INSTRUCTION MANUAL PC20 ELECTRIC
ALLENTOWN SHOTCRETE TECHNOLOGY, INC 421 SCHANTZ ROAD ALLENTOWN, PA. 18104 800-553-3414 610-398-0451 Fax 610-391-1934
INSTRUCTION MANUAL PC20 ELECTRIC
ALLENTOWN SHOTCRETE TECHNOLOGY, INC 421 SCHANTZ ROAD ALLENTOWN, PA. 18104 800-553-3414 610-398-0451 Fax 610-391-1934
W A RNING DO NOT ATTEMPT TO OPERATE THIS EQUIPMENT WITHOUT A THOROUGH UNDERSTANDING OF THE OPERATIONAL, MAINTENANCE AND SAFETY CONSIDERATIONS CONTAINED IN THIS THIS TECHNIC TECHNICAL AL MANUAL. MANUAL .
TO PREVENT DAMAGE TO EQUIPMENT AND/OR INJURY TO YOURSELF OR OTHER PERSONNEL, THESE INSTRUCTIONS MUST BE FOLLOW FOLL OWED ED CAREFULL CAREFULL Y.
A COPY OF THIS MANUAL MA NUAL SHALL SHA LL ACCOMPA NY THE UNIT AT ALL A LL TIMES
.
FOR PARTS AND A ND SERVICE SERVICE PLEASE PLEA SE CALL CAL L OUR TOLL FREE FREE NUMBER NUMBER
PARTS: 800-553-34 800-553-3414 14 Ext. Ext . 214 SERVICE: SERVICE: 800-553-34 800-553-3414 14 Ext Ex t . 213
For best assi stance, st ance, please have the equ equip ipment ment Model and Seri Serial al Num Numbers bers available availabl e at at ti me of inquiry. The Mod Model el Number and Seri Serial al Number are avail available able on th e equip ment Data Tag Tag attached to to the frame of th e equi equipment. pment.
Record the following information on this equipment below: Model No. ________________________ Serial No. ________________________ Date Purchased ___________________
TABLE OF CONTENTS – PC20 ELECTRIC PAGE INTRODUCTION ………………………………………………………………………………
i
SECTION I - SPECIFICATIONS DATA TAG ……………………………………………… ………………………………………………………………………………………… …………………………………………
1-1
SECTION II OPERATIONAL SAFETY …………………………………………… …………………………………………………………………….. ………………………..
2-1
OPERATOR QUALIFICATIONS ……………………………………… …………………………………………………………….. ……………………..
2-4
RESPONSIBILITY OF EMPLOYERS AND OWNERS ……………………………………..
2-5
PRINCIPLE OF OPERATION ………………………………………………… ………………………………………………………………. …………….
2-6
HYDRAULIC SYSTEM - INTRODUCTION ………………………………………………. ………………………………………………...
2-7
HYDRAULIC COMPONENTS ……………………………………………… ……………………………………………………………….. ………………..
2-8
HYDRAULIC SYSTEM …………………………………………………… ………………………………………………………………………. ………………….
2-9
OPERATOR CONTROLS ……………………………………………… ……………………………………………………………………. …………………….
2-10
HYDRAULIC TANK ……………………………………………… ……………………………………………………………………………. …………………………….
2-13
INTERLOCK SAFETY SYSTEM …………………………………………………… ……………………………………………………………. ……….
2-14
DAILY SAFETY CHECK ……………………………………………… ……………………………………………………………………… ………………………
2-15
SET-UP OF EQUIPMENT ……………………………………………… ……………………………………………………………… ………………
2-15
OPERATION OF EQUIPMENT ………………………………………… ………………………………………………………………… ………………………
2-18
START UP PROCEDURE ………………………………………………… …………………………………………………………………… …………………
2-18
FUNCTIONAL CHECK ……………………………………………………… ………………………………………………………………………. ……………….
2-19
LUBRICATING THE MATERIAL DELIVERY LINE ……………………………………………
2-20
PRECAUTIONS DURING OPERATION …………………………………………… ………………………………………………………… ……………
2-21
CLEARING MATERIAL PLUGS …………………..………………… …………………..……………………………………… ……………………
2-24
CLEAN UP…………. ………………………………………………… ……………………………………………………………………….. ……………………..
2-25
SECTION SECTION III - MA INTENANCE MAINTENANCE INTERVALS ……………………………………………… …………………………………………………………………….. ……………………..
3-1
WEAR PARTS REPLACEMENT & ADJUSTMENT …………………………………………
3-3
PROXIMITY SENSOR ADJUSTMENT ……………………………………………… ………………………………………………………. ……….
3-7
RECOMMENDED LUBRICANTS …………………………………………………… ……………………………………………………………. ……….
3-8
TROUBLESHOOTING ……………………………………………… ……………………………………………………………………….. ………………………..
3-10
ELECTRIC SCHEMATICS ……………………………………………………… ……………………………………………………………………. …………….
3-14
SECTION SECTION IV - PARTS CATAL OG MATERIAL PUMP ………………………………………………… ……………………………………………………………………………… ……………………………
4-1
REMIXER ………………………………………… ………………………………………………………………………………………. ……………………………………………...
4-5
HARSH MIX HOPPER …………………………………………… ………………………………………………………………………….. ……………………………..
4-7
OPERATOR CONTROLS …………………………………………………… …………………………………………………………………… ………………
4-9
MICROPROCESSOR …………………………………………………… …………………………………………………………………………. …………………….
4-11
HYDRAULIC SCHEMATIC ……………………………………………… ……………………………………………………………………. …………………….
4-12
HYDRAULIC SYSTEM COMPONENTS …………………………………………………….
4-13
MISCELLANEOUS COMPONENTS …………………………………………… ………………………………………………………… ……………
4-14
SAFETY DECALS ……………………………………………… ……………………………………………………………………………. …………………………….
4-16
INTRODUCTION
The Allentown Powercreter pump is a high-pressure, hydraulically powered piston pump for the mixing, pumping, or spraying of concrete, grout, mortar, and refractories. This manual describes the operation, maintenance, and safety considerations that must be followed. Close attention to these these details by the operator and maintenance maintenance personnel is necessary to assure a minimum of problems while striving for maximum productivity and safety.
Pump operation is dependent on the “pumpability” of “pumpability” of the material to be pumped. Pumpability can be defined as the combination of phy sical properties - of both the material and pump - which determine if the material will flow into the inlet chamber of the pump and can therefore be discharged. discharged. The physical properties of the material which, in varying degrees, determine its pumpability are: water content, size of aggregate and gradation, slump, viscosity, density, presence of reinforcing fibers, and the presence of additives that improve pumpability or influence set time. The Allentown Shotcrete Technology sales department will provide application assistance to determine the Powercreter that best suits your application needs. Call 1-800-553-3414.
Prior to pump operation, the operator must be thoroughly familiar with the operation of the equipment so that itit can be used in a safe manner. After the operator has gained experience in the safe operation of the equipment, he or she can work toward high volume concrete placement. For the safe operation of this equipment, the qualifications qualifications for, and the conduct of the operator, should be as described in Section 2.
i
SPECIFICATIONS
The specifications for this unit with all applicable data are provided on the unit’s DATA TAG, usually located inside the motor starter box.
1-1
OPERATIONAL SAFETY
Any person person assigned assigned to operate, operate, troubleshoot, troubleshoot, maintain or or repair the the Allentown pump, must be thoroughly familiar with the operating and safety instructions. Your safety and the safety of others are at all times very important. To work safely, you must understand the job you do. If in doubt, use extreme caution and obtain assistance from trained personnel. The Allentown pump is constructed with safety features for operating personnel, however, construction features alone cannot ensure complete safety. Safe work practice, observance of O.S.H.A. regulations, specific work methods and procedures, timely maintenance and an alert, well-trained operator are all factors contributing to safe operation. In order to highlight the situations which have historically been the cause of accidents, the information in this manual addressing safety is preceded with a graphic symbol to identify the principal hazard. Within the frame of the graphic symbol, the following signal words indicate the likelihood of occurrence and the degree of potential injury or damage. If in doubt about this classification, assume the worst case since some hazards, which are minor at the time of occurrence, can develop into hazards with a severe degree of potential injury o r damage. damage.
SIGNAL WORD
LIKELIHOOD OF OCCURANCE
DEGREE OF POTENTIAL INJURYOR DAMAGE
DANGER
Will occur if warning is ignored.
Severe
WARNING
Can occur if warning is ignored.
Severe
CAUTION
Will or can occur if warning is ignored.
Minor
Various hazards and their usual causes are described below and shown with the associated graphic symbol. The graphic symbols associated with any of the signal words are repeated throughout this manual when the likelihood of the hazard exists. The symbol provides an index permitting reference to this section for a more extensive discussion of the hazard.
2-1
Never open or remove the hopper grate when the pump is in operation. It protects against contact with moving parts that are capable of amputating the fingers or hand. Serious injury can occur.
The hydraulic system of the Allentown pump operates under high pressure. A pinhole type leak can form a fine stream of hydraulic fluid, which can penetrate skin, fill a large area under the skin, and cause serious infection. This hazard can be avoided by keeping the body parts away from the surfaces of pressurized hydraulic hoses. Feeling with hands for the source of leaks is generally the cause of accidents from this hazard.
The mechanical linkage located on the side of the mixer, opposite the dump control valve, positions the mixer grate when the mixer is dumped. Because of the relative motion of this link, the mixer drum and the hopper produces a scissors movement which can pinch anything in its path. Confirm that this area is clear of all personnel when operating the mixer. Severe bodily injury can occur to any bod bod membe memberr inche inched. d. Reliable operation of this equipment is dependent on proper operation, scheduled cleaning, and maintenance. Failure to follow instructions can result in accelerated wear or equipment failure. During operation, repair, or troubleshooting, problems may arise that seem singular but may be due to several causes. The information in this manual should be used to assist in the safest and best manner to operate the pump. Use caution and safe methods in the repair and operation of the equipment.
2-2
The rapid release of a blocked hose can cause a material hose to whip or move abruptly with potential injury to personnel. Do not attempt to dislodge a blockage with increased or continued pumping pressure. Dislodge the blockage as instructed in the “Clearing Material Plugs” section of this manual. Only trained personnel should be permitted to handle the material hose.
