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SECTION INDEX

SECTION 1

INTRODUCTION AND CONTACT PERSONNEL

SECTION 2

NOMENCLATURES

SECTION 3

HEALTH AND SAFETY REQUIREMENTS

SECTION 4

BASIS OF OPERATION

SECTION 5

INSTALLATION AND COMMISSIONING

SECTION 6

OPERATING INSTRUCTIONS

SECTION 7

MAINTENANCE INSTRUCTIONS

SECTION 8

WARRANTY STATEMENT

SECTION 9

SPARE PARTS

SECTION 10

PARTS LISTS

SECTION 11

SPECIFICATIONS

SECTION 12

REFERENCE DOCUMENTS & DRAWINGS

SECTION 13

APPENDICES

Contents
1. INTRODUCTION AND CONTACT PERSONNEL ................... 3
1.1.
1.2.

Commercial Summary ................................................................... 3


Contact Personnel ......................................................................... 4

2. NOMENCLATURES ................................................................ 5
2.1.

Glossary of terms:.......................................................................... 2

3. HEALTH AND SAFETY STATEMENTS .................................. 3


3.1.
3.2.
3.3.
3.4.
3.5.

Operator Safety ............................................................................. 4


Maintenance Safety ....................................................................... 5
Machine and Operator Safety ........................................................ 6
Rockbreaker Mounting Safety........................................................ 6
Lifting Safety .................................................................................. 7

4. BASIS OF OPERATION .......................................................... 9


4.1.
4.2.

Boom system and hydraulic hammer........................................... 10


Hydraulic Power Unit (HPU) and Components ............................ 10

5. INSTALLATION AND COMMISSIONING ............................. 12


5.1.
5.2.
5.3.
5.4.
5.5.

Packing and Arrival on Site .......................................................... 12


Receipt and Storage .................................................................... 12
Installation Requirements ............................................................ 14
Hydraulic System Installation Guidelines ..................................... 19
Commissioning ............................................................................ 29

6. OPERATING INSTRUCTIONS ............................................. 30


6.1.
6.2.
6.3.
6.4.

Routine Operator Checks ............................................................ 30


Operation of the Rockbreaker ...................................................... 31
HPU Operation ............................................................................ 33
Optional components ................................................................... 39

7. MAINTENANCE INSTRUCTIONS ........................................ 40


7.1. Introduction .................................................................................. 40
7.2. Maintenance Schedule ................................................................ 40
7.3. Operating the grease lubrication pump ........................................ 40
7.4. Hydraulic power unit and Rockbreaker hydraulics ....................... 42
7.5. Hydraulic valves........................................................................... 44
7.6. Slew Bearing................................................................................ 44
7.7. Slew gearbox ............................................................................... 47
7.8. QUICK UNLOCK pin system ....................................................... 50
7.9. Pivot & cylinder pin removal and replacement tooling
(optional extra) ...................................................................................... 52

8. WARRANTY STATEMENT ................................................... 54


8.1.
8.2.
8.3.

New products ............................................................................... 54


Repaired products ....................................................................... 55
Exceptions ................................................................................... 55

9. SPARE PARTS ..................................................................... 56


9.1.

Ordering information .................................................................... 56

10. PARTS LISTS........................................................................ 57


11. SPECIFICATIONS................................................................. 76
11.1. Scope of Supply........................................................................... 76
11.2. Technical Summary and Maintenance Reference Listing ............ 76

12. REFERENCE DOCUMENTS & DRAWINGS ........................ 79


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13. APPENDICES ....................................................................... 81


A. Troubleshooting Guide .......................................................... 82
B. Spare Parts Lists ................................................................... 89
C. Commissioning Records........................................................ 99
D. Maintenance Schedule ........................................................ 100
E. Lubrication Schedule ........................................................... 101
F. Lincoln Grease Pump and Injector Manual ......................... 102
G. Sandvik BR3288 Hydraulic Hammer Manual ...................... 103

1. INTRODUCTION AND CONTACT PERSONNEL


1.1. Commercial Summary
Client

HUDBAY PERU

Contract No.

2172-0020

Contract title

130 SERIES 50/50 TRANSMIN Rockbreaker

Project

HUDBAY PERU CONSTANCIA PROJECT

Transmin Job No.

TM 4215

Contact information

Transmin Pty Ltd


35 Denninup Way
MALAGA WA 6090
Telephone
Facsimile
Email

:
:
:

08 9270 8555
08 9203 2501
sales@transmin.com.au

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:
SPARE PARTS ENQUIRIES Name
Title
Phone No.
Email

: Bob Campbell
: Spare Parts Manager
: +618 9270 8555
: Bob.Campbell@transmin.com.au

SERVICE ENQUIRIES

Name
Title
Phone No.
Email

: Peter Harris
: Service Manager
: +618 9270 8555
: Service@transmin.com.au

OTHER ENQUIRIES

Name
Title
Phone No.
Email

: Peter Warren
: Engineering Manager
: +618 9270 8555
: peter.warren@transmin.com.au

Please provide the following reference information when making enquiries to ensure a prompt
response:
Transmin job number

TM 4215

IOM manual

TM 4215-MAN-01

Equipment / Serial Number

Equipment No.

Site

Rockbreaker
HPU

Constancia
Constancia

Transmin
Serial No.
RB-118
ME-316

Site Equipment No.


3111-BK-001
3111-LU-002

To enquire about Transmins 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.
PERTH OFFICE
Phil Gilbert
Ph: +618 9270 8555
Fx: +618 9249 6116
Phil.Gilbert@transmin.com.au

BRISBANE OFFICE
Martin Holden
Ph: +617 3880 3874
Fx: +617 3880 3874
Martin.Holden@transmin.com.au

2. NOMENCLATURES
A number of warning icons may be used in this manual. Take note of their definition:

Use caution!
Mandatory isolating machine

Hand Crushing Risk


Mandatory alarm horn

Risk of electrical shock

Mandatory head wear


Danger from suspended loads

Mandatory goggle eyewear


Danger from released pressure

Mandatory Guard for Machinery


Danger from hot surfaces

2.1. Glossary of terms:


Transmin

Transmin Pty Ltd

Hudbay Peru

Client

Constancia (Project)

Site/Project Name

IOM

Installation, Operation & Maintenance Manual

Site

Hudbay Peru Constancia Project

Rockbreaker

Boom system with Rockbreaking hammer attached

HPU

Hydraulic power unit (power pack)

HMI

Human machine interface

PM

Preventative Maintenance

PLC

Programmable Logic Controller

MCC

Motor Control Centre

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.

Never operate any machinery unless ALL guards are in position.

Do not carry out adjustments with the machine operating.

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.

Always keep your working area as clean as possible.

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.

Welding of lifting lugs, enlargement of holes, or cutting of new holes to


facilitate lifts is strictly forbidden unless accepted or instructed by
Transmin personnel.

Do not carry out adjustments with the machine operating

Only qualified electricians are


electrical power to the equipment.

authorised to connect

Use safety glasses when operating or carrying out any repairs Always
keep your working area as clean as possible

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.
Welding of lifting lugs, enlargement of holes, or cutting of new holes to
facilitate lifts is strictly forbidden unless accepted or instructed by
Transmin personnel.

DO NOT carry out adjustments with the machine operating

Only qualified electricians are authorised to connect electrical power to


the equipment. DO NOT open any control cabinet doors unless you are
qualified and cleared to do so. IMPORTANT! LETHAL VOLTAGES ARE
PRESENT

Use safety glasses when operating or carrying out any repairs.

Always keep your working area as clean as possible

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.

3.4. Rockbreaker Mounting Safety


Foundations and supports must provide an adequate anchorage for the Transmin Rockbreaker and
hydraulic power unit, and any ancillary equipment to which it may be connected. Subsidence or
subsequent movement of the machine during operation will result in excessive wear of components.
Details of identification and the correct alignment of the machine and supports are dealt with in the
Installation section of this Manual.

3.5. Lifting Safety


The ROCKBREAKER and HPU should only be lifted in accordance with
the lifting diagrams provided.
All lifts must be performed by qualified riggers trained / instructed in the
correct methods of lifting.

BEFORE ANY LIFTING, always ensure that lifting equipment is in good


condition, approved as certified and suitably rated for the load. The use of
damaged or uncertified equipment could potentially lead to damage of
equipment or injury / death of personnel.

The Lifting Lugs provided are rated to allow the ROCKBREAKER and HPU
to be lifted in accordance with the lifting diagrams provided.

Personnel must be instructed against the use of slings or cables on


machined or finished surfaces.

Welding of lifting lugs, enlargement of holes, or cutting of new holes to


facilitate lifts is strictly forbidden unless accepted or instructed by
Transmin.

Personnel must be instructed using of slings or cables on machined or


finished surfaces to avoid damage to the equipment
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.

Figure 1 - Lifting diagram (typical)

4. BASIS OF OPERATION

Figure 2 - 130 Series Rockbreaker (Typical)

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.

4.1. Boom system and hydraulic hammer


4.1.1.

Boom system

The boom system is used to manipulate the hydraulic hammer into a position to either
BREAK or move oversized run of mine ore. It is moved via a combination of hydraulic
cylinders, providing the liner boom movements and hydraulically actuated planetary
gearboxes, providing the rotational movement.

4.1.2.

Radio Control

The control of the Rockbreaker boom system depends on the control system supplied.
The standard machine is controlled via a dual joystick radio control transmitter. The
joystick and push button controls for the transmitter provide boom movement, hammer fire,
power pack start and emergency stop functions.

Figure 3 - Radio Controller (Typical)

4.2. Hydraulic Power Unit (HPU) and Components


4.2.1.

Description

The hydraulic power unit (HPU) can be broken down into the following main components:

Hydraulic pump and electric motor

Oil cooler and fan electric motor

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

10

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.
The control panel consists of the following components:

Main Isolation Switch (Pad-lockable)

Emergency Stop Push Button

Local/OFF/Remote mode selector switch

HMI Panel

The HMI Panel is used to indicate operation of the power pack, alarms, shut-down
conditions and oil temperature.

11

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

Swivel frame and boom assembly

Jib and hammer bracket assembly

HPU

Rockbreaker hammer

Boxes with ancillary components

Additionally, the following items are removed and supplied loose for assembly on site: (These items are
palletized or crated as required)

Radio control transmitter

Radio controller stands (if applicable)

Hose support and bunch binder (if applicable)

Pipe and hose bundle (if applicable)

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.

5.2. Receipt and Storage


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.

12

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.

5.2.1.

Storage of replacement slew bearing

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


ALL INSTALLATION TASKS MUST BE CARRIED OUT AND SUPERVISED BY SUITABLY
EXPERIENCED AND QUALIFIED PERSONNEL AT ALL TIMES.
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.
Any shortages or damage must be reported immediately to Transmin.
Rockbreaker AND HYDRAULIC POWER UNIT INSTALLATION
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 JSAs for the hazardous
tasks.

The following is to commence after the installation location has been


thoroughly checked to ensure that the supporting structure is
satisfactory.

Stage 1 - Off-Loading from Transport


1. Designate a firm, level work area to off-load the equipment.
2. Off-load the equipment using the lifting diagram drawing 600MC0057-02006-DR-ME-0013.
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.
Stage 2 Mounting of slew frame assembly
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.

The unhardened zone of the slew bearing raceway is identified by a


punched letter S on the slew base. This must be positioned outside the
main area of load.

5.3.1.

Concrete pad mounting

Prepare the concrete pad and holding down bolts to the best possible surface, i.e. clean of all oils,
greases and loose debris and ensure that the surface is flat within approximately +/- 5mm. All holding
down bolts cast into the concrete should be fully cleaned and lightly lubricated to ensure that correct
torques can be obtained. By use of a crane set the boom system base over the holding down bolts and
pack underneath in a minimum of 4 places to provide a grout allowance of approximately 30mm. Check
the horizontal alignment of the base by the use of a level.

14

Nip all the bolts uniformly, using a hand spanner only, to achieve a uniform pull down onto the packers.
Insert a full width bed of quality non-shrink grout, such as EPIREZ EGII or EPIGEN 301, under the slew
base. It is essential that you work from one side and force the grout completely under to the other to
ensure a full support bed under the machine. Allow the recommended curing time to obtain full strength
of the grout bed. Tighten down all holding down bolts to a final torque of M36 grade 8.8 -2300 Nm.
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.

5.3.2.

Steel structure mounting

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.

The unhardened zone of the slew bearing raceway is identified by a


punched letter S. The S must be positioned outside the main area of
load adjacent to the S marked on the base.

If rotation of the Rockbreaker boom is required after installation and


hydraulic power is not available, please contact Transmin for instructions.
DO NOT remove slew gearboxes or any other items without first
contacting Transmin.
Stage 3 Mounting of jib assembly (not required if Rockbreaker is shipped as a full assembly)
4. Clean the jib pivot and cylinder pins and caps.
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.

15

Figure 4 5m Boom System

Figure 5 5m Jib System

Stage 4 Mounting of hammer


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.

16

Figure 6 - Hammer and Hammer Bracket (Typical)

Stage 5 Installation of HPU


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


fitted and flushed.

at this stage, all pipes and hoses must be

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.

Only qualified electricians are


to the equipment.

authorised to connect electrical power

Stage 6 Installation of piping and hosing between Rockbreaker and HPU


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-

17

commissioning by looping the circuit and bypassing the control valves.

Failure to loop and flush the system according to the pre-commissioning


instructions will introduce dirt and contaminates into the system which
will damage the pump and valves and void the warranty.

Stage 7 Installation of the grease lubrication pump


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.
16. Install the electrical connection to the HPU.

Only qualified electricians are authorised to connect electrical power to


the equipment.

17. Purge the grease line by pumping grease through it until there is no sign of air in the
system.

Frequently check that there is plenty of grease in the grease pump


reservoir to ensure air does not get into the system.

18. Connect the grease line to the Rockbreaker

18

5.4. Hydraulic System Installation Guidelines


5.4.1.

Piping System Materials

Hydraulic fittings, tube and pipe are to be supplied and installed in accordance with Transmin drawings
and relevant client specifications.

5.4.2.

Delivery Condition of Pipe and Tube

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.
NOTE ON DE-SCALING AND NEUTRALISATION / PHOSPHATE TREATMENT
Acid de-scaling and neutralisation / phosphate treatment is usually carried out after all welding
of fittings and joins has been completed.
In some instances (particularly on remote sites) it may be deemed acceptable to have the pipe
de-scaled and phosphate treated before welding. When fittings are welded at the pipe ends
after cleaning, the scale is mechanically removed and all debris removed by pigging the pipe
several times in both directions.
NO BUTT WELDING OF PIPES SHOULD BE PERMITTED IN THESE INSTANCES AS THE
INTERNAL HEAT AFFECTED ZONES WILL NOT BE ACCESSIBLE FOR MECHANICAL
CLEANING.
It is recommended that the End User be consulted to determine whether this is deemed an
acceptable practice before proceeding in this manner.

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

5.4.3.

Protection During Site 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.

IMPORTANT NOTE: Ports and openings in hydraulic equipment shall


remain plugged, capped, sealed or closed as appropriate (and external
threads sleeved) up until the time of final assembly.

19

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.

5.4.5.

Piping System Installation

IT IS STRONGLY ADVISED THAT A COMPANY SPECIALISING IN HYDRAULICS SYSTEMS IS


ENGAGED TO CARRY OUT OR SUPERVISE THE INSTALLATION OF ALL HYDRAULIC SYSTEMS.
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.

20

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.

5.4.7.

Pipe Bends and Offsets

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.

5.4.8.

Gauge and Bleed Connections

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.

5.4.9.

Mounting of Equipment

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

Hoses shall be to AS1180 and AS3791


Typically hoses are used:

Between moving elements of the equipment,

To facilitate interchange of the equipment,

To suppress the transmission of mechanical vibration or noise,

Where it is more economical to install hoses rather than bend and install tube or pipe for short runs.
Hoses shall be installed such that:

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

21

Hose radii are not to be less than the manufacturers specifications and hoses shall be
installed in a manner which does not place bending or twisting strain on the hose ends
and fittings

They do not rub against other hoses, machinery or structures

If the failure of a hose assembly constitutes a whiplash hazard, the hose assembly
shall be restrained or shielded.

The hose assembly procedure is generally as follows:

Cut hose to the required length,

Pig the hose in BOTH directions until it is clean,

Crimp on the hose fittings,

CAP / PLUG the hose ends to prevent ingress of dirt or foreign matter

5.4.11.

Pipe Support Clamps

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.
Support clamps are to meet the following requirements:

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 terminations shall be supported by a clamp or mounting block.

Under no circumstances shall any pipe supports be welded to the piping.

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.

22

5.4.12.

Cleaning and Inspection before Assembly

Cleanliness during Working


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, REPLUG ALL OPENINGS.
Pipe Welding and De-Scaling Treatment
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.

23

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 manufacturers 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.
Tubes and Hose Assemblies
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.

5.4.13.

Bolted Connections

Ensure that bolted connections are progressively drawn up evenly to avoid distortion of the piping and
hydraulic components.

5.4.14.

Labelling

24

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.

5.4.15.

System Flushing

IT IS STRONGLY ADVISED THAT A COMPANY SPECIALISING IN HYDRAULICS SYSTEMS IS


ENGAGED TO CARRY OUT OR SUPERVISE THE FLUSHING OF HYDRAULIC SYSTEMS.
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.
TEMPORARILY RE-PLUG THE PORTS OF THE COMPONENTS DISCONNECTED.
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.

Ensure bleed hoses and valves are available.

If oil cleanliness samples are required, have suitable clean sample containers from the
nominated testing laboratory ready for sample collection.

5.4.17.

Filling the System

Before filling, all oil bearing parts of the system, in particular oil tanks, filters and pipelines should be
checked for cleanliness.

25

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.

ADDING OIL TO THE SYSTEM IS THE SINGLE BIGGEST CAUSE OF


CONTAMINENTS ENTERING A HYDRAULIC SYSTEM.
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.

WATER SHOULD NOT BE ALLOWED TO INFILTRATE INTO THE SYSTEM.


