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PHE 40hp

Operation and
Maintenance Manual

SerialNumber:R2014107131027
LWT,LLC
1750MadisonAvenue,NewRichmond,WI54017
WWW.LWTPITHOG.COM

+7152462888

OFFLOADING THE DREDGE


Equipment Needed
4 Cable Slings Rated at 10 tons
4 Shackles Rated at 5 tons each
2 50-ft Guide Ropes For guiding the dredge to prevent dredge from turning while
being lifted.
Crane (with crew) An appropriately-sized crane to lift and place the dredge in the
water from the closest stable location. Consult with a crane company to
determine the size of crane needed.
Rigging
When unloading the dredge, be sure ONLY authorized personnel are present.
Steps:
1. Position crane in a safe and stable area close to the basin.
2. Rig the cable slings and shackles on the lifting lugs of the dredge.
3. Attach the guide ropes at the front and back of the dredge. Have two authorized
personnel at these ropes. Their job is to rotate and position the dredge.
4. Attach the slings to the crane. Utilizing proper lifting practices (per rigger) lift the
dredge off the truck.
This is a picture of an LWT PHE 20HP. All LWT PHE dredges have similar lifting points.

LiftingPoints

Operation and Maintenance Manual


This manual should be considered a permanent part of this equipment. It should stay
with the dredge while being operated to provide the operator important operating, safety
and maintenance information. In the event this dredge is sold, this manual should be
given to the new owner to provide them with necessary information for operation and
maintenance. For additional copies of this manual, please contact:
Liquid Waste Technology, LLC
Attn: Parts & Service Department
1750 Madison Avenue
New Richmond, WI 54017
Ph: (715) 246-2888
Fax: (715) 246-2573
All information, illustrations, and specifications in this manual are based upon the latest
product information available at the time of printing. LWT reserves the right to make
changes at any time without notice.

O & M Manual should remain with the


dredge at all times!

SAFETY INFORMATION

SAFETY PROCEDURES
Good safety procedures and practices should be observed at all times to avoid
personal injury and lost time due to accidents. We recommend that a safety
program with rules governing the assembly, operation and maintenance of the
equipment be established and enforced for the benefit of all personnel. The
importance of observing and maintaining good safety practices cannot be overemphasized.
Appropriate rules and regulations governing the work site should be observed.
National, Provincial, State and Industrial laws and applicable regulations should be
observed.
Safety Symbol
This safety alert symbol indicates important safety messages in this
manual. When you see this symbol, followed by DANGER or WARNING,
be alert to the possibility of personal injury and carefully read the message
that follows.
Whenever the word CAUTION appears, follow the recommended procedure to
avoid injury to personnel and damaging the equipment. Any message preceded
by the word NOTE is an advisory to emphasize the content of the statement.

WARNING! SHUT OFF ELECTRICAL POWER TO THE DREDGE


BEFORE PERFORMING ANY ON-BOARD MAINTENANCE TO ANY
OF THE ELECTRICAL, HYDRAULIC OR MECHANICAL SYSTEMS!
TURN OFF ELECTRICAL POWER ON-SHORE AND PLACE THE DISCONNECT
SWITCH IN THE DOWN POSITION ON THE NEMA
ENCLOSURE AT THE STERN OF THE DREDGE. THE AMBER
INDICATOR LIGHT MUST NOT BE ILLUMINATED WHEN
MAINTENANCE IS BEING PERFORMED!

Safety Practices
The following safety practices are recommended as minimums to be in effect at all
times during dredging operations:
1. Shut down electrical power before performing maintenance or repairs on
board the dredge that could result in personal injury due to sudden or
unexpected movement(s).

CAUTION! Personnel should wear life jackets


and hard hats when in the workboat or
on board the dredge.
WARNING! Always disconnect the ECU before
performing any welding on the MudCat. Failure
to do so may result in serious injury or death.
2. Before starting the dredge, check to make sure personnel are clear of all
machinery that rotates or moves when the dredge is running.
3. Do not operate machinery with safety guards removed.
4. Never attempt to remove an object from the auger cutter or the
submersible pump when they are stalled and the hydraulic system is under
pressure.
5. Keep the machinery surfaces clean and free of oil or other slippery
substance.
6. Check all cables for wear and cable clamps for tightness at least on a
weekly schedule.
Operating Parameters
The following precautions should be observed when operating the dredge:
1. The dredges should not be operated in open or
unprotected waterways when the wind velocity exceeds 20
miles per hour.
2. The dredge should not be operated on any waterway when waves exceed
1.5 feet.
DANGER! Personnel should not be on board
the dredge during electrical storms.
Typical Safety Decals and Labels
To avoid serious personal injury, observe the various safety decals on the
dredge and comply with the message(s).
EXAMPLE:

SPECIFICATIONS

SPECIFICATIONS
LWT Pit Hog RUNT
Model RCLPES 40HP with VFD
Electric Radio Controlled Dredge

Physical:
Flotation Two cylindrical pontoons, 28 Dia. x 20-0 O.A.L x 10 gauge steel.
Transportation Length - 24-7 3/8
Transport Width - 8-2 1/2 with auger motors removed
Transportation Height 6-1/4
Operational Weight 5,800 Lbs
Maximum Digging Depth - 14
Operational Draft - 16
Power:
460 VAC, 3 Phases, 60 Hz Electric Power
Slurry Pump Electric Motor - 40 Hp
Hydraulic System Electric Motor 10 Hp

Dredge Controls:
Radio Remote Hand Held Transmitter (1000 feet max)
Slurry Pump On/Off and Speed Control (VFD)
Auger On /Off
Travel Forward/Off/Reverse and Speed Control
Boom Hoist Up/Down Upward Elevation Limit Switch
Multi-Color Light Tree Colored Light for each function

Slurry Pump:
Hayward Gordon XR4-11-S Pump w/ Submersible Motor
Centrifugal, Solids handling Impeller
Basic Construction Super Ni-Hard ASTM A532
Pump Speed 1750 RPM
Suction Diameter 6 Inches
Discharge Diameter 4 Inches
Impeller Diameter, inches - 8.50
Sphere size, inches (max) 4

Design -Capacity:
For 40HP - 900 GPM @ 50 ft head (water)

Auger Head:
Auger with Shroud - Welded Steel Construction
Helix 10 Dia. X 9 pitch 3/8 Thick Flighting
Speed 60 RPM
Torque 3,400 In.-Lbs.
Length, Overall - 8-2
Cutter Knives 7 Left Hand and 7 Right Hand

Propulsion:
Treble Sheave Hydraulic Winch w/ 3/8 Diameter Wire Rope
Hydraulic Motor with Planetary Gear Reducer Drive
Traverse Speed Variable from 0 to 30 FPM
Hydraulics:
Three Circuits Auger-Cutter, Traverse Winch and Hoist Winch
Flow Controls 3-Position, 4-Way Directional Control Valves w/ Electronic Flow Control for Winch Speed
Hydraulic Pump Output @1,750 RPM - 8 GPM
Hydraulic Relief Pressure - 1,500 PSI (124 Bar)
Hydraulic Reservoir Capacity 30 US Gallons
High Oil Temperature and Low Oil Level Shutdown Switch in Reservoir

Coating System:
All weldments shall be sand blasted and given an epoxy powder prime coat followed by a polyester powder top coat for a total coating
thickness of 5 mils minimum. Electric motors, hydraulic components etc. are installed as received with coatings applied by the original
equipment manufacturer.

Liquid Waste Technology is an innovative leader in the design and manufacture of sludge handling equipment including Auger
Dredges, Lagoon Pumpers, Submersible Chopper Pumps, Prop Agitators and Subsurface Land disposal Systems. Call 1-800-2431406, and e-mail at Info@lwtpithog.com or for more information, on the internet at www.lwtpithog.com
Rclpes40hp

Rev: 11/21/08
5

GENERAL INFORMATION

SERVICE POLICY
The service and support of LWT equipment in the field is one of our top priorities.
We maintain an inventory of most of the replacement parts for our equipment.
Whenever possible, we will fill parts orders as quickly as possible.

PARTS
The Parts and Service Departments normal operating hours are 8:00 AM to 4:00
PM (Central Standard Time or GMT -6), Monday through Friday.
To place an order for parts, contact:

Parts Department at 715-243-2132, toll free 800-243-1406


or via email: gbrady@lwtpithog.com AND
lwtandims.dredgeparts@gmail.com.

To insure we provide assistance specific to your equipment, please provide the


following information when contacting LWT:
Equipment
Model

Serial Number

RCLP 40HP

R2014-107-13-1027

If you wish to return an item purchased through the Parts Department, you must
have a Return Authorization Number which will be assigned by the LWT Parts
Department. A restocking fee may be charged on the returned parts based upon
the reason for return.
SERVICE
For operational questions, troubleshooting assistance, or to schedule on-site
service, contact:

Customer Service at 715-243-2159, toll free 800-243-1406


or via email: snelson@lwtpithog.com.

Field service is available at a flat daily rate plus expenses for travel, lodging and
meals.

LIMITED WARRANTY
Liquid Waste Technology, LLC; hereinafter referred to as LWT, warrants equipment of
its manufacture to be free from defects in material and workmanship for a period of one
(1) year from the date of startup or twelve (12) months from the date of shipment,
whichever occurs first.
This limited warranty is effective only if the equipment has been installed and maintained
in accordance with LWTs instructions for the use and service for which it was designed,
and is used as directed. This limited warranty does not extend to any condition arising
from neglect, misuse, or abnormal use in any manner; or caused by an accident or force
majeure; or from failure to properly maintain or service the product or regularly to inspect
it; or where it has been modified in any way so as to affect its stability or reliability; or it
has been altered or improperly repaired by someone other than LWT or its designee.
Due to the widely varying conditions under which LWT products are used or installed,
LWT offers no warranty, expressed or implied, as to the length of service life of
equipment or parts. This warranty does not extend to such wear parts as, but not limited
to, seals, slurry pump wet end components, bearings, tires, or any damages caused by
any failure of such parts. Neither does this warranty extend to damages from corrosion
due to extremes of either high or low pH, or from other chemical or electrolytic reaction
caused by contents in the waters where the equipment is used.
Equipment and accessories not manufactured by LWT, which are incorporated into any
LWT equipment, are warranted only to the extent of the original manufacturers warranty
or guarantee.
As a condition of this warranty, the customer shall, promptly upon its determination of
intent to make any claim against LWT, arising under this warranty, so notify LWT, in
writing, specifically describing the part alleged to be defective; and further, upon request
from LWT, shall ship such part to LWT, prepaid, as directed by LWT, for inspection by
LWT. LWT may, at its discretion, send an authorized service representative, with
transportation and expenses prepaid, to the customers site to perform such inspection.
LWTs sole obligation under this warranty, upon determination that such defectiveness
did in fact exist within the period provided, shall be limited to, at LWTs expense, either
repairing or replacing such defective part.
IN NO EVENT SHALL LWT BE LIABLE HEREINUNDER FOR LOSS OR
CONSEQUENTIAL DAMAGES OF ANY KIND OR CHARACTER CAUSED BY
DEFECTIVE PARTS OR OTHER CHARGES INCURRED BY THE CUSTOMER FOR
BREACH OF ANY WARRANTY OR IN THE REPLACEMENT OR REPAIR OF
DEFECTIVE PARTS. THIS WARRANTY IS LWTS SOLE WARRANTY EXPRESSLY
IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED OR
STATUATORY IN ORIGIN, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR LIABILITIES ON THE PART OF LWT, AND NO
REPRESENTATIVE OF LWT HAS THE AUTHORITY TO CHANGE THE TERMS OF
THIS WARRANTY IN ANY MANNER WHATSOEVER, AND NO ASSISTANCE BY
LWT OR ITS REPRESENTATIVES IN THE REPAIR OR OPERATION OF THE
PRODUCTS COVERED BY THIS WARRANTY SHALL CONSTITUTE A WAIVER OF
THIS WARRANTY, NOR SHALL SUCH ASSISTANCE EXTEND OR REVIVE IT.

ACCEPTANCE OF EQUIPMENT
Equipment Model

Dredge Serial
Number

RCLP 40HP

R2014-107-13-1027

Please initial items reviewed.


CUSTOMER

LWT

1. Dredge Appearance

__________

__________

2. Dredge Maintenance

__________

__________

3. Dredge Functions

__________

__________

4. Dredge Operations & Safety

__________

__________

5. Warranty Policy

__________

__________

At completion of the above, Liquid Waste Technology, LLC certifies that all equipment has
been reviewed with the representatives of ____________________________________ and
is found to be totally satisfactory to all involved parties.
Customer
Signature: _________________________________________

Date:________________

Print Name: _________________________________________


Email: _________________________________________
Phone: _________________________________________
Address: ________________________________________________________________
Shipping
Address: ________________________________________________________________
LWT
Signature: _________________________________________

Date:_________________

Print Name: _________________________________________

Liquid Waste Technology, LLC


1750 Madison Avenue New Richmond WI 54017 Phone: (715)246-2888
Fax: (715)246-2573 Email: info@lwtpithog.com Web: www.lwtpithog.com
REV 0412

OPERATION OVERVIEW

10

OVERVIEW OF DREDGE OPERATION

The LWT Model 40HP RCLPES, an electrically-powered, remotely-controlled,


auger dredge is designed to remove sediments from the bottom of natural waterways or
man-made such as waste treatment ponds and settling lagoons. Solids that have settled
or accumulated within these holding facilities are excavated and transported as slurry
through a hose and/or piping system to a remote location.
Steel pontoons provide the necessary flotation to support the on-board machinery
and equipment in the waterway. Principal features include the auger-head, submersible
pump, boom, boom hoist, traverse winch, electrical and hydraulic system. The
auger-head and the submersible pump are essential for effective solids removal. The
boom hoist vertically positions the auger and submersible pump in the sediment
while the traversing winch propels the machine forward and backward along a wire
rope cable anchored at both ends. This proven design provides one of the most
cost-effective means of hydraulically dredging sediments on the market today.
Prior to operation of the dredge, an anchored cable harness is established for
positioning and propelling the unit in the waterway. Generally, the harness is comprised of
two lateral cables located on opposite ends (or sides) of the pond with a traverse cable
stretched between them. The traverse cable is threaded through the treble sheave winch
and fairlead (cable guide) near the bow and through the lead block (guide sheave) on the
tail frame of the dredge. After pre-tensioning the cable to remove the slack, the traverse
winch propels the unit in both the forward and reverse directions. After floating discharge
hose and/or pipe are connected to the dredge, it is ready to operate. Generally, solids are
excavated while traversing forward only.
All dredge functions are remotely controlled from shore using a hand-held
radio transmitter. A series of push buttons on the transmitter enables the operator to
start and stop all on-board equipment. These functions include Dredge Pump On
or Off, Dredge Pump Speed, Auger-Cutter On or Off, Boom Hoist Down or
Up, Traverse Winch Forward or Reverse, and Traverse Winch Speed.

11

At the starting point, near one end (or side) of the pond, the operator turns on
the electrical power to the dredge, lowers the boom, turns the auger on, turns the slurry
pump on and increases the speed, sets the travel control forward and adjusts the speed to
the desired rate of travel. The dredge travels forward until it reaches the other end (side)
of the pond or the operator stops it. At this point, operator raises the head to a
position above the material and reduces the slurry pump to approximately one-half
speed. NOTE: This keeps the hose pressurized and out of the path of the dredge
during the reverse operating cycle. The operator then sets the travel switch in reverse
and dead-heads the dredge back to the starting point. The traverse speed can be
increased during this cycle to save time. Once the far end of the pond is reached, the
control panel settings, including the digging depth or depth of cut, pump on and/or
speed and traverse speed must be set before starting a new dredging cycle. When all of
the bottom sediments have been excavated in a given area, the dredge is laterally
repositioned and operations are resumed. This procedure is repeated as many times as
necessary until the entire waterway has been cleaned.

12

GENERAL OPERATING TECHNIQUE


The function and/or operation of the dredge controls and displays are discussed in the
Dredge Familiarization and Controls sections. The operator should become familiar with
each of the controls and displays, and have a basic understanding of each of these
before operating the dredge.
With the dredge in position near one end or side of the pond and ready to commence
dredging, perform the following steps to start and complete a typical dredge cycle.
1. Check all switches on the handheld radio transmitter to determine that all
controls are in the OFF positions.
2. Turn on the shore-based power supply to the dredge.
NOTE:

In case of an emergency or when shutting down the dredge, press the


red EMERGENCY STOP button on the top left of the radio transmitter.

3. Release the Emergency Stop button on handheld and turn the handheld power
switch to ON. Once the handheld transmitter has completed its start-up
procedure, turn the power switch to start and release. This will link the transmitter
to the receiver. When a link is established, the hydraulic power unit will turn on
along with the flashing amber light on the light stack, located on the top of the
dredge electrical enclosure.
4. Press the Boom Hoist DOWN switch to lower the boom and auger head.
Pressing and releasing the switch will incrementally lower the boom. If shallow
cuts are to be made, the boom should only be lowered a couple of feet below the
surface of the liquid. When making successive passes in the same cut, the boom
and auger head must be lowered another increment at the start of the pass until
the maximum digging depth of the dredge is reached.
The dredge should not be operated below the maximum depth stated in the
specifications.
If the pontoons rise slightly out of the water, contact with the bottom is indicated.
To avoid damaging the bottom, raise the boom and auger head assembly slightly
until it can be observed that the bow (front) of the pontoons dip slightly into the
water. This indicates that the auger is clear of the bottom.
NOTE:

In very light sludge, it is best to plunge the auger head into the sludge
blanket near the bottom of the pond. This will maximize the solids
content of the slurry.

13

5. Press the pump ON switch to start the pump. To stop the pump, press the switch
a second time.
6. If the dredge is equipped with a VFD, adjust the slurry pump speed as
necessary.
7. Press the auger switch to start the auger. To stop the auger, press the switch a
second time.
MAKE CERTAIN ALL PERSONNEL ARE CLEAR OF THE AREA AROUND
THE AUGER HEAD BEFORE STARTING THE AUGER CUTTER.
8. Set the travel winch switch in the FORWARD direction. Jog (press and release)
the travel speed increase switch until the appropriate rate of travel is obtained
this is normally 6 to 10 feet per minute while dredging. The maximum rate of
travel is 30 feet per minute. If the switch is pressed and held for 7 seconds, this
rate of travel will be achieved. Therefore, jog the switch two or three times (or
hold for 2 to 3 seconds) and observe the movement of the dredge. If too slow, jog
the switch again. If too fast, jog the travel speed decrease switch to slow it down.
9. Observe the operation of the dredge as it moves forward on the travel cable. If
everything goes smoothly, no further adjustments will be necessary and the
dredge will advance until it reaches the opposite end or side of the pond. At this
time the dredge must be stopped and returned to its starting position in the pond.
To STOP the dredge, press Travel Forward again.
NOTE:

It might be necessary to raise or lower the depth of the auger as the


dredge advances if the bottom contour is irregular. If the dredge
stops moving forward as indicated by fish-tailing or the stern raising
out of the water, raise the boom slightly until it begins to move
forward again.

10. Press the slurry pump switch once to stop the pump.
NOTE:

If the dredge is equipped with a VFD, it is generally necessary to


keep the pump running at about half speed to maintain pressure in
the floating discharge line so that it stays out of the path of the
dredge when it is traveling in reverse.

11. Press the auger switch once to stop the auger.


12. Press the boom hoist UP switch to raise the boom slightly.
13. Press the travel winch reverse switch to start the dredge moving in the reverse
direction.

14

NOTE:

It might not be possible to travel in reverse at the maximum rate of


speed of 30 feet/minute in some applications. Once the dredge has
returned to its starting point, the dredge cycle is complete. Adjust
the reverse travel speed so the dredge is moving back as quickly as
possible but make sure to reduce speed as you get near the rear
stopping point.

14. Repeat steps 3 through 5 to start another cycle.


15. Press the red EMERGENCY STOP button on the top left side of the radio
transmitter to shut off the dredge.
16. Place the electrical power disconnect on the shore-based power supply in the
OFF position.

DREDGING PRACTICES AND OPERATING HINTS


1. In soft material, both organic and inorganic, and fluid-like sediments, it is oftentimes
advantageous to plunge the boom into the material prior to starting the main pump.
This minimizes dilution of the slurry and eliminates the pumping of clear fluids.
2. If the auger cutter is stalled due to an obstruction preventing its rotation, the auger
hydraulic pressure relief valve, located on the reservoir, will be tripped. This can be
difficult to detect when the dredge is unmanned and the controls are shore-based.
One indication might be if the dredge fish-tails (moves side to side) or if the dredge
starts rising out of the water. Stop the travel winch and try stopping and starting the
auger cutter a few times to see if the obstruction can be cleared. If this procedure is
successful, start dredging again.
3. If the auger cutter is not cleared after stopping and starting, stop the auger cutter,
slurry pump and travel winch. Raise the boom until the auger cutter assembly is
accessible at the surface of the water. Press the Emergency Stop switch to shut
down all functions and place the shore-based electrical disconnect switch in the OFF
position. Go out to the dredge and check the auger circuit hydraulic pressure on the
gauge located on the reservoir. If the gauge reads zero pressure, use whatever tools
and devices necessary to remove the obstruction from the auger. After removing the
obstruction, return to shore, turn the electrical power back on and start the auger
cutter. If the auger head is rotating freely, resume dredging.
WHENEVER IT IS NECESSARY TO WORK AROUND THE AUGER HEAD, STOP
ALL OF THE FUNCTIONS AND PLACE THE POWER DISCONNECT SWITCH ON
THE ELECTRICAL PANEL IN THE OFF POSITION. NEVER WORK AROUND
THE AUGER WHEN THE AMBER LIGHT IS FLASHING!