The hydraulic system of the Allentown pump operates under high pressure. Fluid at high pressure will discharge at a high velocity if the hydraulic system is opened to atmosphere by venting, loosening of flange bolts, removing fittings, etc., when the power source is operating. Until discharged, the accumulator has a stored charge of oil under pressure that operates the swing tube cylinder. Stop the motor of the material pump and allow sufficient time for the accumulator to discharge. Confirm discharge by checking the pressure gauge, which should read 0 PSI. When removing fittings or removing any hydraulic component, wear safety goggles and cover the joint from which hydraulic fluid will discharge, using a large cloth to absorb and discharge the fluid. If hydraulic fluid gets in the eyes, flush with a generous amount of clean water and consult a physician. In the case of a blocked material line, never open any of the couplings in the material delivery line without first reversing the pump and pumping backward to remove pressure in the system. Discharge can propel particles at high velocity, capable of eye damage. If eye protection is not worn, serious eye injury can result.
Never put hands in the lubricating wash box when the pump is operating. Oscillating linkage can amputate the fingers or hand. Severe injury can result. Never work on any part of the pump that is in motion while the motor is running. Take time to stop the motor and turn off/disconnect power supply.
2-3
OPERATOR QUALIFICATIONS QUAL IFICATIONS Before operation, the operator must be thoroughly familiar with the equipment and its operation so that he can operate it in a SAFE manner. His eligibility to to operate the equipment must be based on the following qualifications:
1. Equipment must be operated operated only by experienced operators operators or trainees under the direct supervisio n of an experienced experienced operator. operator. Unauthor Unauthor ized ized personnel must no t be permit permit ted to assist or remain in the immediate vici nity of t he unit while it is i n operation or dur ing the performance of any maintenance, maintenance, inspectio n, cleaning, cleaning, repair, or start up op erations erations . 2. Individuals who are not familiar with operating instruc tions , have not received received on-the-job on-the-job su pervised training, and are not familiar wit h the signal cod es used at the const ructi on site must not operate equipment. 3. Individuals who cannot comprehend the signs, notices, and and operating operating instr uctio ns that are a part of the job mu st not operate equipment. 4. Equip ment mus t not be operated by anyone under the age age of 21 21 years. 5. Equipment must not be operated operated by anyone anyone with seriousl y defective defective eyesight eyesight or hearing, or anyone with physi cal or mental impairment (such as epilepsy, epilepsy, heart heart dis ease, ease, or progr essive neuro-muscu neuro-muscu lar deterioration). deterioration). Physical and mental qualifications m ust be verified by a physical examination at least least annually. 6. Individuals under the infl uence of alcohol or drugs shall not operate this equipment. 7. Equipment must not be operated operated while operator operator is eating, eating, drinki ng, reading, reading, or is more than six feet distance from t he controls. 8. An operator who has asked to be relieved relieved because because he feels feels phy sically or mentally unfit mu st not op erate erate equipm equipm ent.
2-4
RESPONSIBILITY OF EMPLOYERS AND OWNERS
As an owner owner or employer employer using this equipment, equipment, it is your responsibili responsibility ty to ensure ensure that the the operator is qualified, has read this manual, and has received training in the safe operation of the Allentown pump, and the safe work practices for the job to be accomplished. It is also your responsibility to provide for regularly scheduled preventative maintenance and repair of the pump by trained repair personnel using only parts supplied by Allentown Shotcrete Technology. Modification of any part of this pump can create a new safety hazard. If the pump is modified or rebuilt it must be done under the direction of the Allentown Shotcrete Technology Factory. No field modification of the pump is permitted, unless authorized in writing by Allentown Shotcrete Technology.
It is further the responsibility of the owner or employer to train the operating personnel in all the specific requirements, government regulations, safety regulations, safety regulation of the product liability insurance company, precaution, and work hazards which exist in a work situation and ensure that all involved take the necessary precautions and safety measures. Only a trained and qualified operator who abides by safe work practices can avoid accidents.
2-5
PRINCIPLE OF OPERATION
MATERIAL PUMP
THE MATERIAL PUMP The material pump consists of a receiving hopper and two material pumping cylinders and pistons that are driven by two hydraulic cylinders and a swing tube valve. A continuous flow of material through the delivery line is produced by the sequential operation of the two material material pistons with the swing tube. The swing tube shifts between the two material cylinders under a controlled electronic/hydraulic sequence to direct the flow between the two material cylinders, the hopper, and the discharge outlet. The swing tube allows one material cylinder to be directly open to the hopper on the suction stroke, while simultaneously the other cylinder is directly connected through the swing tube to discharge. At the end of the piston travel the direction changes and the swing tube is shifted to direct the material flow from the other cylinder to discharge.
2-6
THE HYDRAULIC SYSTEM – PC20 ELECTRIC INTRODUCTION
The PC20 has a three pump hydraulic system. The first pump, which is the first main pump coupled to the electric motor, is a variable displacement piston pump. This pump powers the hydraulic pumping cylinders. These cylinders are controlled through a directional valve, which which is operated from from the processor controls. The processor controls gets signals from the proximity switches switches that are located in the the wash box. Each retracted stroke of the hydraulic pumping cylinder will signal the processor controls to switch direction. The next two two pumps are mounted directly to to the first pump. This is a double gear pump. The first section of the the gear pump supplies oil to the accumulator manifold, which powers the hydraulic cylinder that operates the switch of the swing tube. The second gear pump operates the the hopper remixer remixer motor. A single spool valve located off the the hydraulic reservoir operates the blending paddles. For the hydraulic component P/N’s, please see the Hydraulic Schematic with its parts list in this manual.
GEAR PUMP FOR REMIXER
GEAR PUMP FOR ACCUMULATOR ACCUMULATOR MANIFOLD MANIFOLD
2-7
MAIN PUMP FOR PUMPING CYLINDERS
HYDRAULIC SYSTEM COMPONENTS
PROXIMITY SENSORS
PROPORTIONALLY CONTROLLED PUMPING VALVE WITH MANUAL OVERRIDE CONTROL HANDLE
HYDRAULIC OIL COOLER, THERMOSTATICALLY CONTROLLED
RETURN FILTER WITH GAUGE
REMIXER CONTROL VALVE
PRESSURE SWITCH
ACCUMULATOR ACCUMULATOR
ACCUMULATOR ACCUMULATOR MANIFOLD MANIFOLD ASSEMBLY ASSEMBLY FILLER BREATHER CAP
SWING TUBE HYDRAULIC CYLINDER
2-8
HYDRAULIC SYSTEM PUMPING CYLINDERS The two hydraulic cylinders are linked by means of a cross over loop system. This cross over loop is located on the rod side of the cylinders. As one cylinder is pumping, powered from the piston side, the oil on the rod side is being forced out over to the other cylinder’s rod side, thus forcing the other cylinder to retract. See Fig. 1. When the cylinder that is being retracted meets with the proximity sensor, which is detected by the piston adapter, the system will will switch and run the the opposite way. To ensure that there is equal and full travel of both cylinders, there are four check valves located internally of both cylinders (two/cylinder) which add oil to the side that is being pushed back to make certain a full retraction is made. These check valves prevent “short stroking”.
ACCUMULATOR ACCUMULA TOR (SWING (SWING TUBE) CIRCUIT CIRCUIT The hydraulic cylinder switching the swing tube is powered through an accumulator assisted circuit. When the Pump Motor/Mixer button is pressed, the main pump motors will turn on sequentially. Ten seconds after the electric motor/diesel motor/diesel engine starts, the manifold On/Off Valve closes to charge the accumulator to to a preset pressure. Once this pressure is reached, which is determined by a pre-set pressure switch, the system will hold this pressure by means of a check valve that is in the manifold. The On/Off Valve will switch, sending oil back to the tank. At this point, the system will hold and wait for the first response from the processor signaling to switch. After switching, the system will recharge, hold, and wait for the next signal. When the machine is turned off a Dump Valve in the manifold will slowly discharge the pressure from the accumulator back to the tank. There should be no pressure reading on the gauge.
Note: while the charged accumulator circuit is holding for its signal, and that response takes a long period of time, it is common for the system to turn on and off to recharge the accumulator to its preset pressure. The pressure switch has a differential pressure setting of 100 to 200 psi.
2-9
OPERATOR CONTROLS
2
3
4
5
6
7
8
9 1
10
11 17
12 16
15
14
13
2-10
OPERATOR CONTROLS
1.
Pressure test Switch – This switch must be in the “Pump” position for normal operation. If held in the “Pressure Test” position, the pump will make one stroke, stop at the fully extended stroke, and the pump will be at maximum pumping pressure with the flow control fully open.
2.
Start/Stop Remote Switch – This switch will turn the pump on or off at the Control Panel or, when in the “Remote” position, the pump can be turned on or off using the remote control cable. In an emergency the remote can be overridden by placing the switch in the center “Off” position.
3.
Forward/Reverse Forward/Rever se Switch – The Forward/Reverse Forward/Rever se switch is used for manual forward or reverse pumping. Forward sends material out; reverse will pull material back or relieve line pressure.
4.
Manual Cycling Switch – This switch provides a manual override of the automatic cycle of the pumping cylinders. Each time the switch is toggled the material pump goes through alternate strokes of the material cylinders, overriding the proximity sensors. In the event of a failure of the automatic cycle control circuit during pumping operations, the switch will permit manually controlled pumping.
5.
Potentiometer (Flow Control Dial) – This dial controls the output of the material pump. To adjust the output, slowly turn the dial clockwise to increase output and counterclockwise to decrease output.
6.
Hour Meter – Displays the number of hours of pump operation.
7.
Main Power Indicator – This indicator lights when there is power to the system. The main disconnect has been switched to the on position.
8.
Phase Reversed Indicator – This indicator lights when the start motor button is pressed and the incoming power phase lines are reversed in hookup. This will indicate that the electric motor will be trying to run in reverse.
9.
Control Power On and Indicator – By pressing the “On” button, the microprocessor for the pump will become energized and its indicator light will come on. It takes approximately five seconds for the microprocessor to become energized.
10.
Emergency Stop – Pushing on the palm button shuts down the system and, consequently, all power to the motor. To restart the pump the switch must be reset by pulling the knob out.
