM).docx
-3-
D) OPERATION – TEST
Ensure all electrical, control devices and check lists have been fitted, tested & completed prior to proceeding:
Operate rockbreaker and cycle through complete range of all hydraulic cylinders 4x .
Slew fully left & right to check for clashing on the structure. : ______________
Confirm that hoses interconnecting hoses from hose support stand have enough length when slewing
through the full range. : YES / NO (If NOT, do not proceed)
Confirm that slew limit’s are operating correctly. : YES / NO (If NOT,
do not proceed)
Check rockbreaker, power pack & interconnecting tube work for any leaks : YES / NO (If NOT,
do not proceed)
J:\JOBFOLDERS\TM4200-4299\TM4215 HUDBAY PERU AUSENCO (CONSTANCIA PROJECT) Rockbreaker\3 VDDR Documentation\3.22 Commissioning record
(COM)\COMMISSIONING RECORD (ROCKBREAKER BOOM).docx
D. Maintenance Schedule
Compliance with the following maintenance schedule is essential for the correct, safe and reliable
operation of the rockbreaker, HPU and associated equipment.
100
Consumeables Special Tools
Maintenance Period Sub‐System Activity Spare Parts Required Remarks Doc Reference
required Required
After first day of Boom Tighten all M36 base mounting bolts to 2300 Nil Nil Torque
operation Nm Wrench
Tighten all M24 hammer top plate mounting Nil Nil Torque
bolts to 640 Nm Wrench
HPU Change Hydraulic Oil Filler filter
All Check for hydraulic leaks as required Tighten fittings or replace parts as
required
50 hrs after HPU 1st change pressure and return filters Pressure & Return Nil Nil
commissioning Filter Element
40 hours or weekly Boom Inspect all pivot pins externally and check
locking screws for tightness
Inspect hydraulic cylinder glands and fittings
for leaks
Lubrication Check all points supplied by the automatic Nil Fresh grease should be evident at
pivot greaser are being greased. all pivot points
HPU • Check hydraulic pump, filters, tank,
hydraulic lines and fittings for leaks.
• Check these parts for tightness
Hammer Perform hammer maintenance as described Torque
in hammer instruction manual Wrench
Check the slew gearbox oil level. If more than
1 litre (~5%) required for top up, then check DO NOT mix oils of different types
for leaks or grade even of the same make
Hammer Check the hammer tool shank and toll
bushings for wear
Hydraulics Check the condition of all hydraulic lines Replace if damaged
Check for leaking hydraulic fluid Tighten fittings or replace if
necessary
250 hours HPU 2nd change pressure and return filters Pressure & Return Nil Nil
Filter Element
Consumeables Special Tools
Maintenance Period Sub‐System Activity Spare Parts Required Remarks Doc Reference
required Required
500 hours or Quarterly HPU 3rd change pressure and return filters Pressure & Return Nil Subsequent, filter changes at 500
Filter Element hrs intervals or when indicated by
filter gauge
Change Hydraulic Tank Breather Hydraulic Tank Nil Nil
Breather
Change Slew Gearbox Breather Slew Gearbox Breather Nil Nil Subsequent, filter changes at
2000 hrs intervals or when
indicated by filter
Installation Check for leaks
Piping
1000 hours or six monthly Electrical Grease HPU Motor Bearings 27 g of Mobil Polyrex EM 103 TECO Technical Catalogue
Boom Check slew drive backlash Adjust if necessary
Remove pivot pins to examine wear on pins
and bushes
Tighten all M24 hammer top plate mounting Nil Nil Torque
bolts to 640 Nm Wrench
2000 hours or annual Boom Drain slew gearbox/es, flush and refill • Drain oil when hot
servicing • 23 L (nom) Fill to mid‐point of
sight glass
Boom Tighten all M36 base mounting bolts to 2300 Nil Nil Torque
Nm Wrench
HPU • Change hydraulic oil Filler Filter • Rockbreaker must be parked in
• Clean the inside of the reservoir thoroughly standard parking postion
•
101
Confidential 15/06/2012 Page 1
LUBRICATION SCHEDULE
EQUIPMENT No. ITEM DESCRIPTION MODEL NUMBER INITIAL LUBRICATION COMMENTS
SPECIFIC OIL / GREASE MAINTENANCE QUANTITY (EACH) MAINTENANCE PERIOD
QUANTITY (EACH)
Gearbox Oil TBC SHELL OMALA EP 23 litres 23L (nom) - Fill to mid point of sight glass First change - 100 hours,
Thereafter - 2000 hours or Annually Further details will be available from the IOM once complete
Gearbox pinion TBC Moluballoy 777-2 open gear heavy N/A Apply manually Removal of gearbox or replacement of pinion Further details will be available from the IOM once complete
Gearbox pinion TBC Shell Albidia HDX2 N/A 0.016 cc Automatic Further details will be available from the IOM once complete
Slew Bearing TBC Shell Albidia HDX2 N/A 0.016 cc Automatic Further details will be available from the IOM once complete
