Professional Documents
Culture Documents
Operation and
Maintenance Manual
SerialNumber:R2014107131027
LWT,LLC
1750MadisonAvenue,NewRichmond,WI54017
WWW.LWTPITHOG.COM
+7152462888
LiftingPoints
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.
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).
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:
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:
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
LWT
1. Dredge Appearance
__________
__________
2. Dredge Maintenance
__________
__________
3. Dredge Functions
__________
__________
__________
__________
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:________________
Date:_________________
OPERATION OVERVIEW
10
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
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:
10. Press the slurry pump switch once to stop the pump.
NOTE:
14
NOTE:
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
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
18
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
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
INSTRUCTIONS
1. Hookeachgriphoist(1)toastakeintheanchor
plate(5).
2. Hookthecables(4)ontotheredtriangle.
TRAVERSECABLEADJUSTMENT
Thetraversecableadjustmentismadewiththe
traversecable(2)andthegriphoists(1).
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
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
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.
4. Travel Proximity
Switch
3. Travel Guide Pulley
29
HYDRAULIC SYSTEM
3. Electric
Motor
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
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.
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
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.
Press the Auger button once to start the auger cutter. Press the Auger
button a second time to stop the auger cutter.
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.
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.
36
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
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
40
41
42
43
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
13
14
1
1
1105536
1105095
15
16
1
2
17
18
19
20
21
1
1
1
REF
REF
0007256
8000812
0005572
NONE
NONE
22
23
24
REF
1
1
NONE
0006113
1105377
25
26
1
2
8000797
110-1022
GENERAL NOTES:
1.
2.
A
-
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.
23
5
6
16
20
18
20
21
22
18
16
20
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
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
14
13
15
1
17
26
26
56
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
0005207-02
0005207-03
0005207-04
0005207-11
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
57
SUPERSEDES ACAD
REFERENCE P/N
HYDRAULIC OVERVIEW
PHE
DESIGNED
DRAWN
TAZ
SHEET:
SHEET SIZE:
OF
REVIEWED
APPROVED
0005207
COMPONENTS
ITEM
QTY
PART NO.
8000822
REF
8000806
FITTINGS
ITEM
QTY
PART NO.
F1
1105089
F2
1105151
F3
F4
DESCRIPTION
ITEM
QTY
PART NO.
H1
8003218-076
GATES 8M3K
H2 *
8003218-066
GATES 8M3K
1105328
H3 *
8003218-065
GATES 8M3K
1105090
H4 *
8003218-067
GATES 8M3K
T1
REF
0006312
DESCRIPTION
DESCRIPTION
* 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
58
SUPERSEDES ACAD
REFERENCE P/N
HYDRAULIC
CUTTER CIRCUIT
DESIGNED
DRAWN
TAZ
SHEET:
SHEET SIZE:
OF
REVIEWED
APPROVED
0005207-02
COMPONENTS
ITEM
QTY
PART NO.
8002551
REF
8000806
FITTINGS
ITEM
QTY
PART NO.
F1
1105089
F2
1105375
F3
1104498
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
59
SUPERSEDES ACAD
REFERENCE P/N
HYDRAULIC
TRAVEL CIRCUIT
DESIGNED
DRAWN
TAZ
SHEET:
SHEET SIZE:
OF
REVIEWED
APPROVED
0005207-03
COMPONENTS
ITEM
QTY
PART NO.
8000846
REF
8000806
FITTINGS
ITEM
QTY
PART NO.
F1
1105089
F2
F3
DESCRIPTION
QTY
PART NO.
H1
8003218-074
GATES 8M3K
1105151
H2
8003218-066
GATES 8M3K
1105090
T1
REF
0005027
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
60
SUPERSEDES ACAD
REFERENCE P/N
HYDRAULIC
DRAWN
TAZ
SHEET:
SHEET SIZE:
OF
REVIEWED
APPROVED
0005207-04
COMPONENTS
ITEM
QTY
PART NO.
8000806
8000810
REF
FITTINGS
ITEM
QTY
PART NO.
F1
1105089
F2
0005841
F3
8002636
DESCRIPTION
QTY
PART NO.
H1
8003218-028
GATES 8M3K
1105075
H2
8003218-035
GATES 8M3K
1105152
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
61
SUPERSEDES ACAD
REFERENCE P/N
HYDRAULIC
COMMON CIRCUIT
DESIGNED
DRAWN
TAZ
SHEET:
SHEET SIZE:
1 OF 1
REVIEWED
APPROVED
0005207-11
PI444200
9/01
Service Instructions For The
CE (400/401) Series
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)
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
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
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 #______________________________
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
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
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.
319-827-1139
319-827-1140 fax
67
www.bloommfg.com
CAUTION
WARNING
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.
Ensure the correct equipment is obtained and installed for the application.
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
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.
800-394-1139
Section 3
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.
Note:
Base mounted position is
when
h the
h worm shaft
h f iis
below the bronze gear.
Winch
Type
Winch Series
Base Mounted
Position*
Cable
1 Pint
2 Pints
1100
1 Pint
2 Pints
2 Pints
3 Pints
1200 w/ brake
3 Pints
4 Pints
1400
4 Pints
6 Pints
1600
4 Pints
6 Pints
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
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
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
HARDWARE
REQUIREMENTS
57
57
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)
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
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.
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.
PROPER WRAPPING
OF WIRE ROPE
Cable Anchor
Set Screw
Drum
319-827-1139
319-827-1140 fax
73
www.bloommfg.com
74
75
76
77
Service Manual
PGP/PGM315, 330, 350, 365
Effective:
April 15, 2002
Supersedes: July 1, 1998
78
315/330/350/365
Service Manual
General Instructions
These service instructions will familiarize you with
Parker's single and multiple pumps
NOTE:
For PGP315 and PGP330 ONLY - Plug 5
required in position A and position B.