After filling, all filling points should be tightly sealed.

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 Transmins
requirements.A copy of this form is included in this manual. DO NOT
PROCEED UNTIL THIS FORM IS SIGNED AND APPROVED.
5.4.18.

Flushing the System

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.

26

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.

<OPTIONAL> In some applications, it is desirable to flush the system in the reverse


direction to effect more thorough flushing. If this is required, the hosing at the hydraulic
power pack must be isolated at both ends to allow the hoses to be swapped without
draining the lines. The lines should then be flushed continuously for 20 minutes in the
reverse direction.

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.

<OPTIONAL> It may be a requirement to have the oil cleanliness level confirmed by a


third party laboratory testing. This should be confirmed with the end user. The
selected laboratory should be contacted prior to flushing in order to obtain suitable
clean sample jars of the required volume for the testing.

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.

27

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.

5.4.19.

Bleeding the System

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.

28

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.

5.4.20.

Pressure Testing

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 Transmins 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.
IN THE EVENT OF A WARRANTY CLAIM, TRANSMIN WILL REQUIRE THIS FORM TO BE
PROVIDED AS PROOF THAT THE SYSTEM WAS INSTALLED AND COMMISSIONED CORRECTLY

29

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 10C 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 any signs of gearbox oil leaks

Check for signs of hydraulic oil leaks, BUT DO NOT USE FINGERS,

Check the oil level in the HPU,

Check the HPU filters are not indicating the elements need replacing,

Check the HPU oil cooler matrix is free of debris

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.

6.2.1.

HPU Pre-start Settings

To use the rockbreaker and the HPU for normal operation make sure the HPU and radio transmitter is
set to the following:

HPU emergency stop button:

released

HPU main isolator switch:

on

Mode sector switch:

remote mode

HMI screen:

no alarms

Radio transmitter stop button:

released

Radio transmitter key switch:

key inserted, in on position

6.2.2.

Radio Control HPU Start

To start the HPU:


See 6.2.1 for pre settings on the control panel.

Turn the key to the ON position.

Press the P/PACK START on the radio transmitter once (battery indicator light starts
blinking).

Press the P/PACK START on the radio transmitter again.

The pump starts and the rockbreaker can be moved, using the joysticks on the radio
transmitter.

Refer to Figure 7 for the layout of the radio controller.

31

6.2.3.

HPU shut down

To stop the HPU

Using the remote radio controller, park the rockbreaker in its dedicated parking position
and press the STOP button on the radio transmitter.

At the HPU - In an emergency press the red EMERGENCY STOP button.

Figure 7 - Radio Controllers Layout

6.2.4.

Operating the hammer

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.

DO NOT hammer in one position for more than 30 seconds.

DO NOT attempt to continue hammering after BREAK through occurs or


do not hammer directly on to grizzly bars, steel or concrete structures.
32

When BREAKING or levering of the ROCK is required, ensure to use only


the moil end of the hammer to avoid damage to the hose assemblies and
hammer fittings at the mounting end of the hammer.
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

6.3. HPU Operation


6.3.1.

HPU Control Panel

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.
Power source of the HPU is a 460VAC 3phase mains supply.
The operator interface is integrated into the panel door and consists of the following components:

Main Isolation Switch (Pad-lockable)

Emergency Stop Push Button

Local/OFF/Remote mode selector switch

HMI Panel. The HMI Panel is used to indicate alarms and navigate through the HPU
functions.

6.3.2.

Emergency Stop function

Emergency Stopping is achieved via a safety relay rated to Category 2, AS4024 (EN 954). The relay is
tripped via the emergency stop push button on the front of the control panel. This type of emergency
stop is a single channel monitored type circuit. It is designed to detect faults in the safety system;
however faults may lead to a loss of safety function. In order to guard against loss of safety function, the
emergency stop function shall be periodically operated as part of the maintenance routine. The period of
testing shall be determined by the end user based on the expected frequency of use of the Rockbreaker.
The RESET for the emergency stop is found in the HMI.

6.3.3.

HPU Operating Modes

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.

6.3.4.

LOCAL Mode

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.

6.3.5.

REMOTE Mode

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:

Oil Level Low

Oil Temperature High

Any Emergency Stop button depressed

Motor Circuit Breakers

Pump Motor Thermal Overload

Enable input from client Plant Control System is absent.

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)
Figure 8 - HMI Screens

Screen 1: main.
Line 1: HPU mode information
Line 2: HPU status information
Line 3: oil temperature

Screen 2: pump control / status


Line 1: pump mode information
Line 2: pump status information
Line 3: start/stop (in local mode)

Screen 3: cooling fan control / status


Line 1: cooling fan mode information
Line 2: cooling fan status information
Line 3: start/stop (in local mode)

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)

Screen 5: reset alarms


Line 1: current alarms
Line 2: current warnings
Line 3: reset

Screen 6: alarm & warning log


(shown empty)
Use F1 and F2 to scroll through the list,
F3 to clear the log

Screen 7: access screen 8


Use F1 to get to screen 8

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:

Oil Level Sensor

Oil Temperature Sensor

Hydraulic Pump Motor Thermal Overload

Motor Circuit Breakers

All shutdown devices are arranged for failsafe operation and the associated PLC input must be
energised for the power unit to run.
When tripped, these shutdown devices will cause:

Stop the HPU from running

Display the appropriate alarm message on the HMI

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:

Emergency Stop Tripped

Circuit BREAKER Tripped

Pump Contactor Fail to Close

Fan Contactor Fail to Close

Oil Level Low

Oil Temperature High

Hydraulic Pump Thermal Overload Tripped

38

The following warnings are displayed on the HMI panel. These warnings will not cause the power unit to
shut down:

Oil Temperature Low

Oil Pressure Line Filter Blocked

Return line Oil Filter Blocked

Grease Low

Grease Pump Fault

Oil Heater Circuit BREAKER Tripped

Oil Heater Contactor Fail to Close

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.

6.3.9.

HPU signal interface

Voltage free contacts are provided to indicate the HPU status:

HPU healthy (high = healthy, low = fault)

HPU running (high = running, low = stopped)

Lube pump fault (high = healthy, low = fault)

Oil heater fault (high = healthy, low = fault)

Oil filter blocked (high = free, low = blocked)

6.4. Optional components


6.4.1.

Grease Pump

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.

DO NOT carry out adjustments to the Rockbreaker while the system is


activated .

CAUTION: ENSURE that all motors are switched off and isolated and
that pressure is released before attempting to service hydraulic
components and piping

7.2. Maintenance Schedule


Refer to the Maintenance Schedule at appendix C for the Maintenance Schedule Matrix

7.3. Operating the grease lubrication pump


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

Figure 10 - SL-V Injector Bank (typical)

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.

7.4.1.

Hydraulic Oil

The recommended oil for the HPU and Rockbreaker depends on the operating environment, site
conditions and whether an oil heater is fitted in the HPU tank. Refer to section 11.2 specification for tank
capacity.

CAUTION: Depending on the site, ambient conditions can vary widely


over the course of a year. If an oil heater is not fitted into the HPU tank,
and operating the correct viscosity oil for the ambient temperature must
be used or damage to the pump and valve can occur.
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

Return Filter

Second Change 250 hrs

Filling Filter
Hydraulic Tank
Breather

50 hrs after commissioning

Third Change

500 hrs

Thereafter

500 hrs or when


indicated by filter

When hydraulic oil is replaced


First Change: 500 hrs
Thereafter: 2000 hrs or when hydraulic oil is changed

Slew Gearbox
Breather

First Change: 500 hrs


Thereafter: 2000 hrs or when hydraulic oil is changed
Table 1 - Filtration Replacement Frequency

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. Slew Bearing


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.

Figure 11 - Slew bearing

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).

Check soft spots are correctly positioned.

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

Figure 12 - 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

7.6.7.

Re-positioning of the bearing

If the bearing is to be re-positioned, the unhardened zone (soft spot) must be positioned outside the
main area of load.

The unhardened zone of the slew bearing raceway is identified by a


punched letter S. The S must be positioned outside the main area of
load adjacent to the S marked on the base.

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.
To service or repair the gearbox, please contact Transmin.
Refitting the gearbox is the reverse of removal EXCEPT THAT THE BACKLASH BETWEEN THE
PINION AND SLEW BEARING MUST BE CORRECTLY SET.

7.7.1.

Setting of Backlash

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.
The backlash is correct if it is between

Series 100

0.30 and 0.38 mm.

Series 130

0.35 and 0.43 mm.

Series 160 & 200

0.40 and 0.48 mm.

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.

7.7.3.

Slew Motor

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.

Only qualified electricians are


equipment.

7.7.6.

authorised to service electrical

Oil Cooler Motor

If the oil cooler motor requires replacement or repairs, please contact the Transmin Service Department.

Only qualified electricians are


equipment.
7.7.7.

authorised to service electrical

Hydraulic Pump

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

7.7.8.

Cooling Pump

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.

7.8. QUICK UNLOCK pin system


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)

Park the Rockbreaker in its normal parking position

Adequately support the Rockbreaker around the pivot pin to be removed

Disconnect the hydraulic hoses around the pivot point if necessary

Remove the greasing hose and electrical harness (if fitted).

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

Remove the taper bushes and the pivot pin

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.

The pin retaining bolts are ISO grade 10.9


DO NOT USE A LESSER GRADE

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

Figure 13 - Pivot Pin Components

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.

Figure 14 - Pivot Pin Removal and Installation Tooling (Optional Extras)

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.

8.1. New products


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.

The conditions applicable to the warranty given by Clause (a) are:


(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 Transmins 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 Transmins 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 Customers expense.
(v) Any defective part replaced will become Transmins property and the repaired or new
part will be delivered to the Customers 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 Customers 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 Transmins 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.

8.2. Repaired products


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.

(b)

Failures or damage due to misapplication, abuse, improper installation or abnormal


conditions of operation.

(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.

(e)

Products damaged in shipment or without the fault 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 type

Rockbreaker and Hydraulic power unit

Transmin job reference number

TM4215

Equipment serial number

Refer the front of this manual or the nameplate affixed to


the equipment.

Part number

Refer to appendix B.

Description of part

(Describe part and location)

Quantity of parts required

(Number of parts)

56

10. PARTS LISTS


130 SERIES Rockbreaker ASSSEMBLY
ILLUSTRATION NUMBER: IBR00015
ITEM No.

PART No.

DESCRIPTION

1
2
3
4
5
6
7
8
9
10
11

R601192
R600071
R600801
R600702
R600319
R600766
R600077
R600600
R600625
R601221
R601222

SLEW
GEARBOX & MOTOR
130 SERIES 5m BOOM
130 SERIES 5m JIB
130 SERIES BR3288 HAMMER BRACKET
BOOM CYLINDER
JIB CYLINDER
HAMMER CYLINDEER
HAMMER BR3288
LOCKING VALVE KIT, BOOM
LOCKING KIT, JIB

QTY.
1
1
1
1
1
1
1
1
1
1
1

57

58

SLEW BASE ASSEMBLY 130 SERIES


ILLUSTRATION NUMBER: IPBR00016, IPBR00017, IPBR00018, IPB00019
ITEM No.

PART No.

DESCRIPTION

1
2
3
4
5
6
13
14
18
20
22
23
24
25

R600031
R500077
R601193
R600034
R600638
R600152
R600636
R300878
44873
R600342
R601194
R600831
R600853
R508128

FIXED BASE
BEARING - SLEW
SLEW FRAME
RETAINING PLATE
PINION COVER PLATE
RETAINING PLATE - SPECIAL
ELECTRICAL BOX MOUNTING BRACKET
INDUSTRIAL ENCLOSURE PANEL
GREASE INJECTOR
PINION GREASE TUBE
ROCKBREAKER CONTROL VALVE
SLEW DOOR ASSEMBLY R.H.
SLEW DOOR ASSEMBLY L.H
MOTION CONTROL VALVE

QTY.
1
1
1
5
1
1
1
1
2
1
1
1
1
1

59

60

61

GEARBOX & MOTOR 130 SERIES


ILLUSTRATION NUMBER: IPBR00020 & IPBR00021
ITEM No.

PART No.

DESCRIPTION

1
110
2
3
4
100
101

R600081
R600539
R600082
R600012
R500884
R600538
R500883

GEARBOX ASSEMBLY
BOLT HEX, HD
HYDRAULIC MOTOR
20 TOOTH PINION, 12 MODULE
PINION RETAINING PLATE
HYDRAULIC MOTOR BOLTS
PINION RETAINING PLATE BOLTS

QTY.
1
15
1
1
1
4
3

62

63

5m BOOM ARRANGEMENT
ILLUSTRATION No. IPBR00022 & IPBR00023
ITEM No.
1
2
3
4
5
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
100
101
102

PART No.

DESCRIPTION

R600801
R600189 P01
R600189 P02
R600189 P03
R600189 P04
R600243
R508210
R600186
R600185
R600180
R508202
R600175
R600789
R600558
R502282
R502281
44872

130 SERIES ROCKBREAKER 5m BOOM


PIPE BOOM CYL RH
PIPE HAMMER
PIPE BOOM CYL LH
PIPE HAMMER CYL
SPACER
TAPERED CAP
TAPERED CAP
TAPERED CAP
BUSH
PIN JIB CYLINDER (NOT SHOWN)
PIN JIB END
PIN BOOM CYLINDER (NOT SHOWN)
THREADED ADAPTOR, ELBOW
WASHER DISC LOCK
WASHER DISC LOCK
2 INJECTOR MANIFOLD
THREADED ADAPTOR
THREADED ADAPTOR
FLANGE, SPLIT
FLANGE, SPLIT
INSERT, BLANKING
INSERT, BLANKING
PIPE CLAMP ASSEMBLY
PIPE CLAMP ASSEMBLY
THREADED ADAPTOR
PIPE JIB CYLINDER
BOLT, HEX HD M10x50
CAP SCREW, SOC HD M12x55
CAP SCREW, SOC HD M12x70

R601217

QTY.
1
1
2
1
5
6
2
2
2
12
1
1
1
4
12
6
2
2
4
12
4
12
4
6
16
2
2
2
16
48

64

65

5m JIB ARRANGEMENT
ILLUSTRATION No. IPBR00024
ITEM No.

PART No.

DESCRIPTION

QTY.

1
2
3
4
5
6

R600764
R600763
R600558
R600180
R600179
R508211

PIPE, HAMMER
130 SERIES, 5m JIB
THREADED ADAPTOR, ELBOEW
BUSH
BUSH
TAPERED CAP, HAMMER CYLINDER (NOT
SHOWN)

2
1
2
2
2
2

7
9
10
12
13
14
15
16
17
18
19
20
22
23
101
102
103

R5082010
R508204
R508202
R601212
H200500
H200067
H100006
44871

TAPERED CAP, BOOM END (NOT SHOWN)


PIN, HAMMER CYLINDER (NOT SHOWN)
PIN, BOOM END (NOT SHOWN)
PIPE, HAMMER CYLIDNER
FLANGE
INSERT, BLANKING
PIPE CLAMP ASSEMBLY
INJECTOR MANIFOLD
THREADED ADAPTOR
THREADED ADAPTOR
PIPE CLAMP ASSEMBLY
PIPE CLAMP ASSEMBLY
FLANGE, SPLIT
INSERT, BLANK
BOLT, HEX HD M10x50
CAP SCREW, SOC HD M12x55
CAP SCREW SOC HD M12x70

2
1
1
2
4
4
4
2
2
4
1
4
4
4
4
16
16

66

67

130 SERIES HAMMER BRACKET BR3288 HAMMER


ILLUSTRATION No. IPBR00025
ITEM No.

PART No.

DESCRIPTION

QTY.

1
2
3
4
5
6

R600584
R508204
R600172
R600712
R508211
R508210

130 SERIES BR3288 HAMMER BRACKET


PIN
PIN
FORKED BRACKET
TAPERED CAP
TAPERED CAP

1
1
1
2
2
2

7
8
9
10
11
12
50
51

R508209
R502281
44873
R600558

SET SCREW
WASHER DISC LOCK
3 INJECTOR MANIFOLD
THREADED ADAPTOR, ELBOW
THREADED ADAPTOR
THREADED ADAPTOR
SCREW, HEX HD, M12x45
SCREW, HEX HD M10x50

12
12
1
3
2
3
8
2

68

HYDRAULIC POWER UNIT (HPU) HP1100S


ILLUSTRATION No. IPBR00026, IPBR00027, IPBR00028, IPBR00029
ITEM No.

PART No.

DESCRIPTION

QTY.

1
2
3
4
5
6

42738
R600653
R504484
R500429
R501235
R502839

VALVE, BALL
GAUGE, LEVEL
GAUGE ADAPTOR
TEST COUPLING
BREATHER, AIR
VALVE, BALL

1
1
1
1
1
1

7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41

R505369
R601136
R505497
R402271
R600134
R601112
R600136
R600137
R600138
R600139
R600140
R600324
R600146
R600147
R600148
R601082
R601086
49369
R600144
44875
R402272
R300622
R600911
R501082
R600316
R600323
42852
R501239
R402244
R600145
R402244
R600269
R601020
49374-02
R601137

VALVE, BALL
PRESSURE GAUGE
VALVE, BUTTERFLY
SPACER, SIDE PORTED
DRIP TRAY
MOTOR SUPPORT FRAME
OIL COOLER FRAME
HYDRAULIC OIL RESERVIOIR
ROOF
INSPECTION COVER
ADAPTOR PLATE
SUPPORT BRACKET
TANK OUTLET ADAPTOR
SUCTION PIPE
COOLER SUCTION PIPE
OIL COOLER
MOTOR/PUMP ASSEMBLY
ELECTRICAL CONTROL CABINET
SUPPORT BRACKET, LUBRICATION UNIT
8 L LUBRICATION UNIT
DROP TUBE
TEMP SENSOR
FILLER STRAINER MTG PLATE
FILLER C/W STRAINER
RETURN FILTER GASKET
FILLER STRAINER GASKET
TEST HOSE
IMMERSION HEATER
SWITCH, THERMOSTAT
HEATER COVER
VISUAL INDICATOR
MOUNTING PLATE, ELECTRICAL CABINET
MOUNTING PLATE
NAMEPLATE
FILTER, RETURN

2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1

69

42
43
44
45
46
47
48
49
50
51

R600251
49374-03
R507652
R601207
R601206
R601226
R601238
R601239
43246

FILTER, PRESSURE
AUTOMATIC LUBRICATION PANEL
INLINE CHECK VALVE
GASKET, RETURN FILTER
SPACER PLATE, RETURN FILTER
SPACER BRACKET
PRESSURE PIPE, FILTER INLET
PRESSURE PIPE, PUMP OUTLET
TEST COUPLING
THREADED ADAPTOR

1
1
1
1
1
1
1
1
1
1

70

71

72

130SERIES Rockbreaker REMOTE RADIO CONTROL


ITEM

PART No.