Pivot pins TBC Shell Albidia HDX2 N/A 0.016 cc Automatic - Fresh grease should be evident Further details will be available from the IOM once complete
Cylinder pins TBC Shell Albidia HDX2 N/A 0.016 cc Automatic - Fresh grease should be evident Further details will be available from the IOM once complete
Hammer TBC Shell Albidia HDX2 N/A 0.016 cc Automatic Further details will be available from the IOM once complete
HPU Motor Bearings TBC Shell Alvania RL2 12g each point only 12g each point only 1000 hours Further details will be available from the IOM once complete
DOCUMENT:4215-LBS-01 Page 1 / 1
F. Lincoln Grease Pump and Injector Manual
102
Electric Operated Centro-Matic® Pump P653S
24 VDC or 120/230 VAC, 50-60Hz
Table of Contents
Page
Introduction
Explanation of Symbols Used ..................................................3
User’s Responsibility ..............................................................3
Environmental Protection ........................................................3
Service ......................................................................................3
Safety Instructions
Appropriate Use ........................................................................4
Misuse ......................................................................................4
Exclusion of Liability .........................................................4
Regulation for Prevention of Accidents .....................................4
General Safety Instructions .....................................................4
Operation, Maintenance and Repair ........................................4
Repair ...............................................................................4
Disposal .............................................................................4
Operation / Maintenance .....................................................5
Installation..............................................................................5
Assembly and Maintenance of the Hydraulic Hoses ............5
Description of Pump..............................................................6
Description of Operation...........................................................9
Pump Element Operation........................................................10
Pump with Internal Pressure Switch ........................................11
Pump with Internal and External Pressure Switch .................11
Pump with Internal Pressure Transducer ...............................12
Pump with Internal and External Pressure Transducer..............12
!
Filling Reservoir with Grease...................................................13
Air Expel Procedure................................................................13
Pump with Folllower Plate......................................................13
Pump without Follower Plate...................................................14
Keypad and Display.................................................................15
"
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Acknowledging a Fault............................................................19
Programming the Pump.........................................................20
Review of Pump Parameters...................................................25
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List of Lubricants.....................................................................32
Dimensions .............................................................................35
.........................................................39
Mounting Template.................................................................40
Troubleshooting Guide.........................................................41
Parts List...............................................................................42
Introduction
Explanation of Symbols Used User’s Responsibility
The following description standards are used in this manual: To ensure the safe operation of the unit, the user is responsible
for the following:
Safety Instructions 1. The pump/system shall be operated only for the intended
Structure of safety instructions: use (see next chapter “Safety Instructions”) and its design
8
$ &
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8
=
functioning condition and if it is operated in accordance with
8
the maintenance requirements.
8 ><
? 3. The operating personnel must be familiar with this Owner
The following pictograms are used in this manual and are com8 Manual and the safety instructions mentioned within, and
bined with corresponding signal words: observe these carefully.
