Twiflex M1662 Manual

Installation and Maintenance
Manual
“LCS” HYDRAULIC POWER UNIT
Part Number: T7600561
M1662
Transmisiones FU Ibérica, S.L. C/ África 17 · Polígono Industrial Can Mora · 08459 - Sant Antoni de Vilamajor · Barcelona · SPAIN
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Table of content
TABLE OF CONTENT...........................................................................................................1
1. GENERAL..................................................................................................................2
1.1 Who to contact............................................................................................................2
1.2 Safety.........................................................................................................................2
1.3 Symbols used in this manual......................................................................................3
1.4 Disclaimer...................................................................................................................3
1.5 Transportation............................................................................................................3
1.6 Lifting..........................................................................................................................4
1.7 Storage.......................................................................................................................4
1.8 How to order spare parts............................................................................................4
2. INSTALLATION AND COMMISSIONING..................................................................5
2.1 Mounting.....................................................................................................................5
2.2 Connections ...............................................................................................................5
2.3 Before starting the pump unit......................................................................................5
3. DESCRIPTION OF THE HYDRAULIC SYSTEM........................................................7
3.1 General ......................................................................................................................7
3.2 Function .....................................................................................................................7
3.3 Hydraulic diagram.......................................................................................................8
4. MAINTENANCE.........................................................................................................9
4.1 Inspection...................................................................................................................9
4.2 Adjustment .................................................................................................................9
4.3 Checks.......................................................................................................................9
4.4 Function test.............................................................................................................11
4.5 Dismantling the power unit .......................................................................................11
4.6 Changing the oil........................................................................................................11
4.7 Changing the oil and cleaning the reservoir..............................................................12
4.8 Changing the oil filter................................................................................................13
4.9 Changing the air breather.........................................................................................13
4.10 Measuring the gas pressure .....................................................................................14
4.11 Recharging the accumulator.....................................................................................15
5. TROUBLE SHOOTING....................................................................................... 16/17
APPENDIX A - DIMENSION DRAWING..............................................................................18
APPENDIX B –PARTS IDENTIFICATION...........................................................................19
APPENDIX C - ADJUSTMENTS............................ERROR! BOOKMARK NOT DEFINED.20
APPENDIX D –ELECTRICAL DIAGRAM..................ERROR! BOOKMARK NOT DEFINED.
APPENDIX E –RECOMMENDED FLUIDS .......................................................................202
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1. General
1.1
1.2
Thank you for buying a Twiflex Ltd product.
Before using the product please read this
manual carefully.
Who to contact
In case you have any questions regarding
this manual please contact your local
representative or nearest Twiflex Ltd office:
FU IBÉRICA:
www.fuiberica.com
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Safety
The Twiflex Ltd range of brake products is
designed to be applied to a rotating brake
disc for use in conjunction with parking
brake applications, service brake
applications or emergency brake
applications only.
NOTE
Always make sure that you consult Twiflex
Ltd before using tools or any other
equipment not recommended or specified in
this manual.
In order to maintain the warranty always use
original spare parts from Twiflex Ltd.
Customer is responsible for always keeping
the brake and hydraulic aggregate clean,
and free from dirt, grease or oil.
Customer is responsible for ensuring the air
gap between brake pads and brake disc
never exceeds the recommended setting.
Always use a torque wrench when refitting
mounting bolts or valves in order to ensure
the correct torque is obtained.
There should be a copy of the manual
available for the service and maintenance
crew as a minimum.
Hydraulic power unit:
Do not operate the hydraulic power unit
before correctly filling the oil reservoir.
Do not adjust valves or pressure switches to
higher operating pressures than specified in
the manual.
Do not change the size or type of
components.
Do not use hydraulic fluid types other than
those recommended in this manual.
Brakes:
Do not operate the brake before removing
the air from the hydraulic system by
bleeding and re-filling with oil.
Do not use higher operating pressures than
specified on the nameplate of the brake or in
the manual.
Do not change the size or type of spring
pack.
Do not use the brake pads when they are
worn to the minimum thickness as shown in
the manual.
Do not operate the brake if there is dirt,
contamination or residual corrosion
protection on the disc face or brake pads.
Personal safety:
Do not work on the brake/ system before:
The manual has been read and understood.
The brake disc is locked and not able to
rotate before adjusting the brake and/or air
gap.
Securing the brake/spring-pack by using the
‘parked-off’ setting or retraction bolt when
working on a spring applied brake.
Being sure there is no pressure on the
hydraulic power unit or brake circuit.
Being sure the oil pressure in the
accumulator(s) has been relieved.
The control signals have been shut off and
blocked before working on the system.
The electrical power has been shut off.
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1.3 Symbols used in this manual
To make sure you perform certain tasks
properly, please take note of the following
symbols used throughout this manual.
WARNING
Information to prevent personal injury when
trying to complete a task.
CAUTION
Information to prevent damage to the
components when trying to complete a task.
WARNING
Electrical shock hazard.
IMPORTANT
Information you MUST follow to complete a
task.
NOTE
Tips and additional information to aid in
completing a task.
Figures within brackets ( ) relate to
position and Appendix number i.e. (15-B)
refers to position number 15 in Appendix
B
1.4 Disclaimer
Twiflex Ltd reserves the right to revise this
document without prior notification. These
documents have been checked for
accuracy. Despite this, technical and
typographical deviations can sometimes
occur.
