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Transcript of BEKA MAX LUBRICATION SYSTEM INSTALLATION AND OWNER …parconfreiwald.ro/pub/BEKA/Beka_MAX/Komatsu...
Alemlube Pty Ltd
22 Green St Brookvale NSW 2100 www.alemlube.com.au
Ph: 0299382999
Fax: 0299053631
BEKA MAX LUBRICATION SYSTEM
INSTALLATION AND OWNER MANUAL
KOMATSU HD605-7 MINE PACK
*** WATERCART VERSION
WITH REDUCED GREASE
VOLUMES ON RAMS AND
BODY HINGES ***
Alemlube Pty Ltd
22 Green St Brookvale NSW 2100 www.alemlube.com.au
Ph: 0299382999
Fax: 0299053631
BEKA MAX LUBRICATION SYSTEM
INSTALLATION AND OWNER MANUAL
KOMATSU HD605-7 MINE PACK
• General installation notes
• Grease diagrams
• Part lists
• Installation of the pump
• Installation of divider harnesses
• Fixing of grease lines to grease points
• Installation of master divider
• Wiring instructions
• Commissioning
• Assembly of hose connections
• Operation of SX-5 divider valves
• Operating description controller
• Repair instructions and fault finding
• Trouble shooting
• General care and maintenance
• Replacement hose, tube and fittings
• Alemlube National contacts
Alemlube Pty Ltd
22 Green St Brookvale NSW 2100 www.alemlube.com.au
Ph: 0299382999
Fax: 0299053631
BEKA MAX LUBRICATION SYSTEM
INSTALLATION AND OWNER MANUAL
KOMATSU HD605-7 MINE PACK
GENERAL INSTALLATION NOTES! • Before start working, please note the general safety instructions, for example: support the
outrigger or other moving parts.
• Before welding: isolate the electrical system and computer (if required)!
• Carry out drilling and welding works only after reading these installation instructions!
• Connect the earth connection as close as possible to the welding point.
• Grinding: Cover all components, which might be damaged (like glass or hydraulic
cylinders).
• Avoid damage to painting and repaint with original paint after grinding or welding.
• Before removing the lubrication nipples, check that all bearings freely accept grease from a
grease gun. Make sure all bearings are filled. (Important after bearing repairs)
• Please ensure that no contamination can penetrate into the components of the central
lubrication system and the bearings during assembly. Work with clean tools.
• It is critically important that all lubrication system components and lines are fitted tightly
and cannot rub or wear on any other components.
• Avoid running lines over or near sharp objects.
• Avoid installing close to high temperature areas (i.e. turbos, exhaust pipes)
Alemlube Pty Ltd
22 Green St Brookvale NSW 2100 www.alemlube.com.au
Ph: 0299382999
Fax: 0299053631
BEKA MAX LUBRICATION SYSTEM
INSTALLATION AND OWNER MANUAL
KOMATSU HD605-7 MINE PACK
Type of lubrication system: BEKA-MAX Progressive Lubrication System
• Model: Komatsu HD605-7
• Number of lubrication points: 35 points
Alemite Lubrequip Kit No. KO-WT-HD605-7EO-EFP-25PP-0
• Lubrication setting: 5 cycles
• Cycle interval: 0.5 hour
*** WATERCART VERSION
WITH REDUCED GREASE
VOLUMES ON RAMS AND
BODY HINGES ***
Alemlube Pty Ltd
22 Green St Brookvale NSW 2100 www.alemlube.com.au
Ph: 0299382999
Fax: 0299053631
BEKA MAX LUBRICATION SYSTEM
INSTALLATION AND OWNER MANUAL
KOMATSU HD605-7 MINE PACK
Alemlube Pty Ltd
22 Green St Brookvale NSW 2100 www.alemlube.com.au
Ph: 0299382999
Fax: 0299053631
BEKA MAX LUBRICATION SYSTEM
INSTALLATION AND OWNER MANUAL
KOMATSU HD605-7 MINE PACK
BILL OF