The correct installation and connection of tubes and hoses, if
V^
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Lincoln Industrial Technical Services will gladly assist you with
any questions pertaining to the installation.
Environmental Protection
8)%%@%B 8)%%@%B 8B%@ Waste (e.g. used oil, detergents, lubricants) must be disposed
8)C%B 8)C%B 8:BJ%)% of in accordance with relevant environmental regulations.
8')JN 8')JN
The signal words give the seriousness of danger if the follow8 Service
ing text is not observed:
The personnel responsible for the handling of the pump/sys8
ATTENTION refers to faults or damages on machines.
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NOTE indicates improved operation of the device. department for assistance.
IMPORTANT indicates special operating features of the de8
vice. In the event of inquiries pertaining to maintenance, repairs
Y<`$
V
Example: Technical Services to clearly identify the components of your
ATTENTION! pump/system.
When making use of other than the tested
spare parts, serious damage may affect Therefore, always indicate the part, model and series
your device. number.
Therefore, for the operation of your device
always use original parts made by Lincoln
Industrial.
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manual:
Z Listing of applicable statements
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1. Determination of the number or sequence of contents
[
Safety Instructions
Appropriate Use Regulations for Prevention of Accidents
To prevent accidents, observe all city, state and federal safety
%&
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the automatic lubrication of commercial vehicles, industrial,
construction and agricultural machines and wind power plants. General Safety Instructions
The P653S pump has been designed for intermittent opera8 Z Pump P653S is designed for safe operation.
tion and is not suitable for continuous operation. The pump is Z Incorrect use may result in bearing damage caused by
capable of supplying lubricants up to NLGI # 2 grades. (see poor or excessive lubrication.
!(
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Misuse Z Pump without the follower should be mounted vertically
Any use of the P653S pump that is not expressly mentioned upright only.
in this User Manual will be regarded as misuse. If the P653S Z C
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any claim for warranty or liability will be null and void. VVW
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CAUTION ! pump reservoir.
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curs as a result of inappropriate operation, no air has been trapped under the follower and pump is
(e.g. if the safety instructions are ignored pumping lubricant.
or resulting from an incorrect installation
of the P653S pump), no claims or legal
actions may be taken against Lincoln
Operation, Maintenance and Repair
Industrial WARNING!
(
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Exclusion of Liability repair on the P653S pump, make sure
The manufacturer of the P653S pump will not accept any li8 that all lubrication lines of the carrier unit
ability for damages caused by:
Z
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Z the use of contaminated lubricants
Z the use of greases which are not or only conditionally Repair
pumpable by P653S pump J& V($V
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Z inadequate disposal of used or contaminated lubricants personnel who are familiar with the instructions.
as well as of components that have been in touch with
lubricant Operation/Maintenance
Z
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Pumps P653S:
Z the use of unapproved parts Z $
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Disposal
Dispose of used or contaminated lubricants as well as of parts
that were in touch with lubricant according to the legal regu8
lations pertaining to environmental protection. Make sure to
observe the safety data sheets of the lubricants used.
CAUTION!
Do not use the pump in potentially explo8
sive applications.
Description
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Pump with Follower Plate Matic type lubrication systems. The pumps integrated design
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lubrication systems:
8 controller to program and monitor lubrication cycle
8 choice of internal pressure switch or internal pressure
transducer
8 internal vent valve
11 8 three pumping elements connected together
8 external pressure relief valve
8 ?<8?
8 end of lubrication line pressure switch or pressure
transducer choice
8 contacts for remote monitoring
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medium and small mobile construction equipment. Pump can
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stationary industrial type applications with heavy consistency
78%^ 8
> greases (NLGI #1 and #2) and for pumps used at low
temperatures applications in all installations.
Pump without Follower Plate
#^8-! #^8--^
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can lubricate more than 35 bearings.
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that are appropriate for the programmed/set
system pressure.