1
2
3

DESCRIPTION

QTY.

R504016/01 Battery
R507736/01 Bellows - Joystick
R507736/03 Carry Belt - Hip

2
2
1

Figure 15 - Radio Control Layout

130SERIES HPU control panel


ITEM No.

PART No.

DESCRIPTION

QTY.

HPU CONTROL PANEL DOOR EQUIPMENT PARTS LIST


1
R300815
ENCLOSURE 1200x800x300
2
R300719
HMI
3
R300773
EMERGENCY STOP BUTTON ASSEMBLY
4
R300770
SELECTOR SWITCH 3 POS
5
R300769
CONTACT BLOCK 1xNO
6
R300766
COUPLING PLATE
7
R300921
HANDLE PADLOCKABLE

1
1
1
1
1
1
1

HPU CONTROL PANEL EQUIPMENT PARTS LIST


1
R300205
MAIN ISOLATOR
2
R300275
CIRCUIT BREAKER 3POLE 160-250A
3
R300430
CONTACTOR 3P 225A 240VAC COIL
4
R300208
CONTACTOR AUXILIARY CONTACT
5
R300431
THERMAL OVERLOAD 3P 160-400A
6
R300432
POWER SUPPLY 24VDC 10A
7
R300211
MOTOR PROTECTION 3p 4-6.3A
R300212
MOTOR PROTECTION 3p 6.3-10A
R300214
CIRCUIT BREAKER 1P 2A DC

1
1
1
1
1
2
1
1
3

73

R300215
R300286

CIRCUIT BREAKER 1P 4A DC
RCD 10A 30mA 2 P

2
2

R300213
R300292
R300410
R300411
R300720
R300721
R300722
R300623
R300231
R300240
R300241
R300238
R300239
R300222
R300225
R300723
R300226
R300227
R300228
R300229
R300276
R300277
R300433

CIRCUIT BREAKER 1P 2A
CONTACTOR 3P 9A 240VAC COIL
RELAY 2 POLE 24VDC
RELAY BASE 2 POLE
CONTROLLER BASE UNIT
CONTROLLER EXPANSION 16IN
CONTROLLER EXPANSION 8OUT
TRANSMITTER TEMPERATURE
AUXILLARY CONTACT MOTOR CB
TERMINAL 2.5mm2 SINGLE STACK
TERMINAL 2.5mm2 DOUBLE STACK
TERMINAL ENDPLATE
TERMINAL ENDPLATE DOUBLE STACK
TERMINAL STOPPERS
TERMINAL BLOCK LABELS
SAFETY RELAY
CABLE DUCT SLOTTED 25x80
CABLE DUCT SLOTTED 40x80
CABLE DUCT SLOTTED 80x80
DIN RAIL 35mm
TERMINAL COVER FOR ISOLATOR
TERMINAL COVERS
TERMINAL COVERS FOR CONTACTOR
TRANSFORMER 460:220 2200VA
AUXILIARY CONTACT CONTACTOR

1
3
2
2
1
1
1
1
2

R300230

1
1
2
1
4

74

75

11. SPECIFICATIONS
11.1. Scope of Supply
Transmins Scope of Supply for the Rockbreaker System comprises the following:

One (1) 130-50-50 Series Rockbreaker

One (1) BR3288 Sandvik Hammer and one blunt tools

One (1) 110kW non-submerged power pack c/w control panel (derated to 97 kW)

One (1) Automatic lubricating systems

One (1) Radio control systems, transmitter and receiver

11.2. Technical Summary and Maintenance Reference Listing


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
Hammer Model

Sandvik BR3288

Hammer Tools

1 x Blunt

Lubrication System

Automatic Greasing System (8L)

Hose stand kit

NA

Increased Slew Rotation

NA

Faster Slew

NA

Greater Slew Torque

NA

Slew Braking Kit

NA

Options / Variations

Electronic Slew Stops


Automation
Surface Treatment

NA

NA
:

Transmin Std System A

76

Colour

Golden Yellow Y14

Boom Pedestal Mounting Surface

Steel

HYDRAULIC POWER UNIT


Power unit Model

HPU1100S

Power unit Motor Size

110 kW

Tank Capacity

600 L

Tank Materials of Construction

Carbon Steel

Frame Materials of Construction

Skid Mounted - Galvanised

Design Working Pressure

350 Bar (Relief)

Pump Flow Rate

240 litres per minute (max)

Pump Type

Variable axial piston pump

Pump Model

Linde HPR

Control Valve

Proportional electric over Hydraulic

Pump Loading Valve

NA

Hydraulic Connections

Various JIC / Code 61 / 62

Oil Cooler

Included (Oaler A-LAC 033-4)

Oil Heater

Yes

Pump Outlet Pressure Gauge

Yes (100mm diameter gauge)

Tank Temperature Gauge

Yes (Included in level gauge)

Tank Level Sight Glass

Yes

Tank Low Oil Level Switch

No

Tank Low-Low Oil Level Switch

Yes

Tank High Oil Level Switch

No

Tank High Temperature Switch

Yes (60 C degrees)

Oil Cooler Inlet and Outlet Temp. G.

No

Hoses

Duffield

Pressure & Return Line Filters

Yes, standard with visual blocked filter


indication and switches. Stauff Filters.

77

Filling Point

Parker

Filter Magnet

No

Cleanliness Level

17/15/12

Breather

Yes, Parker

Magnet Plug in Tank

No

Isolation

Transmin Standard

Cylinder Lock Out Valves

Bucher CFS on boom full


bore, jib full bore and jib annulus

Control Panel

Yes Mounted on Power unit

Motor Starters

Yes

Power unit Start / Stop Operation

By Transmin with PLC Allen-Bradley 1763

Spill Tray

Yes

Additional Hydraulic Test Points

Yes

Additional Requirements

No

Oil Details

Shell Tellus S2 M 32

Surface Treatment

Transmin Std System A

Colour

Galvanised (for HPU frame)


Golden Yellow Y14 (for tank)
Golden Tan X53 ( for hydraulic pipes)
Grey (for electrical control panels)

Power requirements

460VAC 60Hz 3 phase, 110kW (derated)

78

12. REFERENCE DOCUMENTS & DRAWINGS


Client Document
Reference

Transmin Doc
Reference

49243

R600191

49232

49232

Scope of Supply Drawing

49234

49234

General Arrangement

49233

49233

Reach Profile

49244-SH1

49244-SH1

49244-SH2

49244-SH2

49247

49247

Rockbreaker Lifting Details

49248

49248

Transport Diagram

49249

49249

Boom System Hydraulic Schematic

49250

49250

HPU Hydraulic Schematic

49251

49251

Lubrication Schematic

49374-SH1

49374-SH1

Equipment Nameplates & Labels Details

49374-SH1

49374-SH1

Equipment Nameplates & Labels Details

49693

49693

Movement Limit (3D Model)

49401

49401

Rockbreaker & HOU Nameplate & Label


Location Diagram

Document Title
Boom Mounting and Loading Details

Hydraulic Power Unit General


Arrangement 1 of 2
Hydraulic Power Unit General
Arrangement 2 of 2

79

DRAWING No.

REVISION

260
250 CRS
TYP.

5
TYP.

GENERAL NOTES:
1. ALL LETTERING TO BE ENGRAVED BOLD.
2. ALL LETTERING TO BE COLOUR BLACK

5
TYP.

49374-SH1

0
4-HOLES O4.5 THRU'.

70

ROCKBREAKER NAMEPLATE
PART No

49374-01

DRG REF QTY

DESCRIPTION

190 CRS
TYP.

90

ITEM

REMARKS
110

49374

200

12 TEXT
TYP. 3-LINES

45

1.6SHT 260x200 316 S/S


125
140

7 TEXT
TYP. 5-LINES

155
170
185

1:1
170 CRS
TYP.

5
TYP.

350
5
TYP.

170 CRS
TYP.

49374-02

DRG REF QTY


49374

DESCRIPTION

70

REMARKS

1.6SHT 350x180 316 S/S

170 CRS
TYP.

PART No

12 TEXT
TYP.

ITEM

45

90

180

HPU NAMEPLATE

12 TEXT

6-HOLES O4.5 THRU'

105

7 TEXT
TYP. 5-LINES

120
135
150
165

1:1
AUSENCO PROJECT No:
2172-0020
1
0
B
A
REFERENCE DRAWINGS

REV

DATE

BY

DESCRIPTION

APP'D REV

19/06/2012

RK
RK
DB
DB

AS BUILTS
ISSUED FOR CONSTRUCTION
UPDATED TO CLIENT MARK UPS
ISSUED FOR REVIEW

DATE

BY

DESCRIPTION

18/04/2013
18/04/2013
27/06/2012

TOLERANCES TO AS 1100 UNO


NOM DIM MACHINED OTHER
0.5 - 6
0.1
0.3
DH
>6 - 30
0.2
0.5
DH
>30 - 120
0.3
0.8
>120 - 315
0.5
1.2
DH
>315 - 1000
0.8
2.0
DH >1000 - 2000
1.2
3.0
2.0
4.0
APP'D >2000 - 4000

THIRD ANGLE
COPYRIGHT
THIS DRAWING IS THE PROPERTY OF
TRANSMIN PTY LTD FOR WHICH WE
RESERVE ALL RIGHTS INCLUDING THOSE
RELATING TO PATENTS OR REGISTERED
DESIGNS. IT MUST NOT BE REPRODUCED
OR USED OTHERWISE OR MADE
AVAILABLE TO ANY THIRD PARTY
WITHOUT PRIOR PERMISSION IN WRITING.

AUSTRALIAN ENGINEERING WORLDWIDE

35 DENNINUP WAY
MALAGA. W.A. 6090
PH. (08)9249 5755
FX. (08)9249 6116

DRAWN:
DATE:
APP'D:
DATE:

DB
19/06/2012
DH
19/06/2012

CLIENT: HUDBAY PERU


PROJECT: CONSTANCIA PROJECT

SHEET

1:1 UNO

TM4215

JOB NUMBER

ROCKBREAKER
EQUIPMENT NAMEPLATES & LABELS
DETAILS

CHK'D: DH
DATE: 19/06/2012
SCALE:

OF

DRAWING No.

49374-SH1

A1
REVISION

DRAWING No.

REVISION

49374-SH2

GENERAL NOTES:
1. ALL LETTERING TO BE ENGRAVED BOLD.
2. ALL LETTERING TO BE COLOUR BLACK

110

REMARKS
316 S/S

12 TEXT
TYP.

QTY
DESCRIPTION
1 1.6SHT 110x50

4
TYP.

DRG REF
49374

50

PART No
49374-03

34 CRS

ITEM
3

8
TYP.

AUTO LUBRICATION LABEL

55
TEXT CRS

1:1
6 SLOT
TYP.
8
TYP.

160

49374-04

49374

DESCRIPTION
1.6SHT 160x50

REMARKS

12 TEXT
TYP.
4
TYP.

QTY

50

DRG REF

34 CRS

PART No

80
TEXT CRS

8
TYP.

ELECTRICAL CONTROL
PANEL LABEL
ITEM

94
SLOT CRS

316 S/S
1:1
8
TYP.

6 SLOT
TYP.

144
SLOT CRS

8
TYP.

110
55
TEXT CRS

PART No

DRG REF

QTY

49374-05

49374

DESCRIPTION
1.6SHT 110x50

REMARKS

12 TEXT
TYP.
4
TYP.

ITEM

34 CRS

50

RADIO RECEIVER LABEL


316 S/S
1:1

6 SLOT
TYP.
8
TYP.

94
SLOT CRS

AUSENCO PROJECT No:


2172-0020
1
0
B
A
REFERENCE DRAWINGS

REV

DATE

BY

DESCRIPTION

APP'D REV

19/06/2012

RK
RK
DB
DB

AS BUILTS
ISSUED FOR CONSTRUCTION
UPDATED TO CLIENT MARK UPS
ISSUED FOR REVIEW

DATE

BY

DESCRIPTION

18/04/2013
18/04/2013
27/06/2012

TOLERANCES TO AS 1100 UNO


NOM DIM MACHINED OTHER
0.5 - 6
0.1
0.3
DH
>6 - 30
0.2
0.5
DH
>30 - 120
0.3
0.8
>120 - 315
0.5
1.2
DH
>315 - 1000
0.8
2.0
DH >1000 - 2000
1.2
3.0
2.0
4.0
APP'D >2000 - 4000

THIRD ANGLE
COPYRIGHT
THIS DRAWING IS THE PROPERTY OF
TRANSMIN PTY LTD FOR WHICH WE
RESERVE ALL RIGHTS INCLUDING THOSE
RELATING TO PATENTS OR REGISTERED
DESIGNS. IT MUST NOT BE REPRODUCED
OR USED OTHERWISE OR MADE
AVAILABLE TO ANY THIRD PARTY
WITHOUT PRIOR PERMISSION IN WRITING.

AUSTRALIAN ENGINEERING WORLDWIDE

35 DENNINUP WAY
MALAGA. W.A. 6090
PH. (08)9249 5755
FX. (08)9249 6116

DRAWN:
DATE:
APP'D:
DATE:

DB
19/06/2012
DH
19/06/2012

CLIENT: HUDBAY PERU


PROJECT: CONSTANCIA PROJECT

SHEET

1:1 UNO

TM4215

JOB NUMBER

ROCKBREAKER
EQUIPMENT NAMEPLATES & LABELS
DETAILS

CHK'D: DH
DATE: 19/06/2012
SCALE:

OF

DRAWING No.

49374-SH2

A1
REVISION

DRAWING No.

49401

REVISION

1
ITEM

PART No

DRG REF

QTY

ITEM

PART No

DRG REF

QTY

10

49374-01

49374

ROCKBREAKER BOOM SYSTEM - NAME PLATE

DESCRIPTION

REMARKS

40

49374-02

49374

NAMEPLATE - HYDRAULIC POWERUNIT

20

49374-04

49374

ELECTRICAL CONTROL PANEL LABEL

50

49374-03

49374

AUTOMATIC LUBRICATION LABEL

30

49374-05

49374

RADIO RECEIVER LABEL

DESCRIPTION

REMARKS

40
10

50
20

HPU ISO VIEW


1:10
30

ROCKBREAKER ISO VIEW


1:20

AUSENCO PROJECT No:


2172-0020

1
0
A
REFERENCE DRAWINGS

REV

DATE

BY

DESCRIPTION

APP'D REV

20/06/2012

RK
RK
DB

AS BUILTS
ISSUED FOR CONSTRUCTION
ISSUED FOR REVIEW

DATE

BY

DESCRIPTION

18/04/2013
18/04/2013

TOLERANCES TO AS 1100 UNO


NOM DIM MACHINED OTHER
0.5 - 6
0.1
0.3
>6 - 30
0.2
0.5
DH
>30 - 120
0.3
0.8
>120 - 315
0.5
1.2
DH
>315 - 1000
0.8
2.0
DH >1000 - 2000
1.2
3.0
2.0
4.0
APP'D >2000 - 4000

THIRD ANGLE
COPYRIGHT
THIS DRAWING IS THE PROPERTY OF
TRANSMIN PTY LTD FOR WHICH WE
RESERVE ALL RIGHTS INCLUDING THOSE
RELATING TO PATENTS OR REGISTERED
DESIGNS. IT MUST NOT BE REPRODUCED
OR USED OTHERWISE OR MADE
AVAILABLE TO ANY THIRD PARTY
WITHOUT PRIOR PERMISSION IN WRITING.

AUSTRALIAN ENGINEERING WORLDWIDE

35 DENNINUP WAY
MALAGA. W.A. 6090
PH. (08)9249 5755
FX. (08)9249 6116

DRAWN:
DATE:
APP'D:
DATE:

DB
20/06/2012
DH
20/06/2012

CLIENT: HUDBAY PERU


PROJECT: COSTANCIA PROJECT

SHEET

1:1

TM4215

JOB NUMBER

ROCKBREAKER & HPU


NAMEPLATE & LABEL
LOCATION DIAGRAM

CHK'D: GN
DATE: 20/06/2012
SCALE:

DRAWING No.

49401

OF

A1
REVISION

80

13. APPENDICES
A.
B.
C.
D.
E.
F.
G.

Troubleshooting Guide
Spare Parts Lists
Commissioning Records
Maintenance Schedule
Lubrication Schedule
Lincoln Grease pump and injectors
Sandvik Hydraulic hammer

81

A. Troubleshooting Guide
The following sections are intended to provide a guide to help identify problem areas.
The charts are as follows:

CHART 1 - FAULTY OPERATION


CHART 2 - EXCESSIVE NOISE
CHART 3 - EXCESSIVE HEAT
CHART 4 - INCORRECT PRESSURE
CHART 5 - INCORRECT FLOW

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


A
B

C
D

NO MOVEMENT
No hydraulic pressure
Remedy 1, 5, 6 & 7
Worn or Damaged
cylinder
Remedy 3
Mechanical Binding
Remedy 2 & 3
Broken hose
Remedy 3

A
B

SLOW MOVEMENT
Low Flow
Remedy 1,2 & 5
Worn or Damaged
cylinder
Remedy 3

A
B

C
D

ERRATIC MOVEMENT
Erratic pressure
Remedy 1 & 5
Worn or Damaged
cylinder
Remedy 3
Air in Fluid
Remedy 1 & 6
No Lubrication of
Linkage
Remedy 4

REMEDIES

1.
Fluid

may be too cold or should be changed to clean fluid of correct viscosity.