2-11
OPERATOR CONTROLS
11.
Pump Motor Start, Stop, and Indicator – Pressing the “Start” button will start the electric motor that powers the pumps, which, in turn, operates the accumulator/swing tube circuit and the flow control/pumping rams circuit. To turn the pump off, press the “Stop” button. The indicator light will will then turn off.
12.
Manual Lube Switch – Pushing this button will operate the automatic lubrication device and activate the preset lube cycle. This manual button is to to be used at the end of the day after the equipment has been cleaned or during operation when the auto lube is in between its automatic cycle.
13.
Remote Control Socket – The remote control cord is plugged into this socket. In order to avoid unintentional operation of the machine, set the material pump switches that are located on both the operator control box and the remote to the neutral positions prior to any switchover switchover from local to remote and vice versa. The same applies to connection and disconnection of the remote control.
14.
Pump Pressure Gauge – This gage will indicate the pressure to pump the material when the Pump Start Switch is held in the start position. The resulting material pressure is a function of the diameters of the pistons of both the hydraulic and material cylinders. See Figure 2 and the pump’s data tag for maximum material pressure.
15.
Accumulator Pressure Gauge – This gage indicates the pressure of the Swing Tube Manifold and the Pilot Valve.
16.
Fault Indicator Light – This light will illuminate when the remixer grate is lifted and the safety locking pin is pulled out. This will shut down pump operations. After closing the grate and pushing in the pin, the accumulator will recharge and the pump will be ready for production in a few seconds.
17.
Stroke Counter – The stroke counter counts the number of strokes of the material pump and has a reset to zero button.
2-12
HYDRAULIC TANK
Oil Level Gauge
Temperature Gauge
Hydraulic Reservoir Oil Level Gauge – Never operate the pump when the oil level is not visible in the sight tube. Periodic inspection of the oil level during pump operation and after shut-down is a recommended practice. This will protect against accidental loss of oil. When the pump is running the the oil level should be at mid-point in the the sight glass.
Hydraulic Oil Temperature Gauge – The normal range of the hydraulic oil temperature is 100º F to 160º F. Oil temperature temperature of less than than 50º F is in the cautionary range. The material pump should not be operated at full output until the oil reaches temperatures above 50º F as hydraulic pump damage may occur. Oil that is below 10º F should be preheated by running the motor with the material pump turned off.
2-13
INTERLOCK INTERLOCK SAFETY SYSTEM The purpose of the Interlock System is to prevent operation of the swing tube if the hopper grate is opened. The interlock is achieved with a two position, normally open limit switch that is activated by a roller plunger. In the normal running position position this switch is held in the closed position by the Locking Pin. When the grate is closed and the pin is pushed in and locked, normal pump operation can take take place. Pulling out the pin in order to open the hopper grate will open the limit limit switch and shut down pump operations. After closing the grate and pushing in the pin, the accumulator will recharge and the pump will be ready for production in a few seconds. Before adding material to the hopper, turn on the pump and verify that the limit switch is operating properly. DO NOT operate the pump if this this switch is not functional. It should be repaired or replaced immediately. DO NOT attempt repairs with the diesel engine running.
WARNING – the rotating com ponents in t he hopper can cause cause severe bodil y injury. Do not operate this equipment withou t the safety interlock sys tem operational.
Limit Switch Locking Pin ITEM 1 1
QUANTITY 1 1
PART NUMBER 14311 03318
DESCRIPTION DESCRIPTION LIMIT SWITCH LOCKING PIN
2-14
DAILY DAIL Y SAFETY CHECK OF EQUIPMENT 1. Equipment must not be operated at any new site or at the start of a new shift until a safety check is made of the condition of the equipment. 2. Equipment must have a sign-off sheet attached to the unit where an operator can report any damage, defects, problems, or accidents to the next shift’s operator and work supervisor. 3. Confirm that the unit has received scheduled lubrication. See “Maintenance Intervals” in this section. Inspect the wash box to ensure it contains a lubricant. 4. Walk around the unit and inspect for damaged or missing parts. All safety devices and provisions to protect against accidents such as warning labels, decals, safety guards, etc. must be in place. Do not remove or alter any of these items and replace any which are missing or defective. Safety Decals will be replaced free of charge. See the parts section of this manual. Visually inspect air and hydraulic hoses for indications of leaks or damage. Confirm that no foreign objects are in the hopper or lubricating wash box that would interfere with operation.
SET-UP OF EQUIPMENT – Locating the Equipment on the Jobsite 1. Locate the material pump on the most level ground possible. 2. Prior to placing equipment, check the condition of the soil. Keep sufficient distance from excavations or slopes.
SET-UP SET-UP OF MATERIAL DELIVERY LINE 1. It is the responsibility of each pump owner/operator to check the material delivery system pressure capacity with the manufacturer if these components are not supplied by Allentown Shotcrete Technology. Failure to observe these specifications can result in serious personal injury and damage to the equipment. Allentown Shotcrete Shotcrete Technology Technology recommends recommends the use of only shouldered shouldered or a
2-15
Heavy Duty pipeline system, hose and clamping devices that are specifically designed for material pumping applications. Allentown Shotcrete Technology has connection packages available for the material pump which contain couplings, reducers, material hose, air hose, nozzles, tips, and clean-out balls. Contact our sales department for additional information. 2. The inside diameter of the material pumping pipeline must be at least three times the size of the largest aggregate in the mix, and, with some difficult mixes, four times the size. For example, a difficult mix must have a three inch line to pump 3/4 inch aggregate material. The larger the line diameter, the less pump pressure will be required, or a higher output rate can be achieved with a large line at the same pressure. 3. Ideally, using the same size pipeline as the size of the material cylinder will allow very low pressure pumping at long distances. From a practical standpoint, the larger the line, the heavier and more difficult it will be to set up, place, and clean up. Utilize as little reduction as possible in the line. Additionally, Additionall y, long reducers use less pump output pressure than short reducers. 4. The material delivery line should be set up using a minimum of rubber hose since rubber hose has three times the resistance to material flow as compared to steel pipe. One length of rubber hose at the discharge end of the delivery system will provide flexibility for changing the discharge point and provide the capability to bend the hose for downhill pumping. 5. The most direct line from the material pump to the placement site should be used. 6. Clamp type flanges should be clean and have seals that will retain the slurry in the delivery line. 7. Horizontal pipelines must be adequately supported. Support the pipeline attached to the pump outlet. If the material system crosses rebar, support the pipe/hose so that it does not contact the rebar. 8. If the jobsite has a vertical material delivery system, the vertical pipeline should be anchored to the building every ten feet of height.
2-16
9. Place the hoses or pipe in sufficient length to reach the the farthest delivery point. It is easier to remove sections than to add additional sections after pumping has begun. 10. Material will flow with less back pressure through pipe than through hose. Bends in the hose or elbows in in the delivery line will will require more pressure. These conditions should be taken onto consideration when laying out the delivery system. 11. Vertical and downhill pumping are more difficult than horizontal pumping. Vertical pumping requires higher pumping pressure while downhill pumping can cause separation of the material which may result in a blockage in the material delivery line. 12. When laying pipeline, utilization of as few elbows and reducers as possible is recommended. 13. Replace any worn or damaged hoses, hoses , pipeline, or couplings immediately. 14. In hot and/or dry weather, pre-soak pre- soak the hose in water to avoid absorption abs orption of moisture from the pumped material. 15. Spray a release agent such as WD-40, Form Oil, or Kleen Kote on all a ll accessible parts that will be in contact with the pumped material to ease clean up after operation. Do not use diesel fuel as this has a negative effect on the hopper seals as well as other components.
2-17
OPERATION OF EQUIPMENT Connecting AC Power to the Pump The electrically powered Powercreter Pump can be supplied with a power cable to connect to a power supply. Have a qualified electrician install the cable between the motor control box and the power supply in accordance with local code. Hookup with an undersized power cable will limit power to the machine which can result in reduced performance and/or damage to the motor and control box. When the disconnect switch is in the on position, the green indicator light for the main power should be lit. If the red Phase Reversed light comes on when the Motor Start button is pressed, immediately turn off the machine. The electrician must switch two wires of the three phase power at the power supply. In order to preserve the integrity of the motor starter panel, do not interchange wires in the motor starter panel. WARNING:
Contact with High Voltage can result in serious personal injury or death.
1. 2. 3. 4.
Confirm the daily safety check has been performed. Verify that the pan mixer grate is lowered and in place. Confirm that the Emergency Stop button is reset by pulling outward. With the disconnect switch of the motor starter box in the on position, confirm that the green indicator light for the main power on the control panel is lit. If the red indicator lamp labeled “Phase Reversed” is lit when the motor start button is pressed, two wires of the three phase power must be interchanged. See the “Connecting AC Power to the Pump” in the previous section. 5. Push the “Control Power” start button. The green indicator should light. This will energize the microprocessor. 6. Wait at least five seconds then press the Motor Start button.
NOTE:
Once the system is running, the accumulator system will automatically charge after about ten seconds. Once charged, there should be a reading on the accumulator pressure gauge of the preset psi charge. If this does not happen, shut down motor and follow start up procedure again.
7. In cold weather starts, let the pump run until the hydraulic oil temperature reaches at least 50º F. Once the oil reaches this temperature, pump operation can continue.
2-18
FUNCTIONAL FUNCTIONAL CHECK CHECK
Once the motor is running and all conditions are ready to start production, a functional check of the equipment and any optional accessories should be performed prior to adding material to the hopper.
1. Check to assure the accumulator is charged and holding the preset pressure. This pressure setting is recorded on the equipment’s data tag.
NOTE:
It is common for the accumulator system to recharge periodically when the pump is at idle. A slight internal hydraulic leakage within the system is normal. Once the pressure deviates more than 100 to 200 psi, the system will automatically recharge.
2. Check the swing tube oscillation. Toggle the “Forward/Reverse” “Forward/Rev erse” switch to assure that the swing tube moves freely.
CAUTION:
Make sure that there are no objects in the hopper prior to switching the cylinder.
