Académique Documents
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H. Koskinen 11/2002
Good visibility front Cabin position. Side view is better. More space for maintenance of power train (engine).
Better visibility reversing. Exhaust pipe is far of the cab and hydraulic.
Boom
For 5 high stacking (96)
made to last =welds on the neutral axle rollers for inner boom
low friction =>less power needed = fuel economy
end damping with proximity sensors = smooth operation floating wear pads on the basic boom
easy replacement excellent support
Steering axle
Sandwich - type heavy duty design made to last
same for 25 and 33 tires basic model without brakes disc brakes only as option for 33 tire models built-in gauge for electronic overload system (rear) mechanical stops to limit the axle oscillation improving lateral stability spherical plain bearings on pivot points
A Partek Company
13
DRS ContMaster
Rear view from the cabin Clark Transmission filters
Main hydraulic valves Steering priority valve Fast Hoist valve Signal pressure valve Pressure sensor(s)
PRELIMINARY
Technical data and cooling equipment recommendation DI12 54A, order ref. 10-00
This engine complies to exhaust emission Rating regulations Stage 2 EURO and TIER 2 acc. to 1200 USA. 187 (254) Gross power kW (hp) ICFN IFN 187 (254) Gross torque Nm (kpm) ICFN 1488 (152) IFN 1488 (152) Spec. fuel consumption full load 3/4 load 1/2 load Heat rejection to cooling water to exhaust gas to surrounding air Air consumption Exhaust flow Exhaust temperature kg/min kg/min
Engine speed, r/min 1500 237 (322) 237 (322) 1509 (154) 1509 (154) 195 (143) 199 (146) 205 (151) 134 171 22 23 24 427 1800 240 (326) 240 (326) 1273 (130) 1273 (130) 203 (149) 211 (155) 220 (162) 155 190 23 28 29 399 2100 243 (330) 1105 (113) 220 (162) 233 (171) 242 (178) 189 230 25 31 32 431
g/kWh (g/hph) 195 (143) 200 (147) 203 (149) kW 106 134 22 15 16 501
ICFN, 1800 r/min Air-on temp. 35 C Radiator front area weight Coolant pump flow Fan type power losses number of drive belts (poly-V) speed ratio Air flow free air flow pressure reserve m3/s mm Wc mm kW m2 kg dm3/min 1.0 55 360 Puller 787 9 1 1:1.08 8.5 35 50 C 1.0 55 360 Puller 787 9 1 1:1.08 8.5 30
IFN, 2100 r/min Air-on temp. 35 C 1.0 55 420 Puller 787 21 1 1:1.08 9.8 35 50 C 1.0 55 420 Puller 787 21 1 1:1.08 9.8 30
PRELIMINARY
DI12 54A, order ref. 10-00 (optimized for Clark 36000 transmission)
OUTPUT kW
kW x 1.36 = hp
260
240
220
200
180
160
210 190
140
TORQUE Nm
Nm --------- = kpm 9,81
IFN
Engine QM 11
Air to Air inlet line cooler before Turbo charger of Cummins QSM11 Engine
QSM11
FR 2926
CPL 2828-SC2
Engine Configuration: D353014CX03 Compression ratio: 16.3 Revision: Fuel System: Celect Electronic Rating: 330 hp (246 kW) @ 2,100 RPM 1-Nov-2000 Emission Certification: U.S. EPA Tier 2, CARB Tier 2, NRMM (Europe) Tier 2 All data is based on the engine operating with fuel system, water pump, and 15 in H2O (381 mm H2O) inlet air restriction and with 3 in Hg (76 mm Hg) exhaust restriction; not included are alternator, fan, optional equipment and driven components. Coolant flows and heat rejection data based on coolants as 100% water in U.S. GPM.