Pump P653S
Z pumps greases up to NLGI 2 (per approved list) at
$
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Z develop maximum pressure up to 3,500 psig (240 bar)
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pressure transducer.
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8 8#
Z For mobile applications P653S pumps are equipped with
*8JN"
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8%^ connector.
Code example
p P653S - 4 X L F 8 24 - 2A - AS06
Pump
p model,, basic
X = Grease pump
L = Low-level control
BO = Without follower
F = With follower
Power supply
pp y
24 = 24 VDC
AC = 110 - 240 V ; 50 - 60 Hz
Jumper
p setting
g combinations - Centro-Matic p
pumps
p
Number of
Application: Time (TC)
pressure Low-level F1 fault relay; F2 fault relay;
Industrial or count
Pump combinations switches or control; (31) switch to (31) switch to
(S) -o; Mobil control (CC);
transducers. NO- o; NC - x ground - x ground - x
(M) - x TC -o; CC - x
o - one; x - two
Jumper setting (plugged - x; unplugged - o)
Industrial (AC)
AS01 o o o x x x
AS02 o o x x x x
(S)
Pressure switch
AS03 o o o o x x
AS04 o o x o x x
AS05 x o o x x x
Mobile (DC)
AS06 x o x x x x
(M)
AS07 x o o o x x
AS08 x o x o x x
Industrial (AC)
AS09 o o o x x x
AS10 o o x x x x
Pressure transducer
(S)
AS11 o o o o x x
AS12 o o x o x x
AS13 x o o x x x
Mobile (DC)
AS14
(M)
x o x x x x
AS15 x o o o x x
AS16 x o x o x x
An external pressure switch or external pressure transducer is included with the pumps that have the feature of external pres8
sure monitoring. Also included is a 33 ft (10m) cord to connect the external monitoring device to the pump.
Description of Operation
Pump Operation
Drive
Z The pump housing consists of the following components:
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connected together by internal passages and vent valve.
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transducer.
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to drive the pumping elements and to control the internal
vent valve (Fig. 4).
Z Vent valve is a two way normally closed spring biased
valve.
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(240 bar).
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Fig. 13
Fig. 14
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Pressure Control/Hold Time/Vent Cycle Pump p with internal and external p pressure switch:
Internal pressure switch will close at 3500 psig and open at
Pump p with internal pressure
p switch only:
y 2600 psig. The external pressure switch will close at 2500 psig
Internal pressure switch will close at 3500 psig and open at and open at 1900 psig
2600 psig. After pump starts a lubrication cycle, motor stops when pres8
After pump starts a lubrication cycle, motor stops when pres8 sure at pump reaches preset pressure of 3,500 psig (240 bar).
sure at pump reaches preset pressure of 3,500 psig (240 bar). Pump can go through three holding periods, H1, H2 and H3.
Pump will go through two holding periods, H1 and H2.
Holding Time (H1)
Holding Time (H1) Z
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Z Internal pressure switch must stay closed for 15 consecu8 tive seconds before going to H2. If the internal pressure
tive seconds before going to H2. If internal pressure switch opens during the 15 seconds, the pump will restart
switch opens during the 15 seconds, pump will restart and and run until the internal pressure switch closes.
run until internal pressure switch closes.
Holding Time (H2) - Will last for 30 seconds
Holding Time (H2) - Will last for 30 seconds Z )
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Z At the end of 30 seconds, if the internal pressure switch is and the external pressure switch is closed, pump will
closed, the pump will begin a vent cycle. begin a vent cycle.
Z E3 Fault – A failure to vent at the pump. The internal Holding Time (H3)
pressure switch has 10 seconds to open when the motor Z >
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reverses to locate the vent position ternal pressure switches are closed and then a vent cycle
will take place. If both pressure switches do not close
within the allotted pumping time of 12 minutes, an alarm
will occur. If the internal pressure switch opens during H3,
it will repump until the internal pressure switch closes.
Possible Faults
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the allotted 12 minutes of pumping time.
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ply line.