15

4. The no-load auger hydraulic circuit pressure is 600 to 700 PSI. In soft materials,
there is likely to be only a slight increase in the auger hydraulic circuit pressure when
dredging. This pressure can be observed on the pressure gauge mounted on the
hydraulic control valve on the power unit.
5. If the material spills over the top or the sides of the auger, slow down the rate of
travel or stop travel completely and let the pump and auger continue to operate
momentarily. This is most likely to happen when making initial cuts in shallow water.
6. If the discharge line is plugging, it can normally be cleared by stopping the auger,
raising the boom slightly and pumping clear liquid. This is most likely to occur when
pumping heavy materials such as sand through a long pipeline or to an elevated
disposal area, or a combination of these conditions.
7. When cutting in shallow water, cutting a shoreline or cutting materials projecting
above the water surface, care should be taken to prevent loss of pump prime. The
suction inlet must always be submerged below the liquid surface. In extremely
shallow water, it may be necessary to make several forward cuts in order to create
adequate depth for the machine to float. It takes approximately 16 inches of water to
float the machine.
8. At the end of any operational period the auger head should be raised to its upper
limit at or near the surface of the water and water pumped to clear the line. This will
also prevent freshly cut areas from collapsing and trapping the auger head.
9. The speed of forward travel varies with the type of material being dredged. Optimum
operation matches the auger cutters ability to excavate solids at the flow rate of the
slurry pump. If the dredge moves into the material too rapidly, the unit may tend to
plow materials around or over the auger. If material is more densely packed, the unit
may tend to stand on its nose and begin to dig down into the solids. Either action
would result in an uneven pass.
10. The travel speed will generally be the most commonly used control to optimize
production. It is not possible to pump solids at more concentrated rates than they
exist in the solids bed.
11. The pump must be in the sludge to move solids. With lighter sludge it is possible to
lower the auger head down to the bottom and excavate a large bank of solids that
will continually slough down to the pump. With more rigid or heavier solids it is best
practice to take solids in layers with multiple cuts across the waterway at
increasingly lower depths.
12. Heavier solids and more viscous slurries require higher pressure to move the slurry
through the pipeline. Dilute slurry to increase flow rate.

16

DIAGNOSING OPERATING PROBLEMS


1. The flow rate at the end of the discharge pipe is less than it has been.
a. Plugging of discharge pipeline.
b. Plugging can generally be found by listening to each pipe joint while
pumping clear liquid. A hissing noise will be heard at the obstruction. Such
obstructions can occur at the main pump discharge elbow or in the
discharge pipe leading to the side of the machine. Consequently this
portion of the discharge piping system should not be overlooked.
c. Plugged pump suction.
d. Obstruction in the impeller.
2. Vibration of the machine and discharge pipe.
a. Obstruction in the pump impeller.
3. Travel cable slipping on winch drive sheave.
a. Travel cable is too loose.
b. Auger cutter assembly is digging into bottom or it is too deep in material.
4. Loss of pump prime.
a. Cutting too close to liquid surface.
b. Material viscosity is too thick to flow into the pump.
c. Gas entrapped in material is causing vapor binding.
HIGH WINDS
High winds can affect the dredge, traverse and anchoring system. To counter the
effects of the wind on the system while maintaining operations, adjust the lateral
movement cables as necessary to align the path of the dredge in the pond.
NOTE:

Placing stakes at the ends of the pond will provide reference points for
locating the ends of the traverse cable on successive cuts.

If winds are too intensive to operate the dredge, move the dredge unit close to shore
and tie it off to a suitable anchor. Check that all electrical cabinets are closed and
locked.

17

SETUP AND RIGGING

18

DREDGE SET-UP, RIGGING & HOSE ASSEMBLY


OFF-LOADING THE DREDGE
1. During preparation for launching into the pond, the dredge, floating hose and power
cable should be unloaded on the bank close to the starting location. The gussets at
the base of the head and tail frames have holes for this purpose. Use a crane of
adequate size to handle a 5,800-pound (2630.84 kg) weight at the swing radius
required to place the dredge in the pond. Once the dredge and accessories are
off-loaded, the preparations prior to launching into the pond can commence.
2. The Status Indicator Signaling Light on the NEMA electrical enclosure is normally
removed in preparation for shipping. Install this light on top of the electrical
enclosure at the stern of the dredge and connect the wires, (use the plug-in
electrical connectors, if provided).
3. Check and tighten all bolted connections that might have loosened during shipment.
4. Wire the 4-conductor power cable and the control cable between the shore based
power supply and the NEMA electrical enclosure at the stern (rear) of the dredge in
accordance with the electric schematic supplied in this manual. Perform the
initial functional tests listed below.

DANGER!
ONLY QUALIFIED PERSONNEL SHOULD PERFORM ELECTRICAL WORK!
INITIAL DREDGE FUNCTIONAL CHECKS
1. Check the hydraulic oil level on the side of the reservoir. Add oil if necessary.
Check plumbing for any visible oil leaks. Oil specifications are listed in the maintenance section.
2. Make sure that the electric motor on top of the reservoir is rotating in the proper direction. A reading of 500 to 700 psi on the hydraulic pressure gauge indicates the
motor is rotating in the proper direction.
3. Operate each function; slurry pump, travel winch, auger and boom hoist to assure
proper operation and direction.

19

INSTALLING TRAVERSE CABLE


Note: Refer to Drawing 3856, Sheets 1, 2 & 3 in this section when installing the
earth anchors, traverse cable, cable tensioners and related rigging components.
1. Layout the cable harness or rigging to suit the waterway configuration for the best
operation (traversing and lateral positioning) of the dredge. Normally, this is in
alignment with the length of the pond, but if its a long pond, it might be better to set
the dredge up across the width of the pond. In most installations, the anchors must
be moved and the system re-set to completely dredge a pond.
2. Place the anchor plates on the ground sufficiently far back from the edge of the water so that when the system is tensioned, the lateral move or pullover cables form
a V with the traverse cable. Drive a stake into the ground to hold each of them in
place. Attach the cable tensioners and install a wire rope through the body of each
device and extend the wire ropes to the point of attachment to the triangle. Note:
Do not tighten the tensioners until the traverse cable is attached to the triangles at both ends of the pond and the cable is routed through the winch
sheaves on-board the dredge.
3. As the traverse cable 3/8 (1 cm) diameter wire rope is unwound from the reel, it
must be fed through the snatch blocks on the head and tail frames of the dredge.
Do not feed the cable through the traverse winch sheaves until after it is in
place across the pond. After the traverse wire is in place across the pond, but not
tensioned, feed it through the winch drive sheave and idler sheaves as shown on
the next page.
4. Attach the traverse cable to the triangles using two cable clamps (or two clamps at
one end and a cable dog with cable and tensioner at the other) at the ends of the
pond.
5. Upon tightening the traverse cable, the dredge will move out onto the waterway. It
might be necessary to move the cable dog and/or clamps as the dredge is moved
to its starting position. Once the cable is pre-tensioned, the traverse winch can be
used to position the dredge at the starting location of the first run prior to beginning
operations.
Traverse Winch Cable Routing
Arrows indicate path of travel cable to guide
sheaves on head and tail frames.

Loop cable around bottom of drive


sheave & over tops of idler sheaves

20

EXAMPLE ONLY

21

1 4CableGripHoists:CableTensiometer
2 TraverseCable(DoNOTCut)
5

3 CableDog:ToGrabCable
4 560foot(18.29m)Cables(DoNOTCut)
5 4setsofPlateAnchorswith4Stakes

6 2CableClamps
4

4
2
6

2
3

1750 Madison Avenue


New Richmond, WI

INSTRUCTIONS
1. Hookeachgriphoist(1)toastakeintheanchor
plate(5).
2. Hookthecables(4)ontotheredtriangle.

TRAVERSECABLEADJUSTMENT
Thetraversecableadjustmentismadewiththe
traversecable(2)andthegriphoists(1).

LWT PIT HOG POND DREDGING


SCHEME
MANUAL LATERAL MOVE LAYOUT

DATE:

8-19-13
REVISED

DRAWN BY:

J.J.C.
CHECKED BY:

DRAWING NUMBER

3858
2 OF 3

ALL DRAWINGS AND INFORMATION ARE THE PROPERTY OF LWT AND ARE NOT TO BE REPRODUCED OR USED WITHOUT WRITTEN PERMISSION FROM LWT, LLC.

22

23

DREDGE FAMILIARIZATION

24

SYSTEM FAMILIARIZATION
ELECTRICAL CONTROL PANEL

2. Electrical Transformer
460 to 120 VAC
3. Phase 3 Power
Connect
1. Radio Transceiver

9. 12V Power Supply

4. Fuses

8. Bottom Sense

7. Function Relays

4. Fuses

6. Hydraulic Motor
Contactor-On/Off

25

5. Slurry Pump
VFD

ITEM DESCRIPTION

1. Radio Receiver
Receives the radio signals sent from the remote control transmitter. These
signals are interpreted into these commands:
a. Hoist up and down
b. Auger on and off
c. Travel forward and reverse
d. Pump on and off
e. Travel speed increase and decrease
f. Dredge on and off
2. Electrical Transformer
Transforms 460 VAC to 120 VAC allowing power to the instrumentation.
3. Phase 3 Power Connect
Connects or disconnects the main power source.
4. Fuses
Avoids electrical spikes in the system. If the current escalates too high the fuses
burn out avoiding any potential damage to sensitive components.
5. Slurry Pump VFD
Turns the slurry pump on or off.
6. Hydraulic Motor Contactor-On/Off
Turns the electrical motor for the hydraulic system on and off.
7. Function Relays
Used to open and close the electronic circuit for the functions on the
dredge.
8. Bottom Sense
Detects when the auger is touching the bottom of the pond so the boom can
be adjusted up and down accordingly.
9. 12V Power Supply
Transforms 120VAC into 12VDC allowing power to the instrumentation.

26

WARNING LIGHTS - Located on the door of the electrical box.


1. Hydraulic Low/Hot Oil Light
Indicates when the hydraulic oil level gets too low or gets too hot which will
automatically shut off the dredge. This is to prevent any potential damage to the
hydraulic system.
2. Slurry Pump Seal Fail Light
Indicates when moisture is detected in the electrical motor of the slurry pump
which disables the pump to prevent damage.
2. Slurry Pump
Seal Fail Light

1. Hydraulic Low/Hot Oil Light

LIGHT TREE
The light tree is located on top of the dredge control
panel. The lights indicate when the dredge is running
and what functions are in use. Each light indicates a
different dredge function.
Amber Light = Hydraulic pump motor is running
Blue Light = Travel is running
White Light = Auger is running
Green Light = Pump is running
Red Light = Hoist is running

27

TRAVEL WINCH

1. Idler Pulleys

2. Travel Sheave

1. Idler Pulleys
Guides the travel cable to the travel sheave.
2. Travel Sheave
Moves the dredge forward or in reverse.
3. Idler Pulley Grease Zerks
Use to grease the idler pulleys which should be greased every shift with high
quality EP rated grease.
4. Travel Winch Gear Box
Houses the reduction gears that increase the torque of the motor and also
allows the dredge to travel within the correct speed limits.
5. Travel Winch Motor
Moves the dredge forward or in reverse.
3. Idler Pulley Zerks

4. Travel Winch
Gear Box

5. Travel Winch
Motor

28

FRONT OF DREDGE

2. Bottom
Sense Load Cell

1. Boom Hoist
Winch

1.

Boom Hoist Winch:


Raises and lowers the boom.

2. Bottom Sense Load Cell:


Sends signal to the shore control panel of the cutterhead weight to determine
whether its on the bottom of the pond, so the cutterhead can be automatically
raised or lowered.
3. Travel Guide Pulley:
Guides the travel cable to keep the dredge from moving side to side.
4. Travel Proximity Switch:
Automatically stops the dredge when it reaches the target stop on either end of the

4. Travel Proximity
Switch
3. Travel Guide Pulley

29

HYDRAULIC SYSTEM

3. Electric
Motor

2. Low Oil/Hot Oil


Shutoff Switch

4. Return Filter
Housing

1. Hydraulic
Oil Tank
5. Oil Level/
Temperature
Gauge

1. Hydraulic Tank
Houses the hydraulic oil.
2. Low Oil/Hot Oil Shutoff Switch
Senses when the oil is too hot or too low. If either of these conditions exist the
dredge automatically shuts off and indicator on rear panel will be lit.
3. Electric Motor
Drives the hydraulic pump to provide hydraulic oil flow to the necessary
components.
4. Return Filter Housing
Houses the return filter that filters the oil that returns to the tank as the oil
circulates through the system.
5. Oil Level/Temperature Gauge
Used for checking the hydraulic oil level and temperature.

30

VALVE BANK
1. Manual Overrides - Red Buttons
Used when there is a need to manually actuate the flow control valves.
2. Solenoid Valves
Electronically controlled valves used to turn on and off the flow of hydraulic
oil.
3. System Pressure Gauge
Displays the pressure of the hydraulic system.
4. Travel Speed Flow Control
Varies the flow of hydraulic oil to the travel circuit which allows the dredge to go
slower or faster; 0-100% speed.

4. Travel Speed
Flow Control

1. Manual Overrides

2. Solenoid Valves
3. System
Pressure Gauge

31

CUTTERHEAD
Excavates the material and brings it to the center of the shroud feeding the pump
suction pipe.
1. Auger Motor
There are two auger motors, one on each side of the cutterhead, which rotate
the auger in the forward direction.
2. Auger Shroud
Reduces the amount of turbidity caused by the auger head and keeps
excessive water from being mixed into the slurry.
3. Auger Teeth
Aid in the excavation process and are constructed out of hardened steel and
lined with a carbide tip. The teeth are replaceable.
4. Auger
This is the main part of the excavation process and conveys the sludge toward
the center of the shroud.
2. Auger Shroud
4. Auger
1. Auger Motor

3. Auger Teeth

32

C O N TR O L S

33

DREDGE CONTROLS
Handheld Remote Control

34

REMOTE CONTROL BUTTON FUNCTIONS


1. Emergency Stop ButtonRed button located at bottom of remote control.

Press the Emergency Stop button to shut off power to the dredge in an
emergency or when completely shutting down operationsfor example,
at the end of a shift. If operations are being momentarily suspended, it isnt
necessary to depress this button unless maintenance or repairs of the
dredge are forthcoming. Under normal operating conditions, use the
individual buttons to shutdown the various functions.

2. Radio Transmitter and Hydraulic Power Unit On and Shift Button Green
button located at top of remote control.

Press the button to energize the radio transmitter and start the motor on the
hydraulic power pack. This button must be re-set whenever the Emergency
Stop Button has been used to shutdown electrical power.

Bottom Sense is not installed on this dredge and does not perform any
functions.

WARNING! The Radio Transmitter Power Button only starts the electric motor
on the hydraulic power packthe Power Disconnect switch must be thrown
to shut-off electrical power to the dredge.
NOTE: When the Emergency Stop Button is pressed, all functions on the
dredge are completely shut down but there is still live power present. The
individual buttons must be re-activated to send power to the various
functions.
3. Hoist Up/Down Buttons

Pressing and releasing these buttons raises and lowers the boom. Press the
Up button to raise the boom and press the Down button to lower the
boom. The boom (and auger-head) remains in the position in which it is
placed when the buttons are released when Bottom Sense is not active.

4. Dredge Pump On/Off Button

The Dredge Slurry Pump speed is 1,450 RPM. Press the Slurry Pump
button once to Start the slurry pump. Press the Slurry Pump button a
second time to stop the slurry pump.

NOTE: Turning the slurry pump on/off repeatedly may cause serious
damage to the system.

35

5. Dredge Pump Speed Buttons

The dredge pump speed is variable from 0 to 1,450 RPM. With the pump on
press and hold the pump Increase button to increase the speed. It takes
approximately 10 seconds to reach maximum speed; so holding the button
for 30 seconds will assure that the pump is at full speed. Of course, a lesser
speed can be selected, if desired. Conversely, press and hold the
Decrease button to reduce the pump speed. Pressing and releasing either
of the buttons can select intermediate speeds.

6. Auger On/Off Button

Press the Auger button once to start the auger cutter. Press the Auger
button a second time to stop the auger cutter.

7. Traverse Winch Forward/Reverse Buttons

Press the Forward button to traverse in the forward direction. Press the
Reverse button to traverse in the reverse direction. This button only
determines the direction of travel, not the speed. When the dredge is in
motion pressing either button will stop the travel.

8. Travel Speed Increase and Decrease Buttons

The Travel Speed buttons enable the operator to vary the speed from 0 to
30 feet (9.144m) per minute. Press and hold the Increase (INC) button to
increase the rate of travel or press and hold the Decrease (DEC) button to
decrease the rate of travel. If starting at 0, and the button is held for seven
seconds, the dredge will be traveling at its maximum rate of speed. While
dredging, the likely rate of travel will be in the range of 6 to 10 feet (1.8288 to
3.048 m) per minute. Therefore, press and release the button after only two
to three seconds.

9. Bottom Sense On/Off Buttons

Simultaneously press the Shift button and Bottom Sense On button to


activate the Bottom Sense feature of the dredge. Simultaneously press the
Shift button and the Bottom Sense Off button once to deactivate the Bottom
Sense feature.

36

CONTROLS, GAUGES AND MONITORS ON THE DREDGE


1. Service Entrance Disconnect Switch
The Service Entrance Disconnect Switch is located in the NEMA 4 electrical
enclosure at the stern (rear) of the dredge. Place the switch in the On position
to provide electrical power to the on-board motors, radio receiver and hydraulic
valve(s). Place the switch in the Off position to turn off the electrical power.

DANGER!
DISCONNECT THE POWER SUPPLY ON-SHORE AND OBSERVE THAT THE
AMBER RUN LIGHT IS NOT FLASHING BEFORE PERFORMING ANY
ELECTRICAL WORK ON THE DREDGE! QUALIFIED ELECTRICAL
PERSONNEL SHOULD DO WORK ONLY
2. Light Tree
Located on top of the dredge control panel these light will indicate when the
dredge is running and what functions are in use. The different colored lights indicate the following:
Amber light hydraulic pump motor is running
Blue light travel is running
White light auger is running
Green light pump is running
Red light hoist is running
3. Moisture Detection Light
The red light on the door of the NEMA enclosure at the stern of the dredge illuminates when the Mody Pump Moisture Detection System detects moisture in
the motor oil chamber due to the failure of the lower seal and /or breach of the
stator housing.
4. Hydraulic Oil Pressure Gauge (On hydraulic control valve block)
System and relief pressures are indicated on the gauge. Systems are designed
to operate at pressures up to 1,750 psi. If any of the hydraulic functions (auger,
winch drive or boom hoist) stall, the relief valve pressure setting of 2,000 psi is
indicated.
NOTE: The relief valve pressure is set at the factory and should not be adjusted by operating or service personnel in the field. Changes in this setting
can affect dredge performance, operational safety and will void the warranty.
Contact the factory
before making any changes to the hydraulic system.
5. Hydraulic Oil Level Gauge
Indicates oil level in reservoir. Fill as required.
6. Hydraulic Oil Temperature Gauge
Indicates hydraulic oil temperature in reservoir. Temperature should not exceed
184F.

37

GENERAL OPERATING TECHNIQUE


SETTING THE CONTROLS
Refer to the photo on first page of this section for identification and location
of the various Radio Transmitter Controls discussed below.
The operator should become familiar with the each of the controls and displays and
have a basic understanding of each of these before operating the dredge.
With the dredge in position near one end (or side) of the pond and ready to commence
dredging, perform the following steps to start and complete a typical dredge cycle:
1. Turn on the shore-based power supply to the dredge.
NOTE: IN CASE OF AN EMERGENCY, OR WHEN SHUTTING DOWN THE
DREDGE, PRESS THE RED EMERGENCY STOP BUTTON ON THE BOTTOM
OF THE RADIO TRANSMITTER!
2. Press the Green button at the top of the control to start hydraulic pump motor on
the dredge. When hydraulic pump motor is running the amber light is flashing.
Dredge is now ready to start all other functions.
3. Press the Boom Hoist Down button to lower the boom with the auger-head af
fixed to its lower end. Pressing and releasing the button will incrementally lower
the boom. If shallow cuts are to be made, the boom should only be lowered a
couple of feet below the surface of the liquid. When making successive passes
in the same cut, the boom (and auger-head) must be lowered another increment
at the start of the pass. The maximum digging depth of the dredge is 15 feet.
The dredge should not be operated below this depth. If the pontoons raise
slightly out of the water, contact with the bottom is indicated. To avoid damaging
the bottom, raise the boom (and auger-cutter assembly) slightly until it can be
observed that the bow (front) of the pontoons dip slightly into the water. This
indicates that the auger-cutter is clear of the bottom.
NOTE: In very light sludge, it is best to plunge the auger head into the sludge
blanket near the bottom of the pond. This will maximize the solids content of
the slurry.
4. Press the Pump ON button to start the pump. To stop the pump, press the
button a second time.
5. If necessary, adjust the slurry pump speed. See the discussion in Section V
regarding setting the slurry pump speed.
6. Press the Auger button to start the auger-cutter. To stop the auger-cutter, press
the button a second time.

38

DANGER!
MAKE CERTAIN ALL PERSONNEL ARE CLEAR OF THE AREA AROUND
THE AUGER-HEAD BEFORE STARTING THE AUGER CUTTER!
NOTE: It might be necessary to raise or lower the depth of the auger-head as
the dredge advances forward if the bottom contour is irregular. If the dredge
stops moving forward and the winch is spinning on the travel cable, raise the
boom slightly until it begins to move forward again.
7. Set the Travel Winch button in the Forward direction. Jog (press and release)
the Travel Speed Increase button until the appropriate rate of travel is obtained
this is normally 6 to 10 feet per minute while dredging. The maximum rate of
travel is 30 feet per minute. If the button is pressed and held for 7 seconds, this
rate of travel will be achieved. Therefore, jog the button two or three times (or
hold for 2 to 3 seconds) and observe the movement of the dredge. If too slow,
jog the button again. If too fast, jog the Travel Speed Decrease button to slow it
down.
8. Observe the operation of the dredge as it moves forward on the travel cable. If
everything goes smoothly no further adjustments will be necessary and the
dredge will advance forward until it reaches the opposite end (side) of the pond.
At this time, the dredge must be stopped and returned to its starting position in
the pond.
9. Press the Slurry Pump button once to stop the pump. Note: Generally, it is
necessary to keep the pump running at about half speed to maintain pressure in
the floating discharge line so that it stays out of the path of the dredge when it is
traveling in reverse.
10. Press the Auger button once to stop the auger cutter.
11. Press the Boom Hoist UP button to raise the boom slightly.
12. Press the Travel Winch Reverse button to start the dredge moving in the
reverse direction.
13. If the dredge isnt traveling in reverse at a decent rate of speed, jog the Travel
Speed Increase button until it is. Note: It might not be possible to travel in
reverse at the maximum rate of speed of 30 feet/minute in some applications.
Once the dredge has returned to its starting point, the dredge cycle is complete.
14. Repeat steps 4 through 7 to start another cycle.
15. Turn off all buttons on the radio transmitter at the end of operations.
16. Press the Red (Emergency Stop Button) at the bottom of the radio transmitter to
shut-off the electrical power to the hydraulic pump motor.
17. Place the electrical power disconnect on the shore-based power supply in the
OFF position.