3. To check the pumping cylinders: Turn the pumping speed potentiometer dial to the “2” position. Toggle the “Pump Start” switch and observe for automatic oscillation of the pumping cylinders. Toggle the “Manual Pumping” switch to confirm that the manual override will function each of the pumping cylinders. 4. Actuate the remixer valve. Observe for the rotation of the remixer blending paddles. 5. Turn on the pan mixer paddles using the pan mixer start switch. Raise the pan mixer grate to confirm that the grate cut-out switch is operational. This switch should stop the mixer rotation when the grate is lifted. 6. If there is an optional accelerator pump being used, make sure it is primed and ready for operation. See the accelerator pump manual for start up instructions. • •
•
2-19
LUBRICATING THE MATERIAL DELIVERY LINE An im po rt ant pr erequ er equ is it e of pu mp in g i s the t he p ro per lu br ic ati on of th e pi pel in e or hose system at the start of the pour. Failure Failure to lubr icate the material material delivery line will con tribute to the plugging o f the line, resulting in excessive downtime to clear clear plugs.
The choice of lubricating agents is dependent upon the physical properties of the material being pumped. Contact the Allentown Allentown Shotcrete Technology parts department for line lubricant.
First wet the hopper with lubricating agent and then slowly pump the lubricating agent into the pipeline system. This will provide a smooth coating in the pipeline pipeline system ahead of the material to be pumped while preventing bleeding and cracking of the material. The amount of lubrication required will depend on the length length of the line, the line diameter, and the pumpability of the material material being pumped. The minimum is 5 to 6 cubic feet for short runs of small diameter line. It can be a cubic yard or more for several hundred feet of large diameter line. Experience will indicate the proper amount to be used although it is always safe to have too much rather than too little.
Once material is added to the hopper and begins to flow through the line, the hydraulic pressure gauge and the flow from the material line should be monitored to ensure that a plug or blockage is not forming. forming. Only after pressure and flow are stable should the pump speed be increased to the planned operating rate.
2-20
PRECAUTIONS DURING PUMP OPERATION
1. The operator and nozzleman must always wear eye protection and hard hats. 2. Do not operate the Allentown Shotcrete Technology pump without the hopper grate mounted firmly in place. Never stand on the hopper grate or place any parts of the body into the hopper while the motor is running.
WARNING:
Failure to follow these precautions can result in serious personal injury or death.
3. In the event of downtime during material placement, it may become necessary to stop pumping. During these periods, the material should be moved every 10 to15 minutes. One method to move material is to reverse the pump and convey backwards two or three strokes and then turn the material off for 10 to 15 minutes and then pump forward two or three strokes. If delays continue and the material starts to set, it may become necessary to clean out the material delivery system and the material pump. Experience with each application will determine how long material can be safely held in the system before it becomes necessary to clean out the delivery system and the material pump. If shut down periods exceed 2 to 3 minutes, turn off the motor between moves to prevent separation of the mix in the hopper due to vibration. Separation of the mix in the hopper can cause a blockage in the delivery line when pumping is resumed. 4. When pumping long distances or stiff mixes, expect less volume than with shorter lines and wetter mixes. Water leaking from hose coupling gaskets can cause separation of the mix in the material line and subsequent blockage at that point. Damaged hoses with internal restrictions can also cause blockages.
2-21
6. The maximum material pressure is a function of the maximum hydraulic pressure and the areas of the hydraulic and the material cylinders. (See Fig. 2). Maximum pressure is only obtained under a “no flow” condition. Average pumping pressure will normally be somewhat less than the maximum. Pressures are highest at the material pump outlet and reduce uniformly to zero at the discharge end of the material pipeline under normal pumping conditions. Do not kink the material delivery hose. If the hose is kinked during material placement or if a dry pack or blockage does occur in the material delivery system, the flow of material will be stopped and pressure will build up to maximum in the material delivery system to the point of the blockage. If a plug has formed, follow the instructions in the “Cleaning Material Plugs” section.
7. Downhill pumping can be difficult on some jobs. When the pump is stopped the material can flow slowly in the material line and cause the hose to collapse. A plug can form at the point of hose collapse. To prevent this, the hose can be “kinked off” at the discharge while the pump is stopped. This will prevent the gravity flow. The use of stiffer mixes when pumping downhill will also avoid gravity flow.
2-22
8. When pumping vertically up along the side of a building (above 40 ft.), installation of steel pipe securely fastened at intervals of 10 feet to support the pipe column is recommended. 90º long radius pipe sweeps should be installed at the top and bottom of the steel line. A 25 ft. (or shorter) section of hose off the pump should be used while the balance of the horizontal distance to the vertical line should be pipe. This type of installation has been proven satisfactory on many jobs where material is being pumped to heights in excess of 100 feet. 9. When using snap couplings with gaskets to join hoses, they should be washed and cleaned after each use. Dip both the couplings and the gaskets into water prior to use to permit easier installation.
If the delivery system is blocked for any reason, or the line kinked at the start-up or during the pump operation, the pump pressure could straighten out the kink or force out the blockage. The rapid surge of material could cause the line to whip or move in such a manner that it may cause injury to personnel.
10. A slight pulsation of the delivery hose near the pump will always be noticeable. Excessive pulsation near the pump is normally due to higher than average line pressure caused by stiff, harsh mixes or extremely long pumping distances. The use of hoses with a larger internal diameter than specified in the “Set-Up of Equipment” section will reduce the line pressure. 11. In order to reduce the line pressure, a slight amount of water may be added to the mix. The use of an admixture may also help. (See the ‘Admixture’ section in this manual.)
2-23
CLEARING MATERIAL PLUGS
The probable causes for material plugs are: •
Attempting to pump a mix that is not pumpable. See “Introduction”.
•
Failure to clean up after a previous pour. See “Clean Up at End of Pour”.
•
Poor pipeline set-up. See “Set-Up of Material Line”.
When a blockage occurs in the material delivery system, the pumping pressure gauge will reach the maximum of the hydraulic system and the material will not flow from the material line. To clear the plug: •
Immediately stop the pump.
•
Switch the swing tube from Forward to Reverse.
Switch the pump to Start and pump two strokes in reverse to get the pressure at the plug back to the material pump.
•
Switch the pump to Forward and observe if the plug is is dislodged. If material is flowing, slowly increase the volume to the desired output. If material is not flowing, repeat the previous steps several times.
•
If Reverse pumping did not dislodge the plug, stop the pump and walk along the hose until the point of blockage is found. The hose will be soft immediately past the blockage. Elevate the hose at that point with the blockage hanging down. Shake or hit the hose with a rubber mallet until the blockage is broken up. •
Switch the pump to Forward and observe if the plug is is dislodged. If material is flowing, slowly increase the volume to the desired output.
•
If none of the above methods are effective in dislodging the plug, rotate the section of line containing the plug end for end or replace the section with a clean section of line. •
Even after pumping in reverse, it is possible for sections or all of the material in the delivery line to be under pressure. Clear the immediate area of all personnel and wear eye and body protection prior to opening any flanges. Open any clamps with caution to slowly discharge any pressurized material. Start the pump at a low volume rate until a steady flow of material is being pumped.
2-24
CLEAN CLEA N UP AT END OF POUR Clean the pump as follows: 1. With the pumping speed set low, pump the remaining material out of the hopper until it is half empty and then turn the pump off. 2. Add enough water to the material hopper to make a thin slurry. 3. Place the Forward/Reverse switch to the Reverse pumping mode and turn the pump on. The reverse pumping will cause the water to mix with the material and form a thin slurry. 4. Switch the pump to Forward and pump the slurry through the line followed with a mixer-load of water. 5. Open the hopper clean out door. 6. With the pump turned on and in Reverse pumping mode, turn on a water hose and run water into the discharge outlet. This will draw water into the material cylinders and push rock and sand out through the open hopper door. CAUTION:
Do not insert hose nozzle or hands into outlet whi le engine engine is
running. If material remains in the hopper, turn off the pump. A solenoid operated dump valve built into the accumulator circuit will automatically discharge the circuit when the power is turned off. Check the pressure gauge to ensure that it reads zero psi. There are moving parts in the hopper and lubricating wash box. The operator and any assistant must know and follow the correct procedures and use caution when cleaning the pump. DO NOT put hands or tools into hopper, outlet, or lubricating box while the power is on. Use the clean out tool supplied with the pump to clean the outlet and swing tube area. 7.
Repeat steps 2 through 4 if material remains in the hopper.
8.
If the machine will be left at the jobsite unattended, it should be secured from unauthorized use or movement.
9.
Life of the internal seals of the remixer shaft is extended by cleaning thoroughly. After cleaning cleaning at the the end of the the day, apply apply lubricant lubricant to the the surfaces surfaces that come come into contact with material to inhibit corrosion and act as a release agent to ease removal of subsequent material buildup.
10. Restart
the pump and grease the remixer, the pan mixer, and the material pump seals. This should be done while the paddles and swing tube is in operation to work out any grout that has passed by the seals during operation.
2-25
MAINTENANCE MAINTENANCE INTERVALS INTERVALS
Daily OPERATION Diesel Engine - See Engine Manual Fuel Tank Level Hydraulic Reservior Level Hydraulic Leaks Tires Brake Lining Controls & Gauges Battery Hydrulic Cylinder Seals Wear Parts** Clean up Operational Safety
Week l y
Mo nt nt hl hl y
6 Mo nt nt hs hs
Year l y
…..X …..X …..X …..X …..X …………………X …..X …………………………….. X …………………………….. X
…..X …..X
LUBRICATION …..X Diesel Engine - See Engine Manual Engine Oil Filter Change* …..X Engine Oil Level ………………………… ……………………… … ………………… X Electric Motor Bearings ………………………… ……………………… … ………………… X Wheel Bearings …..X Material Pump Main Shaft …..X Material Pump Outlet …..X Mixer/Re-mixer Seal Housings …………………………….. X Mixer/Re-mixer Bearings Hydraulic Oil Filter* ……………………………………………………….. X Hydraulic Oil Drain, Clean Tank …..X Lubrication Washbox …………………………….. X Mixer Pivot Bearings …………………………….. X Mixer Gear Box Oil *-First 50 hours of operation . Every 200 hours thereafter **-Interval dependant on use and severity of material pumped.