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pressure switch has 10 seconds to open when the motor
reverses to locate the vent position.
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The external pressure switch must be open before the
next lube cycle takes place.
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The internal pressure transducer is set to open at 900 psig (62 ments. The internal pressure transducer is set to open at 900
bar) below the point where it closed at. psig (62 bar) below the point where it closed at.
After the pump starts a lubrication cycle, the motor stops when The external pressure transducer is set to close at 2500 psig
pressure at pump reaches the preset pressure. The pump will
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go through two holding periods, H1 and H2. The following will
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use the factory setting of 3500 psig (241 bar) and the opening is factory set to open at 900 psig.
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pressure at the pump reaches preset pressure of 3,500 psig
Holding Time (H1) (240 bar). The pump can go through three holding periods,
Z Internal pressure transducer must reach 3500 psig and H1, H2 and H3.
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onds before going to H2. If the internal pressure trans8
ducer drops below 2600 psig during the 15 seconds, the Holding Time (H1)
pump will restart and run until internal pressure transducer Z Internal pressure transducer must reach 3500 psig and
reaches 3500 psig (241 bar). stay above 2600 psig for 15 consecutive seconds before
going to H2. If the internal pressure transducer drops be8
Holding Time (H2) - Will last for 30 seconds low 2600 psig during the 15 seconds, the pump will restart
Z At the end of 30 seconds, if the internal pressure trans8 and run until the internal pressure transducer reaches
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vent cycle.
Holding Time (H2) - Will last for 30 seconds
Z If at the end of the 30 seconds the internal pressure trans8 Z At the end of H2, if the internal pressure transducer is
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above 2600 psig and the external pressure transducer
and run until the internal pressure transducer reaches has reached 2500 psig, the pump will begin a vent cycle.
3500 psig (241 bar). When this happens a vent cycle will
take place. Z At the end of H2, if the internal pressure transducer is be8
low 2600 psig, or both the internal pressure transducer is
Z If at the end of 30 seconds the internal pressure trans8 below 2600 psig and the external pressure transducer has
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hold time the internal pressure transducer dropped below The pump will turn on again and pump until the internal
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seconds before a vent cycle begins. internal pressure transducer is above 2600 psig and ex8
ternal pressure transducer has reached 2500 psig, a vent
Possible Faults cycle will take place.
Z E1 Fault – A failure to build pressure at the pump within
the allotted 12 minutes of pumping time. Z If at the end of H2 the internal pressure transducer is
above 2600 psi but the external pressure transducer has
Z E3 Fault – A failure to vent at the pump. The internal not reached 2500 psig, the pump will turn on for 2 sec8
pressure switch has 10 seconds to open when the motor onds and then stop and wait until the external pressure
reverses to locate the vent position. transducer reaches 2500 psig. An H3 will appear on the
display. When the internal pressure transducer is above
Z E3 Fault – A failure to vent at the pump. If at the end of 2600 psig and external pressure transducer has reached
the pause time the pressure of the internal pressure trans8 2500 psig a vent cycle will take place.
ducer has not dropped below 900 psig (62 bar) an E3 fault
will occur. Holding Time (H3)
Z Holding time H3 will remain until the internal pressure
transducer is above 2600 psig and the external pressure
transducer has reached 2500 psig, and then a vent cycle
will take place. If both pressure transducers do not reach
their preset settings within the allotted pumping time of 12
minutes an alarm will occur. If the internal pressure trans8
ducer drops below 2600 psig during H3 it will repump until
the internal pressure transducer reaches 3500 psig.
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“Air Expelling Procedures” if necessary.
Make sure no air is trapped under the follower plate. Grease
should be in full contact with the surface of the follower. It’s
recommended to run the motor by initiating the lubrication
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running motor will help to evenly spread the grease under fol8
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for air trapped under the follower. Use a plastic wire tie to expel
the air: push plastic tie between the follower seal and wall of
the reservoir and push the follower with hand until it completely
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(when the reservoir is empty).