39

DREDGING PRACTICES AND OPERATING HINTS


1. In soft materials (both organic and inorganic) and fluid like sediments, it is often
times advantageous to plunge the boom into the material prior to starting the
main pump. This minimizes dilution of the slurry and eliminates the pumping of
clear fluids.
2. If the auger-cutter is stalled, due to an obstruction preventing its rotation, the
auger hydraulic pressure relief valve (located on the reservoir) will be tripped.
This can be difficult to detect when the dredge is unmanned and the controls
are shore-based. One indication might be if the dredge fish tails (moves side to
side) Stop the travel winch and try stopping and starting the auger-cutter a few
times to see if the obstruction can be cleared. If this procedure is successful,
start dredging again.
3. If the auger-cutter is not cleared after stopping and starting, stop the augercutter, slurry pump and travel winch. Raise the boom until the auger-cutter
assembly is accessible at the surface of the water. Press the Emergency Stop
switch to shut down all functions and place the shore-based electrical
disconnect switch in the OFF position. Go out to the dredge and check the
auger circuit hydraulic pressure on the gauge located on the reservoir. If the
gauge reads zero pressure, use whatever tools and devices are necessary to
remove the obstruction from the auger. After removing the obstruction, return to
shore, turn the electrical power back on and start the auger-cutter. If the auger
head is rotating freely, resume dredging.
DANGER! WHENEVER IT IS NECESSARY TO WORK
AROUND THE AUGER-HEAD, STOP ALL OF THE FUNCTIONS
AND PLACE THE POWER DISCONNECT SWITCH ON THE
ELECTRICAL PANEL IN THE OFF POSITION. NEVER WORK
AROUND THE AUGER WHEN THE AMBER LIGHT IS FLASHING!
4. The no-load auger hydraulic circuit pressure is 600 to 700 PSI. In soft materials,
there is likely to be only a slight increase in the auger hydraulic circuit pressure
when dredging. This pressure can be observed on the pressure gauge mounted
on the hydraulic control valve on the power unit.
5. If the material spills over the top or the sides of the auger, slow down the rate of
travel or stop travel completely and let the pump and auger continue to operate
momentarily. This is most likely to happen when making initial cuts in shallow
water.

40

6. If the discharge line is plugging it can normally be cleared by stopping the


auger, raising the boom slightly and pumping clear liquid. This is most likely to
occur when pumping heavy materials such as sand, through a long pipeline or
to an elevated disposal area, or the combination of these conditions.
7. When cutting in shallow water, cutting a shoreline or cutting materials projecting
above the water surface, care should be taken to prevent loss of pump prime.
The suction inlet must always be submerged below the liquid surface. In
extremely shallow water, it may be necessary to make several forward cuts in
order to create adequate depth for the machine to float. It takes approximately
16 inches of water to float the machine.
8. At the end of any operational period the auger-head should be raised to its
upper limit at or near the surface of the water.
9. The speed of forward travel varies with the type of material being dredged.
Optimum operation matches the auger-cutters ability to excavate solids at the
flow rate of the slurry pump. If the dredge moves into the material too rapidly,
the unit may tend to plow material around or over the auger. If material is more
densely packed, the unit may tend to "stand on its nose" and begin to dig down
into the solids. Either action would result in an uneven pass.
10. The travel speed will generally be the most commonly used control to optimize
production. It is not possible to pump solids at more concentrated rates than
they exist in the solids bed.
11. The pump must be in the sludge to move solids. With lighter sludge it is possible
to lower the auger head down to the bottom and excavate a large bank of solids
that will continually slough down to the pump. With more rigid or heavier solids it
is best practice to take solids in layers, with multiple cuts across the waterway,
at increasingly lower depths.
12. Heavier solids and more viscous slurries require higher pressure to move the
slurry through the pipeline. Dilute slurry to increase flow rate.

41

DIAGNOSING OPERATING PROBLEMS


1. The flow rate at the end of the discharge pipe is less than it has been.
Plugging of discharge pipeline.
Plugging can generally be found by listening to each pipe joint while pumping clear liquid. A hissing noise will be heard at the obstruction. Such obstructions can occur at the main pump discharge elbow, or in the discharge
pipe leading to the side of the machine. Consequently, this portion of the discharge piping system should not be overlooked.
Plugged pump suction.
Obstruction in the impeller.
2. Vibration of the machine and discharge pipe.
Obstruction in the pump impeller.
3. Travel cable slipping on winch drive sheave.
Travel cable is too loose.
Auger-cutter assembly is digging into bottom or it is too deep in material.
4. Loss of pump prime.
Cutting too close to liquid surface.
Material "viscosity" too thick to flow into the pump.
Gas entrapped in material is causing vapor binding.
HIGH WINDS
1. High winds can affect the dredge, traverse and anchoring system. To counter
the effects of the wind on the system while maintaining operations:
2. Adjust the lateral movement cables as necessary to align the path of the dredge
in the pond. Note: Placing stakes at the ends of the pond will provide reference
points for locating the ends of the traverse cable on successive cuts.
If winds are too intensive to operate the dredge:
1. Move the dredge unit close to shore and tie it off to a suitable anchor.
2. Make sure all electrical cabinets are closed and locked.

42

43

* Refer to Special Functions Section for functionality.

44

Receiver Logic
Dredge Emergency Stop Output The Dredge Emergency Stop Output is on when there is a link with the transmitter and off when
the transmitters stop button is pressed. If the transmitter goes out of range or the batteries die the Dredge Emergency Stop Output
remains on. When the Dredge Emergency Stop Output is off all outputs are shut off.
Bottom Sense Output The Hoist Up/Down outputs are disabled and the Hoist Run Light is enabled whenever the Bottom Sense
Output is on.
Hoist Up Limit Input When the Hoist Up Limit Input is off for 250ms, the Hoist Up and Pump outputs are disabled.
Forward Travel Limit Input If the Forward Travel Output is off and the Forward Travel Limit Input is off for 250ms, the Forward
Travel Output is disabled. If the Forward Travel Output is on and the Forward Travel Limit Input is off for 250ms, the Forward Travel
Output will be set off for 3 seconds then the Reverse Travel Output will be set on.
Reverse Travel Limit Input If the Reverse Travel Output is off and the Reverse Travel Limit Input is off for 250ms the Reverse
Travel Output is disabled. If the Reverse Travel Output is on and the Reverse Travel Limit Input is off for 250ms, the Dredge
Emergency Stop Output and all other outputs are shut off and will remain off. All outputs will be disabled until the transmitters stop
button is pressed and the link is reestablished.

45

46

47

48

49

50

51

52

53

HYDRAULICS

54

1
2
3
4
5

1
REF
1
REF
REF

PART
NUMBER
8000847
8001107
8000819
NONE
NONE

6
7
8
9
10
11
12

REF
REF
1
1
1
1
REF

NONE
NONE
8001081
8000824
8001084
8000826
NONE

Washer, 1|2" Flat, Fender., 316SS


Washer, 1|2" Flat, USS Std., Galv.
PUMP, HYDRAULIC COMM 1.55CIR
COUPLING, 1.375 DRIVE SHAFT
COUPLING, DRIVE, .875, .25 KEY
INSERT, DRIVE COUPLING 270H
Bolt, 3|8-16 UNC x 0.75" Lg., Hex Head, Gr.5, Pltd.

13
14

1
1

1105536
1105095

FIITTING, HYD. 6405-20-16


Fitting, F6400-08-16

15
16

1
2

17
18
19
20
21

1
1
1
REF
REF

0007256
8000812
0005572
NONE
NONE

TUBE, SUCTION, 8.5"


FILTER, HYDRAULIC
MOUNT, FILTER, HYD TANK, RUNT
Bolt, 3|8-16 UNC x 0.5" Lg., Hex Head, Gr.5, Pltd.
Washer, 3|8" Lock, Reg. Pltd.

22
23
24

REF
1
1

NONE
0006113
1105377

Washer, 3|8" Flat, USS Std., 316SS


SWITCH, LOW OIL-HI TEMP ASSY 6.6"
Fitting, F6801-08

25
26

1
2

8000797
110-1022

GAUGE, OIL LEVEL & TEMP, Zinga #SG-05-A-T


Plug, Pipe 3|4"-14 NPT, Black

REV ITEM NO. QTY.

GENERAL NOTES:
1.

ALL DIMENSIONS IN PARENTHESIS ARE FOR


REFERENCE ONLY UNLESS NOTED OTHERWISE

2.

BREAK ALL SHARP EDGES, REMOVE ALL BURRS AND


SCALE, UNLESS NOTED OTHERWISE.

A
-

ORIENTATE ITEM MOTOR


AS SHOWN

11

10

DESCRIPTION
MOTOR, ELEC, 10HP W/DRIP
MOUNT, MOTOR TO HYD PUMP
Bolt, 1|2-13 UNC x 1.75" Lg., Hex Head, Gr.5, Pltd.
Washer, 1|2" Lock, Reg. Pltd.

80003218-028 HOSE 08 3000 08FJX-08FJX GATES M3K


1105089
Fitting, F6400-08

23

5
6

16

20

18

20

21

22

18

16

20

GASKET SILICONE BETWEEN


TANK AND MOTOR MOUNT

21

12

16

13

19

14

22

19

GASKET

24
25

15
1

17
25

26
1
1

26
24
23

26

55

REV.

ECN#

BY

THIS DRAWING INCLUDES PROPRIETARY


DATA WHICH IS TH EXCLUSIVE PROPERTY
HYDRAULIC TANK, ASSY
OF LIQUID WASTE TECHNOLOGY, LLC NO
DISCLOSURE OR REPRODUCTION
ALLOWED WITHOUT WRITTEN CONSENT
LWT RUNT
OF LIQUID WASTE TECHNOLOGY, LLC.
THIS PRINT IS NOT TO BE COPIED IN
DO NOT SCALE- ALL DIMENSIONS SHOWN WITHOUT
WHOLE OR IN PART OR USED
DIMENSI0N LINES REFER TO DATUM LINE MARKED "0".
DESIGNED RML
DETRIMENTALLY TO THE INTEREST OF
*ALL DIMENSIONS ARE IN INCHES UNLESS NOTED.*
LIQUID WASTE TECHNOLOGY, LLC
DRAWN
RML
*TOLERENCES (UNLESS OTHERWISE SPECIFIED)
GENERAL FABRICATION: 1/16" ANGULARITY 0 -30'
2008
LIQUID WASTE TECHNOLOGY, LLC
MACHINE SURFACE TEXTURE:
REVIEWED
MACHINE TOLERENCES:
SUPERCEDES ACAD .XX
.030"
APPROVED
.XXX
.015"
DATE APP'D REFERENCE P/N
.XXXX
.005"
YEAR

LIQUID WASTE TECHNOLOGY, LLC


1750MADISON AVENUE
NEW RICHMOND, WI
(715)246-2888*FAX (715)246-2537

SHEET:
7/9/2008
7/9/2008

1 OF 2

SCALE:
EST. WEIGHT:

1:4

SHEET SIZE

REV.

589.10

PART NUMBER/
DRAWING NUMBER:

0005841

26

19

18

20

21

22

25

16

24

23

2
2

23

18

24
2

26
16

25
1

12

SIDE PANEL OF ITEM 1. REMOVED FOR CLARITY

14
13
15
1

17

26
26

56

THIS DRAWING INCLUDES PROPRIETARY


DATA WHICH IS TH EXCLUSIVE PROPERTY
HYDRAULIC TANK, ASSY
OF LIQUID WASTE TECHNOLOGY, LLC NO
DISCLOSURE OR REPRODUCTION
ALLOWED WITHOUT WRITTEN CONSENT
LWT RUNT
OF LIQUID WASTE TECHNOLOGY, LLC.
THIS PRINT IS NOT TO BE COPIED IN
DO NOT SCALE- ALL DIMENSIONS SHOWN WITHOUT
WHOLE OR IN PART OR USED
DIMENSI0N LINES REFER TO DATUM LINE MARKED "0".
DESIGNED RML
DETRIMENTALLY TO THE INTEREST OF
*ALL DIMENSIONS ARE IN INCHES UNLESS NOTED.*
LIQUID WASTE TECHNOLOGY, LLC
DRAWN
RML
*TOLERENCES (UNLESS OTHERWISE SPECIFIED)
GENERAL FABRICATION: 1/16" ANGULARITY 0 -30'
2008
LIQUID WASTE TECHNOLOGY, LLC
MACHINE SURFACE TEXTURE:
REVIEWED
MACHINE TOLERENCES:
SUPERCEDES ACAD .XX
.030"
APPROVED
.XXX
.015"
REFERENCE P/N
.XXXX
.005"

LIQUID WASTE TECHNOLOGY, LLC


1750MADISON AVENUE
NEW RICHMOND, WI
(715)246-2888*FAX (715)246-2537

SHEET:
7/9/2008
7/9/2008

2 OF 2

SCALE:
EST. WEIGHT:

1:4

SHEET SIZE

REV.

589.10

PART NUMBER/
DRAWING NUMBER:

0005841

NOTES:
1. SPEEDS SHOULD BE TOWARD NOMINAL &
UPPER RANGE WHEN NEW AND NO LOAD.
2. SPEEDS MAY BE TOWARD LOWER RANGE
UNDER LOAD & FACTORED BY .90 WITH AGE.

COMPONENTS
ITEM

QTY

PART NO.

0005841

HYDRAULIC TANK ASSEMBLY, PHE - 60 HZ, FSC VALVE

0005207-02

HYDRAULIC CUTTER CIRCUIT, PHE - 60 HZ, FSC VALVE

0005207-03

HYDRAULIC TRAVEL CIRCUIT, PHE - 60 HZ, FSC VALVE

0005207-04

HYDRAULIC LIFT CIRCUIT, PHE - 60 HZ, FSC VALVE

0005207-11

HYDRAULIC COMMON CIRCUIT, PHE - 60 HZ, FSC VALVE

DESCRIPTION

9.80 CIR
GEAR RATIO
5.05 : 1

2
AUGER
6 GPM
60 - 80 RPM

EC1

SV1
M

PRESSURE GAUGE
0 - 4000 PSI
ON VALVE

TRAVEL WINCH
5 GPM
13 - 20 RPM

S2

1B

P1

7.40 CIR
A

1A

S1

SV2
S2
RV1

2B

FR1
S1

2A
SV3

S1

3B

A
B

T1
S2

7.40 CIR

3A

ELECTRIC MOTOR
1750 RPM
60 HZ

3.36 CIR
GEAR RATIO
40 : 1

COMMON
CIRCUIT

4
HOIST WINCH
5 GPM
7 - 9 RPM

HYDRAULIC
PUMP
1.55 CIR
11.7 GPM
1500 PSI
1750 RPM
HYDRAULIC
TANK
30 GALLON
1

REV.

ECN #

BY

DATE
YEAR

APP'D

THIS DRAWING INCLUDES PROPRIETARY


DATA WHICH IS THE EXCLUSIVE PROPERTY
OF LIQUID WASTE TECHNOLOGY, LLC. NO
DISCLOSURE OR REPRODUCTION ALLOWED
WITHOUT THE WRITTEN CONSENT OF LIQUID
WASTE TECHNOLOGY, LLC. THIS PRINT IS
NOT TO BE COPIED IN WHOLE OR IN PART
OR USED DETRIMENTALLY TO THE INTEREST
OF LIQUID WASTE TECHNOLOGY, LLC.
LIQUID WASTE TECHNOLOGY, LLC.

57

SUPERSEDES ACAD

REFERENCE P/N

LIQUID WASTE TECHNOLOGY, LLC

HYDRAULIC OVERVIEW

1750 MADISON AVENUE


NEW RICHMOND, WI
(715) 246-2888 * FAX (715) 246-2573

PHE
DESIGNED

60 HZ, FSC VALVE


THE INFORMATION IN THIS DOCUMENT IS SUBJECT TO CHANGE
WITHOUT NOTICE AND SHOULD NOT BE CONSTRUED AS A
COMMITMENT BY LIQUID WASTE TECHNOLOGY, LLC.

DRAWN

TAZ

SHEET:

SHEET SIZE:

OF

ADB 9/18/2012 SCALE:

REVIEWED

APPROVED

PART NUMBER / DRAWING NUMBER:

0005207

COMPONENTS
ITEM

QTY

PART NO.

8000822

REF

8000806

FITTINGS

HOSE / TUBE ASSEMBLIES

ITEM

QTY

PART NO.

MOTOR, HYD AUGER 7.4 CIR WHITE

F1

1105089

FITTING, HYD. F6400-8-8

VALVE, ASSY 3 BANK HYD RUNT

F2

1105151

F3

F4

DESCRIPTION

ITEM

QTY

PART NO.

H1

8003218-076

HOSE 08 3000 08FJX -08FJX

GATES 8M3K

FITTING, HYD. F2403-8-8-SS

H2 *

8003218-066

HOSE 08 3000 08FJX -08FJX

GATES 8M3K

1105328

FITTING, HYD. F2703-8-8-8-LN

H3 *

8003218-065

HOSE 08 3000 08FJX -08FJX

GATES 8M3K

1105090

FITTING, HYD. F6400-8-10

H4 *

8003218-067

HOSE 08 3000 08FJX -08FJX

GATES 8M3K

T1

REF

0006312

DESCRIPTION

DESCRIPTION

TUBE, HYD .5IN ASSY,BOOM 120LG

* THE LENGTH OF THESE HOSES IS DEPENDENT UPON THE LOCATION OF THE TEE
FITTING MOUNTED TO THE SLURRY PUMP. THIS LOCATION WILL VARY BASED UPON
THE TYPE OF SLURRY PUMP USED CAUSING THESE HOSE LENGTHS TO VARY.
2

H4

EC1
P

SV1

1B

S2

P1

7.40 CIR

1A

S1

F3

B
H4

SV2
S2
RV1

H1

2B

T1

H2

FR1

H1

T1

H2

2A

S1

AUGER
6 GPM
60 - 80 RPM

F4

F4

H3

SV3
T

S1

3B

A
F1

F2

F2

T1
7.40 CIR
S2

3A

H3

NOTES:
1. SPEEDS SHOULD BE TOWARD NOMINAL &
UPPER RANGE WHEN NEW AND NO LOAD.
2. SPEEDS MAY BE TOWARD LOWER RANGE
UNDER LOAD & FACTORED BY .90 WITH AGE.

REV.

ECN #

BY

DATE
YEAR

APP'D

THIS DRAWING INCLUDES PROPRIETARY


DATA WHICH IS THE EXCLUSIVE PROPERTY
OF LIQUID WASTE TECHNOLOGY, LLC. NO
DISCLOSURE OR REPRODUCTION ALLOWED
WITHOUT THE WRITTEN CONSENT OF LIQUID
WASTE TECHNOLOGY, LLC. THIS PRINT IS
NOT TO BE COPIED IN WHOLE OR IN PART
OR USED DETRIMENTALLY TO THE INTEREST
OF LIQUID WASTE TECHNOLOGY, LLC.
LIQUID WASTE TECHNOLOGY, LLC.

58

SUPERSEDES ACAD

REFERENCE P/N

LIQUID WASTE TECHNOLOGY, LLC

HYDRAULIC

1750 MADISON AVENUE


NEW RICHMOND, WI
(715) 246-2888 * FAX (715) 246-2573

CUTTER CIRCUIT
DESIGNED

PHE, 60 HZ, FSC VALVE


THE INFORMATION IN THIS DOCUMENT IS SUBJECT TO CHANGE
WITHOUT NOTICE AND SHOULD NOT BE CONSTRUED AS A
COMMITMENT BY LIQUID WASTE TECHNOLOGY, LLC.

DRAWN

TAZ

SHEET:

SHEET SIZE:

OF

ADB 9/18/2012 SCALE:

REVIEWED

APPROVED

PART NUMBER / DRAWING NUMBER:

0005207-02

COMPONENTS
ITEM

QTY

PART NO.

8002551

REF

8000806

FITTINGS

HOSE / TUBE ASSEMBLIES

ITEM

QTY

PART NO.

DRIVE, TRAVEL, LWT GEARBOX/MTR

F1

1105089

FITTING, HYD. F6400-8-8

VALVE, ASSY 3 BANK HYD RUNT

F2

1105375

FITTING, HYD. F6801-8-10

F3

1104498

FITTING, HYD. 6801-LL-NWO-8-10

DESCRIPTION

DESCRIPTION

ITEM

QTY

PART NO.

H1

8003218-099

DESCRIPTION
HOSE 08 3000 08FJX -08FJX

TRAVEL WINCH
5 GPM
13 - 20 RPM

F2

GATES 8M3K

9.80 CIR
GEAR RATIO
5.05 : 1

EC1
P

SV1

S2

1B

S1

1A

F3

H1

P1

H1
G

SV2

RV1

S2

2B

S1

2A

F1

FR1

SV3
T

S1

3B

S2

3A

T1

NOTES:
1. SPEEDS SHOULD BE TOWARD NOMINAL &
UPPER RANGE WHEN NEW AND NO LOAD.
2. SPEEDS MAY BE TOWARD LOWER RANGE
UNDER LOAD & FACTORED BY .90 WITH AGE.

REV.

ECN #

BY

DATE
YEAR

APP'D

THIS DRAWING INCLUDES PROPRIETARY


DATA WHICH IS THE EXCLUSIVE PROPERTY
OF LIQUID WASTE TECHNOLOGY, LLC. NO
DISCLOSURE OR REPRODUCTION ALLOWED
WITHOUT THE WRITTEN CONSENT OF LIQUID
WASTE TECHNOLOGY, LLC. THIS PRINT IS
NOT TO BE COPIED IN WHOLE OR IN PART
OR USED DETRIMENTALLY TO THE INTEREST
OF LIQUID WASTE TECHNOLOGY, LLC.
LIQUID WASTE TECHNOLOGY, LLC.

59

SUPERSEDES ACAD

REFERENCE P/N

LIQUID WASTE TECHNOLOGY, LLC

HYDRAULIC

1750 MADISON AVENUE


NEW RICHMOND, WI
(715) 246-2888 * FAX (715) 246-2573

TRAVEL CIRCUIT
DESIGNED

PHE, 60 HZ, FSC VALVE


THE INFORMATION IN THIS DOCUMENT IS SUBJECT TO CHANGE
WITHOUT NOTICE AND SHOULD NOT BE CONSTRUED AS A
COMMITMENT BY LIQUID WASTE TECHNOLOGY, LLC.