2. Locate bind and repair.
3. Recondition or replace.
4. Lubricate.
5. Pump damaged, check pump and/or replace.
6. Fluid level too low - Fill reservoir to proper level - (* all return lines that enter oil reservoir must
terminate below fluid level)
7. No electric power - check HPU and advise electrician.

83

CHART 2 - EXCESSIVE NOISE

PUMP NOISY
Cavitation
Remedy 1 & 2

Coupling misaligned
Remedy 3 & 5

Air in fluid
Remedy 2
Pump worn or damaged
Remedy 5

ELECTRIC MOTOR NOISY


RELEIF VALVE NOISY
A Motor worn or damaged A Setting too close to
operating pressure or to
Remedy 5
another relief valve
setting
Remedy 4
B Coupling misaligned
B Worn poppet and seat
Remedy 3 & 5
Remedy 5

REMEDIES
1. Any or all of the following:

Install clean filters


Clean clogged inlet line
Clean reservoir breather vent
Change system fluid

2. Any or all of the following:

Tighten leaky inlet connections


Fill reservoir to proper level -(* see note on Chart 1)
Bleed air from system
Replace air breather

3. Align unit to within 0.1mm parallel alignment and check condition of seals and bearings.
4. Check with pressure gauge and adjust to correct pressure
5. Recondition.

84

CHART 3 - EXCESSIVE HEAT

PUMP HEATED
A

Air in fluid
Remedy 2

Excessive load
Remedy 3

Cavitation
Remedy 1
Fluid heated
Remedy 1
Pump worn or damaged
Remedy 4

D
E

ELECTRIC MOTOR
HEATED
Motor worn or damaged A
Remedy 4 & 6
Excessive load
Remedy 3

C
D
E

FLUID HEATED
System pressure too
high
Remedy 1 & 5
Relief valve or valves
constantly blowing
Remedy 4
Fluid dirty or low level
Remedy 5
Incorrect fluid viscosity
Remedy 5
Faulty fluid cooling
system
Remedy 4
Worn Pump, valve,
motor, cylinder or other
component
Remedy 4

REMEDIES
1.

Any or all of the following:

2.

Any or all of the following:

3.

Fill reservoir
Install clean filters
Clean clogged inlet line
Clean air breather
Change system fluid

Tighten leaky inlet connections


Fill reservoir to proper level - (* see note on Chart 1)
Bleed air from system

Align unit to within 0.1mm parallel alignment and check condition of seals and bearings.

Locate mechanical binding


Check for work load in excess of circuit design

4. Any or all of the following:

Check relief valve setting is correct.

Reduce load to specification

85

Replace or recondition

5. Change filters and also system fluid if improper viscosity.

Fill reservoir to proper level -(* see note on Chart 1)

6. Check voltage supply to motor.

86

CHART 4 - INCORRECT PRESSURE


NO PRESSURE
A

No flow
Remedy 1, 2,
3&5

LOW PRESSURE
A

ERRATIC
PRESSURE
Air in fluid
Remedy 2

Pressure relief
valve blowing
Remedy 1, 2 & 4
Excessive
external leakage
Remedy 2 & 5

Worn relief
valve
Remedy 5

Relief valve stuck


open
Remedy 5

Contamination
in system
Remedy 1
Worn pump or
cylinder
Remedy 5

EXCESSIVE
PRESSURE
Relief valve
maladjusted
Remedy 4
Worn or
damaged relief
valve
Remedy 5

REMEDIES
1. Install clean filters and check fluid level.
2. Any or all of the following:

Tighten leaky inlet connections


Fill reservoir to proper level - (* see note on Chart 1)
Bleed air from system

3. Check rotation of motor.


4. Adjust pressure.
5. Recondition or replace.

87

CHART 5 - INCORRECT FLOW

NO FLOW
Pump not receiving fluid
Remedy 1
Pump drive coupling
sheared
Remedy 3
Pump drive motor turning
in the wrong direction
Remedy 7
Directional control set in
wrong position
Remedy 6

LOW FLOW
Flow control set too low
or failed to open
Remedy 4
Relief or unloading
valve set too low
Remedy 4 & 5
External leak in system
Remedy 2

EXCESSIVE FLOW
Flow control set too high
Remedy 4

Worn Pump, valve,


motor, cylinder or other
component
Remedy 5

Entire flow passing over


relief valve
Remedy 4
Unloading valve failed to
close
Remedy 4, 5 & 8
Damaged pump
Remedy 3

REMEDIES

1. Any or all of the following:

Make sure suction line valve is open


Clean clogged inlet line
Replace and align coupling
Fill reservoir to proper level

2. Tighten leaky connections, bleed air from system.


3. Check for damaged pump or pump drive, replace and align coupling.
4. Adjust to proper setting.
5. Overhaul or replace.
6. Check position of manually operated controls.
7. Reverse rotation.
Check electrical connection and coil.

88

B. Spare Parts Lists

89

OPERATING AND COMMISSIONING SPARES


130 SERIES TRANSMIN ROCKBREAKER BOOM 12 MONTHS OPERATION
ITEM

DESCRIPTION

PART NO

RECOMMENDED
QUANTITY

UNIT COST A$

TOTAL PRICE A$

Slew Gearbox Breather

R600282

$ 128.00

$ 256.00

Seal Kit 200mm Hydraulic Cylinder

R600807

$ 428.00

$ 856.00

Seal Kit 180mm Hydraulic Cylinder

R508155

$ 360.00

$ 720.00

Seal Kit 150mm Hydraulic Cylinder

R508175

$ 325.00

$ 650.00

*5

Solenoid Coil Non Proportional ( Hammer Fire )

R600495

$ 425.00

$ 425.00

*6

Solenoid Coil Proportional ( Cylinder & Slew


Functions )

R600494

$ 468.00

$ 468.00

Motor Slew

R600082

$ 1,983.00

$ 1,983.00

*6

Relief Valve

R600277/220

$ 207.00

$ 207.00

*7

Cartridge Relief Valve

R501238

$ 184.00

$ 184.00

*8

Solenoid Poppet Relief Valve

R501234

$ 254.00

$ 254.00

Test Coupling

R500429

$ 47.00

$ 188.00

10

Hose Assembly Hammer - Pressure

R600634/H20

$ 575.00

$ 1,150.00

11

Hose Assembly Hammer - Return

R600634/H21

$ 447.00

$ 894.00

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 )
One of each item marked * required for commissioning

90

ON SITE INSURANCE SPARES FOR


130 SERIES TRANSMIN ROCKBREAKER BOOM
ITEM

DESCRIPTION

PART NO

RECOMMENDED
QUANTITY

UNIT COST A$

TOTAL PRICE A$

Solenoid Relief Valve

R501234

$ 254.00

$ 254.00

Cartridge Relief Valve

R501238

$ 184.00

$ 184.00

Hydraulic Motor - Slew

R600082

$ 1,983.00

$ 1,983.00

200 mm Dia. Hydraulic Cylinder - Boom

R600766

$ 23,821.00

$ 23,821.00

180mm Dia. Hydraulic Cylinder - Jib

R600077

$ 22,477.00

$ 22,477.00

150mm Dia. Hydraulic Cylinder - Hammer

R600600

$ 21,646.00

$ 21,646.00

Pin 80mm Dia. x 166mm

R508204

$ 466.00

$ 932.00

Pin 100mm Dia. x 198mm

R508202

$ 597.00

$1,194.00

Pin 100mm Dia. x 548mm

R600172

$ 1,763.00

$ 1,763.00

10

Pin 110mm Dia. x 208mm

R600789

$ 660.00

$ 1,320.00

11

Pin 120mm Dia. x 548mm

R600175

$ 1,885.00

$ 1,885.00

12

Pin 120mm Dia. x 588mm

R600174

$ 2,402.00

$ 2,402.00

13

Bush Hardened 120mm x 150mm x 100mm

R600180

$ 988.00

$ 3,952.00

14

Bush Hardened 100mm x 130mm x 80mm

R600179

$ 862.00

$ 1,724.00

15

Tapered Cap 120mm ID

R600186

$ 428.00

$ 1,712.00

16

Tapered Cap 110mm ID

R600185

$ 415.00

$ 1,660.00

17

Tapered Cap 100mm ID

R508210

$ 368.00

$ 1,472.00

18

Tapered Cap 80mm ID

R508211

$ 338.00

$ 1,352.00

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
ITEM

DESCRIPTION

PART NO

RECOMMENDED
QUANTITY

UNIT COST A$

TOTAL PRICE A$

21

Washer - Disc Lock M12

R502281

42

$ 4.50

$ 189.00

22

Washer - Disc Lock M16

R502282

12

$ 5.50

$ 66.00

23

Bearing 80mm Dia.

R508172

$ 177.00

$ 354.00

24

Bearing 100mm Dia.

R508152

$ 318.00

$ 636.00

25

Bearing 110mm Dia.

R600791

$ 441.00

$ 882.00

26

Circlip - 80mm Bearing

R508176

$ 14.00

$ 28.00

27

Circlip - 100mm Bearing

R508156

$ 33.00

$ 66.00

28

Circlip 110mm Bearing

R600790

$ 39.00

$ 78.00

29

Valve Slew Motion Control

R508128

$ 1,646.00

$ 1,646.00

30

Slew Gearbox Assembly

R600081

$ 14,225.00

$ 14,225.00

31

Oil Bottle Gearbox

R600281

$ 462.00

$462.00

32

Breather Assembly Gearbox

R600282

$ 128.00

$128.00

33

Level Gauge Gearbox Oil Bottle

R600280

$ 176.00

$ 176.00

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 )

93

RECOMMENDED ON SITE SPARES FOR


SANDVIK BR3288-020 HAMMER
ITEM

DESCRIPTION

PART NO

RECOMMENDED
QUANTITY

UNIT COST A$

TOTAL PRICE A$

1.

Lower Tool Bush

155206

$ 2,369.00

$ 2,369.00

2.

Top Buffer

154317

$ 876.00

$ 876.00

3.

Side Buffer

155438

$ 492.00

$ 984.00

4.

Tool Retaining Pin

153235

$ 625.00

$ 1,250.00

5.

Tool - Chisel

881

$ 2,090.00

$ 8,360.00

6.

Tool Blunt

884T2

$ 2,190.00

$ 8,760.00

7.

Wear Plate

162598

$ 837.00

$ 1,674.00

8.

Wear Plate

162597

$ 1,155.00

$ 2,310.00

9.

Retaining Pin

155553

$ 265.00

$ 265.00

10.

Plug

104530

$ 186.00

$ 372.00

11.

Retaining Ring

153236

$ 29.00

$ 29.00

PLEASE NOTE: - All prices quoted are Ex-works Transmins factory, Malaga, Western Australia
All prices quoted remain valid until 30th December 2012 - (GST Not Included)

94

COMMISSIONING SPARES
110KW ROCKBREAKER POWERPACK
ITEM

DESCRIPTION

PART NO

RECOMMENDED
QUANTITY

UNIT COST

TOTAL PRICE

Element - Pressure Filter

R600252

A$
$ 516.00

A$
$ 516.00

Element - Return Filter

R600254

$ 446.00

$ 446.00

Breather Hydraulic Tank

R501253

$ 328.00

$ 328.00

Pump Loading Solenoid ( Non Proportional )

R505476

$ 467.00

$ 467.00

PLEASE NOTE: - All prices quoted are Ex-works Transmins 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
ITEM

DESCRIPTION

PART NO

RECOMMENDED
QUANTITY

UNIT COST A $

TOTAL PRICE A $

Battery

R504016/01

$ 356.00

$ 712.00

Bellows - Joystick

R507736/01

$ 144.00

$ 288.00

Carry Belt - Hip

R507736/03

$ 424.00

$ 424.00

PLEASE NOTE: - All prices quoted are Ex-works Transmins 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
ITEM

DESCRIPTION

PART NO

RECOMMENDED
QUANTITY

UNIT COST A$

TOTAL PRICE A$

Hydraulic Cylinder Tools


1

Spanner 200mm Dia. Piston Lock Nut

R601140

$ 330.00

$ 660.00

Spanner 180mm Dia. Piston Lock Nut

R508158

$ 320.00

$ 640.00

Spanner 150mm Dia. Piston Lock Nut

R508178

$ 310.00

$ 620.00

Spanner 200mm Dia. Piston

R601139

$ 295.00

$ 590.00

Spanner 180mm Dia. Piston

R500866

$ 285.00

$ 570.00

Spanner 150mm Dia. Piston

R501297

$ 275.00

$ 550.00

ERP1

$ 3,350.00

$ 3,350.00

Pivot Pin Removal / Installation Tools


7

Power Pack - Ram and Pump Assembly

Adaptor - Pin Puller

R501029

$ 524.00

$ 624.00

Rod Assembly ( suits R501029 )

R501168

$ 65.00

$ 130.00

10

Adaptor 80mm Dia. Pivot Pin

R501026

$ 235.00

$ 235.00

11

Adaptor 100mm Dia. Pivot Pin

R501167

$ 245.00

$ 245.00

12

Adaptor 110mm Dia. Pivot Pin

R501182

$ 255.00

$ 255.00

13

Adaptor 120mm Dia. Pivot Pin

R501169

$ 265.00

$ 265.00

R501254

$ 765.00

$ 765.00

Hydraulic Test Equipment


14

Test Kit Box Pressure Gauges ( 3 Gauge Box )

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-

PRECOMMISSIONING AND COMMISSIONING RECORD


HYDRAULIC SYSTEM
Document No.

: _________________________

Revision

: _________________________

Contract No.

2172-0020

Project

: Hudbay Peru Rockbreaker

Capital Job No.

: TM4215

Site

: Constancia Project

Description

: Hydraulic Power Unit (HPU), and


Site-Run Piping and Hosing

Area / Building : _______________________________

A)

NAMEPLATE CHECK

Hydraulic Power Unit

ME-316

Transmin Serial Number

3111-LU-002

Client Equipment Number

Power Pack Manufacturer:

Transmin Pty Ltd

Power Pack Weight:

DRY 2630KG WET 3200KG (approx)

Power Pack Model Number:

HP1100S

Hydraulic Pump Design Flow Rate:

240 litres per minute (Variable)

System Pressure Relief Valve Setting:

350 Bar

Oil Level in Reservoir Full:

______________

Electric Motor Nameplate Information

Manufacturer:

TECO

Installed Power:

110kW (derated to 97 kW)

Speed:

1780 RPM

Frame Size:

D280S/M

Full Load Current:

164A

Voltage and Frequency:

460V 60HZ

Take multiple date stamped photos of installation.

______________

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-

B)

SYSTEM FLUSHING, BLEEDING AND PRESSURE TESTING


System Flushing is to be completed in accordance with procedure outlined in the Installation, Operation and
Maintenance Manual where applicable.

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.
:
____________________

Hydraulic oil tank filled from clean, new drums.

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

Oil Level in Reservoir Full

____________________

Grease tank filled from clean, new drums.

____________________

Correct Grease grade used as per Transmin specifications. Note if different to Transmin specifications
Transmin must approve the grease in writing.
:
SHELL ALBIDA HDX2

Grease Level in Reservoir Full

____________________

Carry out direction of rotation test See section C)

____________________

System Flushed as per procedure in Manual

____________________

____________________

YES / NO / NA

**Only do above if contaminates were introduced during install. All parts are cleaned and sealed prior to
dispatch.**

No Signs of Leaks anywhere in the System

____________________

Purge air from load sensing line from power pack test point. :

____________________

Purge air from load sensing line from control valve test point. :

____________________

Test grease system is operational and supplying adequate grease.:

____________________

Take multiple date stamped photos of installation.

____________________

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-

C)

DIRECTION ROTATION CHECKS

Motors terminated and approved / ready for Service.

____________________

All relevant site electrical check sheets completed.

____________________

Client Representative Approval and Acceptance


Name : ______________________

Signature

______________________ Date : _________________

Check Emergency stops operate

YES / NO

(If NO, do not proceed)

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


Motor
Pump
Cooler Fan motor (if
fitted)

Confirmed (YES / NO)

NOTE: Directions are when viewed from Non-Drive end of motor


CLOCKWISE
COUNTER CLOCKWISE

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)
: ______________

Take multiple date stamped photos of installation.

______________

Complete Section B).

______________

CLIENT APPROVAL AND ACCEPTANCE OF COMMISSIONING RECORD


Transmin Representative Sign-off
Name : ______________________

Signature

______________________ Date : _________________

______________________ Date : _________________

Client Representative Approval and Acceptance


Name : ______________________

Signature

Client representative to retain a photo copy of commissioning record.

Transmin representative to retain the original commissioning record.

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-

PRECOMMISSIONING AND COMMISSIONING RECORD


ROCKBREAKER BOOM

Project

:Hudbay Peru Rockbreaker

Site

: Constancia Project

Document No. :
Revision
:
Contract No.
:
Transmin Job No. :
Description
:

Area / Building :_______________

A)

_____________________
_____________________
2172-0020

TM4215
Rockbreaker boom assembly

NAMEPLATE CHECK

Rockbreaker Boom Assembly

Hammer

RB-118

Transmin Serial Number

3111-BK-001

Client Equipment Number

OEM Serial Number

Client Equipment Number

Take multiple date stamped photos of installation.

______________

Hydraulic power pack Checklist completed, signed and sighted:

B)

YES / NO (If NOT, do not proceed)

PRE-START CHECK

What is rockbreaker base being attached to?

STEEL / CONCRETE

STEEL STRUCTURE

Slew bearing soft spot is stamped.

: YES / NO / NA

Slew bearing soft spot is installed in correct location.

: Correctly installed

Confirm bolt spacer has been fitted to slew base hold bolt.
do not proceed)

Confirm hold down bolts have all been torque to spec:

YES / NO (If NOT,

YES / NO (If NOT, do not proceed)

CONCRETE FOOTING
Confirm grout spacers have been fitted and levelled.

: YES / NO (If NOT, do not proceed)

Slew bearing soft spot is stamped.