MATERIALS
ALEMLUBE PTY LTD KOMATSU HD605-7EO WATER TANKER
Qty Fitted Qty Loose
Beka Max Part
Number KO-WT-HD605-7EO-EFP-25PP-0 1 EFP-50PP EFP 50KG Pump Station EP Tronic L/L & Grease Shut Of Valve
1 1000912998 Low level cable 0.5m Red Plug
1 1000950017 Intermediate Lube Button Square 12 – 24 Volt
1 1000950022 Signal Lamp Square 12 – 24 Volt
1 0800800628 Pipe Protection Bucket Pin
4 3983A01 SX-5 Inlet Section
4 3983E00 SX-5 End Section
3 3983M110000 SX-5 075 Centre Section
1 3983M210000 SX-5 117 Centre Section
9 3983M410000 SX-5 230 Centre Section
2 3983M510000 SX-5 300 Centre Section
5 3983M610000 SX-5 380 Centre Section
6 090090800513 SX-5 Outlet Plug
1 3983M710N10 SX-5 470 Centre Section With Proximity Swith
2 0802000755 SX-5 3 Section Tie Rod
4 0802000757 SX-5 5 Section Tie Rod
2 0802000761 SX-5 9 Section Tie Rod
3 04012020306 Straight 8mm Tube x 10mm
4 04012021006 Straight 8mm Tube x 1/4BSP
38 JCS0207 Straight 1/8BSP x 7/16 JIC
100 100120200 Hose 8.3mm Dia 380Bar ( grease filled )
22 100120265 Hose 11.2mm Dia 380Bar ( grease filled )
70 TB-0544 7/16 JIC X8.3mm HOSE REUSABLE
8 100121305 11.2 Hose End Sleeve
4 100121301 11.2 Hose End Stud Straight 22mm
4 100121165 11.2 Hose End Stud 90 deg 35mm
Alemlube Pty Ltd
22 Green St Brookvale NSW 2100 www.alemlube.com.au
Ph: 0299382999
Fax: 0299053631
BEKA MAX LUBRICATION SYSTEM
INSTALLATION AND OWNER MANUAL
KOMATSU HD605-7 MINE PACK
Pump location on
deck.
Pump relief valve,
master divider and
fill point filtration
under cover
Alemlube Pty Ltd
22 Green St Brookvale NSW 2100 www.alemlube.com.au
Ph: 0299382999
Fax: 0299053631
BEKA MAX LUBRICATION SYSTEM
INSTALLATION AND OWNER MANUAL
KOMATSU HD605-7 MINE PACK
Front right hand
divider
Alemlube Pty Ltd
22 Green St Brookvale NSW 2100 www.alemlube.com.au
Ph: 0299382999
Fax: 0299053631
BEKA MAX LUBRICATION SYSTEM
INSTALLATION AND OWNER MANUAL
KOMATSU HD605-7 MINE PACK
Front left hand
divider
Alemlube Pty Ltd
22 Green St Brookvale NSW 2100 www.alemlube.com.au
Ph: 0299382999
Fax: 0299053631
BEKA MAX LUBRICATION SYSTEM
INSTALLATION AND OWNER MANUAL
KOMATSU HD605-7 MINE PACK
Rear divider
Alemlube Pty Ltd
22 Green St Brookvale NSW 2100 www.alemlube.com.au
Ph: 0299382999
Fax: 0299053631
BEKA MAX LUBRICATION SYSTEM
INSTALLATION AND OWNER MANUAL
KOMATSU HD605-7 MINE PACK
EP-Tronic Controller Wiring
Installed Options –
• Low level control - red plug
connection
• Proximity switch for stroke
control – blue plug connection
• Red and green signal lamps on
dashboard
• Manual run button on dashboard
Alemlube Pty Ltd
22 Green St Brookvale NSW 2100 www.alemlube.com.au
Ph: 0299382999
Fax: 0299053631
BEKA MAX LUBRICATION SYSTEM
INSTALLATION AND OWNER MANUAL
KOMATSU HD605-7 MINE PACK
EFP-50PP PUMP STATION
EFP-21579010011
EFP EP-Tronic Timer
1000912998
0.5m Low level cable
AL-GFV
Fill point shut off valve
28805
Tank breather
GAR-MF2000-08
Fill point filter
Electrical junction box
2196G0002
EFP-50 bare pump
100091034
Low level switch
Manual greasing point
2152990632001
Pump relief valve
28806
Tank relief valves x 2
Alemlube Pty Ltd
22 Green St Brookvale NSW 2100 www.alemlube.com.au
Ph: 0299382999
Fax: 0299053631
BEKA MAX LUBRICATION SYSTEM
INSTALLATION AND OWNER MANUAL
KOMATSU HD605-7 MINE PACK
COMMISSIONING
•Check pump function by pressing the manual button
•Check pump timer settings are correct
•Manually pump grease through the system from the master divider