DRAWN

TAZ

SHEET:

SHEET SIZE:

OF

ADB 9/18/2012 SCALE:

REVIEWED

APPROVED

PART NUMBER / DRAWING NUMBER:

0005207-03

COMPONENTS
ITEM

QTY

PART NO.

8000846

REF

8000806

FITTINGS
ITEM

QTY

PART NO.

WINCH, BLOOM 10-AS8-40:1

F1

1105089

VALVE, ASSY 3 BANK HYD RUNT

F2

F3

DESCRIPTION

HOSE / TUBE ASSEMBLIES


ITEM

QTY

PART NO.

FITTING, HYD. F6400-8-8

H1

8003218-074

HOSE 08 3000 08FJX -08FJX

GATES 8M3K

1105151

FITTING, HYD. F2403-8-8-SS

H2

8003218-066

HOSE 08 3000 08FJX -08FJX

GATES 8M3K

1105090

FITTING, HYD. F6400-8-10

T1

REF

0005027

TUBE, HYD .5IN, ASSY, RUNT

DESCRIPTION

DESCRIPTION

EC1
P

SV1

S2

1B

S1

1A

P1

SV2

RV1

S2

2B

S1

2A

FR1

F2

F2

SV3
T

S1

3B

S2

3A

H1

T1

H1

T1

H2

T1
H2

F3

F1

F3

3.36 CIR
GEAR RATIO
40 : 1
1
HOIST WINCH
5 GPM
7 - 9 RPM

NOTES:
1. SPEEDS SHOULD BE TOWARD NOMINAL &
UPPER RANGE WHEN NEW AND NO LOAD.
2. SPEEDS MAY BE TOWARD LOWER RANGE
UNDER LOAD & FACTORED BY .90 WITH AGE.

REV.

ECN #

BY

DATE
YEAR

APP'D

THIS DRAWING INCLUDES PROPRIETARY


DATA WHICH IS THE EXCLUSIVE PROPERTY
OF LIQUID WASTE TECHNOLOGY, LLC. NO
DISCLOSURE OR REPRODUCTION ALLOWED
WITHOUT THE WRITTEN CONSENT OF LIQUID
WASTE TECHNOLOGY, LLC. THIS PRINT IS
NOT TO BE COPIED IN WHOLE OR IN PART
OR USED DETRIMENTALLY TO THE INTEREST
OF LIQUID WASTE TECHNOLOGY, LLC.
LIQUID WASTE TECHNOLOGY, LLC.

60

SUPERSEDES ACAD

REFERENCE P/N

LIQUID WASTE TECHNOLOGY, LLC

HYDRAULIC

1750 MADISON AVENUE


NEW RICHMOND, WI
(715) 246-2888 * FAX (715) 246-2573

LADDER LIFT CIRCUIT


DESIGNED

PHE, 60 HZ, FSC VALVE


THE INFORMATION IN THIS DOCUMENT IS SUBJECT TO CHANGE
WITHOUT NOTICE AND SHOULD NOT BE CONSTRUED AS A
COMMITMENT BY LIQUID WASTE TECHNOLOGY, LLC.

DRAWN

TAZ

SHEET:

SHEET SIZE:

OF

ADB 9/18/2012 SCALE:

REVIEWED

APPROVED

PART NUMBER / DRAWING NUMBER:

0005207-04

COMPONENTS
ITEM

QTY

PART NO.

8000806

8000810

REF

FITTINGS
ITEM

QTY

PART NO.

VALVE, ASSY 3 BANK HYD RUNT

F1

1105089

VALVE, HYD FLOW CONTROL

F2

0005841

TANK, HYDRAULIC, ASSY, RUNT

F3

8002636

GAUGE, PRESS. 0-4000 SAE STEM

DESCRIPTION

HOSE / TUBE ASSEMBLIES


ITEM

QTY

PART NO.

FITTING, HYD. F6400-8-8

H1

8003218-028

HOSE 08 3000 08FJX -08FJX

GATES 8M3K

1105075

FITTING, HYD. F6500-8-8

H2

8003218-035

HOSE 08 3000 08FJX -08FJX

GATES 8M3K

1105152

FITTING, HYD. F6400-8-12

DESCRIPTION

DESCRIPTION

2
F1
F2
EC1
P

H1

SV1

PRESSURE GAUGE
0 - 4000 PSI
ON VALVE

S2

1B

S1

1A

P1

SV2

RV1

S2

2B

S1

2A

FR1

F3
F2

SV3
T

H2

S1

3B

S2

3A

T1
ELECTRIC MOTOR
1750 RPM
60 HZ

M
1

HYDRAULIC
PUMP
1.55 CIR
11.7 GPM
1500 PSI
1750 RPM

HYDRAULIC
TANK
30 GALLON
3

NOTES:
1. SPEEDS SHOULD BE TOWARD NOMINAL &
UPPER RANGE WHEN NEW AND NO LOAD.
2. SPEEDS MAY BE TOWARD LOWER RANGE
UNDER LOAD & FACTORED BY .90 WITH AGE.

REV.

ECN #

BY

DATE
YEAR

APP'D

THIS DRAWING INCLUDES PROPRIETARY


DATA WHICH IS THE EXCLUSIVE PROPERTY
OF LIQUID WASTE TECHNOLOGY, LLC. NO
DISCLOSURE OR REPRODUCTION ALLOWED
WITHOUT THE WRITTEN CONSENT OF LIQUID
WASTE TECHNOLOGY, LLC. THIS PRINT IS
NOT TO BE COPIED IN WHOLE OR IN PART
OR USED DETRIMENTALLY TO THE INTEREST
OF LIQUID WASTE TECHNOLOGY, LLC.
LIQUID WASTE TECHNOLOGY, LLC.

61

SUPERSEDES ACAD

REFERENCE P/N

LIQUID WASTE TECHNOLOGY, LLC

HYDRAULIC

1750 MADISON AVENUE


NEW RICHMOND, WI
(715) 246-2888 * FAX (715) 246-2573

COMMON CIRCUIT
DESIGNED

PHE, 60 HZ, FSC VALVE


THE INFORMATION IN THIS DOCUMENT IS SUBJECT TO CHANGE
WITHOUT NOTICE AND SHOULD NOT BE CONSTRUED AS A
COMMITMENT BY LIQUID WASTE TECHNOLOGY, LLC.

DRAWN

TAZ

SHEET:

SHEET SIZE:

1 OF 1

ADB 9/18/2012 SCALE:

REVIEWED

APPROVED

PART NUMBER / DRAWING NUMBER:

0005207-11

White Hydraulics, Inc.


P.O. Box 1127
Hopkinsville, KY 42241
Phone- (270) 885-1110
Fax- (270) 886-8462

PI444200
9/01
Service Instructions For The
CE (400/401) Series

FOR USE WITH SEAL


KIT 400444200

***USE EXPLODED VIEW ON BACK FOR REFERENCE***

A)

Remove all shaft components from the shaft, (21), (i.e., keys, wire rings, nuts). To aid in reassembly of the
motor, make a "V" shaped set of lines from the endcover to the housing using either paint or a marker. With
the shaft facing down, secure the motor in a vise by clamping onto the housing, (8). Loosen and remove the
seven bolts, (20), holding the motor assembly together. Remove the endcover, (18), from the motor.

B)

Remove the balance plate, (16), rotor set, (15), and the manifold, (14), from the motor. Remove all seals from
the components and discard. (Caution - when removing the balance plate, do not allow the three check
balls, (17), to fall out from the plate.) (Caution - do not allow the rolls to drop out from the rotor set
assembly when removing the assembly from the motor.) Remove the manifold from the motor and lay
aside. Remove drive link, (13), from the motor and lay aside. Remove the thrust bearing, (12), from the
housing and lay aside. From the front of the housing, gently tap the shaft, (21), upward and remove through
the rear of the housing.

C)

Using a slide and hammer type bearing puller, (see Figure 1), remove the rear housing bearing, (11), from the
housing. Remove the thrust bearing, (10), and lay aside, remove the thrust washer, (9), and lay aside.
Remove the shaft seal, (4), and discard, remove the back-up seal, (3), and discard, remove the metal shim,
(2), and discard.

D)

At this point, all parts should be cleaned in an oil-based solvent and dried using compressed air, (for safety,
observe all OSHA safety guidelines). All new seals should be lightly coated in clean oil prior to installation.

E)

Place the integral thrust washer/bearing, (10), onto the shaft. The washer side should be against the shoulder of the shaft. Place a thrust washer, (9), onto the shaft on top of the thrust bearing. Coat the shaft seal,
(4), with a light coat of oil and install onto the shaft with the lip side down. Place a light coat of oil on the
back-up seal, (3), and place over the coat of oil on the metal back-up shim, (2), and place over the back-up
seal.

F)

With the pilot of the housing placed down, install the output end of the shaft through the rear bore of the
housing.

G)

The rear bearing is now ready to be installed. With the writing side of the bearing facing up, place the
bearing, (11), into the housing bore. Using a hand press, the bearing should be pressed into the bore. It is
necessary that the bearing be pressed .120 - .130" deep into the bore of the housing to accommodate the
width of the thrust bearing.

H)

Install a thrust bearing, (12), on top of the shaft.

I)

Install a lightly oiled body seal, (1), into the seal groove in the housing. Make sure that this seal is in the
seal groove and protruding approximately .007" over the top of the housing surface. (Caution - if a bump is
felt in the seal remove the seal and make sure that there is no grit on the seal or in the seal groove.)

J)

Install the drive link, (13), into the housing. The proper end of the drive link has a 'hat" machined in the top of
the drive link on the 07-16 displacement. The drive link is to be placed in the shaft with the hat facing up on
these displacements. The 18 displacements and above have a symmetrical head and either end can be put
into the motor. Once the drive link has been installed, the shaft can be seated. This is done by bringing the
arbor of the hand press down and putting pressure on the drive link. (Caution - do not use excessive
pressure as this could deform the thrust bearing and/or bearing races.)

K)

Place the manifold (14), (seven teardrop hole side down) on the housing. Line the bolt hole notches in the
outside diameter of the manifold up with the seven bolt holes in the housing.

L)

Install two oil coated body seals, (5), one on each side, into the seal grooves of the rotor set, (15). Place the
deep groove side of the of the rotor set down on the manifold, (14).

M)

Place the balance plate, (16), on top of the rotor set with the check balls, (17), up. If the check balls were
removed, install three check balls into the countersunk holes on the balance plate, one ball per hole.

N)

Install an oil coated body seal, (6), into the seal groove of the endcover, (18). Place the endcover onto the
motor with the tag holes directly above the housing ports. (Caution - it is very important that the body
seal does not fall out of the endcover while being installed. Extra care must be used to insure this
doesn't happen.)

O)

Install the seven bolts, (20), into the motor. Pre-torque bolts to 10 ft. lbs. The final torque on the bolts is to
be 51.1 + 5.5 ft. lbs.

64

FIGURE 1

CE(400/401) Series Motor Components


1. Housing Seal
2. Metal Back-Up Shim
3. Teflon Back-Up Seal
4. Shaft Seal
5. Body Seals (2)
6. Endcover Seal
7. Front Housing Bearing
8. Housing

9. Thrust Washer
10. Front Thrust Bearing
11. Rear Housing Bearing
12. Thrust Bearing
13. Drive Link
14. Manifold
15. Rotor Assembly
16. Balance Plate
65

17. Steel Balls (3)


18. Endcover
19. I.D. Tag
20. Assembly Bolts (7)
21. Shaft
22. Shaft Key
23. Shaft Nut

BLOOM MANUFACTURING INC.


Safety, Warranty, Maintenance & Repair, Installation and Operation Manual
Bloom Hydraulic Cable Winches
800, 1000, 1100, 1200,
1400 & 1600 Series

Bloom Hydraulic Capstan Winches


1000, 1100, 1000V
& 1400 Series

All Bloom winches have the model and serial number stamped on the gear case cover. Please take a few
minutes to record these numbers for future use. You will need these numbers for ordering parts or gathering
service information from the factory:
Model#______________________________
# 10-A-S8-40
Serial # 52532
Model
Ser #______________________________

Thank you for your purchase of a quality Bloom product !


THIS MANUAL MUST BE KEPT WITH THE WINCH AT ALL TIMES AND
NEW WINCH OPERATORS MUST READ AND UNDERSTAND IT.
IT
REV. 07-2007

Bloom Manufacturing Inc.


Winch Division
1443 220th Street
Independence, IA 50644

www.bloommfg.com
Email: sales@bloommfg.com
engineering@bloommfg.com
66

800-394-1139 tel
319-827-1139 tel
319-827-1140 fax

Table of Contents
1. General Safety Requirements
2. Warranty
3. Maintenance & Repair
( ) Clean
(a)
Cl
andd IInspectt
(b) Oil Change Information
(c) Oil Level
(d) Recommended Gear Oil
(e) Inserts:
- Assembly (specific model)
- Disassemblyy ((specific
p
model))
- Parts List (specific model)
- Assembly Check Valve Kit
- Assembly of Oil Cooled Brake
- Replacement of Clutch Handle and Yoke

4. Winch Break In
5. Winch Installation
6. Winch Operation
( ) Cable
(a)
C bl Considerations
C id ti
(b) The Importance of a Proper Fleet Angle
(c) Wire Rope Anchor & Wrapping
(d) Automatic Safety Brakes & Adjustment

Please note that not all of the sections of the Table


of Contents apply to each model purchased

Merchandise may not be returned without approval from factory. The customer will be charged for placing the returned
goods in salable condition plus a restocking charge of 25%. All returns must be shipped prepaid.

Section 1

General Safety Requirements

THIS SYMBOL MEANS


Attention!
Become Alert!
Your Safety Is Involved
SIGNAL WORDS:

Take Note! This Safety Alert Symbol Found Throughout This


Manual Is Used To Call Your Attention To Instructions Involving
Your Personal Safety And The Safety Of Others. Failure To
Follow These Instructions Can Result In Injury Or Death.

Note the use of the signal words DANGER, WARNING AND CAUTION with the safety messages.
The appropriate signal word for each has been selected using the following guidelines:

DANGER:

Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.
This signal word is to be limited to the most extreme situations typically for machine components
which, for
f functional
f
purposes, cannot be guarded.

WARNING:

Indicates a potentially hazardous situation that, if not avoided, could result in death or serious
injury, and includes hazards that are exposed when guards are removed. It may also be used to
alert against unsafe practice.

CAUTION:

Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate
injury. It may also be used to alert against unsafe practices.

Bloom Mfg Inc.

319-827-1139

319-827-1140 fax
67

www.bloommfg.com

CAUTION

WARNING

Failure to Heed The Following Warnings


May Result In Serious Injury Or Death

Bloom winches are not to be used to lift, hoist, or move people. If your task involves lifting or moving people, you
mustt use the
th proper equipment,
i
t nott this
thi winch.
i h

Cable anchors on Bloom winches are not designed to hold the rated load of the winch. You must keep at least five (5)
wraps of cable on the drum to ensure that the cable doesnt come loose. We suggest that the last 5 wraps of cable be
painted bright red to serve as a visual warning.

Stay clear of suspended loads and of cable under tension. A broken cable or dropped load can cause serious injury or
death.

No equipment should be installed, operated, or maintained by any person who has not carefully read all contents of this
manual. Serious physical injury or property damage can result from failure to read and apply the instructions contained
therein. Therefore, we urge you to read all operating instructions and warnings carefully. If any instruction or warning is
not clear, or if you feel you need additional information, please contact Bloom Mfg Inc. This manual should not be
understood to prepare you for every possible situation. It is the owners and users responsibility to determine the
pp
industry,
y trade association, federal, state, and local regulations
g
suitabilityy of a pproduct for a pparticular use. Applicable
should be reviewed.

Make sure that all equipment, including the winch and cable, is maintained properly. Pay especially close attention to the
clutch, making sure that it fully engages when shifted.
Winches equipped with free spooling dog clutch should never be used in a lifting application.

Avoid shock loads. This type of load imposes a strain on the winch many times the actual weight of the load and can
cause failure of the cable or of the winch.
winch

Bloom products are sold on the strict understanding that all products selection is the full responsibility of the purchaser.

Bloom accepts no liability for the use, misuse or incorrect application of its products.

Leather gloves should be used when handling winch cable.

Ensure the correct equipment is obtained and installed for the application.

Ratings shown in Bloom literature are applicable only to new products.

Working load limits shown are the maximum load the product is authorized to support under normal environmental
conditions. Shock loading and abnormal conditions must be taken into account when selecting products.

In general, products displayed in Bloom literature are used as parts of a system. As a result, we can only recommend
within the working load limits, or other stated limitations, the use of products for this purpose.

Working load limits or safety factors for each Bloom product may be affected by wear, misuse or environmental
conditions. Regular inspection must be conducted to ensure the equipment continues to meet the published standards.
If you have questions not answered in this manual or require additional copies or the manual is damaged, please contact
Bloom Mfg., Inc., 1443 220th Street, Independence, Iowa 50644.
This sample manual is based upon general industry considerations and does not take into account product or manufacturer
specific exposures or needs. This sample manual may not be adopted by a product manufacturer as its manual, but may
be used by the manufacturer in the process of developing its own manual, based upon its specific products and operations,
after consulting with its advisor.
THINK S-A-F-E-T-Y FIRST

Bloom Mfg Inc.


68

319-827-1139

Warranty

Section 2

LIMITED NINETY (90) DAY WARRANTY FOR HYDRAULIC CABLE & CAPSTAN WINCHES
Effective date January 1, 1999
Bloom Mfg. Inc., Independence, Iowa 50644, provides the following LIMITED NINETY (90) DAY WARRANTY on its product to
the purchaser of this product and to any person to whom such product is transferred during the duration of this warranty. The
warrantor's obligation shall be limited to repairing or replacing at the factory in Independence, Iowa, any part or parts which
shall within the NINETY (90) DAY period hereinafter specified be returned to it with transportation prepaid and which upon
examination by Bloom Mfg. Inc. shows to have been defective. This warranty shall not apply if:
(a) the product has been altered, repaired or modified outside the warrantor's factory in any way that would adversely affect
its operation.
(b) the product has been subject to careless or negligent misuse, damage or use of improper oil while in the possession of the
purchaser or any person to whom the product was transferred by the purchaser or was installed or operated other than in
accordance with the manufacturer's operating instructions.
(c) the product was used with accessories not recommended by Bloom Mfg. Inc. or for loads in excess of those listed as rated
for the product.
(d) in the case of hydraulic motors, Bloom Mfg. Inc. will not accept responsibility and warranty will be subject to manufacturer's
warranty.
The NINETY (90) DAY LIMITED WARRANTY period shall commence with the date the product is sold to the purchaser by the
dealer or if this date cannot be established, the date the product was sold by Bloom Mfg. Inc. to the dealer.
THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE ARE LIMITED TO
THE DURATION OF THIS WARRANTY - NINETY (90) DAYS - AFTER SAID (90) DAYS, BLOOM MFG. INC.
EXPRESSLY DISCLAIMS ANY WARRANTY OR MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.
PURPOSE
Purchase or other acceptance of the product by the claimant shall be on the condition and agreement that BLOOM MFG.
INC. SHALL NOT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL OR CONTINGENT DAMAGE, SECONDARY
CHARGES OR LOSS OR EXPENSE RESULTING FROM ANY ALLEGED DEFECT, FAILURE OF ARTICLE TO OPERATE
PROPERLY, OR FOR THE NEGLIGENCE OF OTHERS OR DAMAGES OF ANY KIND.
Bloom Mfg. Inc. is not responsible for the cost, of removal of product, damages due to removal or any other expenses
incurred in shipping the product to or from Bloom Mfg. Inc. or the installation of the repaired or replacement product. The
consumer must bear these expenses.
To make a claim under this warranty, write directly to Bloom Mfg. Inc., Independence, Iowa 50644, identifying the product and
giving its location and follow the company's return instructions which will be provided by the company. Bloom Mfg. Inc. will
p or replace
p
the pproduct,, if found to be defective within the terms of this warranty,
y, within SIXTY
make its best efforts to repair
(60) DAYS after return of the product to the company.
This warranty is exclusive and in lieu of all other warranties whether written, oral or implied (including any warranty of
merchantability or fitness for a particular purpose.

For Best Results, Only Use Bloom Replacement Parts


69

800-394-1139

Section 3

Maintenance & Repair


Make sure that there is no load on the winch cable and that all of the
y
hoses have been disconnected before servicingg unit.
hydraulic

CAUTION
A winch, like other types of machinery, needs to have regular maintenance if it is to perform properly, give lasting service, and
provide safe winching.
(a) Clean and Inspect:
Thoroughly clean all of the parts in a good grade of cleaning solvent; one that is not flammable, not toxic and will not
cause skin
ki rashes.
h
If necessary, use rubber
bb gloves.
l
IInspectt allll parts
t for
f wear, nicks,
i k scratches
t h andd damage
d
that
th t would
ld
render them unusable. If a part is questionable, it is better to replace it rather than take a chance on premature failure
when the winch is placed back in service. Always replace O-rings and seals, and it is a good idea to use new roll pins
as well. Sometimes it is permissible to reuse bearings and bushings...it depends on how much use they have had. The
rollers should not exhibit any surface irregularities. If the rollers show any sign of spalling, corrosion, discoloration,
material displacement or abnormal wear, the bearings should be replaced.
Likewise,, the cage
g should be inspected
p
for unusual wear or deformation,, pparticularlyy the cage
g bars. If there is anyy
damage that will impair the cages ability to separate, retain, and guide the rollers properly, the bearing should be
replaced. The thrust washer contact areas should be free from any surface irregularity that might cause excessive
abrasion or friction. If the winch was disassembled only to replace damaged seals after a short period of service, it is
not necessary to replace the bearings. Experience and common sense, along with a good inspections, will determine if
they can be used again. Always coat O-rings, bearings, bushings and the rubber parts of seals with oil during assembly.
Use a light coat of thread sealing compound on pipe fittings and plugs.
(b) Oil Change Information:
The winch vent/fill and drain plugs are located at the base of the face plate. Oil should be changed every 100 hours of
operating time, or every six months, whichever comes first.
(c) Oil Level:
To check the oil level, remove the level plug. The oil should be level with the bottom of this opening. If more oil is
needed, use the recommended gear oil listed below.

OIL CAPACITY CHART

Note:
Base mounted position is
when
h the
h worm shaft
h f iis
below the bronze gear.

Bloom Mfg Inc.