: YES / NO / NA

Slew bearing soft spot is installed in correct location.

: Correctly installed

Confirm non shrink grout has fully cured.

Confirm M36 grade 8.8 slew base hold down studs have all been torque to spec:
do not proceed)

YES / NO (If NOT, do not proceed)


YES / NO (If NOT,

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

All hydraulic cylinders in good condition. (INSPECT ROD AND BARREL FOR SIGNS OF IMPACT)
: YES / NO (If NOT, do not proceed)

YES / NO (If NOT, do not proceed)

C)

Take multiple date stamped photos of installation.

______________

PROTECTION DEVICES, GUARDING AND OBSTRUCTIONS


Ensure all electrical and control devices have been fitted and tested prior to proceeding:

Control Valve solenoids

: Installed and Secure Electrical Installation Approved

Slew Proximity Sensors (optional)

: Installed and Secure Electrical Installation Approved

Control System Sensors (optional)

: Installed and Secure Electrical Installation Approved

Control System (optional)

: Installed and Secure Electrical Installation Approved

Cylinder Load holding Devices (optional)

: Installed and Secure

Slew Motor Braking Valve (optional)

: Installed and Secure

Guarding Motors, fans, inspection cover on pump bell housing


& pinion guard.
: Installed, Secure and confirmed as adequate

Obstructions

: Moving parts clear of structures, guards and adjacent


equipment.

All isolations removed.

: YES / NO (If NOT, do not proceed)

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. :

Take multiple date stamped photos of installation.

YES / NO (If NOT, do not proceed)

______________

Protective Devices, Guarding and Obstructions checked by:


Name: ____________________

Signature: ___________________

Date: ______________

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 limits are operating correctly.


do not proceed)

YES / NO (If NOT,

Check rockbreaker, power pack & interconnecting tube work for any leaks
do not proceed)

YES / NO (If NOT,

______________

CLIENT APPROVAL AND ACCEPTANCE OF COMMISSIONING RECORD


Transmin Representative Sign-off
Name : ______________________

Signature

______________________ Date : _________________

______________________ Date : _________________

Client Representative Approval and Acceptance


Name : ______________________

Signature

Client representative to retain a photo copy of commissioning record.

Transmin representative to retain the original commissioning record.

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

MaintenancePeriod

SubSystem

Activity

Afterfirstdayof
operation

Boom

HPU
All

TightenallM36basemountingboltsto2300 Nil
Nm
TightenallM24hammertopplatemounting Nil
boltsto640Nm
ChangeHydraulicOil
Fillerfilter
Checkforhydraulicleaks

HPU

1stchangepressureandreturnfilters

Boom

Inspectallpivotpinsexternallyandcheck
lockingscrewsfortightness
Inspecthydrauliccylinderglandsandfittings
forleaks
Checkallpointssuppliedbytheautomatic Nil
pivotgreaserarebeinggreased.

50hrsafter
commissioning
40hoursorweekly

Lubrication

HPU

Hammer

100hours

150hoursorMonthly

Drainslewgearbox/es,flushandrefill

All

Physicallycheckfastenersaretorqued
correctly:
pins
fixedbase
hammer
slewframe
Visuallycheckallotherfastenersforsignsof
looseconnections
Inspectallstructuralfeaturesfordamage

Hammer
Hydraulics

Pressure&Return
FilterElement

Consumeables SpecialTools
Remarks
required
Required
Nil
Torque
Wrench
Nil
Torque
Wrench
asrequired
Nil

Tightenfittingsorreplacepartsas
required
Nil

Freshgreaseshouldbeevidentat
allpivotpoints

Checkhydraulicpump,filters,tank,
hydrauliclinesandfittingsforleaks.
Checkthesepartsfortightness
Performhammermaintenanceasdescribed
inhammerinstructionmanual

Boom

Boom

SparePartsRequired

Torque
Wrench

Drainoilwhenhot
23L(nom)Filltomidpointof
sightglass
DONOTtightentheslewbearing
socketheadcapscrewswhichhas
beenfactoryfittedwithloctite.

Tightenanyloosefasteners

Checktheslewgearboxoillevel.Ifmorethan
1litre(~5%)requiredfortopup,thencheck
forleaks
Checkthehammertoolshankandtoll
bushingsforwear
Checktheconditionofallhydrauliclines

DONOTmixoilsofdifferenttypes
orgradeevenofthesamemake

Replaceifdamaged
Tightenfittingsorreplaceif
necessary

Checkforleakinghydraulicfluid
250hours

HPU

2ndchangepressureandreturnfilters

Pressure&Return
FilterElement

Nil

Nil

DocReference

Consumeables SpecialTools
Remarks
DocReference
required
Required
Nil
Subsequent,filterchangesat500
hrsintervalsorwhenindicatedby
filtergauge
Nil
Nil

MaintenancePeriod

SubSystem

Activity

SparePartsRequired

500hoursorQuarterly

HPU

3rdchangepressureandreturnfilters

Pressure&Return
FilterElement

ChangeHydraulicTankBreather

HydraulicTank
Breather
SlewGearboxBreather Nil

ChangeSlewGearboxBreather

Installation
Piping
1000hoursorsixmonthly Electrical
Boom

2000hoursorannual
servicing

Boom

Boom
HPU

Nil

Subsequent,filterchangesat
2000hrsintervalsorwhen
indicatedbyfilter

Checkforleaks
GreaseHPUMotorBearings
Checkslewdrivebacklash
Removepivotpinstoexaminewearonpins
andbushes
TightenallM24hammertopplatemounting Nil
boltsto640Nm
Drainslewgearbox/es,flushandrefill

27gofMobilPolyrexEM103
Adjustifnecessary

Nil

TECOTechnicalCatalogue

Torque
Wrench
Drainoilwhenhot
23L(nom)Filltomidpointof
sightglass

TightenallM36basemountingboltsto2300 Nil
Nm
Changehydraulicoil
FillerFilter
Cleantheinsideofthereservoirthoroughly

Nil

Torque
Wrench

Changeallfilters

Returnfilter
Pressurefilter
Fillingfilter
Hydraulictank
breather
Slewgearbox
breather

nil

nil

Changefillingfilter

fillingfilter

Nil

nil

Changehydraulictankbreather

HydraulicTank
Breather

Nil

Nil

Rockbreakermustbeparkedin
standardparkingpostion

RoutineInterval
Whenhydraulicoilis
replaced

HPU

Boom

Drainslewgearbox/es,flushandrefill

every500hrs

HPU

changepressure&returnfilters

every2000hrs

HPU

changehydraulictankbreather

every4500hrs

Electrical

GreaseHPUMotorBearings

Drainoilwhenhot
23L(nom)Filltomidpointof
sightglass
Pressure&Return
FilterElement
HydraulicTank
Breather

Nil

Nil

Nil

Nil
27gofMobilPolyrexEM103

MotorTechnicalCatalogue

E. Lubrication Schedule

101

Confidential

15/06/2012

Page 1

CLIENT: HUDBAY Peru

DOCUMENT REF: 4215-LBS-01


DATE: 15-Jun-12

PROJECT: Constancia Rock Breaker

REVISION: A

CONTRACT NO.: 2172-0020

LUBRICATION SCHEDULE
EQUIPMENT No.

DOCUMENT:4215-LBS-01

SPECIFIC OIL / GREASE

INITIAL LUBRICATION
QUANTITY (EACH)

MAINTENANCE QUANTITY (EACH)

Gearbox Oil

TBC

SHELL OMALA EP

23 litres

23L (nom) - Fill to mid point of sight glass

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

ITEM DESCRIPTION

MODEL NUMBER

MAINTENANCE PERIOD

First change - 100 hours,

Thereafter - 2000 hours or Annually

COMMENTS

Further details will be available from the IOM once complete

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

With Follower

JULY 2009

Without Follower

Form 404034

Section

- C8

Page

- 321

Electric Operated Centro-Matic Pump P653S

Table of Contents
Page
Introduction
Explanation of Symbols Used ..................................................3
Users 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
"
 #
 $

Acknowledging a Fault............................................................19
Programming the Pump.........................................................20
Review of Pump Parameters...................................................25
% &  
!
'   
 ($!
'   
 ()$!*
+$#

(-7

8:
 #
$-
List of Lubricants.....................................................................32
Dimensions .............................................................................35
 
   .........................................................39
Mounting Template.................................................................40
Troubleshooting Guide.........................................................41
Parts List...............................................................................42

Page Number - 2

Form 404034

Electric Operated Centro-Matic Pump P653S

Introduction
Explanation of Symbols Used

Users 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:
1. The pump/system shall be operated only for the intended
use (see next chapter Safety Instructions) and its design
& 
&V$  
 ($
2. The pump/system shall be operated only if it is in a proper
functioning condition and if it is operated in accordance with
the maintenance requirements.
3. The operating personnel must be familiar with this Owner
Manual and the safety instructions mentioned within, and
observe these carefully.
The correct installation and connection of tubes and hoses, if

 V^   
 Y 
&_  V 

Lincoln Industrial Technical Services will gladly assist you with
any questions pertaining to the installation.

Safety Instructions
Structure of safety instructions:
8

$
8
#  <
8
 
=

8
  

8
><
?  
The following pictograms are used in this manual and are com8
bined with corresponding signal words:

Environmental Protection
8)%%@%B
8)C%B
8')JN

8)%%@%B
8)C%B
8')JN

8B%@
8:BJ%)%

The signal words give the seriousness of danger if the follow8


ing text is not observed:
ATTENTION refers to faults or damages on machines.
)C%B(
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NOTE indicates improved operation of the device.
IMPORTANT indicates special operating features of the de8
vice.
Example:
ATTENTION!
When making use of other than the tested
spare parts, serious damage may affect
your device.
Therefore, for the operation of your device
always use original parts made by Lincoln
Industrial.

Waste (e.g. used oil, detergents, lubricants) must be disposed


of in accordance with relevant environmental regulations.

Service
The personnel responsible for the handling of the pump/sys8

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assistance, training, etc. Please contact the Technical Service
department for assistance.
In the event of inquiries pertaining to maintenance, repairs
 
Y<` $ 

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Technical Services to clearly identify the components of your
pump/system.
Therefore, always indicate the part, model and series
number.

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manual:
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Listing of applicable statements
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1. Determination of the number or sequence of contents
[   



Form 404034

Page Number - 3

Electric Operated Centro-Matic Pump P653S

Safety Instructions
Appropriate Use
%&
 
8:
$jz-#&V   (
the automatic lubrication of commercial vehicles, industrial,
construction and agricultural machines and wind power plants.
The P653S pump has been designed for intermittent opera8
tion and is not suitable for continuous operation. The pump is
capable of supplying lubricants up to NLGI # 2 grades. (see
!( 
( $$ |
Misuse
Any use of the P653S pump that is not expressly mentioned
in this User Manual will be regarded as misuse. If the P653S
$ 
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&
&  Y
any claim for warranty or liability will be null and void.

Regulations for Prevention of Accidents


To prevent accidents, observe all city, state and federal safety
regulation of the country in which the product will be used.

General Safety Instructions


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CAUTION !
(  W$
 $ 8
curs as a result of inappropriate operation,
(e.g. if the safety instructions are ignored
or resulting from an incorrect installation
of the P653S pump), no claims or legal
actions may be taken against Lincoln
Industrial
Exclusion of Liability
The manufacturer of the P653S pump will not accept any li8
ability for damages caused by:
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    (
&$
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the use of contaminated lubricants
Z
the use of greases which are not or only conditionally
pumpable by P653S pump
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inadequate disposal of used or contaminated lubricants
as well as of components that have been in touch with
lubricant
Z
 
& $ 
 (
&
$ $ 

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the use of unapproved parts
Z
operation without adhering to the minimum pause time
and respectively the maximum lubrication time (see chap8
ter Technical Data)

Pump P653S is designed for safe operation.


Incorrect use may result in bearing damage caused by
poor or excessive lubrication.
P653S pump with follower can be mounted vertically,
& 
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Pump without the follower should be mounted vertically
upright only.
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8

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Install the components of the P653S pump in such way

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pump reservoir.
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&

no air has been trapped under the follower and pump is


pumping lubricant.

Operation, Maintenance and Repair


WARNING!
(  
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repair on the P653S pump, make sure
that all lubrication lines of the carrier unit
 
Repair
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&   


personnel who are familiar with the instructions.
Operation/Maintenance
Pumps P653S:
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8
ments under follower plate.
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operate automatically. However, a regular check (approx.
every 2 days) should be made to ensure that lubricant is
pumped to all lubrication points.
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.

Page Number - 4

Form 404034

Electric Operated Centro-Matic Pump P653S

Operation, Maintenance, and Repair


(continued)

Installation
Z

WARNING!
Pump P653S must be installed by
`  %&  
 (

&!7)$
V   
to the National Electrical code. Before
installing or working on the pump,
disconnect and lock out the incoming
power.

WARNING!
Failure to observe the safety instruc8
tions, (e. g. touching electrically charged
parts when the pump is opened, or
improper handling of the pump P653S)
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&% & 

are exceeded, the device may overheat.
It may damage the pump P653S and
thus impair the electric safety.
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nel who are familiar with the instructions.
Defective printed circuit boards should be appropriately
packed and returned to the factory.
CAUTION!
Electric Voltage!
In the case of pumps where grease is
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in.
CAUTION!
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($
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your hand into the open reservoir while
pump is running!
ATTENTION!
Risk of bursting if the reservoir is
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means of pumps with a large delivery
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mark.

Any safety equipment already installed on the vehicle:


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the system and must be replaced afterwards.
Use only original Lincoln spare parts or parts approved by
Lincoln.
IMPORTANT
Adhere to:
8
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&
vehicle manufacturer with regard to all
drilling and welding procedures.
8
& $ $$ 
 
between the holes and the upper/lower
rim of the frame or between two holes.
IMPORTANT
Route supply lines professionally.
Firmly bolt together any components that
VW



Installation and Maintenance of Hydraulic


Hoses
ATTENTION!
Operational safety of the P653S pump
can only be ensured in the case of a pro8
fessional installation and maintenance of
the hose lines. Make sure to observe the
following recommendations!

Lubrication hose lines


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must not rub against metal components or edges
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are to undergo regular visual checks and must be ex8
changed in the case of wear (at the latest 2 years after
installation)
Pay attention to non-linear installations to allow for a
larger bending radius as possible. Avoid kinks. In constricted installation conditions use pipe elbow unions to
avoid the danger of kinking behind the hose socket. Use
high pressure hydraulic hose for lubrication lines.

CAUTION!
Do not use the pump in potentially explo8
sive applications.

Form 404034

Page Number - 5

Electric Operated Centro-Matic Pump P653S

Description
Pump with Follower Plate

11

jz-#$   (  #|


8
Matic type lubrication systems. The pumps integrated design
   $ 



8:

lubrication systems:
8
controller to program and monitor lubrication cycle
8
choice of internal pressure switch or internal pressure
transducer
8
internal vent valve
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
8
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$(!< ( 

  
medium and small mobile construction equipment. Pump can
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Pump without Follower Plate

$(!7!-7)<  V 
  
stationary industrial type of applications requiring lubrication
(
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Pump basic model can be supplied with follower plate or
without follower plate. Follower plate is recommended in
stationary industrial type applications with heavy consistency
greases (NLGI #1 and #2) and for pumps used at low
temperatures applications in all installations.

 

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can lubricate more than 35 bearings.
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that are appropriate for the programmed/set
system pressure.

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Page Number - 6

Pump P653S
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pumps greases up to NLGI 2 (per approved list) at

$
($87"
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develop maximum pressure up to 3,500 psig (240 bar)
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pressure transducer.
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Electrical connection
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cable is provided by installer.
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For mobile applications P653S pumps are equipped with
 
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connector.
Form 404034

Electric Operated Centro-Matic Pump P653S

      


Code example
p

P653S - 4

F 8 24 - 2A - AS06

Pump
p model,, basic
     

4 = 4L, transparent plastic
8 = 8L, transparent plastic
15 = 15L, transparent plastic
20 = 20L, transparent plastic
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
Electrical cord and connections
1A DC;
- 33 ft. (10 m) cord, 7 conductors
2A DC;
- 33 ft. (10 m) cord, 7 conductors
- 33 ft. (10 m) cord, 4 conductors with bayonet
plugs for external pressure switch or transducer
2A = AC;
- 33 ft. (10 m) cord, 7 conductors
- 4-pole square plug
2A1 = AC;
- 7 poles bayonet plug
- 4-pole square plug
3A = AC;
- 33 ft. (10 m) cord, 7 conductors
- 4-pole square plug,
- 33 ft. (10 m) cord, 4 conductors with bayonet
plugs for external pressure switch or transducer
Pressure control,, PCB setting
g
AS01 - AS08 = Pressure switch (see jumper
setting table)
AS09 - AS16 = Pressure transducer (see jumper
setting table)
Example: P653S-4XLF-24-2A-AS06:
Pump consists of the following:
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QZ % &% &' >?@K 

Form 404034

Page Number - 7

Electric Operated Centro-Matic Pump P653S

Jumper
p setting
g combinations - Centro-Matic p
pumps
p

Pump combinations

Application:
Industrial
(S) -o; Mobil
(M) - x

Time (TC)
or count
control (CC);
TC -o; CC - x

Number of
pressure
Low-level F1 fault relay; F2 fault relay;
switches or
control;
(31) switch to (31) switch to
transducers. NO- o; NC - x ground - x
ground - x
o - one; x - two

AS04
AS05
AS06
AS07
AS08

Pressure transducer

AS09
AS10
AS11
AS12
AS13
AS14
AS15
AS16

Industrial (AC)
(S)

AS03

Mobile (DC)
(M)

Pressure switch

AS02

Industrial (AC)
(S)

AS01

Mobile (DC)
(M)

Jumper setting (plugged - x; unplugged - o)

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.