with a grease gun – 20 to 30 pumps - pressure should be no more
than ¼ to 1/3 maximum effort
•Check to see all grease points are receiving grease
•Check that no fittings are leaking
•Check that all lines are firmly fixed and not rubbing on anything
•Check that all lines to bearings are spiral wrapped and cable tied
every 15cm
•Check that all bolts are tight
Alemlube Pty Ltd
22 Green St Brookvale NSW 2100 www.alemlube.com.au
Ph: 0299382999
Fax: 0299053631
BEKA MAX LUBRICATION SYSTEM
INSTALLATION AND OWNER MANUAL
KOMATSU HD605-7 MINE PACK
Now fix the hose stud to the threaded sleeve in the high pressure hose:
Grease or oil the thread of the hose stud and the end of the hose sleeve well. Fit the tip of the
threaded stud into the sleeve and ensure that the threads start easily. Screw the hose stud into
the sleeve.
Important reference:
The dimensions of the hoses are be able to differ in a slight range. If
the diameter is smaller as standard, the sleeve can be pushed on the
hose without power and without rotary motion.
Remedy:
Press the sleeve on the end where it meets the hose to squeeze it
slightly oval - up to 1 or 2 Millimeters, then when screwing in the
hose stud, the hose will not be pushed out of the sleeve.
Hose stud Threaded sleeve
Assembled pipe connection
Ø6 m
m
Assembly of the high pressure hose:
For connecting the high pressure hose with the distributor, you need a threaded ferrule and a
pipe connector on each side of the high pressure hose.
Assembly the high pressure hose with the high pressure hose:
Grip the high pressure hose securely and apply lubricant (oil or grease) to the end of the hose.
Install the threadedhose sleeve, which has a left hand thread.
Screw up to the dimension in the sketch (11mm).
Threaded hose sleeve High pressure hose11
Ø4 m
m
Ø8,6
mm
Hose GripsHigh pressure hoseThreaded hose sleeve
Alemlube Pty Ltd
22 Green St Brookvale NSW 2100 www.alemlube.com.au
Ph: 0299382999
Fax: 0299053631
BEKA MAX LUBRICATION SYSTEM
INSTALLATION AND OWNER MANUAL
KOMATSU HD605-7 MINE PACK
• Divider Valve Operation
Alemlube Pty Ltd
22 Green St Brookvale NSW 2100 www.alemlube.com.au
Ph: 0299382999
Fax: 0299053631
BEKA MAX LUBRICATION SYSTEM
INSTALLATION AND OWNER MANUAL
KOMATSU HD605-7 MINE PACK
• SX-5 Divider Single and Twin Outlets
Alemlube Pty Ltd
22 Green St Brookvale NSW 2100 www.alemlube.com.au
Ph: 0299382999
Fax: 0299053631
BEKA MAX LUBRICATION SYSTEM
INSTALLATION AND OWNER MANUAL
KOMATSU HD605-7 MINE PACK
Alemlube Pty Ltd
22 Green St Brookvale NSW 2100 www.alemlube.com.au
Ph: 0299382999
Fax: 0299053631
BEKA MAX LUBRICATION SYSTEM
INSTALLATION AND OWNER MANUAL
KOMATSU HD605-7 MINE PACK
Alemlube Pty Ltd
22 Green St Brookvale NSW 2100 www.alemlube.com.au
Ph: 0299382999
Fax: 0299053631
BEKA MAX LUBRICATION SYSTEM
INSTALLATION AND OWNER MANUAL
KOMATSU HD605-7 MINE PACK
Alemlube Pty Ltd
22 Green St Brookvale NSW 2100 www.alemlube.com.au
Ph: 0299382999
Fax: 0299053631
BEKA MAX LUBRICATION SYSTEM
INSTALLATION AND OWNER MANUAL
KOMATSU HD605-7 MINE PACK
Alemlube Pty Ltd
22 Green St Brookvale NSW 2100 www.alemlube.com.au
Ph: 0299382999
Fax: 0299053631
BEKA MAX LUBRICATION SYSTEM
INSTALLATION AND OWNER MANUAL
KOMATSU HD605-7 MINE PACK
2) Re-connect the main pipe to the master divider. Remove the outlet fittings of the divider
one after another and actuate the pump each time.