3-1
WEAR PARTS – REPLA CEMENT CEMENT AND ADJUSTMENT A DJUSTMENT 1. Swing Tube Adjustment – The initial adjustment of the Swing Tube, Item 19, is made with the 2-1/4” Nut, Item 15, on the shaft. The locking bolt and retainer plate mounted to the Swing Arm, Item14, must be removed when adjustments are made. After the initial initial adjustment, adjustment, the cutting ring, ring, Item 20, 20, in the swing-tube swing-tube will automatically automatically adjust for wear. The cutting ring has a rubber expansion band, Item 21, between the body of the swing tube and the diameter of the cutting ring. For proper sealing and operation this rubber must be compressed the correct amount. The correct adjustment is made by tightening the 2-1/4” nut on the shaft, rotating the nut one flat at a time. When the cutting ring contacts the wear plate continue adjustment by 1 or 2 flats of the nut. Install the retainer plate and locking bolt to lock the nut adjustment in place. There should be a minimum of 0.015” gap between the swing tube extension, Item 24, and the Outlet Body, Item 25. NOTE: Additional adjustment will be required when failure of the cutting ring to seal on the wear plate, Item 4 is observed. Attempts to reduce leakage by excessive torque on the nut will accelerate wear of these parts with negligible reduction in leakage. NOTE: (2) Outlet seals, Item 26, and Wear Band, Item 27, must be in place when the adjustments are made. made . 2. Outlet Seals, Item 26, and Wear Band, Item 27, O-Ring, Item 28 – Always replace replace the outlet seals, o-ring, and wear band whenever wear parts are replaced. Replace these components by removing the outlet body. Remove the (6) mounting bolts and install two bolts in the threaded jacking bolt holes located at 12 and 6 o’clock on the outlet flange to back it out of the hopper. Clean the outlet body, swing tube extension, and the hopper piloted area thoroughly before reassembling. Wipe grease on the swing-tube extension and inside the outlet body prior to assembly. The hopper pilot should be coated with a lubricant or anti-seize compound before assembly. 3. Wear Wear Plate, Item Item 4 and Cutti ng Ring, Item 20 – The abrasives in pumping materials and friction of the cutting ring sliding across the wear plate result in constant wear of these parts. The loss of pumping pressure should result in a thorough inspection of these parts. Replace the wear plate and cutting ring whenever deep grooves of wear develop, causing loss of sealing between the two surfaces. The inability to maintain a seal will allow the fines of the mix to be discharged back into the hopper, resulting in lost pumping pressure. The mounting surface must be clean and flat to assure proper performance of the new wear parts. 4. Material Material Cylind ers, Item 6 – The material delivery cylinders have a hard-chrome internal finish for excellent abrasion resistance and provide a smooth sealing surface for the piston cups. Inspect the internal chromed surfaces for wear. A worn cylinder will exhibit feathering of the bright chrome into a dull gray surface. The loss of the chromed surface will reduce the sealing characteristics and accelerate the wear of the piston cups. Exercise care when cleaning the material cylinder ends before installing a new wear plate. Do not trap hardened grout between the two surfaces. Accidental chipping or cracking of the chromed surface will result in premature failure. Replace the o-ring seals in both the valve body and washbox every time the cylinders are removed or replaced. 3-3
5. Replace Piston Cups, Item 31, and Wear Band, Item 16 – Due to the abrasiveness of materials pumped, it will be necessary to periodically replace the piston cups and the piston wear bands. Symptoms of worn piston cups are: excessive accumulation of cement passed into the washbox, lubricating fluid leaking from the wash box into the hopper, overnight, or loss of wash box lubricant when pumping. Replace the piston cups through the hopper as follows: a. Drain and clean the washbox. b. Piston cup removal can be done through the hopper top. The hopper can also
be unbolted and removed with the appropriate equipment. c. Start the motor. On the operator panel, put the Forward/Reverse Forward/Revers e switch in Reverse and toggle the Pump Start/Pump Stop switch between start and stop to activate the accumulator circuit. d. With the motor running and pumping speed at low volume (set on 2), switch the pump to start and hold the pressure test switch on until the piston is fully extended to the hopper and stops. Turn the pump switch to stop. Check to see that the piston head that is forward is not covered by the swing tube. e. If the swing tube is in front of the forward piston head, turn the Pump Start/Pump Stop switch on momentarily and move the Forward/Reverse switch to the opposite position to reposition the swing tube. f. Stop the motor. Lock out and tag the operator controls. g. The accumulator dump valve will automatically discharge the accumulator pressure; the gauge must read zero. Never work in the hopper when the pump power source is operating or the accumulator circuit is pressurized. Severe injury can result from inadvertent actuation of moving parts. For your protection, take time to stop and disable the motor power system and confirm the accumulator pressure gauge reads zero before putting hands in the hopper. h. The piston bolts, Item 65, and the piston cup plate, Item 32, should be able to be seen and felt in the material cylinder. Chip away any material on and around the bold head. i.
Using an air impact gun, remove the 3/8-24 bolts with a 9/16” socket.
j.
Start the motor motor and turn turn the pump pump switch to start for 2-3 seconds. seconds. This will will retract the cylinder rod and piston adapter from the piston cup.
k. Turn the Pump Start/Pump Stop switch to stop and disable the power source.
3-4
l.
Using a punch or blunt object, tap the bottom of the piston cup, Item 31, until it turns side-ways in the material cylinder. It can now be easily removed.
m. Using an air impact gun and 1-1/8” socket, remove the 3/4-16 x 2-1/2” long bolt that holds the piston adapter to the cylinder rod. Remove the steel piston adapter, Item 33, and clean thoroughly. n. Start the motor and turn the pump switch to start. Toggle the manual pumping switch to bring the ram forward in the material cylinder where the piston cup was just removed. removed. o. To install the new piston cup, first place the piston adapter with the piston wear band on the hydraulic cylinder rod and attach with the 3/4-16 x 2-1/2” long bolt coated with a generous amount of anti-seize compound. Install the two 3/8” alignment studs into the piston adapter. Grease the piston cup and tap it into the material cylinder, aligning onto the studs. Do the same with the faceplate and reinstall the 3/8-24 x 1-1/2” long bolts and lock washers. p. Repeat all the above steps to change the opposite piston cup. q. Always inspect all parts for wear and damage whenever working on the pump. Early detection of problems will save time and money. r. When both piston cups have been replaced, fill the wash box with lubricant. Never cycle the pump without lubricant in the wash box and water or pumpable material in the hopper. This will cause damage to the piston cups. If it is necessary to stroke the pump dry, always do it very slowly. Excessive friction will cause heat and damage the piston cups.
Material Material Cylin ders, Item 6 – The material delivery cylinders have a hard chrome internal finish for excellent abrasion resistance and provide a smooth sealing surface for the piston cups. Inspect the internal chromed surface for wear. A worn cylinder will exhibit feathering of the bright chrome into a dull gray steel surface. The loss of the chromed surface will reduce the sealing characteristics and accelerate the wear of the piston cups. Exercise care when cleaning the material cylinder ends before installing a new wear plate. Do not trap hardened grout between the two surfaces. Accidental chipping or cracking of the chromed surface will result in premature failure. 6.
3-5
2
MIXER SHELL
1
3
SET SCREW
MIXER SHAFT 4
RE-MIXER SEAL REPLACEMENT The inner seal of the seal housing is exposed to severe operating conditions and eventually will require replacement. The function of the grease filled seal housing is to prevent solid particles from entering the the flanged ball bearings. The seals need to be replaced when they can no longer retain grease in the Seal Housing, thus permitting eventual premature bearing failure. IT IS RECOMMENDED TO GREASE THE SEAL HOUSINGS AFTER EVERY DAYS USE. THIS WILL HELP FORCE ANY FOREIGN MATTER OUT OF THE HOUSING WHICH MAY MAY HA VE WORKED PAST THE SEAL.
TO REPLACE THE SEALS IN THE HOUSING: 1. Remove the the chain sprocket (See page 4-5). 2. Securely prop the mixer mixer shaft inside the mixer to keep the shaft axially centered. This is done to prevent seal damage during re-installation. 3. Remove the Flanged Ball Bearing (Item 1), and Seal Housing (Item 2). 4. Remove the Seal (Item 3) and O-ring (Item 4). 5. Clean the Seal housing and Mixer Shaft end of material build up. 6. Inspect Flanged Bearing for operation and clean or replace ifif required. 7. Grease the end of shaft and insert New Seal (Item 3). 8. Install new O-ring (Item 4) in Seal Housing, Housing, then insert Housing onto shaft. 9. Install Flanged Bearing. 10. Lock shaft in position with set screws in the inner race of the Flanged Bearing. Bear ing. 11. Fill the Seal Housing with grease until grease comes out of the seal.
3-6
PROXIMITY SENSOR ADJUSTMENT
The Powercreter material pump is delivered with factory set proximity sensors. However, after maintenance or replacement of components, readjustment may be required. The proximity sensor adjustment should be made in the Forward pumping condition. To adjust the sensors: 1. With both sensors assembled as shown in the pictures above, adjust the body of the sensor to ensure the maximum gap is between the sensor and piston adapter. 2. From the operator control panel, start the pump power. With the pump in the Forward mode, switch to Pressure Test to retract one material cylinder piston to end of travel. Shut down motor but retain power to the control circuit. 3. Adjust the gap between the sensor and the piston adapter. The set dimension should be between 1/16” (0.062”) and 3/32” (0.093”). 4. Repeat step 2, except after switching to Pressure Test, toggle the manual pumping switch to retract the other material cylinder piston. Repeat step 3. 5. Restart the motor and start the pump to confirm that the pump cycles automatically with the new sensor adjustments.