Page Number - 8

Form 404034

Electric Operated Centro-Matic Pump P653S

Description of Operation
Pump Operation

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lubrication lines

Drive
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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).
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Vent valve is a two way normally closed spring biased
valve.
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(240 bar).
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psig (240 bar). Pressure setting of the pressure trans8
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($Y77
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bar) in 100 psig (6.9 bar) increments.
Lube Cycle/Pressurization
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tion cycle. As soon as pump starts to operate, the display
rotating segment is turning clockwise also (Fig. 20).
Maximum time to build the preset pressure is 12 minutes.
If pump does not build preset pressure, fault signal E1 or
E2 will appear on the display.
Z
Vent valve (1) is normally closed and stays closed during
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reservoir (see Fig. 4).
Z
The output of three pump elements (4) (Fig. 3) is com8
bined by internal passages.
Z
The eccentric drives the pump elements to pump the lubri8
cant from the reservoir and build the line pressure.
Z
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Supply line can be connected to any one of the pump ele8
ment outlets. The remaining two pump elements outlets
should be plugged.

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Form 404034

Page Number - 9

Electric Operated Centro-Matic Pump P653S

Fig. 6 Activated vent cycle diagram


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Pump Element operation


The pump element (Fig. 13 and 14) is a single stroke spring
biased pump. Motor drives the eccentric (1). Eccentric is in
constant contact with the plunger (2).
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cant passage to create vacuum to prime the pump with lubri8

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supply lines of the system.
Eccentric (1) is pushing the plunger (2) in opposite direction

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valve (4) is open to pass the lubricant to supply lines.
The body of the pump element has a lateral outlet (5) (Fig. 12)
for lubricant crossporting to the internal material passages to
combine the outlet of all three pump elements.
Any one of the three elements can be used as a pump outlet.
The remaining two elements should be closed with plug (A)
(Fig. 12).

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tor.

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Fig. 9 Rotating segmented display during venting


(counterclockwise)

Fig. 13

Fig. 14
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Page Number - 10

NOTE: Use only pump elements designed for operation in the


P653S and P603S pumps. No other pump elements should be
used. See the parts listing for the correct pump element part
number.
Form 404034

Electric Operated Centro-Matic Pump P653S

Pressure Control/Hold Time/Vent Cycle


Pump
p with internal pressure
p
switch only:
y
Internal pressure switch will close at 3500 psig and open at
2600 psig.
After pump starts a lubrication cycle, motor stops when pres8
sure at pump reaches preset pressure of 3,500 psig (240 bar).
Pump will go through two holding periods, H1 and H2.
Holding Time (H1)
Z
Internal pressure switch must stay closed for 15 consecu8
tive seconds before going to H2. If internal pressure
switch opens during the 15 seconds, pump will restart and
run until internal pressure switch closes.

Pump
p with internal and external p
pressure switch:
Internal pressure switch will close at 3500 psig and open at
2600 psig. The external pressure switch will close at 2500 psig
and open at 1900 psig
After pump starts a lubrication cycle, motor stops when pres8
sure at pump reaches preset pressure of 3,500 psig (240 bar).
Pump can go through three holding periods, H1, H2 and H3.
Holding Time (H1)
Z

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&$

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tive seconds before going to H2. If the internal pressure
switch opens during the 15 seconds, the pump will restart
and run until the internal pressure switch closes.

Holding Time (H2) - Will last for 30 seconds


Z
At the end of 30 seconds, if the internal pressure switch is
closed, the pump will begin a vent cycle.

Holding Time (H2) - Will last for 30 seconds


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)

& (>!Y (
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&  
and the external pressure switch is closed, pump will
begin a vent cycle.

If at the end of the 30 seconds the internal pressure


switch is open, the pump will restart and run until the in8
ternal pressure switch closes. When it closes a vent cycle
will take place.

If at the end of 30 seconds the internal pressure switch


is closed, but during the H1 hold time the internal pres8
sure switch did open, the pump will restart and pump for 2
seconds before a vent cycle begins.

)

& (>!Y (
&
 <
&  
both the internal and external pressure switches are open
an H3 will appear on the display. Pump will turn on again
and pump until the internal pressure switch is closed.
When both the internal and external pressure switches are
closed a vent cycle will take place.

(

& (>!
&
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&  
but the external pressure switch is open, the pump will
turn on for 2 seconds and then stop and wait until the
external pressure switch closes. An H3 will appear on
the display. When both the internal and external pressure
switches are closed a vent cycle will take place.

Possible Faults
Z
E1 Fault A failure to build pressure at the pump within
the allotted 12 minutes of pumping time.
Z

E3 Fault A failure to vent at the pump. The internal


pressure switch has 10 seconds to open when the motor
reverses to locate the vent position

Holding Time (H3)


Z
> 
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  =8
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
Z
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the allotted 12 minutes of pumping time.

Form 404034

@!"
)( 
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& (
&8
ply line.

@-"
)( 
?


&$%&
 
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.

Page Number - 11

Electric Operated Centro-Matic Pump P653S

Pump
p with internal pressure
p
transducer only:
y
The internal pressure transducer is factory set to close at 3500
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Yj77 *j
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$
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The internal pressure transducer is set to open at 900 psig (62
bar) below the point where it closed at.
After the pump starts a lubrication cycle, the motor stops when
pressure at pump reaches the preset pressure. The pump will
go through two holding periods, H1 and H2. The following will
use the factory setting of 3500 psig (241 bar) and the opening
(!j77 *V|
Holding Time (H1)
Z
Internal pressure transducer must reach 3500 psig and

V?!j77 *V|(z   
? 8
onds before going to H2. If the internal pressure trans8
ducer drops below 2600 psig during the 15 seconds, the
pump will restart and run until internal pressure transducer
reaches 3500 psig (241 bar).
Holding Time (H2) - Will last for 30 seconds
Z
At the end of 30 seconds, if the internal pressure trans8
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vent cycle.
Z

If at the end of the 30 seconds the internal pressure trans8


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&$< 


and run until the internal pressure transducer reaches


3500 psig (241 bar). When this happens a vent cycle will
take place.

Pump
p with internal and external p
pressure transducer:
The internal pressure transducer is factory set to close at 3500
 !7V|%&
 
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($
Y77 
Yj77 *j
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ments. The internal pressure transducer is set to open at 900
psig (62 bar) below the point where it closed at.
The external pressure transducer is set to close at 2500 psig
!V|%& 
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777 
j*V|

is factory set to open at 900 psig.
After the pump starts a lubrication cycle, the motor stops when
pressure at the pump reaches preset pressure of 3,500 psig
(240 bar). The pump can go through three holding periods,
H1, H2 and H3.
%&(< < 
&(


( 
Holding Time (H1)
Z
Internal pressure transducer must reach 3500 psig and
stay above 2600 psig for 15 consecutive seconds before
going to H2. If the internal pressure transducer drops be8
low 2600 psig during the 15 seconds, the pump will restart
and run until the internal pressure transducer reaches
3500 psig.
Holding Time (H2) - Will last for 30 seconds
Z
At the end of H2, if the internal pressure transducer is
above 2600 psig and the external pressure transducer
has reached 2500 psig, the pump will begin a vent cycle.
Z

At the end of H2, if the internal pressure transducer is be8


low 2600 psig, or both the internal pressure transducer is
below 2600 psig and the external pressure transducer has
not reached 2500 psig, an H3 will appear on the display.
The pump will turn on again and pump until the internal
pressure transducer has reached 3500 psig. When the
internal pressure transducer is above 2600 psig and ex8
ternal pressure transducer has reached 2500 psig, a vent
cycle will take place.

If at the end of H2 the internal pressure transducer is


above 2600 psi but the external pressure transducer has
not reached 2500 psig, the pump will turn on for 2 sec8
onds and then stop and wait until the external pressure
transducer reaches 2500 psig. An H3 will appear on the
display. When the internal pressure transducer is above
2600 psig and external pressure transducer has reached
2500 psig a vent cycle will take place.

If at the end of 30 seconds the internal pressure trans8


  V?!j77 *V|YV
 
&>
hold time the internal pressure transducer dropped below
!j77 *V|Y
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 $(!
seconds before a vent cycle begins.

Possible Faults
Z
E1 Fault A failure to build pressure at the pump within
the allotted 12 minutes of pumping time.
Z

E3 Fault A failure to vent at the pump. The internal


pressure switch has 10 seconds to open when the motor
reverses to locate the vent position.

E3 Fault A failure to vent at the pump. If at the end of


the pause time the pressure of the internal pressure trans8
ducer has not dropped below 900 psig (62 bar) an E3 fault
will occur.

Page Number - 12

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.

Form 404034

Electric Operated Centro-Matic Pump P653S

E2 Fault A failure to build pressure at the end of the


supply line.

Stirring paddle
The stirring paddle (3) (Fig. 2) is attached to the motor and ro8
tates during the lubrication cycle. The paddle is working grease
in the reservoir to make it more pumpable and at the same
time pushing the grease down into the housing and pumping
elements to prevent cavitation.

E3 Fault A failure to vent at the pump. The internal


pressure transducer has 10 seconds to drop below 2600
psig when the motor reverses to locate the vent position.

Low-level control
%&$$jz-# ` <
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grease control as a standard feature.

E4 Fault A failure to vent at the end of the supply line.


The external pressure transducer has to drop below 900
psig before the next lube cycle takes place.

Pump with Follower Plate

Possible Faults
Z
E1 Fault A failure to build pressure at the pump within
the allotted 12 minutes of pumping time.

Venting Cycle/Depressurization
Z
After pump completes preset pressure hold time and
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vent cycle. Hr will be displayed momentarily.
Z
The motor will turn counterclockwise to engage and open
the vent valve. Motor will stop in a position to hold vent
valve open.
Z
The display rotating segment is turning counter clockwise
as well.
Z
%& $|" j| 
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&?
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valve passage of the supply line to the reservoir.
Z
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from the system. The valve stays open during pause time.
Filling reservoir with grease
C

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Make sure no air is trapped under the follower plate. Grease
should be in full contact with the surface of the follower. Its
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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central rod of the reservoir. The switch is sealed and does not
have any contact with grease.
The follower plate bushing has a magnet. As soon as the
follower reaches the preset position at the bottom of the reser8
? Y$ 
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&<
&
  

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level of the grease. The control panel display LL will be on.
The pump can be operational for some time since there is a
small amount of grease left under follower in the reservoir and
$& %&$&V  8
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capacity. The LL display should be off as soon as pump is
 

Caution!
Make sure there is no air trapped under
follower plate. Grease should be in full
contact with surface of the follower. Use
Air Expelling Procedures if necessary.

Air Expelling Procedures for Pumps with Follower


   

&<8?`
V 
" |
and unscrew the top lid (1)0 (Fig. 1) of the reservoir. Remove
   ($
&$#

  
&$) 

&?

 (

&(<Y
    & }
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



&J 
&    

&<8?

 " &
&  (
&? 

The follower spring is completely compressed if reservoir is


full of grease. Exercise extreme caution removing the top of
the pump.

Form 404034

Page Number - 13

Electric Operated Centro-Matic Pump P653S

Pump Without Follower Plate

" z#<
& 
(
&<8? 
(
<& ?   |
1. Pivot bracket with round magnet
-
$
A. Inner orbit of the round magnet

 (
& ?
V }
^^ 

?
|

Grease Reservoir Full of Grease - Fig. 15


Z
The stirring paddle rotates clockwise during the lubrication
cycle.
Z
%& ?
V }
(
&
 |" z| 
completely submerged into grease and grease resistance
to paddle rotation guides the bracket with round magnet 1
inward to orbit (A).
Z

$-|" z| 
& ?
V }
<
&
magnet and outwards, in the direction of the reservoir
wall. Since reservoir is full, grease resistance guides pivot
bracket inward to orbit (A) as soon as bracket passes the
cam (3).
Z
: 
 <8?<
&!| j| 
  
and switch can not be activated.
NOTE: The above mentioned switching parts (1 to 3) (Fig. 15
j|$
 
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&   
& 
Y
$ 
<
&
Grease Reservoir Empty - Fig. 16
Z

 $-| 
& ?
V }
<
&$ 
|
outward. Since there is no grease resistance, the bracket
<
&$ 
|< 

< 
&BV

Z
: 
|<   <
&^<8?#<
& 
?
^^
indicator on a pump display.

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(
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(
(when the reservoir is empty).
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<
& $ 

!^<8?#<
&
-
$
B
V
(
& $ 

D. Position of the Pivot bracket (LL activated)

Page Number - 14

Form 404034

Electric Operated Centro-Matic Pump P653S

Keypad and Display


Membrane Key Pad
8  
!8 ( } <$
((
  
   &  
programming screens.
-8 (
   
 V 
    (
changing programming values.

"  jz-#$$V }

Test Display of the Membrane Key Pad


Z

)

  $<& ?
  8
ments and decimal points are illuminated for 2 seconds.

NOTE
If *EP* is displayed after the display test,

&   

&

&V

 
&}8
pad is defective.

When power is applied to the pump the display will indicate if a


pressure switch or pressure transducer is connected to the pump.
The example indicates an internal pressure switch.
There are four possibilities:
#8 
 <
&
%8 
 
  
TT Internal and external pressure transducer (must be
connected)
SS Internal and external pressure switch (must be connected)
Segment

"  N $


 &
Y< Y 

switch open (off).

" * N $


(
 &
B 
 <
&
closed (on).

Form 404034

Operating mode
Z
) ?
  B |Y
&< &
8& 
$
 
& < <&" |(
&
is only one segment at the bottom this indicates that the
ignition switch is open.
Z
'& <
&  
& 
 <
&Y
&(
8& 8
ment in the display window lights up (Fig. 19).
Z
 
&V 

$(
&$Y  
 8
minated segment appears in the display window of the
membrane key pad (Fig. 20).
Z
If the power supply is interrupted during the pause time,
the pause time continues at the point of interruption after
switching power on again.
Z
If the power supply is interrupted during the lubricating
time the operating time will start at the beginning after
switching power on again.
Page Number - 15

Electric Operated Centro-Matic Pump P653S

Keypad and Display

Fig. 20 Green circulating illuminated segment, lubricating


time, pump is running.

^<8? 

 
&?
(<8?  
& < &^^

" !  (<8?  




IMPORTANT
(<8?    
&V 
8
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

&$$ $<& 


& <8
level signal.

Display is indicating holding times when pump reaches preset


pressure.

Fig. 22 Display of Holding Time

Malfunctions
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
@
@@Y" !-
!j|< V&< &  
&
display of the membrane key pad.
IMPORTANT
If a malfunction is present, E1, E2, E3 or E4
< V& %&$ 
<
&
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.

Fig. 23 Display of the malfunction E1, failure to build pressure


at the pump.

Page Number - 16

E1 fault is a failure to build pressure at the pump.


Z
(
&
&<
&
  ( 

actuate within 12 minutes of pumping this fault will occur.

Form 404034

Electric Operated Centro-Matic Pump P653S

Keypad and Display

Fig. 24 Display of the malfunction E2, failure to build pressure


at the end of the line.

Fig. 25 Display of the malfunction E3, failure to vent at the


pump.

Fig. 26 Display of the malfunction E4, failure to vent at the


end of the line.

E2 fault is a failure to build pressure at the end of the supply


line. You must use an external pressure switch or pressure
transducer to detect this.
Z
(
&
&=
 <
&
transducer fails to reach 2500 psi within 12 minutes of
pumping this fault will occur.

E3 fault is a failure to vent at the pump.


Z
" (
&
 <
&
  
&
10 seconds that the pump motor reverses to locate the
vent position.
Z
" (
&
 
  
*77
V<
&$
$ *77 | 
&7
seconds that the pump motor reverses to locate the vent
position.
Z
(

& (
&
$
&
 
transducer has not dropped below 900 psi an E3 fault will
occur.
E4 fault is a failure to vent at the end of the supply line. You
must use an external pressure switch or pressure transducer
to detect this.
Z
(

& (
&
$
&=
 
switch has not opened an E4 fault will occur.
Z
(

& (
&
$
&=
 
 8
 & 
V<
&$
 @
fault will occur.
To trigger an additional lubrication cycle via the pushbutton,
press the button for 2 seconds.

" ! B


}

  
 V 
   

" ! B


}
 } <(


Form 404034

NOTE
Existing fault signals (Fig. 21 to 26) must
be acknowledged before triggering an
additional lubrication cycle.

To trigger additional lubrication cycles externally


\
Press the pushbutton to trigger additional lubrication
cycles externally. Press the pushbutton for 2 seconds.
- Mobile pump w/ignition switch open.........up to two
times
- Industrial pump w/machine switch open...unlimited

Page Number - 17

Electric Operated Centro-Matic Pump P653S

Factory Settings For Parameters

Programming steps Factory Setting Description

01

Pause time
0 to 59 hours

00

Pause time
0 to 59 minutes
Output of both fault relays

NO

no (normally open)
nc (normally closed)

o2

Two options for signaling a fault


o1 ((Option
p
1))
F1 relay contact
|^<8?(
<  " 



   
b) Pressure fault will cause F1 contact to close and stay closed.
F2 relay contact
)
)<8?(
(
<  
&"! 


  
 
o2 ((Option
p
2))
"(
_ 

<   <8?(

F2 fault relays contact will close on a pressure fault



&(
& 

  V($
   

SP

Option to have the pump start with a pause time or a lube cycle.
SP Pump starts with a pause time
SO Pump starts with a lube cycle
%&$$ 
<   (&?$
&
 
 

35

pressure transducer. (Reading x 100)


35 x 100 = 3500 psi. 3500 psi is the maximum pressure that the pump will build.
)
)W
V($77 
j77  77  $


09

Page Number - 18

%&$$ 
<   (&?$
&
 =
 
pressure transducer. (Reading x 100)
09 x 100 = 900 psi. 900 psi is where the external pressure transducer will open (VENT)
W
V($!77 
777  77  $


Form 404034

Electric Operated Centro-Matic Pump P653S

Acknowledging a Fault
Display

Press

< 2 sec.

< 2 sec.

To acknowledge
g a malfunction:
Z
%&&   & 
 
 &
V
 
&V

  } < | } < 

&(
  Y
&& @Y@!Y@-Y@^^ & 
into permanent light.
Z
Messages which have been acknowledged but have


V $ < & (

&$ 
switched off and on again.
Z
After fault has been acknowledged no more lube cycles
will take place until a successful manual lube cycle has
taken place.

