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

[email protected]

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


Ph: 0299382999

Fax: 0299053631

[email protected]




• 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


Ph: 0299382999

Fax: 0299053631

[email protected]




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


Ph: 0299382999

Fax: 0299053631

[email protected]




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


Ph: 0299382999

Fax: 0299053631

[email protected]




Alemlube Pty Ltd


Ph: 0299382999

Fax: 0299053631

[email protected]




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





6 090090800513 SX-5 Outlet Plug

1 3983M710N10 SX-5 470 Centre Section With Proximity Swith

2 0802000755 SX-5 3 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


Ph: 0299382999

Fax: 0299053631

[email protected]




Pump location on

deck.

Pump relief valve,

master divider and

fill point filtration

under cover

Alemlube Pty Ltd


Ph: 0299382999

Fax: 0299053631

[email protected]




Front right hand

divider

Alemlube Pty Ltd


Ph: 0299382999

Fax: 0299053631

[email protected]




Front left hand

divider

Alemlube Pty Ltd


Ph: 0299382999

Fax: 0299053631

[email protected]




Rear divider

Alemlube Pty Ltd


Ph: 0299382999

Fax: 0299053631

[email protected]




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


Ph: 0299382999

Fax: 0299053631

[email protected]




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


Ph: 0299382999

Fax: 0299053631

[email protected]




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


Ph: 0299382999

Fax: 0299053631

[email protected]




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


Ph: 0299382999

Fax: 0299053631

[email protected]




• Divider Valve Operation

Alemlube Pty Ltd


Ph: 0299382999

Fax: 0299053631

[email protected]




• SX-5 Divider Single and Twin Outlets

Alemlube Pty Ltd


Ph: 0299382999

Fax: 0299053631

[email protected]




Alemlube Pty Ltd


Ph: 0299382999

Fax: 0299053631

[email protected]




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


Ph: 0299382999

Fax: 0299053631

[email protected]




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


Ph: 0299382999

Fax: 0299053631

[email protected]




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


Ph: 0299382999

Fax: 0299053631

[email protected]




Alemlube Pty Ltd


Ph: 0299382999

Fax: 0299053631

[email protected]




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


Ph: 0299382999

Fax: 0299053631

[email protected]




Notes

BEKA MAX LUBRICATION SYSTEM INSTALLATION AND OWNER …parconfreiwald.ro/pub/BEKA/Beka_MAX/Komatsu...

Documents

Transcript of BEKA MAX LUBRICATION SYSTEM INSTALLATION AND OWNER …parconfreiwald.ro/pub/BEKA/Beka_MAX/Komatsu...