3-7
RECOMMENDED LUBRICANTS
LUBRICATION / WASH BOX
Fill the Lubrication/Wash Box to the top of the cylinder rods. There are three recommended lubricants: 1. Water is commonly used. Using only water will give the shortest life of piston cup wear. 2. Soluble oil and water mix will improve the life of the piston cups. 3. Oil only, as compared with water only, will almost double the life of the piston cups. Oil greatly reduces the drag friction between the material cylinder and pistons. This can be used oil, drain oil, vegetable oil, or any type of inexpensive oil. Oil is recommended in freezing weather conditions. HYDRAULIC TANK
Fill the hydraulic tank to the mid-point of the tank level indicator. Use clean SAE 5W-20 Hydraulic Oil which is formulated for operation over a wide temperature range. This oil contains anti-wear and anti-foam additives and contains rust and oxidation inhibitors for internal protection. Use the following typical test data if selecting an equivalent. Low Temp. Pumpability test …… Pass
Viscosity cSt @ 40º C …………23-27
Foam Test ……………………….. Pass
cSt @ 100º C …….….5.4
Rust Test ………………………… Pass Total Acid No …………………….. 0.6
Viscosity index ……………………155
Zinc, % by weight …………....0.06-0.07
API g Gravity Gravity @ 60º 60º F …………...31.2 …………...31.2 Flash point ………………………...370º F
ISO Viscosity Grade ……………...370 F
Pour Point …………………………-45º F
SAE Grade ………………………5W-20
GREASE FITTINGS
Use Multi-Purpose E.P. No. 2 grease, except with electric motors MIXER AND REMIXER LUB RICATION
Pillow block bearings, flange bearings, and the seal housings should be maintained full of grease and lubricated daily. Factory lubricant is NLGI Grade 2 lithium 12 – hydroxystearate base grease.
3-8
LUBRICATION - ELECTRIC MOTOR
Motors with grease fittings fittings should be lubricated every 6 months. Add 1.0 cubic inches of lubricant to 20 and 30 HP motors. Add 1.5 cu.in. of lubricant to 40 HP and above motors. Use the following recommended lubricants: Shell Oil Company - Dollum R Chevron Oil - SRI No.2 Texaco Inc. – Premium RB Lubrication Procedure: 1. Clean the area around the grease fitting fitting and remove the protective cap. 2. With the motor warm and stationary, add the recommended volume volume as listed above, and run the motor for 20 minutes. Note:
All used petroleum based lubricants should be recycled in accordance with environmentally safe methods.
3-9
TROUBLESHOOTING Diesel engine will not start………. start………...
• •
• •
•
•
•
• •
Diesel engine slow to start or running rough……
• •
Electric Electric motor will not st art…….. art……..
Pump makes one stroke, but will not cycle…………….
Confirm “E” stop is reset by turning the knob clockwise. Make certain remixer grate is down and the safety lockout pin is pushed in. Check fuel, prime if necessary. Battery voltage must be 10VDC or greater for controller to operate and supply power to open the fuel shut off. Dirt or water in fuel. Change filter and clean tank if necessary. Check battery voltage, alternator output, battery cables are clean and tight, and controller box cable is connected. Check continuity of ignition circuit through the engine temperature switch, fuel shut off solenoid, ignition switch, operator panel connector, and bulb of alternator indicator. Starter fault, repair or replace. Refer to engine manufacturer’s manual, local engine manufacturer service center, or contact Allentown’s service department.
Clean or replace fuel injectors. Refer to engine manufacturer’s manual, local engine manufacturer service center, or contact Allentown’s service department.
Confirm power wiring, see “Set Up of Equipment” • Check the motor starter box for blown fuses. • Confirm E-Stop is reset by pulling knob outward. •
If pump will cycle with manual pumping switch, adjust the sensors. See “Sensor Switch Adjustment” • If pump will not cycle with manual pumping switch, refer to “Material Pump Does Not Cycle” in this troubleshooting guide. •
3-10
TROUBLESHOOTING
Material Material pum p does not cycle……
Stroke is sh ort…..
Both material pump cylinders stroke forward under pressure test ……
Accu Ac cumu mu lator lat or press pr essur ure e build s slow ………
Flow control must be open. • The accumulator system did not charge on start-up. • Confirm Pumping / Pressure Test switch on the operator control panel is in the “Pumping” position. • Confirm Pump Start / Pump Stop switch on the operators control panel is in the “Pump Start” position. • Proximity sensors or sensor cables - adjust or replace. See “Sensor Switch Adjustment”. • Switching or continuity fault with Pump Start/Pump Stop or Pressure Test switches. • Directional control valve requires cycling voltage to the solenoid coil and continuity in the coil winding. • Confirm the main hydraulic pumps will maintain pressure. • Confirm the pumping circuit relief valve and the swing tube relief valve is set in accordance with specifications on the unit’s data tag. •
Sensors require adjustment. See “Sensor Switch Adjustment” • Pumping cylinder seals worn and require replacing. • The check valves must seal in the checked flow direction for the stroke adjustment circuit to maintain full stroke. Clean or replace. •
•
Faulty check valve. Clean or replace.
Swing tube circuit pump worn and needs replacing Accumulator bladder leaks and and needs replacing replacing.. • Accumulator •
3-11
TROUBLESHOOTING
Swing Tube does not swing ………. ……….
Confirm Pump Start/Pump Stop switch on operator control panel is in Pump Start position. • Confirm relief valve is set as specified on the data tag. • Confirm voltage, circuit and coil continuity, and the spool is shuttling on the Swing Tube directional control valve. • Confirm the dump valve located in the swing tube manifold is working properly. properly . • Confirm the accumulator nitrogen pre-charge is set per the pressure setting listed on the data tag. • Swing tube circuit pump is worn and needs replacement. • Mechanical bind. Check freedom of rotation of the main shaft and outlet to s-tube extension. Also check torque of the 2-1/4" main nut. • Confirm that there are no foreign objects or hardened material in the hopper obstructing travel of the swing tube. •
Swing tube out of timi ng …….. ……..
•
Swing Tube slow s hifti ng …….. ……..
•
Material Material Cylinders stroke but do not build pressure…
Confirm accumulator is pre-charged per data tag. • Swing tube cylinder seals leak and need replacing.
Confirm accumulator circuit relief valve is set per data tag. • Swing tube cylinder seals leak and need replacing.
Worn wear plate, cutting ring, and/or piston cups. See “Wear Parts Replacement or Adjustment”. • Confirm that the relief valve is set per the pressure specified on the data tag. • Swing tube out of timing. Confirm accumulator precharge and swing tube cylinder seals for wear. • Pumping cylinders seals are worn and need replacing. • Main hydraulic pump is worn. Replace pump if the case drain line is producing excessive oil. Consult factory prior to replacement to confirm condition of the pump. •
3-12
TROUBLESHOOTING
Fluctuating Fluctuating pumping press ure …………… ……………
Slurry in the Lubrication/Wash Box Bo x ………………… …………………
Adju Ad just st ment men t of o f flo f lo w control valve does not change m aterial aterial pump speed ………
Worn wear plate, cutting ring, and/or piston cups. See “Wear Parts Replacement or Adjustment”. • Pumping cylinders seals are worn and need replacing. •
•
The piston cups and/or the material cylinders are worn and need to be replaced. See “Piston Cups”.
Confirm the relief valve is set per the pressure specified on the data tag. • Main hydraulic pump is worn. Replace pump if the case drain line is producing excessive oil. Consult factory prior to replacement to confirm condition of the pump. •
3-13
MATERIAL PUMP MODEL 20
ITEM
QUANTITY
PART NUMBER
1
1
33120
VALVE BODY
2
1
33118
WASHBOX, SHP MODEL
3
1
33122
COVER, WASHBOX
4
1
33233
WEAR PLATE, CAST
5
1
33134
DOOR ASSEMBLY, CLEAN-OUT
6
2
33030
MATERIAL CYLINDER
7
2
33022
FLANGE ADAPTER
8
4
33021
O-RING
9
4
33136
TIE ROD
10
1
33270
RETAINER PLATE, SEAL - 4 BOLT
11
1
32642
SEAL, MAIN SHAFT
12
1
32454
MAIN BUSHING, FLANGED
13
2
33060
WEAR BAND
14
1
32479
SWING ARM
15
1
32022
HEX NUT, 2 1/4-12 TH'D
16
1
32470H
17
1
32271
RETAINER PLATE