Winch
Type

Winch Series

Base Mounted
Position*

All Other Mounting


Positions

Cable

800 & 1000

1 Pint

2 Pints

1100

1 Pint

2 Pints

1200 w/o brake

2 Pints

3 Pints

1200 w/ brake

3 Pints

4 Pints

1400

4 Pints

6 Pints

1600

4 Pints

6 Pints

1000 & 1100

1 Pints

2 Pints

1100V

2 Pints

2 Pints

1400

4 Pints

6 Pints

Capstan

319-827-1139

319-827-1140 fax
70

www.bloommfg.com

(d) Recommended Gear Oil:


Use BLOOM ULLTRA-LUBE NO. 601 trans-worm gear oil; available from Bloom in pints or quarts. For emergency
situations when BLOOM ULLTRA-LUBE NO. 601 is not immediately available, use Phillips 66 Company SAE grade
80W90 superior multi-purpose gear oil (Phillips 80W90 SMP) meeting API classification GL-5 or equivalent brand.
Continuous use of oil other than BLOOM ULLTRA-LUBE NO. 601 or Phillips 80W90 SMP oil may shorten the life of the
gears. DO NOT mix BLOOM #601 or Phillips 80W90 SMP with more than 50% of any other kind of oil.

Section 4

CAUTION

Winch Break In
Winches, like any other kind of machinery, require a break in to perform well and to
maximize their life.
Use extreme care when first spooling cable onto the winch.
winch Do not run the winch at
high speeds when performing this operation.
Make sure that the cable is unrolled in a line (to prevent kinks) and slowly inhaul the
winch to install the cable.
Do not exceed one half rated load or one half rated line speed for the first thirty
minutes of operation. This will ensure that the worm and gear have an opportunity to
wear in properly.
Periodically, check the gearbox for temperature rises and allow the winch to cool
down between pulls.

Winch Installation

Section 5

CAUTION

Y
You mustt make
k sure that
th t your winch
i h iis securely
l mounted
t d iin order
d ffor it tto ffunction
ti
properly and to ensure safe operation.
The mount must be flat to ensure proper alignment between the gearbox side, the
drum, and the clutch.
Winches must never be fastened directly to the frame of a truck. Mounting
brackets should be used.
y
y driven winch,, make sure the hydraulic
y
system
y
is clean and that
With a hydraulically
all components function properly, especially the relief valve.
Winch Series

800

1000

1100

1200

1400

1600

1/2

1/2

1/2

1/2

Angle Mounts (steel)


Length
Width
Thickness

2-1/2
2-1/2
1/4

2-1/2
2-1/2
1/4

2-1/2
2-1/2
1/4

2-1/2
2-1/2
1/4

3
3
1/2

3
3
1/2

Capscrews (Hexhead)
Size
Thread
Grade

1/2
1/2
13 UNC 13 UNC
5
5

1/2
13 UNC
5

1/2
13 UNC
5

57

57

Base Mount (steel)


Thickness

HARDWARE
REQUIREMENTS

57

Torque / Tightening (foot pounds)

THINK S-A-F-E-T-Y FIRST

57

Bloom Mfg Inc.


71

5/8
5/8
11 UNC 11 UNC
5
5
112

319-827-1139

112

Winch Operation

Section 6

To familiarize yourself with the winch, run it for a few minutes to understand the controls and the feel of the winch.
Pay particular attention to the controls and how they operate. Make sure you understand which way the winch will
rotate when the control lever is moved.
Always make sure that all people are clear of the load and of the cable area before beginning a winching operation.
Ensure that proper protective wear is worn while operating winch.
A broken cable can fly in any direction.
Do not attempt to defeat the relief valve
valve.
If you have any doubts about the capability of the winch to lift or move a load, either put a snatch block in the line or
get a bigger piece of equipment.
Winch lifting application:
(1) Attach winch cable to load.
(2) Make sure no one is in the immediate area of the load or of the cable
(3) Begin winching the load slowly, watching carefully to ensure that the load is moving normally.
(4) When the load is positioned where you want it, stop the winch.

Winch Series

DRUM CAPACITY
(FEET)

Cable Diameter (inches)


3/8
7/16
1/2

3/16

1/4

5/16

S*
S8
L
L8
XL10
8-13**

--------------------1325

120
260
175
390
840
750

70
160
105
240
550
450

45
105
65
160
340
325

30
75
45
110
250
225

1400

L14

-----

-----

1223

712

1600

L145

-----

-----

1214

842

800
1000, 1100 & 1200

* For series 1000 only


** For series 1000K only

Drum
Designation

9/16

5/8

25
55
30
80
170
155

-------------------------

-------------------------

517

409

295

200

662

425

318

303

Consult your local cable supplier for recommendations on the best type of cable
and hardware to use in your specific application.
(a) Cable Considerations:
As the number of layers of cable on a winch increases, the rated lifting capacity of the winch goes down. If you are
operating at near the top of the drum flanges, the effective rating of the winch is about half of what it is on the first layer.
You should, therefore, only keep as much cable on the winch as you need for your job.

For Best Results, Only Use Bloom Replacement Parts


72

800-394-1139

Never use larger or smaller cable on your winch than is recommended for it. The use of larger cable will not allow you to
pull larger loads and may, in fact, break easier than the proper size cable. The use of smaller cable may overheat the
winch due to the increased running time with more cable.
(b) The Importance of a Proper Fleet Angle:
Maintaining the proper fleet angle is important to the success of your winching operation, the life of your winch and the
life of the cable you are using. The fleet angle can best be described by the following diagram:
The fleet angle should be kept as small as possible to ensure proper spooling and to maximize cable and winch life. To
promote even cable spooling, keep the fleet angle below three degrees. Never pull directly against the flange of the
winch cable drum as this may cause the cable or the winch to break. Adherence to these instructions will ensure better
spooling.
(c) Wire Rope Anchor & Wrapping:
Prepare the end of the wire rope as recommended by the wire rope manufacturer. Pass the free end of the wire rope
through the small opening of the cable drum anchor pocket. Lock the cable into the drum by tightening the cable anchor
set screw.

Centerline

PROPER FLEET
ANGLE

LOAD
Cable

Fleet Angle
3 Deg. Max.

Direction To Raise Load


Cable

PROPER WRAPPING
OF WIRE ROPE

Cable Anchor
Set Screw
Drum

Drum will turn counter clockwise


to spool cable onto drum
(d) Automatic Safety Brake:
Some Bloom winches are equipped with an automatic hydraulic brakes to hold suspended loads. If your winch is not
equipped
i d with
ith one, it is
i intended
i t d d for
f pulling
lli loads
l d only.
l If you wish
i h to
t lift andd suspendd loads
l d with
ith your winch,
i h it can be
b
retrofitted with a brake. Please consult the factory for details. The safety brake is an important feature of your winch and
must be maintained properly. There are two types of brakes used on Bloom winches:
Adjustable Automatic Safety Brake (Drag)
An oil cooled automatic safety brake disengages when a load is lifted and automatically engages when power is
removed or the load is lowered.
Automatic Hydraulic Fail-Safe Brake (Spring applied hydraulic release)
Spring applied hydraulic release brake automatically holds load when hydraulic pressure is released. Double counter
balance valve adds additional load holding capability by locking hydraulic oil in motor.
Bloom Mfg Inc.

319-827-1139

319-827-1140 fax
73

www.bloommfg.com

74

75

76

77

Service Manual HY09-SM300/US

Service Manual
PGP/PGM315, 330, 350, 365

Effective:
April 15, 2002
Supersedes: July 1, 1998

PGP/PGM 300 Series

78

PGP/PGM 300 Series


Service Manual HY09-SM300/US

315/330/350/365
Service Manual
General Instructions
These service instructions will familiarize you with
Parker's single and multiple pumps

their component parts


the relative position of each part
proper methods for assembly or disassembly of
the units
To facilitate the repair of these units and before any
work is done, we suggest that you first read all of the
steps used in disassembly and assembly.
Dirt is the enemy of any hydraulic system. The first
requirement for good maintenance of hydraulic
equipment is cleanliness. MAKE SURE YOU
DISASSEMBLE AND ASSEMBLE YOUR
HYDRAULIC EQUIPMENT IN A CLEAN AREA.
The pictures show Model PGP365. Notes in the
text cover variations between this unit and the
other models.
It is important to airblast all parts and wipe them with
a clean, lintless cloth before assembly.

Items shaded apply to


multiple assemblies only.

USE CAUTION IN GRIPPING ALL PARTS


IN THE VISE TO AVOID DAMAGING
MACHINED SURFACES.

NOTE:
For PGP315 and PGP330 ONLY - Plug 5
required in position A and position B.

A pump must be driven in the direction of rotation for


which it was built; otherwise, pressure will blow the
shaft seal. Check the exploded view and notes at right
for proper direction of rotation.

For PGP350 and PGP365 ONLY - Plug 5 in


position B gives clockwise rotation. Plug 5 in
position A gives counterclockwise rotation.

Parker's
Replacement Parts

PARTS LIST
1.
2.
3.
4.
5.
6.
7.
8.
9.

Snap Ring
Outboard Bearing
Seal
Shaft End Cover
Plug
Bushings
Channel Seal
Thrust Plates
Integral Drive Shaft
and Gear Set
10. Gasket Seal

Parker's replacement parts are of original equipment


standards. For assured quality of material and workmanship, and for compatibility in assembly, USE
ONLY GENUINE PARTS.
Check all replacement parts before installing them to
be certain that they were not damaged in shipment.

3
79

11. Dowel Pins (Solid for


PGP/PGM 315, 330 and
350. Hollow for PGP/PGM
365 ONLY.)
12. Gear Housing
13. Bearing Carrier
14. Connecting Shaft
15. Matched Gear Set
16. Gear Housing
17. Port End Cover
18. Studs or Cap Screws
19. Washers
20. Nuts

Parker Hannifin Corporation


Gear Pump Division
Youngstown, OH

PGP/PGM 300 Series


Service Manual HY09-SM300/US

Tool List
Arbor press
Awl
1 1/2" Dia. steel ball
Bearing puller (Owatonna Tool Co.
M D - 956 or equivalent)
Bushing remover tool (See A)
Clean, lintless cloths
Deburring tool (an old file with
cutting teeth ground off)
Machinist's hammer
Soft hammer
Permatex Aviation Form-A-GasketTM
No. 3 non-hardening sealant or equivalent
Medium grit carborundurn stone
Seal removal tool (See B)
Oil and grease
Snap ring pliers
Prick punch
Bushing installation tool (See C)
Scale ( 1/32" or 1/64" graduations)
Small screw driver
Torque wrench
Vise with 6" minimum opening.
Bar for lip seal installation
Note: For PGP/PGM315 use 1 5/8" dia. x 2" bar.
For PGP/PGM330 use 1 3/4" dia. x 2" bar.
For PGP/PGM350 use 2 1/2" dia. x 2" bar
For PGP/PGM365 use 2 1/2" dia. x 2" bar.
Special steel sleeve ( see sketch )

Bushing Puller: The bushings in PGP/PGM315, 330, 350 and 365


pumps may be removed from their bores, using blind hole collet-type
bushing pullers similar to those manufactured by Owatonna Tool Co.
The table below illustrates the modifications necessary to adapt the
OTC collets to this task. Equivalent pullers from other suppliers may
be modified in similar fashion.

A
PGP/PGM
315
PGP/PGM
330
PGP/PGM
350

Seal Removal Tool


Easily made from an
old screw driver. Heat
the tip and bend as
shown. Grind the tip
to fit the notch behind
the shaft seal.
Special Steel Sleeve
The special steel sleeve is
used to insert the drive shaft
through the lip seal without
damage and can be made
from bar stock: For the PGP/
PGM315 use a 1 " dia. x 3-1/
8" bar; for the PGP/PGM330
use a 1-1/8" or 1-1/4" dia. x
4- 5/8" bar; for the PGP/
PGM350 use a 1-3/8" dia. x
4-5/8" bar; for the PGP/
PGM365 use a 1- 1 /2" dia. x
4-5/8" bar. The drawing and
chart give details for making
this special tool.

PGP/PGM
315
PGP/PGM
330
PGP/PGM
350
PGP/PGM
365

PGP/PGM
315

PGP/PGM
330

PGP/PGM
350

PGP/PGM
365

4
80

Parker Hannifin Corporation


Gear Pump Division
Youngstown, OH

PGP/PGM 300 Series


Service Manual HY09-SM300/US

Start Disassembly Here


CAUTION:
1. If prying off sections becomes necessary, take extreme care not to mar or damage machined surfaces. Excessive force while prying
can result in misalignment and seriously damage parts.
2. If parts are difficult to fit during assembly, tap gently with a soft hammer (never use an iron hammer).
3. Gears are closely matched, therefore they must be kept together as sets when removed from a unit. Handle with care to avoid
damage to the journals or teeth. Avoid touching gear journals.
4. Never hammer bushings into bores; use an arbor press.

1) Place the pump in a


vise with the drive shaft
pointIng down. Caution:
DO NOT GRIP ON OR
NEAR ANY MACHINED
SURFACES DURING
ASSEMBLY OR
DISASSEMBLY.
Match-mark all sections.
Be sure to align these
marks when
reassembling.

2) Use a socket wrench


to remove the 4 cap
screws on single units or
the 4 hex nuts, studs
and washers of multiple
units.

3) Lift off the port end


cover. If prying is
necessary, be careful not
to damage the machined
surfaces. Dowel pins will
remain in either the port
end cover or the gear
housing.

4) Remove the thrust


plate. Examine and
replace if necessary.
See wear guide page 10.

5) Carefully remove the


drive and driven gears.
Avoid tapping the gear teeth
together or against other
hardened surfaces. Keep
these gears together
because they are a matched
set. Examine and replace if
necessary. (See page 10).
Remove the thrust plate
from the bearing carrier.
Examine and replace if
necessary.

6) Lift the gear housing


from the bearing carrier.
If prying is necessary,
take care not to damage
machined surfaces.
Examine and replace
if necessary.
(See page 10)
For multiple assemblies
only

For multiple assemblies only

5
81

Parker Hannifin Corporation


Gear Pump Division
Youngstown, OH

PGP/PGM 300 Series


Service Manual HY09-SM300/US
7) Carefully lift or pry off
the bearing carrier to
prevent damage to
contact face and edges.
Dowel pins will remain in
either the bearing carrier
or the gear housing.
DO NOT REMOVE THEM.

For multiple assemblies only

8) Remove the
connecting shaft.
Remove the thrust plate.
Examine and replace if
necessary. (See page
10). Remove the driven
gear and the integral gear
and drive shaft. Keep
these together as they
are a matched set.
Examine and replace if
necessary. (*See page
10). Be careful not to
damage the machined
surfaces of the gears.

9) Lift or pry off the first


section gear housing. Be
careful not to damage
machined surfaces.
Examine and replace if
necessary (see page 10).

10) Inspect all bushings


for scoring or
discoloration and
replace if necessary.
Use a bushing puller as
shown in the tool list to
remove bushings (see
page 4).

11) If the pump is


equipped with an
outboard bearing, place
the shaft end cover in
the vise with the
mounting face up.
Remove the snap ring
with snap ring pliers. If a
unit is equipped with a
spiral-lock retaining ring,
remove with a small
screwdriver or awl.

12) Use a bearing puller


to remove the outboard
bearing.

13) Grip the shaft end


cover in a vise with the
mounting face down.
Remove double lip seal
by inserting the special
seal removal tool (see
Tool List) into the notch
between the double lip
seal and the shaft end
cover. Tap the seal out
and discard.
Remove and discard all
rubber and polymer seals.

6
82

Parker Hannifin Corporation


Gear Pump Division
Youngstown, OH

PGP/PGM 300 Series


Service Manual HY09-SM300/US

Start Assembly Here


1) Stone all machined
surfaces with a medium
grit carborundurn stone.

2) If the bushings have


been removed, deburr
the bushing bores with an
emery cloth. Rinse parts
in a solvent. Air blast all
the parts and wipe with
a clean, lintless cloth
before starting assembly.

3) Grip shaft end cover in


vise with mounting face
down. Examine plug or
plugs* to be sure they're
tightly in place.
Replacement is necessary
only if parts are damaged.
Remove with screwdriver.

4) New plugs should be


screwed in tightly. Stake
the plug with a prick
punch at both ends of the
screwdriver slot and
around edges. Peen the
edge of the hole 1/32" to
1/16" with a1-1/2"
diameter steel ball.
NOTE: If new plug or
plugs are being installed,
coat threads with
LoctiteTM thread sealant.

*PGP/PGM315 and 330


have two plugs in both the
shaft end and port end
covers. PGP/PGM350 and
365 have one plug on the
outlet side of their shaft end
and port end covers.
5) Note: Assembly steps 5, 6, 7 & 8
apply to shaft end cover, bearing
carrier and portend cover.
Any bushings removed from the
shaft end cover, portend cover
or bearing carrier should be
assembled in the drive bores with
the groove to the top of unit (12
o'clock). Assemble the bushings in
the driven bores with the groove to
the bottom of the unit (6 o'clock).
The PGP/PGM315 does not have
grooved bushings, therefore the
bushing seams should be placed
at the 12 and 6 o'clock positions.

6) Bushings should be
pressed into the bores,
one at a time, using the
special installation tool
and an arbor press. Be
sure the that the grooves
(or seams) are positioned
as stated in Step #5. The
bushings must be pressed
into the bores flush with
the casting face. Be sure
to support the castings
so that they are square
and level.

7) Repeat Steps 1 and 2,


stone and rinse parts.

8) See that dowel pins


are in place in any new
castings. Examine all of
the dowels. Before
inserting, make certain
that the hole is clean and
free from burrs. Gently
start the pin straight into
the hole and tap lightly
with a soft hammer.

7
83

Parker Hannifin Corporation


Gear Pump Division
Youngstown, OH

PGP/PGM 300 Series


Service Manual HY09-SM300/US
9) Before inserting a new lip
seal in the shaft end cover,
coat the outer edge of the
lip seal and its recess with
Permatex Aviation
Form-A-Gasket No. 3
non-hardening sealant or
equivalent. With the metal
side of the lip seal up, press
it into the mounting flange
side of the shaft end cover
with an arbor press and bar
(see Tool List on page 4).
Be careful not to damage
the lip of the seal. Press in
until flush with the recess.
Wipe off excess sealant.

10) If the unit is equipped


with an outboard bearing,
guide the bearing into its
recess in the shaft end
cover. This is a light
press fit. It may be
necessary to lightly tap
the bearing into the
bore.

11) Install the snap ring in


the groove to retain the
outboard bearing.

12) Grease the new gasket


seals and insert them into
the grooves in both sides of
all gear housings. Position
the first gear housing over
the shaft end cover and
dowels. Tap it with a soft
hammer until it rests tightly
against the shaft end cover.
Be careful not to pinch the
gasket seal. Also be sure
that the large rounded core
is on the inlet side.

13) Assemble the channel


seals into the grooves in
the thrust plates with the
flat side of the seal facing
away from the thrust plate
as shown below.

14) Gently slip the thrust


plate through the gear
housing and into place on
the shaft end cover. The
channel seal from Step
#13 should face the shaft
end cover. The relief
groove in the plate should
face the outlet side of the
pump.

Flat Side
of Seal

Thrust
Plate

15) Slide the driven gear


through the housing and into
the bushing in the shaft end
cover. Coat the steel sleeve
tool with grease. Place the
lightly-greased drive shaft
inside the sleeve and slide
both through the shaft end
cover with a twisting motion,
until the integral gear rests
against the thrust plate.
Avoid damaging the double
lip seal. Remove the steel
sleeve. Squirt clean oil over
the gears.

8
84

16) Slip the thrust plate


with the seal over the gear
journals and into the
housing bore. The flat side
of the seal should face up
with the relief groove
facing the outlet side. (For
single pump assemblies
go directly to Step #21).

Parker Hannifin Corporation


Gear Pump Division
Youngstown, OH

PGP/PGM 300 Series


Service Manual HY09-SM300/US

17) Place the bearing


carrier onto the journals
of the drive and driven
gears. Be sure to line up
the dowel holes over the
dowel pins. When the
parts are parallel,
squeeze them together
or alternately tap over
each dowel until the
parts are together.

18) Insert the connecting


shaft into the spline of
the drive gear. Position
and place the second
gear housing on the
bearing carrier as
outlined in Step #12.

19) Place the thrust plate


in the gear housing per
Step #14. Insert the drive
and driven gears of the
second section in their
respective bearings. Make
certain the gears are in
contact with the thrust
plate face. Place the port
end cover plate in the
housing per Step #16.

20) Check the plug or


plugs in the port end
cover to be sure that
they are tight. Follow the
procedure outlined in
Step #4 for new plugs.

For multiple assemblies


only

For multiple assemblies


only

For multiple assemblies


only

22) Thread the fasteners


into the shaft end cover
and tighten alternately or
cross corner. Rotate the
drive shaft with a 6"
wrench to check for
binding. If there is no
internal binding, torque
diagonally opposed
fasteners to 200 ft. lbs.
(2400 in. lbs.); 141 ft. lbs.
(1700 in. lbs.) for PGP/
PGM315 models; 450 ft.
lbs. (5400 in lbs.) for PGP/
PGM365.

21) Place the port end


cover over the gear
journals. Align the dowels
with the holes in the
mating casting. Being
careful not to pinch the
gasket-seal, tap the port
end cover lightly in the
center between bearing
bores to engage the
dowels and to move parts
together in the final
seating.

9
85

Parker Hannifin Corporation


Gear Pump Division
Youngstown, OH

PGP/PGM 300 Series


Service Manual HY09-SM300/US

Guideline for acceptable wear


Gear Housings

Dowel Pins

Wear in excess of .007" cut-out necessitates


replacement of the gear housing. Place a straight-edge
across bore. If you can slip a .007 feeler gage under
the straight-edge in the cut-out area, replace
the gear housing.

If either the dowel or dowel hole is damaged,


the dowel or machined casting, or both, must
be replaced.
If more than reasonable force is required to
seat dowels, the cause may be poorly deburred
or dirty parts; cocking of the dowel in the hole or
improper pin-to-hole fit.

Pressure pushes the gears against the


housing on the low pressure side. As the
hubs and bushings wear, the cut-out
becomes more pronounced. Excessive
cut-outin a short period of time indicates excessive
pressure or oil contamination. If the relief valve settings
are within prescribed limits, check for shock pressures
or tampering.
When the cut-out is moderate, 007" or less, the gear
housing is in good condition and may be reused.