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NOTE
If *EP* is displayed after the display test,
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pad is defective.
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IMPORTANT
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ing time, the current operating cycle will still
be completed. However the pump does not
switch on automatically any more. It can only
be switched on again by a manual lube cycle.
Furthermore, it is not possible to change to
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level signal.
Malfunctions
Fig. 22 Display of Holding Time Z If there is no feedback from the pressure switch or pres8
sure transducer within 12 minutes of pumping time, the
pump switches off immediately. One of the fault signals
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display of the membrane key pad.
IMPORTANT
If a malfunction is present, E1, E2, E3 or E4
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on automatically any longer. It can only be
triggered via an additional lubrication cycle.
Furthermore, a change to the programming
mode is not possible while in alarm.
Pause time
01 0 to 59 hours
Pause time
00 0 to 59 minutes
Acknowledging a Fault
Display Press
To acknowledgeg a malfunction:
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< 2 sec.
< 2 sec.
< 2 sec.
Step 1
Setting of Pause Time P1 (hours) and P2 (minutes).
Display Press To access the programming mode, press both buttons at the
same time > 4 seconds, so that “P1” appears in the display.
Programming
g g options:
p Pause time:
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P2 0 – 59 minutes
> 4 sec.
Min. pause time 4 minutes
Max. pause time 59 hours 59 minutes
Step 2
P1: Setting of hours
When releasing the two buttons, the currently set value
appears.
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“Hour“ is indicated by a dot on the right-hand side.
Press button.
Settings are made in one direction:....... 0, 1, 2, 3,....59 hours
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Press button.
Settings are made in one direction:... 0, 1, 2, 3, 4, 5, .... 59 min
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IMPORTANT
If “Hours” are set to “00”, the display will
show minimum pause time of 4 minutes.
Press button.
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contact will open.
Step 5
P5: Two options for signaling a fault condition with alarm
relays F1 and F2.
Press button so that “P5“ appears in the display.
o1 (Option 1) P4 is set to the default of Normally Open.
F1 relay contact
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open and close.
b) A pressure fault will cause the F1 contact to close and stay
closed.
F2 relay contact
Factory Setting )<8?(
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close and stay closed.
Step 6
Display Press
P6: Upon applying power to the pump you can program
whether it starts with a pause time SP or starts with a lube
cycle SO.
Press button, so that “P6“ appears in the display.
The currently set values appear as to whether the cycle is to
start with the pause time or the lubricating time.
The default setting for the pump is set to start with a pause
time SP (Start Pause time).
Press button.
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bricating time SO (Start Operation|)(
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time the preset pause time will be valid.
Step 7
Completing the programming
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pletely in order to save the new values.
NOTE
If the button “additional lubrication” is not
pressed within 30 seconds, the changed
parameters will not be saved and the
previous programming remains valid.
IMPORTANT
After completion of the programming,
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ating mode once again.
Step 7
IMPORTANT
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have a pump that has an internal pressure
transducer.
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ducer will close. This is the maximum pressure that the pump
can reach. Factory setting is 3,500 psi.
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increments.
Step 8
IMPORTANT
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appear if you have a pump that has an
external pressure transducer connected.
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able from 200 psi to 1,000 psi in 100 psi increments. Factory
set opening point (vent pressure) is 900 psi. The closing point
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pletely in order to save the new values.
NOTE
If the button “additional lubrication” is not
pressed within 30 seconds, the changed
parameters will not be saved and the
previous programming remains valid.
IMPORTANT
After completion of the programming,
check the parameter settings in the
review mode.
Pause Time
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after one sec. External pressure transducer will open at 900 psi.
Technical Data
Electrical data for DC pump Pump elements K7
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7$ Number of Pumping Elelments............... 3
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Weights
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Common electrical data for DC and AC pumps valve, empty
: $$
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The weights above include the following equipment:
from 1,400 to 4,600 psig Pump kit with three pump elements, pressure relief valve,
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End of line pressure switch
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End of the line transducer vent pressure is factory preset at 900
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Z Use only high pressure 5,000 psig minimum hydraulic
Operating temperature hose for supply lines.