18
2
32457
OILITE BUSHING
19
1
33125
SWING TUBE, KEYED
20
1
33232
CUTTING RING, CARBIDE INSERT
21
1
33123
EXPANSION EXPANSION BAND, RUBBER
22
2
33029
O-RING
23
5
32655
LOCKWASHER, LOCKWASHER, WEDGE, 5/8"
24
1
33019
S-TUBE EXTENSION
25
1
A507199
TAIL PIPE HOUSING, 4" HD
26
2
A505885
OUTLET SEAL
27
1
A510807
WEAR BAND
28
1
32221
PLUG, WASHBOX
29
1
33229
SWING TUBE CYLINDER
30
2
33063
PISTON, MATERIAL CYLINDER
31
2
33052
PISTON CUP
32
2
33058
RETAINER, RETAINER, PISTON CUP
33
2
33237
HYDRAULIC CYLINDER, PUMPING - SHP
34
4
32641
KEY, 5/8" SQUARE
35
1
32458
HANDLE GRIP (NOT SHOWN)
36
3
82001
GREASE FITTING
37
2
11480
CYLINDER CLEVIS PIN, 3/4" STN STL
38
1
33223
BAFFLE, WASHBOX
DESCRIPTION
MAIN SHAFT, KEYED
4-3
MATERIAL PUMP MODEL 20
ITEM
QUANTITY
PART NUMBER
39
2
32145
PROXIMITY SWITCH
40
1
11489
WEAR SLEEVE
41
1
33134
DOOR WELDMENT
42
1
33023
DOOR GASKET
43
4
FLAT HEAD CAP SCREW, 5/16-18 x 1
44
1
HEX HEAD BOLT, 1/2-13 X 2
45
1
LOCKNUT, 1/2-13
46
1
47
2
HEX HEAD BOLT, GR.5, 3/4-16 X 2 1/2
48
8
HEX NUT, GR.8, 7/8-14 TH'D
49
2
LOCKWASHER, 3/4"
50
4
51
9
52
6
53
3
FLAT HEAD CAP BOLT, 5/8-11 X 3
54
3
HEX NUT, 5/8-11
55
3
LOCKWASHER, 5/8"
56
1
HEX HEAD BOLT, GR.5, 3/8-16 X 1
57
3
SOC. HEAD CAP BOLT, 3/8-16 X 1 1/4
58
1
SET SCREW, CONE PT., 1/4-20 X 3/8
59
6
HEX HEAD BOLT, GR.8, 3/8-24 X 1 3/4
60
6
LOCKWASHER, GR 8, 3/8"
61
4
"E" STYLE RETAINING RING
62
1
LOCKWASHER, 3/8"
63
8
BELLEVILLE WASHER, 5/8"
64
1
33145
33190
DESCRIPTION
HINGE PIN
HEX HEAD BOLT, F911, 5/8-11 X 2 1/2 HEX HEAD BOLT, GR.8, 5/8-11 X 3
33638
A510302
HEX HEAD BOLT, F911, 1/2-13 X 2 1/2
O-RING
4-4
PC20 STANDA RD REMIXER HOPPER COMPONENTS COMPONENTS
EXPLODED VIEW
4-5
PC20 STANDARD REMIXER HOPPER COMPONENTS
ITEM
QUANTITY
PART NUMBER
1
1
03298
MIXER GRATE
2
2
03305
SEAL HOUSING
3
2
03310
SEAL
4
4
03311
SEAL, O-RING
5
1
03272
MAIN SHAFT
6
1
09201
HYDRAULIC MOTOR
7
2
11059
FLANGE BEARING
8
1
32519
TORQUE ARM
9
3
04014
PADDLE ARM
10
1
04055
MIXING PADDLE, 14", RH
11
1
04056
MIXING PADDLE, STRAIGHT
12
2
04054
BOTTOM SCRAPER
13
2
04061
RUBBER SCRAPER
14
1
04062
MIXING PADDLE, 14", LH
15
1
03277
LIFTING ARM, (FOR OPTIONAL MIXER)
16
2
11488
WEAR SLEEVE, 2"
17
8
FHCS, 1/2-13 x 2-1/2
18
8
LOCK WASHER, 1/2"
19
8
HEX NUT, 1/2-13
20
8
LOCK WASHER, 3/8"
21
8
HEX NUT, 3/8-16
22
8
FLAT WASHER, 3/8"
23
8
HEX HEAD BOLT, 3/8-16 x 1-1/4
24
6
HEX HEAD BOLT, 5/8-11 x 1-3/4
25
6
LOCK NUT, 5/8-11
DESCRIPTION
4-6
PC20 HARSH MIX HOPPER COMPONENTS
8 ,9
11
13
4-7
PC20 HARSH MIX HOPPER COMPONENTS
ITEM
QUANTITY
PART NUMBER
1
1
03288
STUB SHAFT, IDLER END
2
1
03293
REMIXER SHAFT
3
1
03287
STUB SHAFT, DRIVE END
4
4
03310
SEAL
5
2
03311
SEAL, O-RING
6
2
03305
SEAL HOUSING
7
2
11059
FLANGE BEARING
8
1
11048
CHAIN
9
1
11049
CONNECTION CONNECTION LINK
10
1
11402
SPROCKET, DRIVEN, 60T
11
1
11403
SPROCKET, DRIVE, 18T
12
1
03294
CHAIN COVER (NOT SHOWN)
13
1
09192
HYDRAULIC MOTOR
14
16
15
4
04059
SCRAPER, BOTTOM
16
2
04060
SCRAPER, SIDE
17
8
FHCS, 1/2-13 x 2-1/2
18
4
HEX HEAD BOLT, GRADE 8, 1/2-13 x 2-1/2
19
16
HEX HEAD BOLT, GRADE 8, 1/2-13 x 1
20
24
LOCKNUT, 1/2-13
21
2
DESCRIPTION
FLAT WASHER, 1/2"
11488
WEAR SLEEVE, 2"
4-8
OPERATOR CONTROLS
2
3
4
5
6
7, 8
8, 9
10 1
11, 12
22
13 20, 21
19
16, 17, 18
4-9
14, 15
7, 8
OPERATOR CONTROLS
ITEM
QUANTITY
PART NUMBER
1
1
14031
TOGGLE SWITCH, PRESSURE TEST
2
1
14033
TOGGLE SWITCH, ON/OFF/REMOTE
3
1
14032
TOGGLE SWITCH, FORWARD/REVERSE
4
1
14044
TOGGLE SWITCH, MANUAL PUMPING
5
1
14442
POTENTIOMETER, POTENTIOMETER, FLOW CONTROL
6
1
14027
HOUR METER
7
3
14196
LENS, GREEN
8
4
14149
PILOT LIGHT
9
1
14195
LENS, RED
10
1
14119
E-STOP
11
1
14158
BOOT, RED
12
1
14139
PUSH BUTTON SWITCH, N.C.
13
1
45019
MANUAL AUTOLUBE BUTTON
14
2
14159
BOOT, GREEN
15
2
14140
PUSH BUTTON SWITCH, N.O.
16
1
14047
CONNECTOR, CONNECTOR, REMOTE
17
1
14048
CAP
18
1
14329
REMOTE PENDANT (NOT SHOWN)
19
2
30124
PRESSURE GAUGE, 0-5000 PSI
20
1
14386
PANEL LIGHT
21
1
14387
LIGHT BULB, 12VDC
DESCRIPTION
4-10
MICROPROCESSOR CONTROLLER
ITEM
QUANTITY
PART NUMBER
DESCRIPTION
1
1
14327
MICROPROCESSOR (SEE NOTE)
NOTE: The microprocessor has a program specifically designed to run this pump. The
pump will not run correctly if the program is not installed by Allentown Shotcrete Technology. Please contact Allentown Shotcrete Technology if replacing the microprocessor. If the pump is not functioning correctly contact the Allentown Shotcrete Technology service department.
4-11
HYDRAULIC SYSTEM COMPONENTS
ITEM
QUANTITY
PART NUMBER
1
1
09382
PROPORTIONAL VALVE, PVG-32
2
1
35106
DIRECTIONAL CONTROL VALVE, SWING TUBE
3
2
32332
COIL, DCV, 12VDC
4
2
30124
PRESSURE GAUGE, 0-5000 PSI
5
1
32122
ACCUMULATOR
6
1
09361
ACCUMULATOR BLADDER
7
1
30532
CONTROL VALVE, REMIXER
1
09201
HYDRAULIC MOTOR, STANDARD REMIXER
1
09192
HYDRAULIC MOTOR, 15 CU FT REMIXER
9
1
09343
MAIN HYDRAULIC PUMP
10
1
32103
DOUBLE GEAR PUMP
11
2
33237
HYDRAULIC CYLINDER, PUMPING, WITH INTERNAL CHECKS
12
1
33229
HYDRAULIC CYLINDER, SWING TUBE
13
1
09328
HYDRAULIC TANK
14
1
09332
RETURN FILTER ELEMENT, IN TANK
15
1
09406
GAUGE, RETURN FILTER INDICATOR
16
1
09331
RETURN FILTER ASSEMBLY
17
1
09311
FILLER BREATHER CAP
18
1
09335
OIL GAUGE AND THERMOMETER
19
1
09324
OIL COOLER
20
1
09711
TEMPERATURE SWITCH
21
1
09447
MOTOR ASSEMBLY, OIL COOLER
22
4
32222
CHECK VALVE
23
1
09303
CONTROL VALVE, 12VDC, REMIXER GRATE CUTOUT
24
1
35094
ACCUMULATOR MANIFOLD
25
1
09292
CHECK VALVE
26
1
09291
RELIEF CARTRIDGE
27
2
09306
COIL, CONTROL VALVE, 12VDC
28
1
09294
ON/OFF VALVE, SWING TUBE
29
1
09294
DUMP VALVE, SWING TUBE
30
1
09333
PRESSURE SWITCH
31
1
32416
DAMPENING HOSE, PRESSURE SWITCH
8
DESCRIPTION
4-13
MISCELLANEOUS COMPONENTS
1
11
5
4
2
3
9 6
7
10
8
4-14
MISCELL MISCELL ANEOUS COMPONENTS COMPONENTS
ITEM
QUANTITY
PART NUMBER
1
1
55049
A-FRAME JACK
2
1
14135
WIRE HARNESS
3
2
01037
SAFETY CHAIN
4
1
01393
LUNETTE EYE
5
1
14300
BREAKAWAY SWITCH
6
2
14071
TAIL LIGHT
7
2
01204
FENDER
8
2
01330 & 01368
9
2
01411
OUTRIGGER, MANUAL
10
2
01216
HITCH PIN
11
1
55050
TOP PLATE, A-FRAME JACK
12
1
30535
CONTROL VALVE, OPTIONAL HYDRAULIC OUTRIGGERS
13
2
09358
HYDRAULIC CYLINDER, OPTIONAL HYDRAULIC OUTRIGGERS
DESCRIPTION
TIRE & RIM
4-15
SAFETY DECALS Safety Safety deals must be in place at all all times. Missin g or illegib le decals decals will be replaced replaced fr ee of charge upon request.
P/N 07001
P/N 07006
P/N 07101
P/N 07099
P/N 07102
P/N 07105
P/N 07106
4-16
P/N 07108
Models 94012, 94024 CHASSIS LUBE ELECTRIC GREASE PUMP Series "C" OWNER/OPERA OWNER/OPE RATOR TOR MANUAL
© ©
Do not use pump without pressure relief valve.
SPECIFICATIONS Electrical Requirements Model 94012 Model 94012 ........ ............... ........... .... Model Mod el 94024.. 94024..... ...... ...... ...... ...... ...... ... Enclosur Encl osure e Rating. Rating....... ............ ......
12 VDC @ 3.5 amps 24 VDC VDC @ 2 amps amps IP 6K9K6K9K- Prot Protecte ected d from from water water sprayed in all directions. On Time .............. .................... ............ ........ 2 minutes minutes minimum minimum 30 30 minutes minutes maximum in 2 minute increments Off Time ................ ...................... ........... ..... 1 hour minimu minimum m 15 hours hours maximum in 1 hour increments Pump Outp Output ut ......... ............... .......... .... 0.171 cu. in./min in./min (2.8 (2.8 cc/min) cc/min) Outlet Out let Connect Connection ion... ...... ....... ...... .. 1/8 1/8"" NPT (femal (female) e) Maximum Recommended Operat Ope rating ing Pr Press essure ure ... ..... .. 3600 360 0 psi psi (24 (248 8 bar bar)) Reservoi Rese rvoirr Capacity.... Capacity.......... ...... 122 cu. in. (200 (2000 0 cc) cc) Lubricant....... Lubric ant................... ................... ....... Grea Greases ses up up to NLGI NLGI grade grade 2 ( depending on the operating temperature and type of lubricant) Temperatur Tempe rature e Range....... Range......... -13° F (-25° (-25° C) to +158° +158° F (+70° C) Pressure Relief Valve ........ 4000 psi +/- 250 psi (276 bars) +/- (17 bars)
DESCRIPTION The chassis tube pump is electrically operated and used in a progressive type centralized lubrication system. The pump consists of a pump housing, electric gear motor, a timer and a plastic reservoir with stirring paddle. The high operating pressure allows the pump to supply lubricant up to NLGI 2 grease.