Bushings
If gears are replaced, bushings must be
replaced. Bushings should fit into the bore with
a heavy press fit.
Seals and Gaskets
Replace all rubber and polymer seals,
including all "0" rings, thrust plate channel
seals, shaft seal and gasket seals.

Gears
Any scoring on gear hubs necessitates
replacement. Scoring, grooving, or
burring of the outside diameter of the
teeth requires replacement. Nicking,
grooving, or fretting of teeth surfaces also
necessitates replacement.

Plugs
Examine the plugs in the shaft end and port
end cover to make sure that they are in the
proper position and tight. The PGP/PGM315 and
PGP/PGM330 should have two plugs in both the
shaft end and port end in tandem units only. The
PGP/PGM350 and PGP/PGM365 have one plug in
their shaft and port ends high pressure side only.

Drive Shafts
Replace if there is any wear
detectable by touch in the seal
area or at the drive coupling. The
maximum allowable wear is .002".
Wear in the shaft seal area indicates oil
contamination. Wear or damage to splines, keys,
or keyways necessitates replacement.
Thrust Plates
The thrust plates seal the gear section at
the sides of the gears. Wear here will allow
internal slippage, that is, oil will bypass
within the pump.
A maximum of .002" wear is allowable. Replace
thrust plates if they are scored, eroded or pitted.
Check center of thrust plates where the gears mesh.
Erosion here indicates oil contamination.
Pitted thrust plates indicate cavitation or oil aeration.
Discolored thrust plates indicate overheating, likely due
to insufficient oil.

10
86

Parker Hannifin Corporation


Gear Pump Division
Youngstown, OH

PGP/PGM 300 Series


Service Manual HY09-SM300/US

Lubrication and Oil


Recommendations
General Recommendations:

All parts, with the exception of the outboard bearing,


are lubricated by the hydraulic oil in the circuit.
Particular attention must be paid to keep clean oil in
the circuit system. Whenever there is a pump or
motor failure, and there is reason to feel that metal
particles may be in the system, the oil must be
drained, the entire system flushed clean and any
filter screens thoroughly cleaned or replaced. New oil
should be supplied for the entire system. Oil suitable
and recommended for use in circuits involving
Parker's pumps and motors should meet the following
specifications:

A good-quality hydraulic oil conforming to the


characteristics listed above is essential to the
satisfactory performance and long life of any
hydraulic system.
The oil should be changed on regular schedules in
accordance with the manufacturer's recommendations,
and the system periodically flushed.
The oil temperature in the reservoir must not exceed
200 F., (93.3 C.) with a maximum temperature of
180 F. (82.2 C.) recommended. Higher temperatures
will result in rapid oil deterioration.

Viscosity:
50 SSU minimum @ operating temperature
7500 SSU maximum @ starting temperature

Reservoir capacity should equal in gallons the pump


output in gpm or the total gpm of all pumps, where
there is more than one in the system.

150 to 225 SSU @ 100 F. (37.8C.) (generally)


44 to 48 SSU @ 210 F. (98.9 C.) (generally)

Oil poured into the reservoir should pass through a


100-mesh screen. Pour only clean oil from clean
containers into the reservoir. A 100-mesh screen may
be used in the suction line leading to the pump. A
suction filter should be of sufficient size to handle
twice the pump capacity. It must be cleaned and
checked regularly to avoid damage due to
contamination and cavitation.

Approximate SSU @

Normal Temperatures:
O F. (-1 8 C.) to 100 F. (37.8 C.) Ambient 100 F.
(37.8 C.) to 180 F. (82.2 C.) System. Be sure your
oil is recommended for the temperatures you expect to
encounter.

Viscosity Index: 90 minimum


Aniline Point: 175 minimum
Recommended Additives: Foam depressant,
rust and oxidation inhibitors. Filtration: 10 micron
recommended for maximum pump life.

Cold Weather Operation:


Oils for use in cold weather should have a viscosity
not exceeding 7500 SSU at the minimum start-up
temperature. A pour point of at least 20 F. below
start-up temperature is recommended. Start-up
procedures should allow for a gradual warm-up until
the oil reaches a reasonably fluid state.

Other Desirable Characteristics:


Stability of physical and chemical characteristics.
High demulsibility (low emulsibility) for separation
of water, air and contaminants.
Resistant to the formation of gums, sludges, acids,
tars and varnishes.
High lubricity and film strength.

Continued on the following page.

11
87

Parker Hannifin Corporation


Gear Pump Division
Youngstown, OH

PGP/PGM 300 Series


Service Manual HY09-SM300/US
Continued from the previous page

Recommended Start-up
Procedure For New or
Rebuilt Pump

The Use of Other Fluids:

Before installing a new or rebuilt pump, back off


the main relief valve until the spring tension on the
adjusting screw is relieved. This will avoid the
possibility of immediate damage to the replacement
unit in the event that the relief valve setting had
been increased beyond the recommended operating
pressure, prior to removing the old unit.

Automatic Transmission Fluid (ATF): In general, ATF


performance is satisfactory; however these fluids are
sometimes too expensive for normal use in hydraulic
systems.
Diesel Fuel or Kerosene (Coal Oil): Though
sometimes used as dilutants for cold weather
operations, they are not recommended, as they
are not sufficiently refined.

Before connecting any lines to the pump, fill all ports


with clean oil to provide initial lubrication. This is
particularly important if the unit is located above the
oil reservoir.

Fire Resistant Fluids: DO NOT USE ANY FIRE


RESISTANT FLUIDS OR NON-PETROLEUM OILS
WITHOUT CONSULTING OUR TECHNICAL SERVICE
DEPARTMENT.

After connecting the lines and mounting the


replacement unit, operate the pump at least two
minutes at no load and at low rpm (400 min.) During
this break-in period, the unit should run free and not
develop an excessive amount of heat. If the unit
operates properly, speed and pressure can then be
increased to normal operating settings.

These suggestions are intended as a guide only.


OBTAIN YOUR FINAL FLUID RECOMMENDATIONS
FROM YOUR FLUID SUPPLIER.

Reset the main relief valve to its proper setting while


the pump is running at maximum operating engine
(motor) speed for the vehicle.

ALWAYS USE AN ACCURATE GAUGE


WHEN ADJUSTING THE RELIEF VALVE
PRESSURE SETTING.

12
88

Parker Hannifin Corporation


Gear Pump Division
Youngstown, OH

PGP/PGM 300 Series


Service Manual HY09-SM300/US

Recommended
Test Procedure
Many repairmen measure the output at normal
operating speed and at zero pressure, then again at
1000 psi (or the operating pressure of the equipment)
and allow a volume decrease approximating the listing
below. It is a suggested reference only which makes
allowance for reused parts.

Make certain that there is an adequate supply of oil for


the pump; at least one gallon of oiI for each gpm of
pump capacity.
If one section of a tandem pump is being tested,
make sure that all other sections not being tested
are adequately supplied with oil. If any of the other
sections run dry, or if plugs are left in ports, serious
and permanent damage will result.

At test speeds other than 1800 rpm, gpm delivery will


vary almost proportionately, but the same (drop-off)
figures should be used.

The oil should be a good quality hydraulic oil rated at


150 SSU at 100 F., with the oil temperature held at
120 F. plus or minus 50 F. (Test procedures are
described in detail in SAE handbooks; see Hydraulic
Power Pump Test Procedure, SAE J745c.)

Be sure to run the pump in the direction for which it


was designed and built. Driving the pump in the wrong
direction will build up pressure behind the shaft seal,
damaging it and necessitating replacement.
After completing testing procedures, the pump is
ready for installation and immediate duty operation
on equipment. Again, it must be remembered that
to prevent seizure, hot oil must not be fed into a
cold pump.

The feed line must be of adequate size with no more


than 5" mercury vacuum adjacent to the pump inlet. As
a rule, the feed line must provide a feed flow velocity
not in excess of 8 feet per second.
Feeding hot oil into a cold pump may cause the pump
to seize. Jog the pump by momentarily starting and
stopping repeatedly the driving engine or motor to
gradually equalize pump and oil temperatures.
Run the pump at least two minutes at no load and
moderate speed (not over 1500 rpm). If the pump
becomes excessively hot, shut down immediately and
locate the problem source.
Gradually increase pressure on pump, in 500 psi
increments until the desired test pressure has been
reached. This should take about five minutes.
Delivery should run close to rated catalog performance
figures, which are averaged from testing several
pumps. A 5% lower reading may be used as a rated
minimum if new or relatively new parts have been
used. When rebuilding the pump with parts from the
original pump, which, while worn, appear satisfactory
for reuse, a 10% or 15% lower reading may be
permitted, depending on the performance expected
from the equipment. One's own experience will prove
the best guide here.

13
89

Parker Hannifin Corporation


Gear Pump Division
Youngstown, OH

PGP/PGM 300 Series


Service Manual HY09-SM300/US
Offer of Sale
The items described in this document and other documents or descriptions provided by Parker Hannifin Corporation, its subsidiaries and its authorized
distributors are hereby offered for sale at prices to be established by Parker Hannifin Corporation, its subsidiaries and its authorized distributors. This offer and
its acceptance by any customer ("Buyer") shall be governed by all of the following Terms and Conditions. Buyers order for any such items, when communicated
to Parker Hannifin Corporation, its subsidiary or an authorized distributor ("Seller") verbally or in writing, shall constitute acceptance of this offer.
items sold hereunder, even if such apparatus has been specially converted or adapted for such manufacture and notwithstanding any charges
paid by Buyer. Unless otherwise agreed, Seller shall have the right to alter,
discard or otherwise dispose of any special tooling or other property in its
sole discretion at any time.
8. Buyers Property: Any designs, tools, patterns, materials, drawings,
confidential information or equipment furnished by Buyer or any other
items which become Buyers property, may be considered obsolete and
may be destroyed by Seller after two (2) consecutive years have elapsed
without Buyer placing an order for the items which are manufactured using
such property, Seller shall not be responsible for any loss or damage to
such property while it is in Sellers possession or control.
9. Taxes: Unless otherwise indicated on the face hereof, all prices and
charges are exclusive of excise, sales, use, property, occupational or like
taxes which may be imposed by any taxing authority upon the manufacture, sale or delivery of the items sold hereunder. If any such taxes must
be paid by Seller or if Seller is liable for the collection of such tax, the
amount thereof shall be in addition to the amounts for the items sold. Buyer
agrees to pay all such taxes or to reimburse Seller therefore upon receipt
of its invoice. If Buyer claims exemption from any sales, use or other tax
imposed by any taxing authority, Buyer shall save Seller harmless from
and against any such tax, together with any interest or penalties thereon
which may be assessed if the items are held to be taxable.
10. Indemnity For Infringement of Intellectual Property Rights: Seller
shall have no liability for infringement of any patents, trademarks, copyrights, trade dress, trade secrets or similar rights except as provided in this
Part 10. Seller will defend and indemnify Buyer against allegations of
infringement of U.S. Patents, U.S. Trademarks, copyrights, trade dress
and trade secrets (hereinafter Intellectual Property Rights). Seller will
defend at its expense and will pay the cost of any settlement or damages
awarded in an action brought against Buyer based on an allegation that an
item sold pursuant to this contract infringes the Intellectual Property Rights
of a third party. Sellers obligation to defend and indemnify Buyer is
contingent on Buyer notifying Seller within ten (10) days after Buyer
becomes aware of such allegations of infringement, and Seller having sole
control over the defense of any allegations or actions including all
negotiations for settlement or compromise. If an item sold hereunder is
subject to a claim that it infringes the Intellectual Property Rights of a third
party, Seller may, at its sole expense and option, procure for Buyer the right
to continue using said item, replace or modify said item so as to make it
noninfringing, or offer to accept return of said item and return the purchase
price less a reasonable allowance for depreciation. Notwithstanding the
foregoing, Seller shall have no liability for claims of infringement based on
information provided by Buyer, or directed to items delivered hereunder for
which the designs are specified in whole or part by Buyer, or infringements
resulting from the modification, combination or use in a system of any item
sold hereunder. The foregoing provisions of this Part 10 shall constitute
Sellers sole and exclusive liability and Buyers sole and exclusive remedy
for infringement of Intellectual Property Rights.
If a claim is based on information provided by Buyer or if the design for an
item delivered hereunder is specified in whole or in part by Buyer, Buyer
shall defend and indemnify Seller for all costs, expenses or judgments
resulting from any claim that such item infringes any patent, trademark,
copyright, trade dress, trade secret or any similar right.
11. Force Majeure: Seller does not assume the risk of and shall not be
liable for delay or failure to perform any of Sellers obligations by reason
of circumstances beyond the reasonable control of Seller (hereinafter
Events of Force Majeure). Events of Force Majeure shall include without
limitation, accidents, acts of God, strikes or labor disputes, acts, laws, rules
or regulations of any government or government agency, fires, floods,
delays or failures in delivery of carriers or suppliers, shortages of materials
and any other cause beyond Sellers control.
12. Entire Agreement/Governing Law: The terms and conditions set
forth herein, together with any amendments, modifications and any
different terms or conditions expressly accepted by Seller in writing, shall
constitute the entire Agreement concerning the items sold, and there are
no oral or other representations or agreements which pertain thereto. This
Agreement shall be governed in all respects by the law of the State of Ohio.
No actions arising out of the sale of the items sold hereunder or this
Agreement may be brought by either party more than two (2) years after
the cause of action accrues.
9/91-P

1. Terms and Conditions of Sale: All descriptions, quotations, proposals, offers, acknowledgments, acceptances and sales of Sellers products
are subject to and shall be governed exclusively by the terms and
conditions stated herein. Buyers acceptance of any offer to sell is limited
to these terms and conditions. Any terms or conditions in addition to, or
inconsistent with those stated herein, proposed by Buyer in any acceptance of an offer by Seller, are hereby objected to. No such additional,
different or inconsistent terms and conditions shall become part of the
contract between Buyer and Seller unless expressly accepted in writing
by Seller. Sellers acceptance of any offer to purchase by Buyer is
expressly conditional upon Buyers assent to all the terms and conditions
stated herein, including any terms in addition to, or inconsistent with those
contained in Buyers offer, Acceptance of Sellers products shall in all
events constitute such assent.
2. Payment: Payment shall be made by Buyer net 30 days from the date
of delivery of the items purchased hereunder. Amounts not timely paid
shall bear interest at the maximum rate permitted by law for each month
or portion thereof that the Buyer is late in making payment. Any claims by
Buyer for omissions or shortages in a shipment shall be waived unless
Seller receives notice thereof within 30 days after Buyers receipt of the
shipment.
3. Delivery: Unless otherwise provided on the face hereof, delivery shall
be made F.O.B. Sellers plant. Regardless of the method of delivery,
however, risk of loss shall pass to Buyer upon Sellers delivery to a carrier.
Any delivery dates shown are approximate only and Seller shall have no
liability for any delays in delivery.
4. Warranty: Seller warrants that the items sold hereunder shall be free
from defects in material or workmanship for a period of 18 months from
date of shipment from Parker Hannifin Corporation. THIS WARRANTY
COMPRISES THE SOLE AND ENTIRE WARRANTY PERTAINING TO
ITEMS PROVIDED HEREUNDER. SELLER MAKES NO OTHER WARRANTY, GUARANTEE, OR REPRESENTATION OF ANY KIND WHATSOEVER. ALL OTHER WARRANTIES, INCLUDING BUT NOT LIMITED TO, MERCHANTABILITY AND FITNESS FOR PURPOSE,
WHETHER EXPRESS, IMPLIED, OR ARISING BY OPERATION OF
LAW, TRADE USAGE, OR COURSE OF DEALING ARE HEREBY
DISCLAIMED. NOTWITHSTANDING THE FOREGOING, THERE
ARE NO WARRANTIES WHATSOEVER ON ITEMS BUILT OR ACQUIRED WHOLLY OR PARTIALLY, TO BUYERS DESIGNS OR
SPECIFICATIONS.
5. Limitation Of Remedy: SELLERS LIABILITY ARISING FROM OR IN
ANY WAY CONNECTED WITH THE ITEMS SOLD OR THIS CONTRACT SHALL BE LIMITED EXCLUSIVELY TO REPAIR OR REPLACEMENT OF THE ITEMS SOLD OR REFUND OF THE PURCHASE
PRICE PAID BY BUYER, AT SELLERS SOLE OPTION. IN NO EVENT
SHALL SELLER BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY KIND OR NATURE WHATSOEVER, INCLUDING BUT NOT LIMITED TO LOST PROFITS ARISING
FROM OR IN ANY WAY CONNECTED WITH THIS AGREEMENT OR
ITEMS SOLD HEREUNDER, WHETHER ALLEGED TO ARISE FROM
BREACH OF CONTRACT, EXPRESS OR IMPLIED WARRANTY, OR IN
TORT, INCLUDING WITHOUT LIMITATION, NEGLIGENCE, FAILURE
TO WARN OR STRICT LIABILITY.
6. Changes, Reschedules and Cancellations: Buyer may request to
modify the designs or specifications for the items sold hereunder as well
as the quantities and delivery dates thereof, or may request to cancel all
or part of this order, however, no such requested modification or cancellation shall become part of the contract between Buyer and Seller unless
accepted by Seller in a written amendment to this Agreement. Acceptance
of any such requested modification or cancellation shall be at Sellers
discretion, and shall be upon such terms and conditions as Seller may
require.
7. Special Tooling: A tooling charge may be imposed for any special
tooling, including without limitation, dies, fixtures, molds and patterns,
acquired to manufacture items sold pursuant to this contract. Such special
tooling shall be and remain Sellers property notwithstanding payment of
any charges by Buyer. In no event will Buyer acquire any interest in
apparatus belonging to Seller which is utilized in the manufacture of the

14
90

Parker Hannifin Corporation


Gear Pump Division
Youngstown, OH

Power Wheel Service Manual


Model 6 Single Reduction
Wheel Drives

AUBURN, INDIANA 46706-3499


U.S.A.

PHONE: (219) 925-3200


FAX: (219) 925-4725
3
1
2
4
5
6
7

11

7
12
13
17

14
16

18
9
10
15

19

24
20

21
22

25

23

26
27
29

30

28

31

OPTIONAL
91

ITEM
NO.

DESCRIPTION*

NO. USED
IN ASSY.

ITEM
NO.

DESCRIPTION*

NO. USED
IN ASSY.

Coupling

17

Ring Gear

Input Shaft

18

Carrier Assembly

Spindle

19

Sun Gear

Boot Seal 604401

20

Retaining Ring

Oil Seal 14-00-044-010

21

Thrust Washer

Bearing Cone 04-01-101-35

22

Disengage Plunger

Bearing Cup 04-01-102-12

23

Wheel Bolt

O Ring 614101
Aluminum Cover 10-00-141-113
Cast Iron Cover 614101

24
Hex Head Bolt (Grade 8)

6-12

Large Cover
Aluminum Cover 14-02-039-004
Cast Iron Cover 603915

9
10

Flat Washer 14-00-047-002

6-12

25

Hex Head Bolt

11

Hub

26

Magnetic Plug 14-00-052-002

12

Bearing Cone 04-01-101-17

27

Disengage Cover 14-02-039-005

13

Retaining Ring Kit 14-02-410-003

28

Hex Head Bolt 618305

14

Retaining Ring 613912

29

Quick Disconnect Gasket

15

Washer 14-02-193-002

30

Quick Disconnect Assembly

16

Disengage Spring 14-02-156-001

31

Hex Head Bolt

* Contact Auburn Gear with part number and order code of drive to obtain the appropriate parts list.
Refer to parts list for the specific part numbers and quantities.

Model 6 Power Wheel Service Kits


Part No.

Description

Included Items

14-02-410-003
641008**
641017**

Retaining Ring Kit


Bearing and Seal Kit
Seal Kit

13 (7 Retaining Rings)
5, 6, 7, 12, 13 and 23
5, 13 and 23

** Indicates kit also includes a tube of sealant, part number 604101.


MH422 - 0397

Power Wheel is a registered trademark of Auburn Gear


92

IDENTIFICATION
IMPORTANT: All Power Wheel units and kits are shipped with a nameplate that includes the Auburn Gear part number and order code as shown.

Power Wheel
Example:

ORDER CODE: 6WB13156C


PART NO.: 6000236
SERIAL NO.: 143434

AUBURN, IN U.S.A.

In addition to the nameplate, Power Wheel drives are stamped with an identification number which appears on the cover or hub flange as shown.
Example:

6000236-A-4-9

When ordering parts, the information included on the nameplate or the stamped identification number is necessary to accurately identify the drive
and obtain the correct replacement parts. Once this information has been obtained, contact Auburn Gear for the appropriate parts list.

DISASSEMBLY OF POWER WHEEL


STEP 1

STEP 7

Slide the coupling (1) from splines on input shaft (2).

Remove the input shaft (2) from spindle (3). Remove the retaining rings (14),
washers (15), and disengage spring (16) from input shaft (2) only if replacement is required.

STEP 2
Position the assembly upright on face of spindle (3).

STEP 8

STEP 3

Remove the 6 or 12 bolts (9) and washers (10) from hub (11) and remove ring
gear (17). It may be necessary to strike ring gear (17) with a rubber mallet to
loosen from hub (11).

Remove the disengage cover (27) if necessary.


STEP 4
Remove bolts (25) and the large cover (24) from the unit. The thrust washer
(21) and the disengage plunger (22) usually remain attached to the large
cover (24) when it is removed. Remove thrust washer (21), disengage plunger
(22) and O ring (23) from the large cover (24).
STEP 5
Remove sun gear (19) and thrust washer (20), used in aluminum cover units
only, from end of input shaft (2).
STEP 6
Remove the carrier assembly (18).

STEP 9
Remove the retaining ring (13) from in front of the bearing cone (12) and lift
hub (11) from spindle (3). If bearings are not a loose fit, it may be necessary to
press spindle (3) from hub (11). NOTE: Use a retaining ring expander tool to
remove retaining ring (13).
STEP 10
Remove the oil seals (4) and (5) and bearing cones (6 & 12) from hub (11).
Inspect bearing cups (7) in position and remove only if replacement is
required.

ASSEMBLY OF POWER WHEEL


STEP 1

STEP 5

Press new bearing cups (7) in each side of the hub (11). It is recommended
that bearing cups (7) and cones (6 & 12) be replaced in sets.

Assemble a retaining ring (14) in groove opposite pilot end of input shaft (2).
Assemble a washer (15), spring (16), a second washer (15), and a second
retaining ring (14) in the middle grooves of input shaft (2). Some shafts have a
shoulder and require only one retaining ring (14).