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Operating temperature
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Number of outlets
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Lubricant .................................. up to NLGI grade 2 1)
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7"
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z 3/min 2) backpressure 1,450 psig (100 bar). Different pressures, temperature
(24.6 cm3/min) and grease can change the output results.
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** Must connect red and black wires together if no machine switch is used.
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lubrication system can accept no liability
for:
The proven lubricants (see following tables) have been 8 $
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tested by Lincoln with regard to their pumpability and venting that are not or only conditionally
behavior. Lincoln can recommend them for an application up $V
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to the indicated minimum delivery temperature
8 systems.
Matic lubrication systems. During the tests these lubricants did 8 $
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not cause any damage due to incompatibility with the material lubrication system caused by chemical
used by Lincoln. or biological changes of the lubricant
used.
The lubricants Lincoln recommends on the basis of the 8 $
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manufacturer’s data sheet (see following tables) can be used with other materials.
in Lincoln’s lubrication systems up to the indicated minimum The liability is limited to pumpable
delivery temperature. V
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systems.
IMPORTANT
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Proven Lubricants
Manufacturer Designation Thickener Min. Operating Temp.
CATERPILLAR Moly Ultra 5 NLGI #1 CA-Complex 10° F (-12° C)
CATERPILLAR Arctic Platinum NLGI #0 CA-Complex Synthetic Base Oil -40° F (-40° C)
CATERPILLAR Auto-Lube NLGI #1 Ca-Complex 10° F (-12° C)
FUCHS-LUBRITECH Stabil Eco EP2 Li/Ca -13° F (-25° C)
"C># N
$zz Li -40° F (-40° C)
FUCHS Renocal FN 745 Ca-12-OH-stearat -13° F (-25° C)
FUCHS Renoral FN3 Ca -4° F (-20° C)
FUCI-IS Renolit LZR 2 t l Li -4° F (-20° C)
FUCHS Renolit HLT 2 Li -13° F (-25° C)
MOBIL Mobilith SHC 100 Li-complex -13° F (-25° C)
SHELL Retinax EPL 2 Li-12-OH-stearat 14° F (‘-10° C)
SHELL Retinax CSZ Li/Ca -31° F (-35° C)
IMPORTANT
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IMPORTANT
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Caution!"
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with grease is very critical for proper
pump operation. The pump may be
shipped with a small amount of Fuchs
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going to use and remove the test grease
if necessary.
Pump with follower plate:
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no air is trapped under the follower plate. Grease should be in
full contact with the surface of the follower. It’s recommended
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of the reservoir. The stirring paddle of the running motor will
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pockets. The reservoir has a vent hole (11) (Fig.1). Fill grease
to the maximum follower position until follower seal will slightly
cross the vent hole. If air is still trapped under the follower, add
some more grease to expel air through the vent hole.
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It’s recommended to run the motor by initiating the lube cycle
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running motor will help to evenly distribute grease in the reser8
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Pump cleaning:
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organics such as alcohol, methyl alcohol, acetone or similar
solvents.
Troubleshooting
Mode of failure Solution
Pump motor does not run. No green right corner segment lit on &
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Pump does not deliver lubricant but runs if manual lube switch
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on display (Fig. 19 page 15).
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pressure switch.
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SPECIFICATIONS
Minimum operating pressure – 1850 psi [128 bar]
Maximum operating pressure – 6000 psi [413 bar]
Recommended operating pressure – 2500 psi [172 bar]
Maximum vent (recharge) pressure – 1000 psi [69 bar]
Temperature Range - -40°F to 180°F [-40°C - 80°C]
Lubricant output (adjustable):
SL-V - 0.015 to 0.080 cu. in. [0.25 to 1.31 ccm]
SL-V XL - 0.015 to 0.305 cu. in. [0.25 to 5.00 ccm]
Injectors can be mounted in any position and can be used
in circuits with SL-1, SL-11, SL-32 and/or SL33 injectors.
