Lincoln ALS Hyd Manual

Owner Manual

Lincoln Auto Lubrication System Hydraulic Operated Type

LINCOLN AUTO LUBRICATION SINGLE LINE SYSTEM ON MINING EQUIPMENT INSTALLED BY PT. FLUIDCON JAYA

MANUAL BOOK 1

Owner Manual


SPECIFICATIONS

Pump Model High Chief Pump

03-000921

Hydraulic Supply Inlet Pressure Hydraulic Inlet Flow Seals Operating Temperature Max. Hyd. Fluid Temp Hydraulic Filtration Hydraulic Inlet Port ( P ) Tank Return Port ( T ) Pump Outlets

20-200 BAR 0.25 – 3.0 L/min Viton -10 0 C to +60 0 C 980 C 10 micron 7/16” JIC 9/16” JIC ¼” NPT

Grease For Container Output Pressure Output Flow Output per cycle Grease Output Port To System Grease Recommendation Recommendation

40kg Tank 242 Bar ( 3500 PSI ) @ 15 cycles/mm 132cm3/min 8.8cm3/min ¾” JIC Min NLGI-2

Electric Voltage Input Current

24V DC 1.6 A max

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DESCRIPTION The Hydraulic pump stations that is designed for use in bulk filling under pressure and is designed to create centralized lubrication systems utilizing single line parallel grease injector components. The units incorporate the High Chief Hydraulic Double Acting Pump, which dispenses lubricant on both the up and down strokes. The Pump stations have all the hydraulic control components to cycle a single line pararllel grease injector system, EXLUDING THE TIMER CONTROLLER (Lubrication System Timer Controllers). The main component are as follows : High Chief (Hydraulic Double Acting) Grease Pump Hydraulic Direct Acting Vent Valve Grease Pressure Switch Grease Pressure Gauge 3 Way Hydraulic Valve Light weight metal reservoir for placing 40kg grease pump • • • • • •

High Chief Pump Owner / Operator Responsibility It is the owner/operator responsibility to properly use and maintain this equipment. The instructions and warning contained in this manual shall be read and understood by the owner/operator prior to operating equipment. If an owner/operator does not understand English, a request must be made to have the contents of this manual explained in the owner/operator native language to maintain the legibility of all warning and instruction labels. The owner/operator shall retain this manual for future reference to important warning, operating and maintenance instructions.

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SAFETY INSTRUCTION This equipment generates very high grease pressure. Extreme caution should be used when operating this equipment as material leaks from loose or ruptured component can inject fluid through the skin and into the body causing serious bodily injury including possible need for amputation. Adequate protection is recommended to prevent splashing of material onto the skin or into the eyes.

INSPECTION If over pressurizing of the equipment is believed to have occurred, contact PT. FLUIDCON JAYA or your nearest service center.

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G2 Pulse Lubrication Controller The G2 Pulse Lubrication Controller is specifically designed for use on systems incorporating a pumps well as a solenoid valve and pressure switch. The unit can be programmed for pause cycles from 1 second to 50 hours, maximum pump cycle times of 1 to 50 minutes and solenoid valve times of 1 to 50 seconds. The systems can run from 10 to 30 volts DC making it suitable for 12 or 24 volt systems. Low level monitoring is also available as well as an additional output to drive a fault lamp if required.

SET UP MODE To enter setup mode apply power while holding the button down for 2 seconds. The fault led will illuminate to indicate that the unit is in Setup Mode. The first parameter is the Pause Time. This can be from 1 second to 50 hours. The range leds will indicate the range of the current s etting. To determine the exact setting turn the dial until the range led starts to blink, this indicates that the dial and range leds are pointing to the current setting. To select a different setting turn the dial until the range leds and the dial indicate the desired setting, press and hold the button for 2 seconds. The range led will now start to blink indicating the new setting has been accepted, This step can be repeated if necessary. To move to the next parameter simply press the button briefly. Note that the position of the dial is not significant when simply moving to the next parameter.