STEP 2
Assemble bearing cone (6) into cup (7) at seal end of hub (11) and press a
new seal (5) into hub (11). Install boot seal (4) on hub (11) if unit is so
equipped.

STEP 6
Assemble the splined end of the input shaft (2) down into spindle (3).

STEP 3

STEP 7

Position spindle (3) upright on bench. Lubricate lips of seals (4 & 5) and lower
hub (11) onto spindle (3). Hub (11) should be centered as it is lowered over
spindle (3) to prevent seal damage.

Assemble the carrier assembly (18) to spindle (3) at splines.

STEP 4
Assemble bearing cone (12) over spindle (3) and into bearing cup (7). If
bearings (6, 7, &12), hub (11) or spindle (3) is replaced, a new retaining ring
(13) is required for proper bearing setting. Do not re-use snap ring after it has
been installed and removed from unit. Select the thickest retaining ring (13)
that can be assembled into the ring groove of the splined end of spindle (3)
above bearing cone (12). Bearing should have from .000 .006 inches of end
play when proper retaining ring (13) is installed.

STEP 8
Clean mating surfaces and apply a bead of silicone sealant to face of hub (11)
that mates with ring gear (17). {See instructions on sealant package.} Hub
(11) is attached to ring gear (17) with 6 or 12 3/8-24 grade 8 hex head cap
screws (9) and flat washers (10). Torque cap screws to 52 60 lb. ft. (70 81
Nm).
STEP 9
Assemble sun gear (19) over input shaft (2). Rotate sun gear (19) to align
input shaft (2) to gear splines and gear teeth in carrier assembly (18).

2 93

STEP 10

STEP 13

For units with the aluminum cover (24) assemble the small thrust washer (20)
over input shaft (2) and against shoulder of input shaft (2).

Assemble the disengage cover (27) with dimpled center protruding out if
wheel is to be used to drive the vehicle. Assemble and torque the two 5/16-18
x 1/2 inch bolts (28). Torque bolts to 10 20 lb. ft. (13 27 Nm).

STEP 11
For units with the aluminum cover (24), lubricate O ring (23) and assemble in
groove of the disengage plunger (22). Assemble disengage plunger (22) over
end of input shaft (2) and against thrust washer (20). For units with cast iron
cover (24), lubricate O ring (23) and assemble in groove inside cover hole,
push plunger (22) into cover with pointed end facing inside of unit.

STEP 14
Invert the Power Wheel assembly and assemble the coupling (1), with
counterbore out, to the input shaft (2).
STEP 15

STEP 12

After motor is assembled to drive or drive is sealed at spindle, fill with lubricant
to proper level and replace all plugs.

Assemble the thrust washer (21) with tangs engaged with cover (24). NOTE: A
small amount of grease applied to the back side of thrust washer (21) will hold
washer in place. Apply a bead of silicone sealant to end of face of ring gear
(17). Assemble cover (24) aligning holes of cover and ring gear. Assemble the
eight 5/16-18 x 1 inch hex head bolts (25). Torque bolts to 20 25 lb. ft. (27
34 Nm).

NOTE: When installing a hydraulic motor to the Power Wheel drive it is


necessary to place an O ring or gasket (not supplied by Auburn Gear)
between the motor and the planetary drive. O ring sizes: SAE A 2-042, SAE
B 2-155, SAE C 2-159.

CARRIER ASSEMBLIES
It is recommended that the carrier assembly (18) be replaced in its entirety to protect the integrity of the Power Wheel drive.

LUBRICATION RECOMMENDATIONS
IMPORTANT: POWER WHEEL PLANETARY DRIVES ARE SHIPPED WITHOUT LUBRICANT AND MUST BE FILLED TO THE PROPER LEVEL PRIOR
TO START UP.
Observe lubrication recommendations given by the original equipment manufacturer. When specific recommendations are not available, use mild extreme
pressure lubricant API-GL-5, No. 80 or 90 when filling the Power Wheel under normal temperature ranges between 0 - 120F (-18 to 49C). Power Wheel is to
be half full of oil when unit is mounted level and horizontal. Use drain and fill plugs located in cover and ring gear. Oil is to be changed after first 50 hours of
operation with subsequent changes every 1000 hours or yearly, which ever comes first. If unit is to be operated vertically, if ambient conditions are outside the
specified range, or if the oil temperature exceeds 200F (93C) contact Auburn Gear for oil and level recommendations.

TOWING VEHICLE
CAUTION: The Power Wheel will not normally be damaged by towing; however, the hydraulic drive components may be damaged unless the Power Wheel is
disengaged from the drive motor. Road speeds in excess of 25 MPH should be avoided unless clearly specified to be permissible by the equipment manufacturer.

TO DISENGAGE POWER WHEEL


CAUTION: For units equipped with the standard spring disconnect, assemble the disengage cover (27) with the dimpled center protruding inward. For units
equipped with the optional quick disconnect, push in center plunger of disconnect.

STORAGE
A protective film is applied to the Power Wheel at the factory to prevent rust during shipment. Additional protection may be required if the Power Wheel is to be
stored for an extended period of time.

SEALING COMPOUND
Silastic RTV732 sealer and General Electric Silimate RTV No. 1473 or RTV No. 1503 are currently recommended for sealing gasket surfaces. Sealant should
be applied in a continuous bead, which should be centered on the surface to be sealed but should move to the inside of the hole at each bolt hole location. For
service requirements order Auburn Gear part number 604101.

SPECIFICATIONS
Maximum intermittent output torque ................................................................................................................................................. 22,000 lb. in. (2,485 Nm)
Maximum input speed ....................................................................................................................................................................................... 3,500 RPM
Oil capacity ................................................................................................................................................................................................... 25 oz (738 ml)
94 3

ELECTRICAL

95

96

97

98

Adjustable
Frequency AC
Drive for
Fan & Pump
Applications
FRN 2.xx

User Manual

www.abpowerflex.com

99

Chapter 4

Troubleshooting
Chapter 4 provides information to guide you in troubleshooting the
PowerFlex 400 drive. Included is a listing and description of drive faults
(with possible solutions, when applicable).
For information on
Drive Status
Faults

See page For information on


4-1
Fault Descriptions
4-1
Common Symptoms and
Corrective Actions

See page
4-3
4-5

Drive Status
The condition or state of your drive is constantly monitored. Any
changes will be indicated through the integral keypad.

LED Indications
See page 2-3 for information on drive status indicators and controls.

Faults
A fault is a condition that stops the drive. There are two fault types.
Type Fault Description
Auto-Reset/Run When this type of fault occurs, and A163 [Auto Rstrt Tries] is
set to a value greater than 0, a user-configurable timer, A164
[Auto Rstrt Delay], begins. When the timer reaches zero, the
drive attempts to automatically reset the fault. If the condition
that caused the fault is no longer present, the fault will be reset
and the drive will be restarted.
Non-Resetable This type of fault may require drive or motor repair, or is
caused by wiring or programing errors. The cause of the fault
must be corrected before the fault can be cleared.

100

4-2

Troubleshooting

Fault Indication
Condition
Drive is indicating a fault.
The integral keypad provides
visual notification of a fault
condition by displaying the
following.
Flashing fault number
Flashing fault indicator
Press the Escape key to regain
control of the integral keypad.

Manually Clearing Faults


Step
Key(s)
1. Press Esc to acknowledge the fault. The fault information will be
removed so that you can use the integral keypad.
Access b007 [Fault 1 Code] to view the most recent fault information.
2. Address the condition that caused the fault.
The cause must be corrected before the fault can be cleared.
See Table 4.A.
3. After corrective action has been taken, clear the fault by one of these
methods.
Press Stop if P037 [Stop Mode] is set to a value between 0 and 3.
Cycle drive power.
Set A197 [Fault Clear] to 1 or 2.
Cycle digital input if T051-T054 [Digital Inx Sel] is set to option 10 Clear
Fault.

Automatically Clearing Faults


Option / Step
Clear a Type 1 fault and restart the drive.
1. Set A163 [Auto Rstrt Tries] to a value other than 0.
2. Set A164 [Auto Rstrt Delay] to a value other than 0.
Clear an OverVoltage, UnderVoltage or Heatsink OvrTmp fault
without restarting the drive.
1. Set A163 [Auto Rstrt Tries] to a value other than 0.
2. Set A164 [Auto Rstrt Delay] to 0.

Auto Restart (Reset/Run)


The Auto Restart feature allows the drive to automatically perform a
fault reset followed by a start attempt without user or application
intervention. This allows remote or unattended operation. Only certain
faults are allowed to be reset. Certain faults (Type 2) that indicate
possible drive component malfunction are not resettable.
Caution should be used when enabling this feature, since the drive will
attempt to issue its own start command based on user selected
programming.

101

Troubleshooting

4-3

Fault Descriptions
Type(1)

Table 4.A Fault Types, Descriptions and Actions

No.
F2

Fault
Auxiliary Input

F3

Power Loss

F4

UnderVoltage

F5

OverVoltage

F6

Motor Stalled

F7

Motor Overload

F8

Heatsink
OvrTmp

F12

HW OverCurrent

F13

Ground Fault

F15

Load Loss

F29

Analog Input
Loss

(1)

Description
Auxiliary input interlock is open.

Action
1. Check remote wiring.
2. Verify communications
programming for intentional fault.
DC bus voltage remained below 1. Monitor the incoming AC line for
85% of nominal.
low voltage or line power
interruption.
2. Check input fuses.
DC bus voltage fell below the
Monitor the incoming AC line for low
minimum value.
voltage or line power interruption.
DC bus voltage exceeded
Monitor the AC line for high line
maximum value.
voltage or transient conditions. Bus
overvoltage can also be caused by
motor regeneration. Extend the
decel time or install dynamic brake
option.
Drive is unable to accelerate
Increase P039 - A147 [Accel Time x]
motor.
or reduce load so drive output
current does not exceed the current
set by parameter A179 [Current
Limit 1].
Internal electronic overload trip. 1. An excessive motor load exists.
Reduce load so drive output
current does not exceed the
current set by parameter P033
[Motor OL Current].
2. Verify A170 [Boost Select] setting
Heatsink temperature exceeds a 1. Check for blocked or dirty heat
predefined value.
sink fins. Verify that ambient
temperature has not exceeded
45C (113F) for IP 30/NEMA 1/UL
Type 1 installations or 50C (122F)
for IP20/Open type installations.
2. Check fan.
The drive output current has
Check programming. Check for
exceeded the hardware current excess load, improper A170 [Boost
Select] setting, DC brake volts set
limit.
too high or other causes of excess
current.
A current path to earth ground
Check the motor and external wiring
has been detected at one or
to the drive output terminals for a
more of the drive output
grounded condition.
terminals.
Check for load loss (i.e., a broken
Output current has dropped
below the level set in A184 [Load belt).
Loss Level].
An analog input is configured to 1. Check parameters.
fault on signal loss. A signal loss 2. Check for broken/loose
has occurred.
connections at inputs.
Configure with T072 [Analog In
Loss].

See page 4-1 for a description of fault types.


102

Troubleshooting
Type(1)

4-4

No.
F33

Fault
Auto Rstrt Tries

F38
F39
F40

Phase U to Gnd
Phase V to Gnd
Phase W to Gnd

F41
F42
F43

Phase UV Short
Phase UW Short
Phase VW Short

F48

Params
Defaulted

F63

SW OverCurrent

F64

Drive Overload

F70

Power Unit

F71

Net Loss

F81

Comm Loss

F94

Function Loss

F100 Parameter
Checksum

Description
Drive unsuccessfully attempted
to reset a fault and resume
running for the programmed
number of A163 [Auto Rstrt
Tries].
A phase to ground fault has been
detected between the drive and
motor in this phase.

Action
Correct the cause of the fault and
manually clear.

1. Check the wiring between the


drive and motor.
2. Check motor for grounded
phase.
3. Replace drive if fault cannot be
cleared.
Excessive current has been
1. Check the motor and drive output
detected between these two
terminal wiring for a shorted
output terminals.
condition.
2. Replace drive if fault cannot be
cleared.
The drive was commanded to
1. Clear the fault or cycle power to
write default values to EEPROM.
the drive.
2. Program the drive parameters as
needed.
Programmed A183 [SW Current Check load requirements and A183
Trip] has been exceeded.
[SW Current Trip] setting.
Drive rating of 150% for 1 minute Reduce load or extend Accel Time.
or 200% for 3 seconds has been
exceeded.
Failure has been detected in the 1. Cycle power.
drive power section.
2. Replace drive if fault cannot be
cleared.
The communication network has 1. Cycle power.
faulted.
2. Check communications cabling.
3. Check network adapter setting.
4. Check external network status.
RS485 (DSI) port stopped
1. Check RS485 wiring connection.
communicating.
2. Check if a communications
adapter or HIM was
disconnected.
3. Increase C106 [Comm Loss
Time] to an appropriate time for
application.
4. Change C105 [Comm Loss
Action] to a value other than 0
(fault), if appropriate for the
application.
P036 [Start Source] is set to
Close input to terminal 01 and
setting 6. The input to terminal 01 re-start the drive.
has been opened.
The checksum read from the
Set P041 [Reset To Defalts] to option
board does not match the
1 Reset Defaults.
checksum calculated.

103

No. Fault
F122 I/O Board Fail

(1)

Type(1)

Troubleshooting

4-5

Description
Action
Failure has been detected in the 1. Cycle power.
drive control and I/O section.
2. Replace drive if fault cannot be
cleared.

See page 4-1 for a description of fault types.

Common Symptoms and Corrective Actions


Motor does not Start.
Cause(s)
No output voltage to the motor.

Indication
None

Drive is Faulted

Flashing red status light

104

Corrective Action
Check the power circuit.
Check the supply voltage.
Check all fuses and disconnects.
Check the motor.
Verify that the motor is
connected properly.
Check the control input signals.
Verify that a Start signal is
present. If 2-Wire control is used,
verify that either the Run
Forward or Run Reverse signal
is active, but not both.
Verify that I/O Terminal 01 is
active.
Verify that P036 [Start Source]
matches your configuration.
Verify that A166 [Reverse
Disable] is not prohibiting
movement.
Clear fault.
Press Stop
Cycle power
Set A197 [Fault Clear] to option 1
Clear Faults.
Cycle digital input if T051 - T054
[Digital Inx Sel] is set to option 7
Clear Fault.

4-6

Troubleshooting
Drive does not Start from Start or Run Inputs wired to the terminal block.

Cause(s)
Drive is Faulted

Indication
Flashing red status light

Incorrect programming.
None
P036 [Start Source] is set to
option 0 Keypad or option 5
RS485 (DSI) Port.
T051 - T054 [Digital Inx Sel] is
set to option 5 Local and the
input is active.
None
Incorrect input wiring.
See 1-20 for wiring examples.
2 wire control requires Run
Forward, Run Reverse or Jog
input.
3 wire control requires Start and
Stop inputs
Stop input is always required.
Incorrect Sink/Source DIP switch
None
setting.

Corrective Action
Clear fault.
Press Stop
Cycle power
Set A197 [Fault Clear] to option 1
Clear Faults.
Cycle digital input if T051 - T054
[Digital Inx Sel] is set to option 7
Clear Fault.
Check parameter settings.

Wire inputs correctly and/or install


jumper.

Set switch to match wiring scheme.

Drive does not Start from Integral Keypad.


Cause(s)
Indication
Corrective Action
Integral keypad is not enabled. Green LED above Start key is Set parameter P036 [Start
not illuminated.
Source] to option 0 Keypad.
Set parameter T051 - T054
[Digital Inx Sel] to option 5
Local and activate the input.
I/O Terminal 01 Stop input is None
Wire inputs correctly and/or install
not present.
jumper.

105

Troubleshooting

4-7

Drive does not respond to changes in speed command.


Cause(s)
No value is coming from the
source of the command.

Indication
The drive Run indicator is lit
and output is 0 Hz.

Incorrect reference source is


being selected via remote
device or digital inputs.

None

Corrective Action
Check d301 [Control Source] for
correct source.
If the source is an analog input,
check wiring and use a meter to
check for presence of signal.
Check b002 [Commanded Freq]
to verify correct command.
Check d301 [Control Source] for
correct source.
Check d302 [Contrl In Status] to
see if inputs are selecting an
alternate source. Verify settings
for T051 - T054 [Digital Inx Sel].
Check P038 [Speed Reference]
for the source of the speed
reference. Reprogram as
necessary.
Review the Speed Reference
Control chart on page 1-24.

Motor and/or drive will not accelerate to commanded speed.


Cause(s)
Indication
Acceleration time is excessive. None

Corrective Action
Reprogram P039 [Accel Time 1] or
A147 [Accel Time 2].
Compare b003 [Output Current] with
A179 [Current Limit 1].
Remove excess load or reprogram
P039 [Accel Time 1] or A147 [Accel
Time 2].
Check for improper A170 [Boost
Select] setting.
Verify b002 [Commanded Freq].
Check d301 [Control Source] for the
proper Speed Command.
Check P035 [Maximum Freq] to
insure that speed is not limited by
programming.

Excess load or short


None
acceleration times force the
drive into current limit, slowing
or stopping acceleration.

Speed command source or


value is not as expected.

None

Programming is preventing the None


drive output from exceeding
limiting values.

106

4-8

Troubleshooting
Motor operation is unstable.

Cause(s)
Motor data was incorrectly
entered.

Indication
None

Corrective Action
1. Correctly enter motor nameplate
data into P031, P032 and P033.
2. Enable A194 [Compensation].
3. Use A170 [Boost Select] to
reduce boost level.

Drive will not reverse motor direction.


Cause(s)
Indication
Digital input is not selected for None
reversing control.

Digital input is incorrectly


wired.
Motor wiring is improperly
phased for reverse.
Reverse is disabled.

None

Corrective Action
Check T051 - T054 [Digital Inx Sel]
and P036 [Start Source]. Choose
correct input and program for
reversing mode.
Check input wiring. (See page 1-18)

None

Switch two motor leads.

None

Check A166 [Reverse Disable].

Drive does not power up.


Cause(s)
No input power to drive.

Indication
None

Jumper between Power


Terminals P2 and P1 not
installed and/or DC Bus
Inductor not connected.

None

Corrective Action
Check the power circuit.
Check the supply voltage.
Check all fuses and disconnects.
Install jumper or connect DC Bus
Inductor.

107

SLURRY PUMP

108

109

110

111

112

113

114

115

116

117

118

119

120

121

122

123

124

125

126

127

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128


 


RECEIVING AND HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2, 3
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4, 5
THERMAL PROTECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 6
MOISTURE DETECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 7
LEAD COLOR CODING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STANDARD REPLACEMENT SEAL CROSS REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STANDARD REPLACEMENT O" RING CROSS REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STANDARD REPLACEMENT SNAP RING CROSS REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10



* ) #&%(*$* ** *) $)*(+* %$)  )*+  / * &()%$$" $)*"" $ $ %&(* $
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Copyright Reliance Electric Industrial Company, 1996.


Revisions to this manual require Hazardous Approval Engineering and/or UL approval.
Reliance and DutyMaster are registered trademarks of Reliance Electric Industrial Company

0
129

RECEIVING AND HANDLING


ACCEPTANCE
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motors are listed for Class I, Group D only.
Reliance Electric stocks common ratings
through 100 HP continuous duty submerged
in liquid, 15 minutes duty in air at nameplate
horsepower. Designs through 250 HP and
special continuous in air ratings are also
available. (Continuous in Air Designs have a
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CONTINUOUS OPERATION GASES OR
VAPORS
It is the driven equipment manufacturer's
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properly applied.

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131

        

   


 When
removing impeller warm slightly with a torch
and pry impeller off evenly with either small
pry bars or a wheel puller.
When the submersible pump motor leaves the
factory it is ready for installation. No adjustment,
venting or oil filling is required. For THREE
PHASE motors the only connection to the motor
lead cable is the power supply. For SINGLE
PHASE motors the motor lead cable and power
supply must be properly connected at the
Control Box. Motor will operate successfully with
frequency not more than 5% and voltage not
more than 10% above or below nameplate data.
Performance within this range will not necessarily
be the same as the established performance at
exact rated voltage and frequency.
All submersible pump motors will operate in
either direction of rotation. To reverse direction
of a THREE PHASE motor, interchange any
two motor leads at the starter. To reverse
direction of rotation of a SINGLE PHASE motor
the proper connections must be made in the
motor connection chamber; refer to the W/D's
supplied in the motor connection chamber and
Control Box.
Lifting eyes are supplied for purpose of
installation and servicing. 
' &'* +) %'*'(
$  $ ) !'( $#!*#&" % &) Normal care
should be exercised to prevent mechani
cal damage to the seal, the frame and the
insulated cable.




 Surface temperature of motor
enclosure may reach temperatures which can
cause discomfort or injury to personnel acci
dentally coming into contact with hot sur
faces. (When installing, protection should be
provided by user to protect against accidental
contact with hot surface) .
On initial start up the motor and pump should
be checked for proper rotation prior to final
application.
The unit is designed to protect all power connec
tions against moisture. All Reliance Submersible
Pump Motors have a lead connection chamber.
- THREE PHASE dual voltage motors have 9
motor leads and SINGLE PHASE dual voltage
motors have 8 motor leads in this chamber. All
Submersible Pump Motors have 2 thermal pro
tector leads and 2 moisture sensing probe leads
in this chamber.
Leads are tagged for easy identification. A con
nection diagram is provided in the lead chamber.
Motors can be connected for either high or low
voltages. (Some motor ratings are built as single
voltage units and as such are not reconnectable).
The motor lead cable assembly for all
Submersible Pump Motors has 3 marked power
leads plus two ground leads, two thermal leads
and two moisture sensing probe leads in
standard cable lengths of 25 feet.
Leads are brought through an epoxy sealed con
nector providing a mechanically strong water tight
seal. The cap and cable assembly are available
from Reliance Electric as a replacement part as
sembly. When replacing the lead wire cap, care
should be taken not to nick or damage the O" ring
seal. Replace any damaged or nicked O" rings.
         
 
 
     ,
    
  
 

LIFT MOTOR ONLY USING BOTH ATTACHMENT POINTS.


EYENUTS & EYEBOLTS MUST BE SEATED & IN LINE AS
SHOWN BELOW.
PREFERRED METHOD - USE SPREADER BAR.