The outlet or point being blocked is in the hose which when it’s disconnected, the
system functions as expected, but when that hose is reconnected, the pump relief valve
activates. After the master divider has been checked and the point of blockage has been
detected, the pertaining secondary divider has to be checked up to the point of
lubrication, by the same method.
Remember - the pump operates slowly and these tests require patience to see the pressure
build.
In case of big systems it is an advantage to install a grease nipple at the divider and check
then the divider for correct operation, using a grease gun as shown.
Remove the divider from the system, noting the sequence of section units. Remove the
plugs from the piston holes and move the pistons to and fro (don`t take them out); re-insert
the plugs. Check the each section until the piston b eing blocked is identified. Push the piston
of the blocked section unit out and check the drilling of the section unit and the piston
surface for scratches and deficiencies. Renew the compete if it is damaged. THE PISTONS
ARE CUSTOM FITTED IN EACH SECTION AND CANNOT BE MIXED OR SWAPPED.
Repair of a divider when blocked:
Deposits of hardened grease detected at pistons and drillings of section units must be
eliminated by washing and blowing. The drillings in section units must be free of residues of
grease. This should be checked by use of some thin wire.
Hardening of grease indicates that the lubricant being used is not suitable for the central
lubrication system. Ask for advice by the supplier of the lubricant. After having checked all
section units, re-assemble the divider complying with the sequence noted down previously.
In order to avoid jamming of pistons, tighten the tie rods to the correct torque for the screw
size. (MX-F 12Nm)
Check the divider for correct operation, using oil or grease
Install the divider in the system
Start operating the system and check it for correct operating pressure
The repair work has to be done under maximum cleanliness.
Caution!
Important!
·
·
·
Alemlube Pty Ltd
22 Green St Brookvale NSW 2100 www.alemlube.com.au
Ph: 0299382999
Fax: 0299053631
BEKA MAX LUBRICATION SYSTEM
INSTALLATION AND OWNER MANUAL
KOMATSU HD605-7 MINE PACK
Pump does not work Failed integrated electronic
control unit
Electric cable is broken
Pump motor is defective
Replace the control unit.