Rating Type:
Intermittent Torque
RPM 700 900 1,000 1,100 1,200 1,400 1,600 1,800 2,000 2,100 lb-ft 800 1,050 1,200 1,235 1,235 1,235 1,083 963 867 825 N-m 1,085 1,424 1,627 1,674 1,674 1,674 1,468 1,306 1,175 1,119
Power Output
RPM 700 900 1,000 1,100 1,200 1,400 1,600 1,800 2,000 2,100 hp 107 180 228 259 282 329 330 330 330 330 kW 80 134 170 193 210 245 246 246 246 246
Fuel Consumption
RPM 1,400 1,500 1,800 2,000 2,100 lb/hp-hr 0.328 0.32 0.316 0.325 0.33 gm/kW-hr 200 195 192 198 201
Curves shown above represent gross engine performance capabilities obtained and corrected in accordance with SAE J1995 conditions of 29.61 in. Hg(100 kPa) barometric pressure [300ft.(91m) altitude] 77F (25 C) inlet air temperature, and 0.30 in Hg (1kPa) water vapor pressure with No.2 diesel fuel. The engine may be operated up to 12,000 ft (3,657.6 m) altitude before electronic derate is applied.
Final
CHIEF ENGINEER:
Richard D Johnston
Cummins Confidential
FR 2926
(Continued) Page: 2
30 delta deg F
Exhaust System:
Maximum exhaust back pressure: 3 in-Hg 76 mm Hg
Lubrication System:
Nominal operating oil pressure At minimum low idle: At maximum rated RPM: Minimum engine oil pressure for engine protection devices At maximum rated speed: At minimum low idle: 15 psi 35 psi 28 psi 10 psi 103 kPa 241 kPa 193 kPa 69 kPa
Fuel System:
Maximum supply fuel flow: Fuel cooling requirements (with diesel fuel) Maximum heat rejection to return fuel at max. coolant and inlet fuel temperature: At fuel return flow rate of: At fuel return temperature prior to cooler: Maximum return fuel flow: Minimum torque required to hold throttle at full travel ( Mech. System) Engine fuel compatibility (consult Appl. Eng. For appropriate use of low viscosity fuels) 591 lb/hr 260 572 212 572 BTU/min lb/hr deg F lb/hr lb-in DF1, DF2 268 kg/hr 4.57 259 100 259 kW kg/hr deg C kg/hr N-m
Performance Data
Engine low idle speed: Maximum low idle speed: Minimum low idle speed: Maximum allowable governor droop: Maximum allowable governor regulation: Maximum no load governed speed: Governor break speed: Maximum torque available at closed throttle low idle speed: Maximum power available from the front of the Crankshaft -Consult Cummins Application Engineer for Information RPM 1,200 RPM 600 RPM % % 2,350 RPM 2,130 RPM 1,220 N-m
900 lb-ft
Cummins Confidential
FR 2926
Governed Power Engine Speed Output Power Torque Friction Horsepower Intake Manifold Pressure Turbo Comp. Outlet Pressure Turbo Comp. Outlet Temperature Intake Air Flow Charge Air Flow Exhaust Gas Flow Exhaust Gas Temperature Fuel Flow to Pump *Heat Rejection to Coolant Heat Rejection to Aftercooler Coolant (LTA) Heat Rejection to Fuel Heat Rejection to Ambient **Steady State Smoke 330 825 -61 46 49 333 875 62 1,860 745 427 4,800 hp lb-ft hp in-Hg in-Hg deg F ft3/min lb/min ft3/min deg F lb/hr BTU/min BTU/min 2,100 246 1,119 -46 1,165 1,228 167 413 28 878 396.1 194 84.4 RPM kW N-m kW mm Hg mm Hg deg C L/s kg/min L/s deg C kg/hr kW kW 330 963 -45 49 52 337 810 56 1,780 780 360 4,450 Peak Power hp lb-ft hp in-Hg in-Hg deg F ft3/min lb/min ft3/min deg F lb/hr BTU/min BTU/min 1,800 246 1,306 -33 1,241 1,304 169 382 26 840 416 163 78.25 RPM kW N-m kW mm Hg mm Hg deg C L/s kg/min L/s deg C kg/hr kW kW 329 1,235 -28 56 59 365 710 50 1,750 905 250 4,700
(Continued) Page: 3
Peak Torque 1,400 245 1,674 -21 1,418 1,482 185 335 23 826 485 113 82.65 RPM kW N-m kW mm Hg mm Hg deg C L/s kg/min L/s deg C kg/hr kW kW
hp lb-ft hp in-Hg in-Hg deg F ft3/min lb/min ft3/min deg F lb/hr BTU/min BTU/min
*Engine with dry manifold. ** Note for Nat. Aspirated Engines: When operating Naturally Aspirated engine above SAE J1995 conditions, it should be noted that smoke levels will increase due to combustion inefficiencies associated with a reduction in the air to fuel mixture.