692.FF

45
MAX.

3
132


  
With proper application and installation of
monitoring devices, periodic inspection of motor
seals is not required. Should a malfunction occur
the motor has been equipped with a moisture
detection system and thermal protection which
will provide advance warning of impending
failure allowing the user to plan a maintenance
program before failure occurs.
    
1. Reliance Submersible Motors utilize an
explosionproof Class I, Groups C and D,
tandem seal design, with an oil chamber
separate from the winding area.

6. When replacement cable assembly is


required, order from Reliance Electric
Industrial Co. using motor identification
number.
 
 

U/L listed motors must be returned to an
authorized Reliance Electric Service Facility for
repairs other than to replace the outer seal. (See
note on Table of Content page.)
To inspect the outer seal proceed as follows:
1. Remove outer snap ring (3), replace as
needed.

2. Wound Stators - Reliance Submersible Mo


tors utilize a wound stator which has been
pressed into the frame. The stator insulation
system has been designed for the tempera
ture and electrical rating involved. If the motor
failure is analyzed to encompass a winding
failure, return the motor to an authorized Re
liance Electric Service Shop.
3. Encapsulated Lead Connector Assembly The lead connector assembly has been
especially encapsulated to insure integrity of
the motor. The connector can be removed
from the motor in order to reconnect leads.
Should the lead connector assembly be
damaged or the integrity of the encapsulation
be in question, it is required that a replace
ment lead connector assembly be ordered
from Reliance Electric Company.





MOTOR MAY CONTAIN GAS UNDER


PRESSURE DUE TO HIGH TEMPERATURES FROM OPERATION WITHOUT
BEING SUBMERGED.
DISASSEMBLY
MAY CAUSE BODILY INJURY. FOR ASSISTANCE CONTACT A RELIANCE OFFICE.
4. Hardware - All hardware is stainless steel
and should be replaced with the same type.
5. If the Conduit Connection is used, a corrosion
resistant conduit such as stainless steel is
recommended.

2. Remove rotating outer seal (4), replace as


needed.
3. Approved lubricating and insulating oil shall
meet Reliance approved source sheet 4824
18AF. Manufacturer's materials currently
meeting this specification are as follows:

ITEM

MANUFACTURER

MANUFACTURER'S
IDENTIFICATION
OF MATERIAL

Sun Oil Company

Sun Fleet Regular SAE 10W

Standard Oil Co.

Sohio 62 SAE 10W

Shell Oil Company

Rotella 10 SAE 10W




After assembly, run motor in shaft down position
for 30 seconds minimum to one minute
maximum to allow seals to seat; then check for
oil leakage. In some cases, a slight oil mist will
appear around the seal. Wipe clean after test.


   


Before painting motor, cover exposed seal.
Remove any paper, tape, etc., from seal area
before crating motor. These motors can be
shipped in shaft up or shaft down position. Care
must be taken that exposed seal is not damaged
during shipment. Carton must protect exposed
seal from dirt, dust and damage.

4
133



    

1. Loosen four bolts, securing lead cable


connector (1), two complete turns.

CABLE
CONNECTOR

2. Attempt to break the cable connector seal


thus relieving gas pressure within the motor.
If gas pressure is not relieved loosen the
bolts another turn and try again. Continue
this process until the pressure is relieved
and/or the cap is removed. Be extremely
careful until the cable connector assembly
is removed.
MOISTURE
SENSORS (2)

3. Remove cable connector and reconnect to


desired voltage as shown on connection
diagram inside the cable connector.

OUTER SEAL

OUTER SNAP
RING

 
The cable connector assembly may be removed
to reconnect the leads without negating the U/L
listing or the warranty.


 

4. Insulate connectors with 482413AU heat


shrinkable plastic. If the 482413AU shrink
able plastic is not available, tape may
be used, but it should be an oil resistant
type. Enough wraps should be used to
insure the buildup will be sufficient to prevent
the connector from breaking through the
insulation. The following procedure should
be employed: Five layers of plastic elec
trical tape followed by two layers electrical
grade woven adhesive tape, such as
Mystik 7020 or 3M #27, for oil and abrasion
resistance.
5. Place O" ring over fit and coat fit with
Chevron SRI grease (not excessive).

MOTOR MAY CONTAIN GAS UNDER


PRESSURE DUE TO HIGH TEMPERATURES FROM OPERATION WITHOUT
BEING SUBMERGED. DISASSEMBLY
MAY CAUSE BODILY INJURY. FOR ASSISTANCE CONTACT A RELIANCE OFFICE.

6. Place cable connector back on motor, install


four bolts, and tighten.


    

   


Thermostat leads marked P1 & P2 must be con


nected in series with the stop button of the 3wire
pilot circuit of the magnetic motor controller, so
that the thermostat will open the circuit before
dangerous temperatures are reached.



  '$% '" !&!$% $


#'"" )& &$ "$!&&! (%
'$ &! "$!"$* ! & !$ '&+ &%
%*%& (!% !&!$ )$$ &*

5
134

Alternating Current

Thermostats are automatic reset for use in a


normally closed circuit where the thermostat is
connected in series with the holding coil of the
magnetic starter. Thermostats provide Over
Temperature Protection 2" in accordance with
NEMA MG 112.53. When the motor is so marked
locked rotor protection is not provided by the
winding over temperature protector. It is
suggested that over current protection be used
in the motor starter to insure locked rotor
protection.
!

Volts

Continuous
Amperes

Inrush
Amperes

110120

3.0

30

220240

1.5

15

440480

0.75

7.5

550600

0.6

6.0
STARTER

P1

AC LINE

P2

WARNING

(2)

STOP

MOTOR CONTROLLER MAY HAVE AUTOMATIC OR MANUAL OVERLOAD RESET.


DISCONNECT ALL POWER LEADS TO
MOTOR WHEN PERFORMING ANY WORK
ON MOTOR OR DRIVEN EQUIPMENT.

(1)

L1
L2
L3
AC LINE

START

T1 T2 T3

GRD

P2
MOTOR
P1

A MANUAL, MOMENTARY START


SWITCH IS REQUIRED TO PREVENT AUTOMATIC RESTART OF MOTOR WHEN
THERMOSTAT RESETS.

P1 & P2 Normally Closed Thermostat Leads


(normally open thermostats are not acceptable to UL)
(1) Starter Holding Coil
(2) Holding Coil Contacts - N.O.

THERMOSTATS

FIGURE 2
TYPICAL THERMAL PROTECTOR
WIRING DIAGRAM

If current through the thermostat will exceed the


values listed in Figure 2 an intermediate control
circuit relay must be used to reduce the current
or the thermostat will not work properly.

MOISTURE DETECTION SYSTEM


MOISTURE SENSING PROBES
!

IMPORTANT

Reliance Submersible Pump Motors are


equipped
with
moisture
detection
devices. Failure to properly connect or
utilize this system voids motor warranty.
Moisture sensing probes, leads marked W1, and
W2, must be used in conjunction with an
induction relay. This device will detect moisture
entering the oil chamber due to failure of the
outer seal and, when properly connected to a

warning device, will provide notification of


needed maintenance. Integrity of system
requires periodic test.
CONTROLS AND SIGNAL DEVICES
A control and signal device (not supplied by
Reliance) must be installed at the job site to
complete the moisture detection system.
Compatible controls are available from:
Charles F. Warrick Co., Normandy Court,
Royal Oak, Michigan 48073, (810) 5494900.

6
135

        


   
    

"& .'$, + * &'%"&$ .$-+ & %0  &0/!* *'% &'%"&$ %"&-+  ,' &'%"&$ ($-+ 

 
    
 
$$ ,0(
2 '&,*'$+ * "&,"" 0 
+("" '%('&&, &-%* /!"! '$$'/+ ,!
'*%,
2 /!* ,! + * *($
0&-%*+ & $,,*+ "&",". ' ,! 2
+-(($0 $"& .'$,  & *)-&0 '&,,
'&" -*,"'& & &$'+-* ! '&,*'$ !+ 
, $$ '& ,! *" !, !& +" ' ,! ,*%"&$
$'# & ","'& ! &$'+ '&,*'$ !+
&',!* , $$ '& ,! '-,+" ' ,!
&$'+-* '.*
'-&, ,! '&,*'$ '&  .*,"$ +-* /",! ,!
,*&+'*%* '& ,! $, !& +" & '%($"+!
$$ "&", /"*"&  *%"&$+ '& ,! '&,*'$
*&-%* & * "& ,! +% *$,".
('+","'& + ,! ,*%"&$+ +!'/& '& ,! /"*"&
" *%


136

*%"&$ ("* 2
%-+,  '&,"&-'-+$0 &* "1
*'% & 2 +-(($0 $"& ' $,*"$ !*,*2
"+,"+ +!'/& '& ,! , $$
'&,,+ %-+,  /"* "&,' ,! $,*"$ $'
"*-",+ ' ,! /*&"& ."+ + *)-"*
! '&,, -+ '* $' -,0 %-+,  /"*
"& +*"+ /",! ,! $' & ,!, +*"+ *&!
"*-", '&&, *'++  ('/* +'-*
'%(,"$ /",! ,! $'
"*"& %-+,  (*'." *'% ,! %'"+,-*
,,'* +&+'* (*' $+ ' ,! 
 %','* +" &,  & 
,'
,*%"&$+  &  ' ,!
2 '&,*'$
'&,*'$ $+ +!'-$ &',  "&+,$$ "& ,! +%
'&-", + ('/* $+ &- .'$,  &
-+ $+ %'"+,-* +" &$+

 
Normally open load contacts close and normally
closed load contacts open when the sensor
probes detect the influx of moisture within the
motor.


 #


  
A normally closed pushbutton and neon
indicating lamp are provided as means of
checking the moisture sensing components.

#

When the pushbutton is depressed, the


indicating lamp will be illuminated to indicate (A)
power is supplied to the control, (B) the control
is operative, and (C) wiring to the moisture
sensing probes in the motor is intact. This
procedure should be performed periodically to
confirm integrity of circuit.


 !







#


 !
The signal device may be audible (bell, buzzer,
horn or siren) or visible (incandescent or neon
lamp) or both - a signal device of your choice
may be obtained from your local electrical supply
house.


"

 
  
# 

# 

   

It is recommended that upon indication (by warn


ing light, etc.,) of outer seal failure that the motor
be removed from the installation and the oil and
outer seal be replaced as soon as possible.

"

"



WIRING BY WARRICK
WIRING BY OTHERS
CONTROL ENCLOSURE

If reconditioning is not performed within a 30 day


period it is recommended that the inner seal be
thoroughly inspected and replaced if required.

 
  
#"

When ordering parts or reporting trouble give


Sales Office complete Nameplate Data.

  

Power
Cable
Control Cable




"











Polyphase

T1

T2

T3

Ground

Single
Phase

T1

T4

TA

Ground

All

P1

P2

W1

W2

Ground

8
137

MAINTENANCE

138

MAINTENANCE PROCEDURES
GENERAL MAINTENANCE SCHEDULE
SAFETY NOTES:
! LOCK OUT ALL ELECTRICAL POWER BEFORE SERVICING !

Avoid wetting electrical components


Bleed off all hydraulic pressure before working on the hydraulic system
Keep all safety guards in place
Follow all other plant safety steps
Keep loose clothing away from moving parts

DAILY TASKS:

Inspect hydraulic reservoir oil level (look for evidence of fluid leaks).
Check hydraulic oil temperature after dredge has been operating for at least
hour (maximum temperature is 184 F).
Check area around auger motor shafts (power off) and clean out as required.
Check boom hoist winch cable for wear and cable clamps for tightness.
Inspect traverse pulleys for wear.
Check lock collar set screws for tightness.
Grease idler sheaves (one or two strokes as required).
Grease travel guide pulleys.
Check for vibration indicating slurry pump or hydraulic system problems.
Check for loose fasteners, worn parts or misalignment.

NOTE: Check hydraulic fluid level in sight glass with boom up and power unit off
WEEKLY TASKS:

Grease boom trunnions (pivot points) two to three strokes


Inspect boom hoist winch bolts for tightness.
Inspect hydraulic system for leaks.
Check hydraulic filter clean or replace as necessary.
Inspect traverse winch idler sheaves - grease, as required
Inspect auger motors and taper locks for wear - using a pry bar, check for
movement.
Check auger motor seals for leakage (raise head and look for oil around the
seal)
Inspect slurry pump bearings for wear* using a pry bar, through suction or discharge, apply a load to the pump impeller and check for movement.

Note: This check might not be practical for some pump installations. Therefore,
perform this check if problems in the slurry pump are apparent.

139

Check traverse winch bolts in mounting bracket for tightness.


Check auger motor bolts for tightness.
Check auger-cutter teeth (if part of assembly) for wear and bolt for tightness.
Check cable clamps and fittings.

MONTHLY TASKS

Check traverse gear reducer lubricant level and condition.


If Low: Add Oil
If Dirty: Change Oil
**See Oil and Lubricant specifications below
Check boom hoist winch lubricant level and condition.
If Low: Add Oil
If Dirty: Change Oil
**See Oil and Lubricant specifications below
Inspect hydraulic lines and hoses for wear and/or leaks.

BIANNUAL TASKS (1000 HOURS)

Change travel winch gear reducer oil. Fill to level plug (capacity is approximately
17 ounces) **See oil specification below.
Change boom hoist gearbox oil. Fill to level plug. **See oil specification below.
Clean hydraulic system and check air breather cap clean if necessary.
Replace hydraulic return-line filter.
Check electric motors (slurry pump and hydraulic drive), slurry pump and the
various system components for vibration and wear.
Inspect mounts for loose or missing fasteners-tighten or replace as required.

ANNUALLY

Clean off and wash down dredge.


Replace or repair all parts of dredge.
Repeat any of the above checks and/or inspections appropriate at this interval
and perform the necessary maintenance or service as required.
OIL AND LUBRICANT SPECIFICATIONS

**OIL SPECIFICATIONS
Hydraulic oil for this system should meet the following requirements:

Hydraulic oil: ISO 46


Winch: 80W-90 Gear Oil. Must be EP-rated.
Traverse Gear Reducer Lubricant:
Pennzoil Synthetic Gear Oil - SAE 75W - 140
Alternate must meet API - GL - 5 specs and be EP - rated.

140

Grease
Fittings

Oil Drain Plug


(In 6 oclock
position)

Oil Level
Check & Fill Plug

Photo 10-2 Travel Winch Idler Sheave Grease Points & Oil Check, Fill & Drain Plugs
Hydraulic
Motor

Oil Drain
Plug

Photo 10-3 - Typical Boom Hoist Winch Oil Check, Fill & Drain Plugs
Oil Level
Check & Fill
Plug

Auger-Cutter
Hydraulic Drive
Motor
Photo 10-4 - Typical Auger-Cutter Hydraulic Drive Motor
4
141

SPECIFIC EQUIPMENT & COMPONENTS MAINTENANCE SCHEDULE

AUGER SYSTEM

DAILY
Clean area around motor shaft (See safety warning below).

WEEKLY
Inspect auger out-board bearing for wear.
Inspect auger-bearing bolts for tightness
Inspect auger cutter blades bolts for tightness
Inspect hydraulic hoses and fittings for leaks and wear
Inspect hose system for leakage or wear
Inspect power cord and control cable (if part of system).

ANNUALLY
Replace worn cutter blades
Replace hydraulic motor seal and shaft if badly worn or leaking
Replace all other worn parts
Clean off and wash down dredge.
Replace or repair all parts of dredge.

SLURRY PUMP

DAILY
Check Boom Hoist winch cable for wear and cable clamp U-bolts for tightness

WEEKLY
Check pillow block bearings for wear
Grease drive shaft bearings every four hours

BI-ANNUALLY
Check other parts for wear

DANGER! Turn Off Electric Power Before Servicing

142

TRAVERSE WINCH DRIVE SYSTEM

DAILY
Inspect traverse drive pulley for wear
Grease idler sheave shafts (one or two strokes as required)
Check lock collar set screws for tightness.
Grease guide pulley front and rear

WEEKLY
Inspect travel cable for wear and cable clamps for tightness.
Inspect travel winch support bracket bolts for tightness.
Inspect travel winch snatch blocks for wear and hardware for tightness.

MONTHLY
Check travel winch gear reducer oil level. If low, fill with oil per the specifications listed above.

ANNUALLY
Replace travel winch gearbox oil. See recommended oil specifications below.
Check drive sheave and idler sheaves for wear and proper alignment.
Check for loose hardware items.
Check snatch blocks or guide sheaves on head and tail frames for wear.
DANGER! Turn off electric power to dredge before servicing. Follow all other
plants safety steps. Keep all safety guards in place.

BOOM HOIST WINCH

DAILY
Check lift cable for wear
Check cable clamps and hardware for tightness

WEEKLY
Check lift winch bolts for tightness
Check lift cable and clamps for wear

MONTHLY
Check winch gear reducer oil. If low, add oil per recommended lubricant

143

OTHER COMPONENTS

DAILY
Check for evidence of hydraulic oil leaks in motor or hoses

WEEKLY
Inspect hydraulic motor and hoses for leakage or wear
Inspect power cord and control cable (if part of system)

MONTHLY
Inspect all pins
Grease boom trunnion (pivot) bearings
Wash down dredge as required
Check discharge hose gaskets for leakage replace as required

STORAGE AND WINTER PREPARATION


To store for any length of time LWT recommends that the pump volute and discharge plumbing should be drained of liquid. Any hydraulic oil, which is contaminated
with water, should be drained and replaced.
Floats should be checked for any water infiltration. Any that have accumulated
water should be drained and patched. Any flat hose type hose should be well flushed,
rolled and stored off the ground away from direct sunlight, excessive hot or cold temperatures and rodents.
In climates where freezing weather is likely to occur, the unit should be removed
from the pond and stored. If water cannot be entirely removed from the volute, antifreeze should be added at the mix ratio stated by the manufacturer for the anticipated
low temperature.
REMOVAL FROM STORAGE
1. Check all lubricant oil levels hydraulic reservoir, winch gear reducer, boom hoist
gearbox and slurry pump drive (bearing assembly or electric motor)
2. Check for the presence of water in all oils due to condensation
3. Start unit and run hydraulic system for a minimum of one-half hour
4. Check each hydraulic or electrical function for proper operation
5. Again, check fluid levels and quality of oil
6. Make any final repairs or adjustments to the various systems

144

Preventive Maintenance Schedule


Dredge operator is responsible for performing all maintenance at each interval without exception. Failure to
comply with maintenance will cause component failure and possible warranty termination. If you are uncertain
on how to maintain any component, contact an LWT representative.
Hourly Intervals

Daily

Weekly

Monthly
Bi-Annually
OR AS NEEDED

Annually

Auger System
Clean area around motor shaft and inspect for leaks
Inspect auger mounting bolts for tightness
Inspect auger cutter blade bolts for tightness
Inspect hydraulic hoses and fittings for leaks and wear
Check auger for stuck debris
Replace worn cutter blades
Replace hydraulic motor seal and shaft if badly worn or
leaking

X
X
X
X

X
X
X

Slurry Pump
Ensure intake is free of clogs or debris

Check for motor power cable damage


Check other parts for wear

X
X

Traverse Winch Drive System


Inspect traverse drive pulley for wear
Grease idler sheave shafts one or two strokes as required
Check lock collar set screws for tightness
Grease snatch block pulley(s)
Inspect travel cable for wear and cable clamps for tightness
Inspect travel winch support bracket bolts for tightness
Inspect travel winch snatch blocks for wear and hardware
for tightness
Check travel winch gear reducer oil level
Replace travel winch gearbox oil
Check drive sheave and idler sheaves for wear and proper
alignment

X
X
X
X
X
X
X
X
X
X

Check for loose hardware items

Hoist System
Inspect hoist cable for wear and cable clamps for tightness

Check hoist winch gearbox fluid


Check lift winch bolts for tightness
Ensure hoist winch operates in correct direction

X
X
X

PHE/070313
145

Preventive Maintenance Schedule (continued)


Daily

Hourly Intervals

Weekly

Monthly
Bi-Annually
OR AS NEEDED

Annually

Other Components
Check for evidence of hydraulic oil leaks in motor and
hoses
Inspect power cord and control cable
Inspect all pins
Check discharge hose gaskets for leakage; replace as
required
Inspect hydraulic reservoir oil level in sight glass
Check hydraulic oil temperature after dredge has been
operating for at least 30 minutes (Max Temp: 184 F)
Check area around auger motor shafts with power off and
clean out as required
Check for vibration indicating slurry pump or hydraulic
system problems
Grease boom trunnion (pivot) bearings
Check hydraulic filter, clean and replace as necessary
Inspect slurry pump bearing for wear
Check auger motor bolts for tightness
Check cable clamps and fittings
Check boom hoist winch lubricant level and condition
Change winch gear reducer oil (Max Capacity:17 oz.)
Change boom hoist gearbox oil
Clean hydraulic system and check air breather cap
Replace hydraulic return-line filter
Check electric motors for vibration and wear
Inspect mounts for loose or missing fasteners, tighten or
replace as required
Clean off and wash down dredge
Reapply anti-foulant to required parts (Min: 4 mils wet, 2.5
mils dry)

X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X

Cable/Rail System (when used)


Check tensiometer reading to ensure proper cable tension,
if applicable
Check cable clamps and hardware for tightness
Grease closed loop sheaves
Grease tension cable sheaves
Grease all fittings on trolley
Inspect cable for damage or wear
Inspect and grease closed loop, tension winches, and
tensiometers when used

X
X
X
X

X
X
X

PHE/070313
146

ASSEMBLY/DISASSEMBLY OF AUGER MOTOR DRIVES

Photo 10-5 - Typical Auger Assembly Taper Lock Bushing Being Inserted into Auger

Splined Taper
Lock Bushing

Install & Tighten


2 Set Screws
Photo 10-6 - Typical Auger Assembly Splined Taper Lock Bushing

5
147

DISASSEMBLY/ASSEMBLY OF TRAVERSE WINCH

Shaft set screw

2 each 1
washers

Gear Reducer
Shaft

Bearing shaft (1 x 6 )
Photo 10-7 - Typical Traverse Winch Assembly - Drive Sheave and Idler Sheaves
Removed
7 5/8 Dia. Sheave

Bearing insert
2 each 1 washers

Photo 10-8 - Typical Traverse Idler Sheave Assembly

6
148

1 lock collar

2 lock collar

Photo 10-8 - Typical Traverse Winch Assembly Drive Sheave Removed

Grease Fittings

2 Lock Collar

Photo 10-9 - Typical Traverse Winch Sheave Assembly


NOTE: Tighten all lock collars securely to the shafts.
7
149

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