Check and repair the electric
cable
Check and replace the motor
Pump is working, but
does not supply of
lubrication
Cavitatation
Reservoir below minimum level
Defective pump element
Bleed the pump
Re-fill the reservoir
Replace the pump element
Pump does not work
System cycle time is too long or
period of lubrication is too short
Refer to “Pump does not
work” Reduce the cycle
time or increase the period of
lubrication
No grease collar at
some points of
lubrication
No grease collar at
some points of
lubrication
Feed pipes for auxiliary distribu-
tor is burst or this is leakage
Leakage at screwed union
Renew the pipe
Re-tighten or renew the
screwed union
No grease collar at one
point of lubricaton
The pertaining lubricating pipe
is burst or there is a leakage
Leakage at a fitting
Renew the pipe
Re-tighten or renew the
screwed union
Reduced pump speed High pressure in the system Check the system / bearing
points
Not a defectiveness (1 or
2 intermediate lubrication
cycles may be useful)
Leakage of grease at
Pressure relief valve
Excessive pressure in the system
Progressive divider is blocked
System is blocked
Defective relief valve spring
Check the system
Replace the divider
Clogged seized bearing
points repair
Replace the pressure
relief valve
Fault Origin Remedies
Alemlube Pty Ltd
22 Green St Brookvale NSW 2100 www.alemlube.com.au
Ph: 0299382999
Fax: 0299053631
BEKA MAX LUBRICATION SYSTEM
INSTALLATION AND OWNER MANUAL
KOMATSU HD605-7 MINE PACK
GENERAL CARE AND MAINTENANCE
1. Always fill with clean premium quality grease.
2. Check daily that the trailer has adequate grease at all points – check for correct pump operation by
pushing the manual run button.
3. Check daily that all grease points are connected and no lines are broken, damaged or leaking.
4. Never plug off or block a divider valve outlet – if a line breaks, let the grease spill from that outlet until the
line can be properly repaired. Other grease points connected to that divider valve will receive their proper
lubrication.
5. The grease nipple on the master dividers valve can be used to purge the system, to check for correct
divider operation or to prime new lines or bearings.
6. In case of pump failure, the whole machine can also be greased from these manual grease nipples until
pump repairs are effected.
Alemlube Pty Ltd
22 Green St Brookvale NSW 2100 www.alemlube.com.au
Ph: 0299382999
Fax: 0299053631
BEKA MAX LUBRICATION SYSTEM
INSTALLATION AND OWNER MANUAL
KOMATSU HD605-7 MINE PACK
Alemlube Pty Ltd
22 Green St Brookvale NSW 2100 www.alemlube.com.au
Ph: 0299382999
Fax: 0299053631
BEKA MAX LUBRICATION SYSTEM
INSTALLATION AND OWNER MANUAL
KOMATSU HD605-7 MINE PACK
Alemlube Pty Ltd
22 Green St Brookvale NSW 2100 www.alemlube.com.au
Ph: 0299382999
Fax: 0299053631
BEKA MAX LUBRICATION SYSTEM
INSTALLATION AND OWNER MANUAL
KOMATSU HD605-7 MINE PACK
Alemlube Pty Ltd
22 Green St Brookvale NSW 2100 www.alemlube.com.au
Ph: 0299382999
Fax: 0299053631
BEKA MAX LUBRICATION SYSTEM
INSTALLATION AND OWNER MANUAL
KOMATSU HD605-7 MINE PACK
Head Office
22 Green Street
Brookvale NSW 2100
Phone: 02 9938 2999
Fax: 02 9938 6605
New South Wales
15 Green Street
Brookvale NSW 2100
Phone: 02 9939 0711
Fax: 02 9939 0411
Victoria
31-33 Cyber Loop
Dandenong Victoria 3175
Phone: 03 8787 8288
Fax: 03 8787 8266
Queensland
Unit 1 / 19 Hinkler Court
Brendale QLD 4500
Phone: 07 3889 8480
Fax: 07 3889 8490
Western Australia
31 Resource Way
Malaga WA 6090
Phone: 08 9209 3066
Fax: 08 9209 3933
South Australia/
Northern Territory
Unit 2, 91 Harrison Road
Dudley Park SA 5008
Phone: 08 8241 7111
Fax: 08 8241 7011
Tasmania - Agent –
PRM Marketing
2 Merino Street
Kingsmeadow TAS 7249
Phone: 03 6343 0477
Fax: 03 63430911
Alemlube Pty Ltd
22 Green St Brookvale NSW 2100 www.alemlube.com.au
Ph: 0299382999
Fax: 0299053631
BEKA MAX LUBRICATION SYSTEM
INSTALLATION AND OWNER MANUAL
KOMATSU HD605-7 MINE PACK
Notes