The next parameter is the Solenoid Cycle Time. This is the seconds of the solenoids on and off cycles (e.g. if this is set to 1.5 seconds the solenoid will switch at a rate of 1.5 seconds on and 1.5 seconds off). This setting can be from 1 second to 50 seconds and can be changed as with the Pause Time. 7

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To move to the next parameter again press the button briefly. The last parameter is the Pressure Timeout. This is the maximum time the system can take to build up pressure. If the pressure switch does not close within this time the unit will assume there is a fault and go into Fault Mode. Valid range for this setting is from 1 minute to 50 minutes. Change as per Pause Time. This value must be suitably longer than the maximum possible pressurizing time of the system to ensure no false alarm. To move past this parameter press the button briefly. The last stage of Setup Mode is a Test Mode, this is indicated by the Fault led flashing. The level and pressure leds will indicate if the level or pressure switches are closed. Holding the button down will drive the solenoid and pump. CAUTION, note that this will continue for as long as the button is pressed, regardless of whether the pressure switch is closed or not. To exit Setup Mode remove power. OPERATING MODE •

•

RUN During a run cycle the pump is on continuously while the solenoid cycles at the rate specified in Setup. The dial and range leds can be used to determine how much time has elapsed. Once the pressure switch contact closes the unit will enter a Pause cycle. If however, the pressure switch contact has not closed before the Pressure Time out expires, the unit will enter a Fault Mode. Pressing the button at any point will terminate the Run cycle and initiate a Pause cycle. PAUSE During a pause cycle the pumo and solenoid are off and the unit counts down to zero starting from the Pause Time specified in Setup. The dial and range leds can be used to determine how much pause time remains. Once the time counts to zero the unit will attempt to start a new Run cycle. If the pressure contact is still closed, however, the unit will enter a Fault mode instead. Pressing the button will terminate the Pause cycle and start a Run cycle only if the pressure switch contact is open. If the pressure switch contact is still closed pressing the button will have no effect. The Pressure led will remain lit so long as the pressure switch contact is closed.

•

FAULT The are three possible fault conditions 1. Reservoir low level indicated by the level led being on. This occurs if the Level switch contact is closed at any point during a Run cycle after the initial four seconds have elapsed. 2. Cycle Timeout indicated by the Pressure led being on. This occurs if the pressure switch contact does not close within the period specified by the Pressure Timeout in Setup. 3. Pressure Fault indicated by the pressure led blinking. This occurs if the Pressure Switch contact has not opened before the end of a Pause cycle. 8

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In fault mode the dial and range leds can be used to determine how long the fault has existed (up to 50 hours max). Note that pressing the button will terminate the Fault mode and start a Pause cycle. The unit must go through a complete Run and Pause cycle first before the fault time will be reset to zero. If another fault occurs first, the fault time will continue counting from where it left off. G2 PULSE WIRING The G2 incorporates a fuse on the negative supply line. This has been done deliberately as most applications are automotive and the majority of vehicles are positive earthed. This configuration ensures that any wiring shorts to earth will draw current through the fuse and thus protect the system. Note that on negative earth systems it is possible to have a short circuit that by passes the fuse and may cause damage to the unit. It is recommended to incorporate an external 8 Amp fuse on the positive supply line on installations on negative earth machines. Also be sure to use the return wiring points provided and do not introduce negative or positive circuits from other points to attempts to simplify the wiring, doing so would create alternate paths can by pass the fuse in event of short circuits. The low level switch and the pressure switch circuit will work off normally open contact as well as NPN N/O two and three wire proximity switches. If a three wire proximity switch is used take the proximity supply from the fault lamp positive terminal. If low level monitoring is not needed simply leave unconnected.

NB : This unit incorporates MOSFET transistor to drive the pump, solenoid and lamp. Excessive short circuits on these could destroy the MOSFETs before the fuse blows. Take extra precaution to avoid the possibility of short circuits. Damage to the MOSFETs from short circuits is not covered by warranty.