Emissions
Noise Emission: Top Right Side Left Side Front
Estimated Free Field Sound Pressure Level at 3.28ft. (1m) and Full-Load Governed Speed (Excludes Noise from Intake, Exhaust, Cooling System and Driven Components)
Gaseous Emissions Limits per ISO 8178, are equal to or less than: Weight Specific Nox Weight Specific HC Weight Specific CO Weight Specific Particulate
End of Report
Cummins Confidential
Drive axle
Rockwell 7534 series
* proven & well known globally * practically wear-resistant WDB * filtering after forced cooling * 18.00-25 tire with 26.0 ratio * 18.00-33 tire with 30.45 ratio Different ratios will give the uncompromised acceleration & speeds in all operating conditions
A Partek Company
22
Access to and from the cabin is safe with steps on both sides of the machine
DRS ContMaster Main contactor, Fuses, Cab transfer unit, First version
Batteries
Fuses F34, F35 15A F36, F37, F38, F39 and F41 10A F40 25A F42 to F49 are Options A81 MCC2212 MODULE Hydraulic, Cab transfer, Accelerate and Indication light of the spreader XQS2 Only for Cummins QSM11 for Cummins Service Group
Maintenance Key S3. When watching values of input/output from the Display
A84 CONTROL UNIT MCKC. Input orders from cabin instruments (info position of the cab switches) A82 CONTROL UNIT MCC2212. Engine control, Auto gear,Stab 1/2, Mini steer, Idle stop, Vertical lift, Load scale.
Alarm buzzer
Maintenance key
DRS ContMaster Forced Motion Switches RH-side drivers seat on the back wall
S186 S187 S188 S186 Engine Throttle selector 1300 RPM. Switch position 1 S187 First (1) position Engine Power ON. Second (2) position Engine Start. S188 Gear selector Forward or Reverse and II-gear only.
Transformer A12
Over load by-pass Twist Lock auto or manual closed Automatic T-L Length adjusting selector
Cabin transfer Dumping sensors: Forward S97A Reverse S97B Location RH-side Cabin under and inside profile
L = Lift LTO = Lift Telescope Out LTI = Lift Telescope In TO = Telescope Out CC = Twist Lock Close
A81:D18 = FCV auto/manu RL = Fast Lift RC = T-Lift Rotate Clockwise RC.= T-Lift Rotate Counter Clockwise
N:o 3K5692470
N:o 2K5692460
One way valve # 20 for back pressure 5 bar Fill up dumping cylinders
-Brake hydraulic tank for brake system and cooling. -Cooler for brake oil 50 C fan start running. -Main hydraulic oil tank is separate and normal ISOstandard oil. -Lincoln central lube system is complete Lincoln design.
CLARK
Brake pump #16, 33 l/min gear type,PM22
ENGINE
LH-side Variable pump #17/98 (PM3) 206 l/min 2100 RPM
Intra vane pump #67 (PM4), 142 l/min 2100 RPM (oil to the Spreader)
Pistons
Bias piston
Only 3040 bar open the LSspool and pressure behind the control piston regulate the swash plate to zero flow. Control piston Bias piston
Load signal pressure to adjust swash plate angle as in demand. Pump outlet pressure and LS - pressure are balancing Load Sensing Spool and oil volume is ordered level.