MOUNTING THE PUMP Select an easily accessible place of installation which allows access to the timer and lubricant reservoir filler fitting. The pump must be mounted vertically on an even surface by means of two bolts.
TO FILL RESERVOIR Fill the reservoir through the grease fitting located at the base of the reservoir, using a hand operated grease pump. Refill reservoir when grease reaches “MIN” mark located on the reservoir. Fill the reservoir up to the “MAX” mark located on the reservoir.
TO PRIME SYSTEM Pump & Supply Line: After reservoir has been filled with recommended lubricant, lubricant, loosen the supply line fitting. Operate the pump until lubricant flows from outlet, then tighten fitting. Feed Lines: Pre-fill each feed line with lubricant before connecting to outlet of divider valve and bearing.
© Indicates Indicates Change Change
One Lincoln Way St. Louis, Missouri 63120-1578 (314) 679-4200
DEC - 2003
- Q3 - 2F
Section Copyright 2003 Printed in U.S.A.
Page
FORM 403301
SYSTEM ACCESSORIES De s cr ip t ion
Qt y. Par t No .
8 A mp Fus e
1
241052
8 A mp Fus e Holder
1
241053
Lighted Manual Sw i tc tc h ( 12 12 V DC DC)
1
241419
Lighted Manual Sw i tc tc h ( 24 24 V DC DC)
1
241484
Remote Manua anuall Lube Pow er Co Cord
1
256 256276
©
©
©
©
© Note: Note: Use Use loctite 545 when assembling pressure relief assemlby (34) to pump element (32).
© © © Indica Indicates tes Change
Page 2
Form 403301
ELECTRICAL CONNECTIONS Connect black power cord as follows: Red wire connects to 8 amp fuse then to Battery (+). White wire connects to Battery (-). Blue wire connects to ignition switch, to 8 amp fuse, then to B attery (+).
PARTS LIST ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 28 29 20 31 32 33 34 35 36 37 38
DESCRIPTION R es e rvoi r H os e Stirrin g p ad d le Wa s h e r Be arin g ri n g Be arin g 0-ring In ter m e d iate p late Sh im Sn ap ring In ne r rin g Ecce ntric ca m Screw Wa s h e r 0-ring Pu m p hou s i ng C l o s u re p l u g 3 Wi re Po w e r C o rd/Plug 6 Wi re Pl ug 6 Wi re Po w e r/R e m o te Ma nu a l Lube Cord/Plug (Optional) Se ali ng plu g N ip ple Screw Grea s e fittin g Pri nte d circui t b oard Wo od ruff key R ad ia l s e a l 12 VDC m o tor 24 VDC m o tor H ou s in g co ve r H os e C he ck val ve Pu m p ele m e nt Gas ke t Pre s s u re reli e f as s 'y. Pl u g for m o tor Grea s e ca p Ad a p ter for reli ef a s s y. Se Se al
QTY. 1 1 1 1 2 1 2 1 1 2 1 1 3 3 3 1 2 1 1 1 1 1 10 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
PART NUMBER/KIT NUMBER REMOTE MANUAL LUBE p a r t o f Ki t 2 4 6 4 3 2 PUSHBUTTON p a r t o f Ki t 2 4 6 4 3 3 If a remote manual lube pushbutton p a r t o f Ki t 2 4 6 4 3 3 is required, order a 256276© Manual pa rt o f Ki ts 24 6 43 3 & 2 4 6 43 4 Lube cord/plug© (consisting of a p a r t o f Ki t 2 4 6 4 3 4 33© ft. cord and plug) and: p a r t o f Ki t 2 4 6 4 3 4 2 4 6 4 2 4 , p a r t o f Ki t 2 4 6 4 3 2 for a 12 volt pump, order 2 4 6 42 5 241419 - Lighted Manual Lube p a r t o f Ki t 2 4 6 4 3 4 Switch p a r t o f Ki t 2 4 6 4 3 4 for a 24 volt pump, order p a r t o f Ki t 2 4 6 4 3 4 241484 - Lighted Manual Lube 2 4 6 42 7 pa rt o f Ki ts 24 6 43 5 & 2 4 6 43 6 Switch pa rt o f Ki ts 24 6 43 5 & 2 4 6 43 6 part of Kits 2 4 64 3 5 , 2 4 64 3 6 & 2 46 4 37 2 4 6 42 6 2 4 6 42 2 2 5 6 27 4 © 2 5 6 27 7 © 2 56 276 © 2 46 423 2 2 6 - 1 4 1 0 5 -5 2 0 6 - 1 3 7 9 6 -7 5 0 50 2 4 6 42 0 p art o f kits 2 4 6 43 5 & 2 46 4 36 part of Kits 2 4 64 3 5 , 2 4 64 3 6 & 2 46 4 37 p a r t o f Ki t 2 4 6 4 3 5 p a r t o f Ki t 2 4 6 4 3 6 2 4 6 42 1 not s o ld p a r t o f Ki t 6 0 0 - 2 6 8 7 6 - 2 p a rt o f K i t 6 0 0 -2 6 8 7 6 - 2 p a r t o f Ki t 6 0 0 - 2 6 8 7 6 - 2 2 7 0 86 4 pa rt o f Ki ts 24 6 43 5 & 2 4 6 43 6 2 4 2 12 5 3 04 -19 6 14 -1 © 2 4 9 56 9
© Indicat Indicates es Chang Change e
Form 403301
Page 3
©
© © ©
Par t n o. 5050 242125 246420 246421 246422 246423 246424 246425 246426 246427 304- 19614- 1 270864 249569 226- 14105- 5 206- 13796- 7 256287 256277 256276
Qt y. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 10 1 1 1 1
246432 1 1 246433 1 1 1 246434 1 2 1 1 2 1 246436 3 3 3 1 1 1 1 246437 3 1 600600-26 2687 8766-2 2 1 1 1
De s cr ipt io n Gr eas e Fitting Gr Gr eas e Cap Pr inted Cir c uit Boar d Hous ing Cov er Clos ur e Plug Sealing Plug O- r ing Inter mediate plate Pump Hous ing Ecc entr ic Cam A dapter f or r elief as s y . Pr es s ur e Relief as s y . Seal Nipple Ni Sc r ew 3- w ir e pow er cor d/plug 6 w ir e inter nal plug 6 w i re re pow e r/ r/r em emote manual lube c or or d ( op optional) Res er v oir Kit Contains : Res er er vo voir O- r ing Paddle Kit c ontains : Hos e Stir r ing Paddle Was her Bear ing & Seal Kit c ontains : Was her Bear ing Ring Bear ing Shim Snap Ring Inner Ring 12 V DC DC Motor Kit c ontains : Sc r ew Was her O- r ing W Wo oodr uf f Key Radial Seal 12 VDC VDC Motor otor Pl Plug f or Motor Hous ing Seel Kit c ontains : O- Ring Radial Seal Pump Elemen ementt Assem Assembly cont contai ains: n s: Chec k V alv e Pump Element Pu Gas ket
It e m No. 24 36 25 29 17 21 7 8 16 12 37 34 38 22 23 18 19 20
1 7 2 3 4 4 5 6 9 10 11 13 14 15 26 27 28 35 15 27 31 32 33
© Indicates Change
RETAIN THIS INFORMATION FOR FUTURE REFERENCE When ordering replacement parts, list: Part Number, Description, Model Number and Series Letter. LINCOLN provides a Distributor Network that stocks equipment and replacement parts.
Page 4
Form 403301
LIMITED WARRANTYLincoln warrants the equipment it supplies to be free from defects in material and workmanship for one (1) year following the date of purchase. If equipment proves to be defective during this warranty period it will be repaired or replaced, at Lincoln’s discretion, without charge provided that factory authorized examination indicates the equipment to be defective. To obtain repair or replacement, you must ship the equipment, transportation charges prepaid, with proof of date of purchase to a Lincoln authorized warranty and service center, within one (1) year following the date of purchase.
LIMITED 5 YEAR WARRANTY (Series 20, 25, 40 Bare Pumps, Heavy Duty and Golden Standard Bare Reels)Lincoln warrants series 20, 25, 40 bare pumps, and heavy duty and golden standard bare reels it supplies to be free from defects in material and workmanship for one (1) year following the date of purchase. If equipment proves to be defective during the warranty period it will be repaired, or replaced, at Lincoln’s discretion, without charge provided that factory authorized examination indicates the equipment to be 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 one (1) year following the date of purchase. Additionally, in years two (2) and three (3) the warranty on this equipment is limited to repair with Lincoln paying parts and labor only. In years four (4) and five (5), the warranty on this equipment is limited to repair with Lincoln paying for parts only. This warranty is extended to the original retail purchaser only. It does not apply to equipment damaged from accident, overload, abuse, misuse, negligence, faulty installation or abrasive or corrosive material, or to equipment repaired or altered by anyone not authorized by Lincoln to repair or alter the equipment. This warranty applies only to equipment installed and operated according to the recommendations of Lincoln or its authorized field personnel. No other express warranty applies. Any implied warranties applicable to equipment supplied by Lincoln, including the warranties of merchantability and fitness for a particular purpose, will last for only one (1) year from the date of purchase. Some jurisdictions do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you. In no event shall Lincoln be liable for incidental or consequential damages. Lincoln’s liability on any claim for loss or damages arising out of the sale, resale or use of equipment it supplies shall in no event exceed the purchase price. Some jurisdictions do not allow the exclusion or limitation of incidental or consequential damages, so 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.
Form
Page 5