< 2 sec.

< 2 sec.

< 2 sec.

Form 404034

Page Number - 19

Electric Operated Centro-Matic Pump P653S

Programming the Pump


Programming Mode: Pump with Pressure Switch
Key

Function

Key

Key for modifying


the parameters in the
programming step

Press

> 4 sec.

Step 2

IMPORTANT! Pump
Power must be on to
start programming.

Key for switching to


the next programming
step

Step 1
Display

Function

Setting of Pause Time P1 (hours) and P2 (minutes).


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



P2
Min. pause time
Max. pause time

Pause time:
78z*&
0 59 minutes
4 minutes
59 hours 59 minutes

P1: Setting of hours


When releasing the two buttons, the currently set value
appears.
@=$(
8
?&
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


   V&




  
` }` 
@=$!&

Step 3
P2: Setting minutes
Press button, so that P2 appears in the display.

When releasing the button, the currently set value appears


&
&(
8
?7$ 
|
Minute is indicated by a dot on the left-hand side.

Press button.
Settings are made in one direction:... 0, 1, 2, 3, 4, 5, .... 59 min


   V$ 





  
` }` 
@=$-7$ 

IMPORTANT
If Hours are set to 00, the display will
show minimum pause time of 4 minutes.

Page Number - 20

Form 404034

Electric Operated Centro-Matic Pump P653S

Programming Mode, continued


Step 4
Display

Press

P4: Programming of the output signal for both alarm


relays. The default setting on the printed circuit board for
the alarm contacts is switching to battery minus.
Press button so that P4 appears in the display.

When releasing the button, the currently set value appears



& &
&(
8
?BY $ 
contact). On a fault condition the alarm contact will close.

Press button.
%&=
 (
 

 $ V$$ 

 $  

B (
  
 
&$
contact will open.

Step 5

Factory Setting

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
|)<8?(
<  
&" 




open and close.
b) A pressure fault will cause the F1 contact to close and stay
closed.
F2 relay contact
)<8?(
(
<  
&"! 



close and stay closed.
o2 (Option 2) P4 is set to the default of Normally Open.
"(
_ 

<   <8?(
 

closed.
F2 fault relays contact will close on a pressure fault and stay
closed.

&(
& 

  V($
   
Press pushbutton to change to Option 1.

Form 404034

Page Number - 21

Electric Operated Centro-Matic Pump P653S

Programming Mode, continued


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.
@ &
$
&$ <
& Y
< 

<
&
&8
bricating time SO (Start Operation|)(

& 
V 

time the preset pause time will be valid.

Step 7

Completing the programming


V

 8  


IMPORTANT
)< 

&$$  $8
pletely in order to save the new values.

Press this key (additional lubrication) to complete the pro8


gramming and to save the entered parameters.
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,
& }
&$


 
&8
ating mode once again.

Programming of the pump with pressure switch is complete.

Page Number - 22

Form 404034

Electric Operated Centro-Matic Pump P653S

Programming Mode: Pump with Pressure Transducer


Complete Steps 1 through 6 of Pump with Pressure
switch
Display

Press
Step 7
IMPORTANT
%&$$ <   (
have a pump that has an internal pressure
transducer.

$
&

(<&
&
 
 8
ducer will close. This is the maximum pressure that the pump
can reach. Factory setting is 3,500 psi.
Press button to change value.
Reading x 100 = Transducer setting in psi
35 x 100 = 3500 psi.
%& 

 W
V($77 
j77  77 
increments.
Step 8
IMPORTANT
%&$$ $
<  
appear if you have a pump that has an
external pressure transducer connected.

$
&

(<&
&=
 
 8
 <  %& 
?
| W
8
able from 200 psi to 1,000 psi in 100 psi increments. Factory
set opening point (vent pressure) is 900 psi. The closing point
(
&=
 
    = (
<
!z77
psi.
Press button to change value.
Reading x 100 = Transducer setting in psi
9 x 100 = 900 psi.

Form 404034

Page Number - 23

Electric Operated Centro-Matic Pump P653S

Programming Mode, continued


Step 9

Completing the programming


V

 8  


IMPORTANT
)< 

&$$  $8
pletely in order to save the new values.

Press this key (additional lubrication) to complete the pro8


gramming and to save the entered parameters.
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.

Programming of the pump with pressure transducer is


complete.

Page Number - 24

Form 404034

Electric Operated Centro-Matic Pump P653S

Review of the Pump Parameters

Press the button > 2 seconds.


or

NOTE
The following display sequence is shown
once. The change of display occurs every
two seconds. Example of the pump set to
lubricate each 12 hours 30 minutes and
remaining pause time (rP) is 5 hours 10
minutes.

Pause Time

after one sec.

12 .

(hours)

. 30

(minutes)

after one sec.

rP

(remaining pause time)

after one sec.

5.

(hours)

after one sec.

. 10

(minutes)

after one sec.

Form 404034

Page Number - 25

Electric Operated Centro-Matic Pump P653S

Review of the Pump Parameters


Operating Mode
B


& 

 $

!

B
 !8><" "!<   (


SP

Pump starts with a pause time

after one sec.

after one sec.

after one sec.

Will only appear if pump has an internal pressure transducer.


Maximum pressure the pump will build.
after one sec.

after one sec.

Indicates that the internal pressure transducer will close at


3500 psi.

after one sec.

Will only appear if pump has an internal and external pressure


transducer. Setting where external transducer will open.

after one sec.

External pressure transducer will open at 900 psi.

Indicates software version.


The next two displays will indicate software version.

or

Page Number - 26

Termination of the Reviewing of Parameters.

Form 404034

Electric Operated Centro-Matic Pump P653S

Technical Data
Electrical data for DC pump
 $ ?
!? 8!7-7
:= $$ 
 7$
@=
 " 7$
$|
J?


  
Electrical data for AC pump
 $ ?
 77
!7?
:= $$ 
$
"` 
j-&
B

($< !? z$
@=
 " -$
$|

Common electrical data for DC and AC pumps


: $$
$ $ 
:= $$
$ z*&z*$ 

$ $
 $ &
:= $$$ 
$ !$ 
@ 
 j*@:)|
Rating for fault relay contact:
#<
& ?
 $=!-7? !7? !?
#<
&  
 $=$ 
?
Minimum switching current...... .1 ma
Pump P653S
Operating pressure with:
8<
& -Yz77 !7V|
8
   -Yz77 !7V|

    VW



from 1,400 to 4,600 psig
*j
-V|
End of line pressure switch


!Yz77 !V|

W
V|
End of line pressure transducer


!Yz77 !V| 


W
V
End of the line transducer vent pressure is factory preset at 900
 j!V|  VW
($!77
Y777 

7V| 77 V| $

Operating temperature
 ($ 87"
z"1)
87
7|1)
Operating temperature
 ()$ -!"
!!"1)
7
z7|1)
Number of outlets
 

 | 
Lubricant .................................. up to NLGI grade 2 1)
B

 z 3/min 2)
(24.6 cm3/min)
J?  Y^ YYz !7
^V 
   
  N

Form 404034

Pump elements K7
 
  $
 $$
Number of Pumping Elelments............... 3
(connected together)
Tightening torques
 
$ --(
8V$|
@
 $
 &  (
8V!$|
$$
 &  z(
8V!7$|
 & (
8V!$|
J
    
 & (
8V78!$|
% (z !7? (
8V7$|
Weights
z8? <
&-$$
Y<
&
 (
valve, empty
$jz-#<
&
  
 V !V*j}|
$jz-#?  ) !--V7j}|
$jz-#?  -) !jV!}|
8? Y
 
$jz-#<
&
  
 V *V*7}|
$jz-#?  ) !V*j}|
$jz-#?  -) !jV7j}|
8? Y
 
$jz-#<
&
  
 V*V}|
$jz-#?  ) !-V*}|
$jz-#?  -) !-V7z}|
The weights above include the following equipment:
Pump kit with three pump elements, pressure relief valve,
  z}|
Packing (cardboard box)
Attaching parts
Operating Instructions
Installation
Z
Use only high pressure 5,000 psig minimum hydraulic
hose for supply lines.
Z
C &  
 


&
 
(

&$$8

$

Note #1: See the list of the approved and recommended lubricants.


^   (V 
  
 
& 


!%&V 


 $
7"!| 
backpressure 1,450 psig (100 bar). Different pressures, temperature
and grease can change the output results.

Page Number - 27

Electric Operated Centro-Matic Pump P653S

CONNECTIONS FOR 24 VDC 653 PUMP

Page Number - 28

Form 404034

Electric Operated Centro-Matic Pump P653S

CONNECTIONS FOR 110-230 VAC 50/60 Hz


653 PUMP

** Must connect red and black wires together if no machine switch is used.
     
V 
jj8-zz78|

Form 404034

Page Number - 29

Electric Operated Centro-Matic Pump P653S

JUMPER SETTINGS FOR 653 PUMP PCB

Page Number - 30

Form 404034

Electric Operated Centro-Matic Pump P653S

Centro-Matic System Schematic with P653S Pump

8C:N>BC#N-C:@^@:@%#|
!8:B%BJ
-8B%JB^^@JY@B)J'%>#^)
8%@J)^J@##CJ@#'%>#|BJJ@##CJ@%J)#C@J%|
z8%@J)^@%)^@
j8J@#@JBJ'%>^<8?B%JB^
8J@##CJ@J@^@"YzY777#-z7)J|@%@J)^
8>N>J@##CJ@#C^^@
*8+@%BJ#Y#^8Y#^8YBJ#^8-!Y#^8--Y #^8^+@%BJ#
78J@##CJ@#'%>#|BJJ@##CJ@%J)#C@J%|Y@%@J)^YB%B)^
)8B'@J#C^!BJ!7)YB%B)^|

"
 (
&
8:

$Y?
V( =
V 
   

& ( &V
8V<*77 j!V|(#^8 #^8^
( W

8V<j77 V|(#^8
( W

8V<!77 -V|(#^8-!--
( W


Form 404034

Page Number - 31

Electric Operated Centro-Matic Pump P653S

Lincoln List of Lubricants


IMPORTANT
Absolute cleanliness is essential when
handling lubricants. Impurities will
remain suspended in the lubricant and
cannot settle. This will result in damage
to the lubrication system and thus to the
bearing.

Grease pumpability and venting behavior depend on ambient


temperature range of the application, and may be different
for the same NLGI grade of grease. This refers in particular

<
&$
& -&
^    


&
 ? $$ 
 (  8
tions.

%&
8:
$     $$ 

^N!
 

$
 
The proven lubricants (see following tables) have been
tested by Lincoln with regard to their pumpability and venting
behavior. Lincoln can recommend them for an application up
to the indicated minimum delivery temperature 
8
Matic lubrication systems. During the tests these lubricants did
not cause any damage due to incompatibility with the material
used by Lincoln.
The lubricants Lincoln recommends on the basis of the
manufacturers data sheet (see following tables) can be used
in Lincolns lubrication systems up to the indicated minimum
delivery temperature.

IMPORTANT
%&$ (
(
& 
 
lubrication system can accept no liability
for:
8 $

&(
that are not or only conditionally
$V  
 V 
 
systems.
8 $ 
(
& 
 
lubrication system caused by chemical
or biological changes of the lubricant
used.
8 $

& $
V 

with other materials.
The liability is limited to pumpable
V 
  
 V 
 
systems.

IMPORTANT
 
^  ^   
 V
J

?V( V 
<
& 
?

Proven Lubricants
Manufacturer

Designation

Thickener

CATERPILLAR

Moly Ultra 5 NLGI #1

CA-Complex

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)

Li/Ca

-13 F (-25 C)

FUCHS-LUBRITECH Stabil Eco EP2

Min. Operating Temp.


10 F (-12 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)

Page Number - 32

Form 404034

Electric Operated Centro-Matic Pump P653S

Lincoln List of Lubricants, continued

IMPORTANT
 
^  ^   
 V
J

?V( V 
<
& 
?

Form 404034

Page Number - 33

Electric Operated Centro-Matic Pump P653S

Lincoln List of Lubricants, continued

IMPORTANT
 
^  ^   
 V
J

?V( V 
<
& 
?

Page Number - 34

Form 404034

Electric Operated Centro-Matic Pump P653S

Form 404034

Page Number - 35

Electric Operated Centro-Matic Pump P653S

Page Number - 36

Form 404034

Electric Operated Centro-Matic Pump P653S

Form 404034

Page Number - 37

Electric Operated Centro-Matic Pump P653S

Page Number - 38

Form 404034

Electric Operated Centro-Matic Pump P653S

 
   
Caution!" 

$  (
&? 
with grease is very critical for proper
pump operation. The pump may be
shipped with a small amount of Fuchs
J  "z^B^
( 

  
 %&

& }  8!8B>8


& } $
V 
(
&J  "
z^B^<
&
&
going to use and remove the test grease
if necessary.
Pump with follower plate:
C

*|" |
  ? :}
no air is trapped under the follower plate. Grease should be in
full contact with the surface of the follower. Its recommended

 
&$
V


&V   
& 
 
of the reservoir. The stirring paddle of the running motor will
&
?  
 V
 (<$ $   
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.
Pump without follower plate:
C
&$

*|" |
  ? 
Its recommended to run the motor by initiating the lube cycle
 
& 
 (
&? %&
 (
&
running motor will help to evenly distribute grease in the reser8
? $ $    }

%    (
&$Y

  V
 <
&< ?  
 


 &&($


  $
Caution! There is a risk of reservoir
V
 (? '&   
&
? <
&

  
$Y 
= 
&$= $$ 
mark.
Pump cleaning:
C
$V  V  
  


 8Y &
&  $ ?
 

organics such as alcohol, methyl alcohol, acetone or similar
solvents.

Form 404034

Page Number - 39

Electric Operated Centro-Matic Pump P653S

Page Number - 40

Form 404034

Electric Operated Centro-Matic Pump P653S

Troubleshooting
Mode of failure
Pump motor does not run. No green right corner segment lit on
 " z|

Solution
& }< (

Pump does not deliver lubricant but runs if manual lube switch
-" z| & (
  $


on display (Fig. 19 page 15).

 
 
 $ & <
&
  &$

 ! !*

^^  & J?  $


$


$<
&(<8 ? $<
&
(<
 ?  &<
&-|" |


$ 
lube cycle.

@  & $( 


?
 8
sure in 12 minutes.

&<
&!|" |
 } <
&(



manual lube cycle. Investigate and correct possible causes
air pockets, broken line, connections leakage, worn pumping
element, failed internal pressure switch or pressure transduc8
er. Initiate manual lube cycle.

@!  & $( 


?

&
end of the line (pump with external pressure switch or pres8
sure transducer)

&<
&!|" |
 } <
&(



manual lube cycle. Investigate and correct possible causes
air pockets in lubrication line, connections leakage, grease
consistency changed with low temperatures, failed end of line
pressure switch or pressure transducer.

@-  & $( 


?


&$

&<
&!|" |
 } <
&(



manual lube cycle. Investigate and correct possible causes
pump eccentric did not stop in a proper position, vent valve
failed

@  & $( 


?


& (
&
line (pump with external pressure switch or pressure trans8
ducer).

&<
&!|" |
 } <
&(



manual lube cycle. Investigate and correct possible causes
restriction in lubrication line, grease consistency changed
with low temperature, failed end of line pressure transducer or
pressure switch.

Grease is coming out of the pressure relief valve (6) (Fig.1).


& } W


(
&
  ( 
pressure switch.

Form 404034

Page Number - 41

Electric Operated Centro-Matic Pump P653S

Pump with Follower


Page Number - 42

Form 404034

Electric Operated Centro-Matic Pump P653S

Pump with Follower

Form 404034

Page Number - 43

Electric Operated Centro-Matic Pump P653S

P653S PUMP with follower (housing and reservoir)


Item # Part Number
1
2
3
4

Description

-j8j8 HOUSING
!z7!

:B%BJYJ@!

z8z!8 %@J:@)%@B%%B:
!zzz

PINION GEAR, DRIVE

QTY Item #
1

45

Part Number

Description

QTY

z8z-8

SUPPORT SLEEVE, 4L RESERVOIR

z8z!8

#CBJ%#^@@@Y^J@#@JBJ

z8z!8

SUPPORT SLEEVE, 15L RESERVOIR

z8z-j8

SUPPORT SLEEVE, 20L RESERVOIR

zz8--7z8

J@#@JBJY^'@%%C@)^)@^#

z8z!8 THREADED SLEEVE

!z787j-8 @)JN!!j

zz8--78

J@#@JBJY^'@%%C@)^)@^#

jz8!*8 C:@^@:@%Y

zz8--78

J@#@JBJYz^'@%%C@)^)@^#

!z7877*8 @)JN7!j

zz8--7-8

J@#@JBJY!7^'@%%C@)^)@^#

10

!!78!!-8- #@)^YJ))^)z":7!!

-778*j78

#JNY"B^^B'@JY"BJ^)^J@#@JBJ

-778j!8

SPRING, FOLLOWER, FOR 15L AND 20L RESERVOIR

11

!zzz

N@)JY@@%J

46

12

!z787j8j @)JN!-!=7

!*87j8j

B8JN!J777777

13

z8!jj8 SHAFT F.DRIVE with RETAINING RING AND KEY

49

z8z-!8

INSERT, RESERVOIR

14

!7*8-78* ')#>@J#%!8!77>

50

!778-7!!8

#J@'Y>@Y:j=!7



!z787j8 @)JN!!

51

!78!7*8*

#J@'Y#B@%>@Y:j=j



z8!z-8 ):YJ@^@"C%

52

87-8

B@JYJ@#@JBJ

20

8!-*8 PRESS RING

53

!-87j*-8j

B%)%JBY^J@#@JBJ

21

!78!7j8 #J@'Y#BY>@:z!7

!-87j*-8

B%)%JBY^J@#@JBJ

22

!*87j8j B8JN!J7Y77Y77

!-87j*-8

B%)%JBYz^J@#@JBJ

23

!*87-*78- B8JN!J*zY77=-Y77

!-87j*-8*

B%)%JBY!7^J@#@JBJ

24

zz8-!*7j8 JB@J)J:Y)##_YJ@^@"C%

54

!78!!8!