Vickers displacement hydraulic pump PVH LS - signal pressure is higher level than max pressure limiting spool. Pump outlet oil pressure to adjust swash plate angle to zero as in demand.
First spool Pump connection both side Second spool Leakage from service port to tank From A- or B-port: max. 20 cm/min at 100 bar, oil 50 C and viscosity 30 mm/s (cSt).
Components front end middle of frame and diagram is done like mounted
352bar Pilot pressure reducing Priority valve of steering
Left side
Boom
Right side
Lift/Low
To steering valve
View from the Cabin and components are like diagram shows
PM4 1255bar
Forward
PM10 Main pressure 2105 /30 bar PM8 Pilot pressure 352 bar
Shuttle valve #33. LS-signal either from steering valve or main directional valve
PM4 1255bar
FWD
Pressure Sensor B6 from Right Lifting Cylinder Pressure. Purpose: Fast Hoist and Reducing lowering speed
Pilot restrictor for smooth control, sizes available from 0,45..1,6 mm diameter
NOTE! If you remove remote control valve, check those restrictors when you assembly!
Proportional solenoid valve for L90LS, K220 and M400 directional valves
Pilot restrictor off from remotecontrolled spool actuator Restrictor mounted. Available different diameter, marked dots. Note check that restrictor is with the spool!
PM4 1255bar
FWD
Pressure Sensor B6 from Right Lifting Cylinder Pressure. Purpose: Fast Hoist and Reducing lowering speed
Right turn
Neutral oil to EF
Left turn
Steering valve now L output position. Double shock valves 245 bar with anticavitation valves.
Priority valve. Always steering is first. When no steering oil flow from EF gate to main valve. Pump #74 155 l/min LS-signal from steering valve or main directional valve
PP-signal 0,8mm
EF
LS-signal pressure Orifice 0,81,2mm
CF
Main hydraulic
Steering
Finger Tip Steering Valve of DRS 2002 Over pressure from cylinder
+
Port A Port B
Pilot restrictor for smooth control, sizes available from 0,45..1,6 mm diameter
NOTE! If you remove remote control valve, check those restrictors when you assembly!
Leakage line
Safety
Driving prevented if
low brake system pressure (< 90 bar) high rpm => no gear connection (rush start) high speed => no direction change accepted parking brake engaged
A Partek Company
39
Change the flow by turning two valves so that there is only one output
A Partek Company
Solution
A Partek Company
210 bar both end ratio 10:1 (return flow need 20 bar to get back) PS1 100 bar max. pump pressure PM1
Pressure relief valve of max. operating pressure PS1 1205 bar. When you adjust pressure, take off sockets from directional valve.
Note! Arrow points downwards and this side facing towards motor.
Mechanic limiter side way tilt oft he main frame Preload of the King pin bearings START TO MOVE 150 to 170Nm
Stub Axle Hub Bearing Nuts and Locking Ring & Preload Instruction
First nut against the bearing Locking plate NOTE! Dont use locking plate twice! Preload of bearings: 30 - 50 Nm continues rolling resistance (means about 1000 Nm tightening torque to FIRST nut but always rolling resistance is final check)
Wet brake cooling oil pressure check point and orifice 5 mm before
Oil cooler of brake cooling return line from the wheel hub
Lincoln central lube pump and electric control center
Wet brake cooling oil cooler before brake oil tank Brake oil tank with level glas and temperature gauge
Signal Pressure
System Pressure
A Partek Company
T P T P
A Partek Company
T P T P
A Partek Company
Pressure check point PM26 1605 bar (Parking brake open) Charging valve
Filter #5
Solenoidiventtiili laskun lukkoventtiilin avaukseen, normaalisti kiinni. Solenoid poppet valve 2/2 way, normally closed, high pressure.