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INJECTOR SL-1 INJECTOR series “H” SINGLE AND MANIFOLD TYPE For Dispensing Fluid Lubricant and Grease Not to Exceed N.L.G.I.#1 Grade SPECIFICATIONS Minimum operating pressure 1,850 PSI Maximum operating pressure 3,500 PSI Recommended operating pressure 2,500 PSI Maximum vent (Recharge) pressure 600 PSI Lubricant output is adjustable 0.008 cu.in to 0.08 cu.in Injectors can be mounted in any position and can be used in circuits with SL-32 and/or SL-33 Injectors.

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SYSTEM OPERATION

STAGE 1 The injector piston is in its normal or rest position. The discharge chamber is filled with lubricant from the previous cycle. Under the pressure of incoming lubricant, the slide valve is about to open the passage leading to the measuring chamber above the injector piston.

STAGE 2 When the slide valve uncovers the passage, lubricant is admitted to the measuring chamber above the injector piston which forces lubricant from the discharge chamber through the outlet port to bearing.

STAGE 3 As the injector piston completes its stroke, it pushes the slide valve past the passage, cutting off further admission of lubricant to the passage and measuring chamber. The measuring injector piston and slide valve remain in this position until lubricant pressure in the supply line is vented (relieved at the pump).

STAGE 4 After venting, the injector spring expands, causing the slide valve to move, so that the passage and discharge chamber are connected by a valve port. Further expansion of the spring causes the piston to move upward, forcing the lubricant in the measuring chamber through the passage and valve port to refill the discharge chamber. Injector is now ready for next cycle.

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Adjustments and Priming Initial Priming of Lubricant Supply Lines (After Installation) A Remove plug from tee or injector manifold closest to the pump B Start pump operation C When lubricant begins to flow freely from Tee or injector manifold opening, stop pump operation and replace plug D Follow same procedure for Tee or injector manifold on the next shortest supply line, or branch supply line E Follow same procedure for remaining supply lines and the branch lines, progressively working to the last and longest supply line run

After all air is expelled and all plugs replaced the pump will build up lubricant pressure and complete its operation cycle To prime feed lines Use a manual or power operated grease gun to prime the feed line. NOTE : The same lubricant used in the centromatic system must be used in the grease gun.

A B

Remove filter fitting cap Contact injector filler fitting with the grease gun nozzle. Pump lubricant through the injector and feed line until there is evidence if lubricant flow at the bearing C Replace filler fitting cap. Repeat procedure for each injector in the system

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SYSTEM OPERATION This system describes the operation of the Hydraulic Pump Station and how it function with order component in the system. The system operates as follows : A The Lubricant System controlled by a timer controller. Whatever timer controller is used it must have a variable pause time and run time and have an input for a pressure switch. B The High chief and 3 Way Valve are connected electrically in parallel. When the system controller pause time is completed, a 24V DC signal (pulse) is supplied to High Chief and 3 Way Valve. This will closes the Vent Valve by oil from the pump (P1) and begins the reciprocating action of the pump, building grease pressure in the system until the pressure switch set pressure is reached (170 to 200 bar). The grease will be direct to all injector and injector will be deliver grease to each of pin or bearing who covered in the system. C The pump will continue to reciprocate until the system timer operating period ceases or the grease pressure switch is activated. This will terminate the signal (pulse) de-energizing the pump and the vent valve. Thus stopping the reciprocating action of the pump and opening the vent valve. D As the vent valve opens, grease pressure in the system main line is vented back to the tank. E The system is now at rest, ready for another lube cycle and the sequence repeats it self. Adjustment of the Pump Reciprocating Rate The pump reciprocating cycle timer is factory set at 2 seconds ON and 2 seconds OFF, which results in a cycle rate 15 cycles/minute. For information on the High Chief and Vent Valve, see the relevant service sheet 14

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Sample System Layout on Grader

Sample System Layout on Dozer

Sample System Layout on Excavator 15

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Sample System Layout on Truck