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
3
79
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 )
A
PGP/PGM
315
PGP/PGM
330
PGP/PGM
350
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
5
81
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.
6
82
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
83
Flat Side
of Seal
Thrust
Plate
8
84
9
85
Dowel Pins
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
Viscosity:
50 SSU minimum @ operating temperature
7500 SSU maximum @ starting temperature
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.
11
87
Recommended Start-up
Procedure For New or
Rebuilt Pump
12
88
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.
13
89
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
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
20
Retaining Ring
21
Thrust Washer
22
Disengage Plunger
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
6-12
25
11
Hub
26
12
27
13
28
14
29
15
Washer 14-02-193-002
30
16
31
* 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.
Description
Included Items
14-02-410-003
641008**
641017**
13 (7 Retaining Rings)
5, 6, 7, 12, 13 and 23
5, 13 and 23
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:
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.
STEP 7
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).
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.
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.
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).
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.
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
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.
101
Troubleshooting
4-3
Fault Descriptions
Type(1)
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].
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.
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.
Indication
None
Drive is Faulted
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.
105
Troubleshooting
4-7
Indication
The drive Run indicator is lit
and output is 0 Hz.
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.
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.
None
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.
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
None
Indication
None
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
''#"*"&% %)*##*"&%
% '(*"&%
#"%.
%$ # "% # %
&#-'!) +*- )*(. /
+$()"# +$' &*&()
")* &(
#))
(&+')
%
"% *( &( ,
!&(* "$ +*-
$"%+*) "% "(
Solutions
You Can
Trust
%)*(+*"&%%+#/
/
'("#
128
RECEIVING AND HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2, 3
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4, 5
THERMAL PROTECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 6
MOISTURE DETECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 7
LEAD COLOR CODING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
* ) #&%(*$* ** *) $)*(+* %$) )*+ / * &()%$$" $)*"" $ $ %&(* $
* ) '+ &#$* *%(%+"/ %( )*(* $ & *) $)*(+* %$) %( +*+(
(($
#%*%() )& $ * ) $)*(+* %$ %%! ( " )* %( &&" * %$ $ "))
(%+&) $ .&"%) %$1&(%% $, (%$#$*) "" (& () %*( *$ " (%$$*) $
%+*( )" (&"#$* )"" &(%(# / $ +*%( 0 " $ )(, " */ $/
%*( (& () &(%(# / * +)*%#( %( $%$1" $ )(, " * ) $*) *
" )* $ $ #%*%( -(($*/
0
129
- ,0$- 4 *) '' (*/*-. ) '-" '$./ '.. -*0+. )
# . 1$ .
- )*/ - *")$5 4 !*- (*/*-. ' .. /#)
0/ - $)'0 4 '$) !*- $/$*)'
(*/*- +-*/ /$*) Motors less than 1 HP are
supplied with a cautionary label and are
suitable on applications where vapor or gas
ignition temperatures exceed 280C. These
motors are listed for Class I, Group D only.
Reliance Electric stocks common ratings
through 100 HP continuous duty submerged
in liquid, 15 minutes duty in air at nameplate
horsepower. Designs through 250 HP and
special continuous in air ratings are also
available. (Continuous in Air Designs have a
1.0 Service Factor.)
*-(''4 /# - - !*0- *)$/$*). 0-$)" 2#$#
.0( -.$' . 2" +0(+ (4 *+ -/
$) ". . *- 1+*-.
# ) /# 2 / 2 '' $. $)" 2/ -
# ) /# +0(+ (*/*- .. ('4 $. $)"
'*2 - *2) /# "0$ -$'. # !'*2 !-*(
/# +0(+ $. ) 0-$)" /# $)./''/$*)
+-* .. /* $).0- /#/ .*'$. - ' - !-*(
/# $.#-" !')" - /* $).0- +-*+ . /$)"
# ) '*26' 1 ' 0/*!! *)/-*'. !$'
# ) '*26' 1 ' . ).*-. - +*.$/$*) / /#
*//*( *! /# +0(+ .. ('4
CONTINUOUS OPERATION GASES OR
VAPORS
It is the driven equipment manufacturer's
responsibility to insure this motor product is
properly applied.
130
# +'& +)- -)+, '.,-
, '+% (
)(( -
$".+
131
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.
,
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.
ITEM
MANUFACTURER
MANUFACTURER'S
IDENTIFICATION
OF MATERIAL
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
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.
5
134
Alternating Current
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
(1)
L1
L2
L3
AC LINE
START
T1 T2 T3
GRD
P2
MOTOR
P1
THERMOSTATS
FIGURE 2
TYPICAL THERMAL PROTECTOR
WIRING DIAGRAM
IMPORTANT
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.
#
!
#
!
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.
"
#
#
"
"
WIRING BY WARRICK
WIRING BY OTHERS
CONTROL ENCLOSURE
#"
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 !
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:
Note: This check might not be practical for some pump installations. Therefore,
perform this check if problems in the slurry pump are apparent.
139
MONTHLY TASKS
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
**OIL SPECIFICATIONS
Hydraulic oil for this system should meet the following requirements:
140
Grease
Fittings
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
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
142
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.
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
144
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
X
X
X
X
X
X
X
X
X
X
X
X
Hoist System
Inspect hoist cable for wear and cable clamps for tightness
X
X
X
PHE/070313
145
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
X
X
X
X
X
X
X
PHE/070313
146
Photo 10-5 - Typical Auger Assembly Taper Lock Bushing Being Inserted into Auger
Splined Taper
Lock Bushing
5
147
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
6
148
1 lock collar
2 lock collar
Grease Fittings
2 Lock Collar