24 V DC 19 W, 0.79 Amps, 30, 30 Max internal oil leak at 210 bar 3000 PSI At 38 cSt 180 SSU 0.33 ml/min (5 drops/ min) 40 Nm 44400o
1/1
Varo- ja imusuojaosuus Nostosylinterien lukkoventtiileist Lift cylinder lock valve pressure relief and vacuum preventer
The ratio between control pressure (opening X) and load pressure (opening B) is 1:20.
Figure 1. Pre-controlled pressure limiting valve equipped with a magnet controlled pressure release, type DBW.
PM4
PS4 125bar
Y56 Free circulation valve #32, Y56 and pressure relief valve
S72 Temperature switch for controlling cooler fan start point is >50 C PM 4 Spreader pressure check max 1255 bar Free circulation valve #32 (Y56 and PS4)
Inner oil leakage to tank is 4 l/min when operating pressure is 210 bar. Tightening torque of the valve housing bolts for OMT 120 Nm (1050 90 lbf in) OMV 200 Nm (1750 90 lbf in) Tighten the cover bolts at torque 10 Nm (90 lbf in) See also timing marks.
Rotating Y59a/b
COUNTERBALANCE VALVE 0 to 120 L/min Nominal Series 2 Cartridge T-2A Cavity Installation Torque 60 to 65 Nm Turn screw clockwise to reduce setting and release load. Complete adjustment range in 3 turns.
-adjust main relief valve (#85) back to 1255bar -lock the adjusting screws -mount cabs Y62
SPREADER LENGTH, SHORT, TWIST LOCK VALVES TOP OF THE SPREADER RH SIDE
Lengthening Shortening Valves Twist Locks valve
30 position sensor
Landing pin every corner. All 4 are connected series and all of them must be activated until twistlock open or close operation is possible.
Spreader rotation limit sensor (one each side +200 -100 degrees)
When you weld - unplug connectors when power is turn off. When plug in power must be off.
24 V out pin no 42 Operation: LED 1 Supply +24V out (pin no 36) LED 2 Supply +24V out (pin no 42) LED 3 Active when power on (main switch is closed) LED 4 Active when pin of processor PE0/DSACK0 is grounded
24 V out pin no 42
Operation: LED 1 Supply +24V out (pin no 36) LED 2 Supply +24V out (pin no 42) LED 3 Active when power on (main switch is closed) LED 4 Active when pin of processor PE0/DSACK0 is grounded
Module MCC2212
Scrolling of displays
Displays. Following picture there are all the displays. The text can be 13 languages
0.1
Kalmar tai machine type
0.2
OK
Load parameters
OK
46
A M
3x during 2s
M
39
Calibration Are you sure? OK
55 56 57 58
ENGINE WATER TOO HOT ENGINE OIL PRESSURE LOW ERROR R60 ERROR R61 ERROR B6 ERROR B8 ERROR CAN A81 ERROR CAN A82 ERROR CAN A83 ERROR CAN A84 ERROR CAN ENGINE ERROR ENGINE TEMPERATURE ERROR OIL PRESSURE ERROR ENGINE RPM ERROR ENGINE ERROR ENGINE _____________ ERROR A312 LOW BRAKE PRESSURE
47
F/R SELECTED
10 4
Engine water (C)
18
26
34
48
59 60 61 62 63 64 65
40
OK OK OK OK
Calibrate Stability 1
OK 40.1 40.2 40.3
49
5
Engine oil (bar)
11 12
DI 123456789012 000000000000 A1 0.00 A2 0.00 A3 0.00 A4 0.00 A5 0.00 A6 0.00 A7 0.00 A8 0.00 DO 123456789012 000000000000 PR1 00% PR2 00% PR3 00% PR4 00% PR5 00% PR6 00% PR7 00% PR8 00% PR9 00% PR10 00%
19 20 21 22
DI 123456789012 000000000000 A1 0.00 A2 0.00 A3 0.00 A4 0.00 A5 0.00 A6 0.00 A7 0.00 A8 0.00 DO 123456789012 000000000000 PR1 00% PR2 00% PR3 00% PR4 00% PR5 00% PR6 00% PR7 00% PR8 00% PR9 00% PR10 00%
27 28 29 30
DI 123456789012 000000000000 A1 0.00 A2 0.00 A3 0.00 A4 0.00 A5 0.00 A6 0.00 A7 0.00 A8 0.00 DO 123456789012 000000000000 PR1 00% PR2 00% PR3 00% PR4 00% PR5 00% PR6 00% PR7 00% PR8 00% PR9 00% PR10 00%
35 36 37 38
41
Calibrate accel.