C%Y)'%>')#>@J!7*8-78z

25

B%C#@

55

!-87jj-8j

J@##CJ@%J)#C@J'%>#@)^JN!7*8!z8j

26

B%C#@

56

!-87!z8-

@%@J)^J@##CJ@%J)#C@J

!

B%C#@

z

jj8-zj8*

)^@)##Y7:B^@

j8-zz78j

B@%BJ"BJ@%@J)^J@##CJ@#'%>
%J)#C@J

!
29
30
31

z88 "JB%B@J'@B)J!-j8-78
z8!!8 JB"^@)N
!-j87jzz8 J%@JC%B)J
!zjjj

B@JY>BC#N

z

59

60

jj8-!8- )^@)##Y7:YB^@

jj8-zj*8

B@%BJ"BJ#N)^)^@B^@#)C:|

jj8--7-8

B@%BJ"BJ#N)^)^@B^@#C:|

32

!78!7j8j #J@'Y#BY>@:zj

61

!-j8-!8*

)
)B'@J)^@^CN

33

zz8--7!8 RELIEF ELEMENT

62

jj8-z8j

^B'^@@^B%JB^#'%>)^@^J@#@JBJ|

35

!7j8-78j #J@'Yj7=7'%>#@)^!!7878

jj8-z8

^B'^@@^B%JB^#'%>)^@^J@#@JBJ|

-

!-87!-8 J@##CJ@#'%>'%>#@)^JN!7*8!z8j

jj8-z8z

^B'^@@^B%JB^#'%>)^@z^J@#@JBJ|

39

!7j8-*j8* #J@''')#>@J

jj8-z8

^B'^@@^B%JB^#'%>)^@!7^J@#@JBJ|

40

-78*j*8 ))%@J:!!=z'NJ@)#@"%%N!z87z8*
)

63

41

zz8--7-8 STIRING PADDLE ASSEY

64

!z*7j

42

z8!j8 C#>N

65

j8-zz78 ^CNYB^@+C:@J

POWER SUPPLY

jj8-!8

:B%BJB@%BJ

43

z8---78 FOLLOWER PLATE ASSY

66

jj8-zj*8!

%@J)^)^@"BJ)C:

44

!778!7778- #J@'Y>@Y:j=7

j

!-87!z8

@%@J)^J@##CJ@#'%>

j!88 ^)@#%@8778J8%

!!*

!!j87z8z

>BJB%)^:BC%NJ)@%

)
))%@J#!z!7888!z

 '&  


  
!-j87jzz8Y 


 $
V ? 

&W$

%& $


  
& <
&
 (


"$
<}Y
& $


  
W$

$
 

&  
  


Page Number - 44

Form 404034

Electric Operated Centro-Matic Pump P653S

or
55

PUMP WITHOUT FOLLOWER


Form 404034

Page Number - 45

Electric Operated Centro-Matic Pump P653S

PUMP WITHOUT FOLLOWER


Page Number - 46

Form 404034

Electric Operated Centro-Matic Pump P653S

P653S Pump without Follower (Housing and Reservoir)


Item # Part Number
1
2
3
4

Description

-j8jz8 HOUSING
!z7!

:B%BJYJ@!

z8z!8 %@J:@)%@B%%B:
!zzz

PINION GEAR, DRIVE

QTY Item #

Part Number

Description

QTY

40

-78*j*8

)
))%@J:!!=z'NJ@)#@"%%N!z87z8*

41

!-87!-8j

JB:%#'%>

42

zz8--7*-8

STIRING PADDLE ASSEY

43

!778!7778-

#J@'Y>@Y:j=7

44

z8z-8

SUPPORT SLEEVE, 4L RESERVOIR

z8z!8 THREADED SLEEVE

!z787j-8 @)JN!!j

z8z!8

#CBJ%#^@@@Y^J@#@JBJ

jz8!*8 C:@^@:@%Y

z8z!8

SUPPORT SLEEVE, 15L RESERVOIR**

!z7877*8 @)JN7!j

z8z-j8

SUPPORT SLEEVE, 20L RESERVOIR**

10

!!78!!-8- #@)^YJ))^)z":7!!

zz8--7z8

J@#@JBJY^'@%%C@)^)@^#

zz8--78

J@#@JBJY^'@%%C@)^)@^#

11

!zzz

N@)JY@@%J

45

12

!z787j8j @)JN!-!=7

zz8--78

J@#@JBJYz^'@%%C@)^)@^#

13

z8!jj8 SHAFT F.DRIVE with RETAINING RING AND KEY

zz8--7-8

J@#@JBJY!7^'@%%C@)^)@^#

14

!7*8-78* ')#>@J#%!8!77>

46

!*87j8j

B8JN!J777777



!z787j8 @)JN!!

z8z-!8

INSERT, RESERVOIR



z8!z-8 ):YJ@^@"C%

!778-7!!8

#J@'Y>@Y:j=!7

20

8!-*8 PRESS RING

49

87*78

"@)^@

21

!78!7j8 #J@'Y#BY>@:z!7

50

87j8

B@JYJ@#@JBJ

22

!*87j8j B8JN!J7Y77Y77

55

!-87jj-8j

J@##CJ@%J)#C@J'%>#@)^JN!7*8!z8j

23

!*87-*78- B8JN!J*zY77=-Y77

56

!-87!z8-

@%@J)^J@##CJ@%J)#C@J

24

zz8-!*7j8 JB@J)J:Y)##_YJ@^@"C%

z

jj8-zj8*

)^@)##Y7:B^@

z

j8-zz78j

B@%BJ"BJ@%@J)^

25

B%C#@

26

B%C#@

B%C#@

59

60

!
!
29
30
31

z88 "JB%B@J'@B)J!-j8-78
z8!!8 JB"^@)N
!-j87jzz8 J%@JC%B)J!
!zjjj

B@JY>BC#N

J@##CJ@#'%>%J)#C@J

1
1

61

jj8-!8- )^@)##Y7:YB^@

jj8-zj*8

B@%BJ"BJ#N)^)^@B^@#)C:|

jj8--7-8

B@%BJ"BJ#N)^)^@B^@#C:|

!-j8-!8*

)
)B'@J)^@^CN

63

32

!78!7j8j #J@'Y#BY>@:zj

64

jj8-zz78 ^CNYB^@+C:@J
!z*7j

33

zz8--7!8 RELIEF ELEMENT

66

35

!7j8-78j #J@'Yj7=7'%>#@)^!!7878

j

-

!-87!-8 J@##CJ@#'%>'%>#@)^JN!7*8!z8j

39

!7j8-*j8* #J@''')#>@J

!!*

!!j87z8z

POWER SUPPLY

jj8-zj*8!

%@J)^)^@"BJ)C:

!-87!z8

@%@J)^J@##CJ@#'%>

j!88 )^@#%@8778J8%

>BJB%)^:BC%NJ)@%

)
))%@J#!z!7888!z

 '&  


  
!-j87jzz8Y 


 $
V ? 

&W$

 %& $




  
& <
&
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& $


  
W$

$
 

&  
  

$ 
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z
8
!jj
$ 
? V }

  ?
 

!7
8
!jjz

Form 404034

Page Number - 47

Electric Operated Centro-Matic Pump P653S

Americas:
One Lincoln Way
#
^ Y:Bj-!78z
USA
& -j*!77
"=77!z-z*
Page Number - 48

Europe/Africa:
>  &8>
8#
!8
8j*-'(
Germany
& *j!!--7
"=*j!!--!z*

) 
z&   }

!
7*87j%&#  

# j7jj
& jzjz7
"=jzjz--

 &
!77*
Printed in USA
Web site:
www.lincolnindustrial.com

Form 404034

Model No. 85770-1, -2, -3, -4, -5, -6, 85771, 85772
85780-1, -2, -3, -4, -5, -6, 85781 and 85782
85785-1, -2, -3, -4, -5, -6, -7, -8, -9, -10
SL-V INJECTOR
Series B
SINGLE AND MANIFOLD TYPE INJECTORS
for dispensing fluid lubricants and greases not
exceeding Lincoln ventmeter viscosity of 600 psi.

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 - -40F to 180F [-40C - 80C]
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.

U.S Patent Number 6,705,432, 6,810,998, 6,863,157, 6,986,407


Foreign Patents Pending

One Lincoln Way


St. Louis, MO 63120-1578
Phone +1.314.679.4200
Fax +1.800.424.5359

OCT - 2008

Copyright 2007
Printed in USA
Web site:
www.lincolnindustrial.com

- C8
Page - 301E

Section

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

MANIFOLD TYPE INJECTORS


Model

Injector

SL-V

SL-V XL

Type

Dimension A

Dimension B

in.

[mm]

in.

[mm]

85770-1

Single Injector Manifold

2-1/2

[63.5]

85770-2

Two Injector Manifold

[76.2]

85770-3

Three Injector Manifold

1-1/4

[31.8]

4-1/4

[108]

85770-4

Four Injector Manifold

2-1/2

[63.5]

5-1/2

[140]

85770-5

Five Injector Manifold

3-3/4

[95.3]

6-3/4

[171]

85770-6

Six Injector Manifold

[127]

[203]

85771

Replacement Injector

N/A

Dimension C
in.

[mm]

8-3/4

[222]

11-3/16

[284]

N/A

85780-1

Single Injector Manifold

2-1/2

[63.5]

85780-2

Two Injector Manifold

[76.2]

85780-3

Three Injector Manifold

1-1/4

[31.8]

4-1/4

[108]

85780-4

Four Injector Manifold

2-1/2

[63.5]

5-1/2

[140]

85780-5

Five Injector Manifold

3-3/4

[95.3]

6-3/4

[171]

85780-6

Six Injector Manifold

[127]

[203]

85781

Replacement Injector

N/A

N/A

* Single Mounting Hole

Single Unit Injectors


Injector

Model

Type

Dimension D
in.

Page Number - 2

[mm]

SL-V

85772

Single Unit Injector

7-3/4

[191]

SL-V XL

85782

Single Unit Injector

10-3/16

[248]

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

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
system installation and preventative
maintenance.

Remove Lock Nut


Install Sleeve

To install a spectrum adjustment


sleeve:
Remove and discard the Lock Nut (Item
4), place Sleeve onto Adjusting Screw
(Item 3) and tighten.

SL-V SPECTRUM ADJUSTMENT SLEEVES


Ratio from

Ratio from

Sleeve

in

Output
(cc)

Minimum Ouput

Maximum Output

Color

0.015

(0.25)

0.2

N/A

85785-1

0.03

(0.50)

0.4

Red

85785-2

0.045

(0.75)

0.6

Silver

85785-3

0.06

(1.00)

0.8

Gold

85785-4

0.075

(1.25)

1.0

Green

Part #
N/A

SL-V XL SPECTRUM ADJUSTMENT SLEEVES


Part #

Output

Ratio from

Ratio from

Sleeve

N/A

0.015 (0.25)

Minimum Output

Maximum Output

Color

0.050

N/A

85785-1

0.03

(0.50)

0.100

Red

85785-2

0.045 (0.75)

0.150

Silver

85785-3

0.06

(1.00)

0.200

Gold

85785-4

0.075 (1.25)

0.250

Green

85785-5

0.112 (1.87)

7.5

0.375

Black

85785-6

0.15

10

0.500

Purple

in

(cc)

(2.50)

85785-7

0.188 (3.12)

12.5

0.625

Blue

85785-8

0.225 (3.75)

15

0.750

Orange

85785-9

0.262 (4.37)

17.5

0.875

Brown

20

1.000

Yellow

85785-10

Form 403786

0.3

(5.00)

Inconsistent or much smaller


grease output can be a result of the
improper injectors installation.
In smaller systems or in applications
where injectors are installed close to
a high output pump, it is important
that line pressure in the system is not
increased quickly. The time to pressurize the system should allow the
measuring pistons of the injectors to
move fully downward to reload for the
next lubrication cycle.
Lincoln recommends a length of high
pressure hose be added between the
pump and injectors to slow down the
pressure increase in such cases.
Contact Lincoln Technical Service
Department for the length and size of
the hose.

Page Number - 3

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

**

13*

1
12
2

14
3
15
4
14
16

5
6

17

7
8
9

18

10
19*

11a
(SL-V)
20
Torque to
30-40 In. Lbs.

11b
(SL-V XL)

21
* Etched surfaces of #13 and #19
must be aligned and face to the front
of the manifold assembly.
** The SL-V injector is designed with a weep hole
which indicates worn or damaged internal seals.
Please refer to the Centromatic System Planning
Manual for a more detailed description of this design
characteristic. The weeping which occurs is a slow
release of grease which may bypass the lower seal
over many cycles. This weeping may always be
present to a small amount on the injector. The weep
becomes a leak when the amount of grease increases
each time the injector cycles. When this occurs it is an
indication that the injector requires attention and should
be serviced soon.
Indicates change

Page Number - 4

22

25
Torque to
40 - 45 Ft. Lbs.

23
24
Torque to
40-45 Ft. Lbs.
MANIFOLD
INJECTORS

SINGLE UNIT
INJECTOR

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

SERVICE PARTS
Item

Description

Qty.

No.

Part No.
SL-V

Protective Cap (polycarbonate)

O-ring (nitrile)

Adjusting Screw

Lock Nut

Piston Stop Plug

SL-V XL

273088

273089
*

272803

272819

11624
273090

273091

O-ring

Backup Washer

U-cup (polyurethane)

O-ring (polyurethane)

10

Piston Assembly

273092

*
273987

11a

O-ring (polyurethane)

N/A

11b

U-cup (polyurethane)

N/A

12

Fitting Assembly

13

Injector Body

*
90471

275330

275331

14

O-ring (fluorocarbon)

15

O-ring (fluorocarbon)

16

Spring

17

Spring

18

Spring Seat

272798

19

Body and Plunger Assy.

275332

20

Socket Head Screw (8-32 x 1-1/2)

272796

21

Gasket

22

Single Injector Manifold

12658

Two Injector Manifold

11962

Three Injector Manifold

11963

Four Injector Manifold

11964

Five Injector Manifold

11965

Six Injector Manifold

246965

23

Gasket

24

Adapter Bolt

273097

25

Adapter

273098

* Included in 272970 Repair Kit

Form 403786

Page Number - 5

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

SL-V Injector Operation


Indicator
Stem

Stage 1
The injector starts in its normal or rest position.
Incoming lubricant is directed through the slide
valve to both sides of the piston. The pressure
of the incoming lubricant acting on both sides of
the piston causes the piston to move downward
against the shoulder and fills the measuring
chamber. The indicator stem is fully retracted
away from the stop of the adjusting screw.

Piston

Springs

Stage 2
Further increase in pressure causes the slide
valve to move against the force of the springs. As
the slide valve moves, it closes passage 1 and
opens passage 2 to the outlet port. The pressure
of the incoming lubricant is now acting only upon
the bottom of the piston. The incoming lubricant
displaces the piston which forces the lubricant in
the measuring chamber to be dispensed through
passage 2, through the slide valve and through
the outlet port to the lube point.

Slide
Valve
Lubricant
Supply

STAGE 1

Stage 3

Passage 1
Outlet
Port
Passage 2
Slide
Valve

STAGE 2

The piston will dispense lubricant until the


indicator stem hits the stop of the adjusting
screw. The volume of lubricant dispensed can
be adjusted by limiting the travel of the piston.
The piston and slide valve remain in this position
until the lubricant pressure in the supply line is
vented.

Adjusting
Screw
Indicator
Stem

Stage 4
As the pressure in the supply line vents to 1000
psig [69 bar], the slide valve moves downward
and closes passage 2 and opens passage 1. The
lubricant pressure in the supply line is now acting
upon both sides of the piston causing it to move
downward. As the piston moves downward, a
volume of lubricant flows from the underside of
the piston, past the slide valve, through passage
1 and to the upper side of the piston. Since the
volume on top of the piston is greater than the
volume under the piston, an additional volume of
lubricant flows from the supply line to the upper
side of the piston. This volume of lubricant leaving
the supply line causes the pressure to drop very
quickly. The piston may or may not fully return
to the shoulder, depending upon the volume of
lubricant in the supply line. The injector is now
ready for the next cycle.

Piston

Slide Valve

STAGE 3
Page Number - 6

Passage 1

Passage 2
Lubricant
Supply

STAGE 4
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

Lincoln Industrial Standard Warranty


LIMITED WARRANTY
Lincoln warrants the equipment manufactured and supplied by Lincoln to be free from defects in material and workmanship for a
period of one (1) year following the date of purchase, excluding therefrom any special, extended, or limited warranty published by
Lincoln. If equipment is determined to be defective during this warranty period, it will be repaired or replaced, within Lincolns sole
discretion, without charge.
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 equipment 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. Lincolns 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.

Lincoln Industrial Special Limited Warranty


SPECIAL LIMITED 2 YEAR WARRANTY
SL-V Series, Single Injectors-85772, 85782, and Replacement Injectors-85771, 85781
Lincoln warrants the SL-V Injector series to be free from defects in material and workmanship for two (2) years following the date
of purchase. If an injector model (single or replacement) is determined to be defective by Lincoln, in its sole discretion, during this
warranty period, it will be repaired or replaced, at Lincolns discretion, without charge.

Lincoln Industrial Contact Information


To find Lincoln Industrials Nearest Service Center
Call one of the following numbers, you may also use our wbsite
Customer Service - 314-679-4200
Website - www.lincolnindustrial.com

Form 403786

Page Number - 7

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

Declaration by the manufacturer as defined by


machinery directive 89/392/EEC Annex IIB
Herewith we declare that the supplied model of
SL-V
is intended to be incorporated into machinery covered by this
directive and must not be put into service until the machinery
into which it is to be incorporated has been declared in conformity with the provisions of the directive.
Applied harmonized standards in particular:
EN292 T1/T2
prEN 809

Paul Conley,
Chief Engineer

Page Number - 8

Form 403786

G. Sandvik BR3288 Hydraulic Hammer Manual

103