Sample System Layout on Loader

Sample System Layout on Articulated Truck 16

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Pump Grease Set 03-000555FJ

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TROUBLE SHOOTING If the following procedures do not correct the problem, contact PT. FLUIDCON JAYA or a FLUIDCON JAYA authorized service centre. When submitting equipment to be repaired, be sure to state the nature of the problem and indicate if a repair cost estimate is required. PROBLEM No or Low hydraulic pressure at auxiliary port 1 No system pressure to the pump 2 Pressure reducing valve set to low. Increase setting by ½ turn to check operation. Pump pressure build very slowly or not at all 1 No pulsing signal from reciprocation timer 2 Pressure reducing valve may be set to low 3 Grease viscosity may be to high for temperature at which pump is operating 4 If pressure is not building at all, the reciprocation solenoid may be inoperative 5 Pump piston ball check and inlet checks may have foreign matter trapped causing leakage. Remove, inspect and clean if necessary. 6 Inspect sealing surfaces between upper and lower inlet checks. Replace if rough or pitted 7 Replace shovel rod if rough or fitted. Replace shovel rod packing 8 Inspect lubricant supply line for leaks or breaks. Lubricant volume to bearing LOW 1 Output adjustment screw injector setting incorrect 2 Worn or damaged LOWER slide valve seal injector 3 Worn or damaged LOWER slide valve body o-ring injector 4 Plunger spring injector broken or worn Lubricant volume to bearing too High 1 Output adjustment screw injector setting incorrect 2 Worn or damaged UPPER slide valve seal injector 3 Worn or damaged UPPER slide valve body o-ring injector 4 Plunger spring injector broken or worn 5 Worn or damaged slide valve injector assy External leakage at body injector 1 Damaged or worn body o-ring External leakage at fitting assembly injector 2 Loose cap 3 Damaged fitting External leakage at indicator rod injector 1 Worn or damaged indicator rod packing 2 Worn or damaged indicator rod

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FLUIDCON CONTACT ADDRESS:

HEAD OFFICE JAKARTA

Cilandak Commercial Estate Building 111 M3 Jl Raya Cilandak KKO, Jakarta 12560 Tel :(+62-21)7890550 (hunting) Fax :(+62-21)7890549 E-Mail :[email protected] Webpage :www.fluidcon.co.id

SATELITE SUPPORT FACILITIES -

Gunung Bayan Coal Mine Drillshop Newmont Sumbawa Bengalon – KPC Mine Site Bontang – PT.Banpu Kitadin Mine Site

OUR BRANCHES BALIKPAPAN:

SUMBAWA:

PT Fluidcon Jaya Hidup Baru Industrial Estate Jl.Mulawarman No 21 Rt 023 Rw 007 Manggar -Balikpapan 76116 East kalimantan Tel :(+62 – 542))743389 (hunting) Fax :(+62 – 542))743383 Email :[email protected]

Concentrator Area – Buin Batu Batu Hijau Project Newmont Nusa Tenggara Sumbawa – NTB Ph :(+62 – 372))635012 Fax :(+62 – 372))635013 Email :[email protected] Newmont Extension Tel :(+62-21)5799 4600 ext :47364 Email :[email protected]

SAMARINDA:

Jl.Ir. Sutami Blok LL No. 9-10 Kelurahan Karang Asem Samarinda 75126 East Kalimantan Tel :(+62-541) 270909 (Hunting) Fax :(+62-541) 272625 Email :[email protected] SANGATTA:

Road 9 Area PT.Kaltim Prima Coal Swarga Bara,Sangatta 75387 Kab.Kutai Timur -East Kalimantan Phone :(+62 -549 )21103 Fax :(+62 -549 )21778 E-mail :[email protected]

GOSOWONG:

Gosowong Gold Project PT.Nusa Halmahera Mineral,Gosowong Tel.:(+62-21)788 46967 ext :4793 Email :[email protected] BANJAR BARU:

Jl.A.Yani Km.33,5 Banjar Baru -South Kalimantan Phone :(+62-511)4774843 Fax :(+62-511)4777630 Email :[email protected]

ADARO:

Adaro Site KM7.3 Tanjung South Kalimantan Tel/fax :(+62-526)2707774 Email :[email protected]

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Lincoln ALS Hyd Manual

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