OK 41.1 41.2 41.3
50
51
6
Operating hours
13 14
42
52
66 67
Container counter
43
Calibrate Stability 2
OK
15 8
Autom. gripping
23
31
53
43.1 43.2 43.3 43.4 43.5 44.1 44.2 44.3 44.4 44.5 44.6 44.7 45.1 44.8 44.9 44.10 44.11 44.12 44.13 44.14
HAND BRAKE
68 69
16
24
32
44
Language
OK
54
OK 17 9
Autom. changer
70 71 72
25
33
45
OK
DRIVERS DISPLAY
SERVICE DISPLAYS
ALARMS
CRITICAL ALARMS
22.11.02
Version management There is only one (the latest) version of each module program in use. The list of parameters is in practice always different according to the options asked by the client.
56(62)
22.11.02
57(62)
22.11.02
In IO-program to the point of Display Parameters it will come date and time of the latest loading of parameters (on the display). The value of Module A81, Module A82 and Module A83 -field is the version number of the module program and in the same time it tells if the modules are in the bus, otherwise ERROR-text. F2 tell the frequency of the transmission in hertzes, F1 is spare for later use. In IO-program the propo-outputs can be seen in percents and milliamperes (accuracy 4mA). Digital inputs and outputs are 1 or 0. Analog inputs are percents and volts (accuracy 20mV). Load tells the container weight in accuracy of tenth of ton and as difference with the display result it will be updated all the time. Reach tells the reach in accuracy of deci-meters. The stability point tells stability at the moment in question in accuracy of one percent without average calculation; the reading is not limited to 100% as it is on the display. The angle is shown in accuracy of one degree. 59(62)
T-beam
Spreader Frame
Sliders of the Spreader Frame. Around of outer end.
SISTEMA DE LUBRIFICAO
SISTEMA DE LUBRIFICAO
SISTEMA DE LUBRIFICAO
SISTEMA DE LUBRIFICAO
SISTEMA DE LUBRIFICAO
SISTEMA DE LUBRIFICAO
SISTEMA DE LUBRIFICAO
SISTEMA DE LUBRIFICAO
SISTEMA DE LUBRIFICAO
SISTEMA DE LUBRIFICAO
SISTEMA DE LUBRIFICAO
SISTEMA DE LUBRIFICAO
SISTEMA DE LUBRIFICAO
SISTEMA DE LUBRIFICAO
SISTEMA DE LUBRIFICAO
Operating Instructions
Grease Lubrication System for Patria Vammas PSB5500H
LINCOLN GmbH Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259
Operating Instructions
Grease Lubrication System for Patria Vammas PSB5500H
SAFETY INSTRUCTIONS
Appropriate Use Use of the 203 pump and progressive divider valves only for dispensing lubricants in centralized lubrication systems. The system is designed for intermittent operation. General Safety Instructions The progressive centralized lubrication system connected to the QUICKLUB pump Model 203 must always be secured with a safety valve. Incorrect use may result in bearing damage caused by poor or over-lubrication. Unauthorized modifications or changes to an installed system are not admissible. Any modification must be subject to prior consultation with the manufacturer of the lubrication system. Use only original LINCOLN spare parts (Parts Catalog) approved by LINCOLN Regulations for Prevention of Accidents Adhere to the regulations for prevention of accidents, which are effective in the country where the system is to be used. Operation, Repair and Maintenance Repair should only be performed by: - Authorized and - Instructed personnel who are familiar with the centralized lubrication systems. This is a brief Owner Manual only. More detailed safety and operation instructions are described in the following Owner Manuals that are available: Manual Name Quicklub Pump model 203 Quicklub, Progressive Metering Devices for Oil and Grease Printed Circuit Board for Pump 203 Quicklub Parts Catalogue For technical service contact Lincoln customer service at: LINCOLN One Lincoln Way St. Louis, MO 63120-1478 Phone 314-679-4200 Fax 314-679-4359 www.lincolnindustrial.com Manual number 2.1A-30001-C99 2.2A-10001-C99 2.6A-20002-C00 2.0A-20001-E00