SPECTRUM ADJUSTMENT
SYSTEM
Adjusting Screw
The spectrum adjustment system
consists of a set of color-coded anodized
aluminum sleeves that provide an
easy way to adjust the output of the
injectors and gives a clear indication of
the output setting. This allows for easy
Remove Lock Nut system installation and preventative
Install Sleeve maintenance.
**©
©
13*
1
12
2
14
3
15
4
14
5 16
6
7 17
9
18
10
19*
11a
(SL-V)
11b 20
(SL-V XL) Torque to
30-40 In. Lbs.
21
SERVICE PARTS
Item Description Qty. Part No.
No. SL-V SL-V XL
1 Protective Cap (polycarbonate) 1 273088 273089
2 O-ring (nitrile) 1 *
3 Adjusting Screw 1 272803 272819
4 Lock Nut 1 11624
5 Piston Stop Plug 1 273090 273091
6 O-ring 1 *
7 Backup Washer 1 *
8 U-cup (polyurethane) 1 *
9 O-ring (polyurethane) 1 *
10 Piston Assembly 1 273092 273987
11a O-ring (polyurethane) 1 * N/A
11b U-cup (polyurethane) 1 N/A *
12 Fitting Assembly 1 90471
13 Injector Body 1 275330© 275331
14 O-ring (fluorocarbon) 2 *
15 O-ring (fluorocarbon) 1 *
16 Spring 1 *
17 Spring 1 *
18 Spring Seat 1 272798
19 Body and Plunger Assy. 1 275332
20 Socket Head Screw (8-32 x 1-1/2) 2 272796
21 Gasket 1 *
22 Single Injector Manifold 1 12658
Two Injector Manifold 1 11962
Three Injector Manifold 1 11963
Four Injector Manifold 1 11964
Five Injector Manifold 1 11965
Six Injector Manifold 1 246965
23 Gasket 1 *
24 Adapter Bolt 1 273097
25 Adapter 1 273098
* Included in 272970 Repair Kit
Stage 2
Stage 4
STAGE 3 STAGE 4
Page Number - 6 Form 403786
Model No. 85770-1, -2, -3, -4, -5, -6, 85771, 85772
85780-1, -2, -3, -4, -5, -6, 85781, 85782
85785-1, -2, -3, -4, -5, -6, -7, -8, -9, -10
SL-V INJECTOR
This warranty is conditioned upon the determination of a Lincoln authorized representative that the equipment is defective. To
obtain repair or replacement, you must ship the equipment, transportation charges prepaid, with proof of purchase to a Lincoln
Authorized Warranty and Service Center within the warranty period.
This warranty is extended to the original retail purchaser only. This warranty does not apply to equipment damaged from accident,
overload, abuse, misuse, negligence, faulty installation or abrasive or corrosive material, equipment that has been altered, or equip-
ment repaired by anyone not authorized by Lincoln. This warranty applies only to equipment installed, operated and maintained in
strict accordance with the written specifications and recommendations provided by Lincoln or its authorized field personnel.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT
NOT LIMITED TO, THE WARRANTY OF MERCHANTIBILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
In no event shall Lincoln be liable for incidental or consequential damages. Lincoln’s liability for any claim for loss or damages
arising out of the sale, resale or use of any Lincoln equipment shall in no event exceed the purchase price. Some jurisdictions do
not allow the exclusion or limitation of incidental or consequential damages, therefore the above limitation or exclusion may not
apply to you.
This warranty gives you specific legal rights. You may also have other rights that vary by jurisdiction.
Customers not located in the Western Hemisphere or East Asia: Please contact Lincoln GmbH & Co. KG, Walldorf, Germany, for
your warranty rights.
SL-V
EN292 T1/T2
prEN 809
Paul Conley,
Chief Engineer
103