LINCOLN GmbH Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259
Operating Instructions
Grease Lubrication System for Patria Vammas PSB5500H
P203 Pump
Reservoir
Test button
LINCOLN GmbH Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259
Operating Instructions
Grease Lubrication System for Patria Vammas PSB5500H
LINCOLN GmbH Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259
Operating Instructions
Grease Lubrication System for Patria Vammas PSB5500H
Reservoir filling
Always fill through the filling nipple. The best practice is to use standard refinery drums or pails. Impurities in grease can greate operational problem. NLGI 2 greases are applicable up to 20 C (-4 F) Use NLGI 1 in extreme temperatures Do not mix two greases - Consult your grease supplier first
Emergency lubrication
The pump can be by-passed by feeding grease manually through the manual grease fitting attached on the pressure relive valve. Alternatively by attaching a manual fitting on a divider valve will make manual greasing possible. Pressure relief valve with a by-pass fitting
Filling nipple
LINCOLN GmbH Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259
Operating Instructions
Grease Lubrication System for Patria Vammas PSB5500H
Indicator lights
Once the power is connected to the pump the left side LED is lit.
LINCOLN GmbH Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259
Operating Instructions
Grease Lubrication System for Patria Vammas PSB5500H
PUMP ELEMENT AND PRESSURE RELIEF VALVE OPERATION Pump element operation
Suction phase
Pumping phase
System blockage
In case the system is blocked the pressure relief valve will start to bleed at 5000 psi (350 bar). Since the system piping will hold the pressure after the pump has stopped the blockage can be detected by carefully loosing the supply line fittings between the main valve and secondary valves (A, B, C). If necessary use manual grease gun to apply more pressure through the by-pass fitting. The secondary valve feed line fitting that will bleed grease is blocked. It is fastest to detect the blockage in a secondary valve loop by attaching a manual fitting in the valve inlet. The blockage can be found with grease gun by opening lubrication feed lines. A
B C
Feed lines
LINCOLN GmbH Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259
Operating Instructions
Grease Lubrication System for Patria Vammas PSB5500H
LINCOLN GmbH Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259
Why NLGI 2 greasing system? Better sealing Wide temperature range Harder grease stays better in bearings and bushings Lower usage - cleaner machine and environment
Basic solution: Single nipple system Option A: Pump with timer Option B: Pump with timer and system monitoring
Economical initial system Cuts lube service time by 80-90 % Improves workers safety Easy to automate - just add a pump
0,2 cm per outlet Sizes from SSV6 to SSV22 metal-to-metal construction (no seals) mechanical or electrical monitoring capability (option)
Outlet Crossporting
Outlets are combined to increase the amount of lubricant for that outlet:
0.2, 0.4, 0.6 ccm, etc
Lubricant from a plugged outlet is redirected to the next outlet on the same side of the block
KEY COMPONENTS
PUMP P203 Power supply versions: 12, 24, 110 and 230v Pump elements: Output: Output pressure: Op. Temperature: Pumpable grease: Protection class: Reservoir:
Circuit board Pump element:
1, 2, or 3 0.6.4ccm / element Max 350 bar +80C -40C up to NLGI 2 (-25C) IP54 IP 6K 9K 2, 4 or 8 l
EN - approval
Pump element
Suction phase
Pumping phase
K5 element: 0.122 cu in/min (2.0 ccm/min) K6 element: 0.171 cu in/min (2.8 ccm/min)
Pump element
1 2
Range setting: P=pause time hours (minutes) I =operating time minutes (seconds)
Test button
Setting:
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
A 10
B 11
C 12
D 13
E 14
F 15
1 2
2 4
3 6
4 8
5 10
6 12
7 14
8 16
9 18
A 20
B 22
C 24
D 26
E 28
F 30
Indicator lights
Power connected
Pump operates
Wiring diagram
Always use a filling nipple (never fill from top the 4 and 8 liter vesions) P203-pump allows the use of NLGI 2 grease up to -25C If grease quality is changed check grease compatability with your supplier
Loose the plug and press the test button for 2 seconds The wiper/blender inside the pump turns and pump feeds grease Verify the operation by loosening one feed line (Note: Wait until pump has competed the cycle)
System check
ContMaster Assembly
This instruction is applicable in cases when a Contmaster must be finally assembled on site after transportation. Necessary space and devices In the assembly there is needed a crane with min. lift capacity of 15 tons. Necessary amount of lift belts to lift boom, spreader and hoist cylinders and manual wire hoisters with binding belts to tie hoist cylinders. Additionally there are needed stout stands and wooden bars to temporarily support boom and spreader, see pictures.
Assembly phases:
1 Fixation of hoist cylinders to the boom Set the boom to a sloping position, see pic.1. Fix the hoist cylinders to the boom with assistance of the crane. Tie a lift belt to a cylinder under the hydraulic pipe and making sure the fixation will not slip. Lubricate the bearings. Tie cylinders to shown position with binding belts & wire hoisters (1) either to the lugs in the boom front end (A) or around the boom (B), see pic. 1.
14000 kg B
700 kg 1
Ksuun on Ki1011[H]:\\Yhteis\Doktuot\RSD_kop.doc
1,5 m
2 Fix the hoisting belts thus the booms stays in a desired sloping when lifted. Lift with two hooks (A) or with one (B), see pic. 2. Move the cabin to its rear position. Lift the boom over the machine. Fix first the rear fastening and then the cylinders. Note! The both bearing lines of the rear fastening must be in line at the same time otherwise you cannot slot in the pins. Manual wire hoister connected to binding belt makes adjusting much easier.
A LB + 1,5 m
B LB
LA+1 m
14000 kg
Pic. 2 Assembly of boom + cylinders Lubricate all bearings Connect the cables and hydraulic lines of boom and cylinders Be extremely careful in joining the hydraulic couplings to avoid any impurities to intrude into the hydraulic system
Ksuun on Ki1011[H]:\\Yhteis\Doktuot\RSD_kop.doc
LA
3 -
Spreader assembly Lift the spreader at least 1,2 m over the ground see pic. 3. (it can be lifted even over a container) Move the reach stacker to meet the spreader and lower the boom to its attachment points. Note! When the boom is operated before the electrics of spreader arent yet connected, you must use by-pass of hoist prevention (switch S194) and by-pass of stability control (switch S85) Fix the spreader onto the boom Lubricate the bearings Connect the electric and hydraulic lines of spreader
7600 kg
4 -
Test drive Test drive movements of boom and spreader. Make sure there are no leakages in hydraulic joints. Test drive with a container.
Ksuun on Ki1011[H]:\\Yhteis\Doktuot\RSD_kop.doc
M in 1,2 m
SERVICE IS ALWAYS #1