This document is updated on a regular
basis; changes will be published in future
printings. Improvements and/or changes to
the described products or manual can be
implemented at any time without preceding
notice.
In no event should Twiflex Ltd be liable for
any special, incidental, consequential or
punitive damages. This includes, but is not
limited to: damage to other property or
person, inconvenience, loss of goodwill, lost
profits or revenue, loss of use of this product
or any associated equipment, cost of
substitutive equipment, downtime costs or
claims of any party such damages, resulting
from any misspellings or inaccurate
information in this users guide.
This document or parts hereof may in no
event be copied, reproduced, changed or
translated to other languages without explicit
written permission from Twiflex Ltd.
1.5 Transportation
When leaving the factory the hydraulic
power unit is always packed to ensure
maximum security for the product during
transport.
CAUTION
If the hydraulic power unit has been sent by
air freight note that the gas (N2) pressure
may have been released from the
accumulator(s).
A label (see figure 1.1) is then attached to
the accumulator.
In such a case it must be recharged before
usage. See section 4.11 –“Recharging the
accumulator”for details
Normally there is no hydraulic oil in the unit.
A warning label is attached to it.
WARNING
WARNING
FOR TRANSPORT REASONS
THE PUMP IS SHIPPED
WITHOUT OIL
FILL WITH RECOMMENDED OIL
BEFORE STARTING
REFER TO MANUAL
The hydraulic power unit must be filled with
oil according to Appendix F of this manual
before use. If run dry the pump may be
permanently damaged.
FIGURE 1.2
FIGURE 1.1
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1.6 Lifting
The hydraulic power unit weighs
approximately 30 kg. If it is necessary to
use a lifting harness, under no circumstance
place it around valves, gauges or
accumulators (see correct lifting process,
below).
If not mounted in cabinet the hydraulic
power unit may be lifted in the motor –see
figure 1.3
CAUTION
Do not lift the hydraulic power unit in the
valves etc. –see figure 1.4
If the hydraulic power unit is mounted in a
cabinet the entire assembly may be lifted by
using the lifting point in the supporting
frame.
1.7 Storage
Hydraulic power units must be stored
indoors in a clean, dry area. They must be
stored in such a way that they cannot be
damaged by passing or falling objects.
For indoor storage for up to 3 months the
hydraulic power units do not need any
surface treatment. For longer periods they
should be covered with a plastic or canvas
cover to protect against dirt.
1.8 How to order spare parts
When ordering spare parts please refer to
the specific item number in the parts list –
see appendices.
For full identification of the hydraulic power
unit please provide the assembly part
number or the details recorded on the label
attached to the manifold or tank.
FIGURE 1.3 –Correct Lifting Procedure
FIGURE 1.4 –Incorrect Lifting Procedure
FIGURE 1.5 –Correct Lifting Procedure
FIGURE 1.6
Transmisiones FU Ibérica, S.L. C/ África 17 · Polígono Industrial Can Mora · 08459 - Sant Antoni de Vilamajor · Barcelona · SPAIN
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2. Installation and
commissioning
2.1 Mounting
In the back of the manifold there are 2
threaded M10 x 15mm holes for wall
mounting. See (Appendix A).
Optionally, a foot-mounting bracket is
available.
2.2 Connections
Hydraulic pressure ports out of the manifold
are G1/4” or G1/2”. All connection points are
plugged with VSTI-plugs.
All pipes, hoses, fittings etc. mounted to the
total system, should be flushed to meet the
demands of NAS 1638 Class 8 or ISO 4406
Class 19/17/14.
2.3 Before starting the pump unit
The power unit may have been sent without
nitrogen gas (N2) in the accumulator,
depending on global or local regulations for
transport of pressurised equipment. If the
unit has been sent without pressure, a label
(see figure 2.1) is attached to the
accumulator.
If the accumulator is not pre-charged it must
be charged before usage. See section 4.11
– “Recharging the accumulator”.
After recharging you should remove the
label.
If the accumulator is pre-charged –proceed
to section 2.3.1
Mount the connection fitting to the brakes in
one of the points shown on the hydraulic
diagram
2.3.1 Fill the tank with oil of the recommended
quality (see Appendix E).
The oil fill volume is approximately 3 litres.
Remove the air breather (5b), and add
filtered oil.
2.3.2 Fill the oil reservoir to the top level mark in
the sight glass located on the reservoir
sidewall.
CAUTION
Use only filtered oil of the right viscosity for
refilling (see Appendix E).
NOTE:
Stated oil volumes are approximate and
must be checked for correct fill level
according to the sight glass in the tank.
Additional oil volume may be required for
bleeding.
Oil must be filtered through a 10-micron
nominal filter.
For more details see Appendix E.
2.3.3 Connect the electrical power. Check that the
rotation of the electric motor is correct as
indicated on the motor –i.e. Counter
clockwise viewed from the fan end.
WARNING
External electrical cables must be connected
to the junction box according to the electrical
wiring, diagrams see Appendix D, or
separate documentation supplied along with
the equipment.
The unit must only be connected by a skilled
electrician.
FIGURE 2.2
FIGURE 2.1
FIGURE 2.3
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The customer is responsible for ensuring all
electrical connections are made according to
national and international regulations for the
installation of electrical equipment.
The device must be supplied from an
isolated source and protected by an over
current device to ensure the limited voltage
circuit requirements according to national
and international standards.
No warranty will be considered if this is not
completed accordingly.
2.3.4 Start the electric motor and let the unit run
10 cycles (pressurising/de-pressurising):
With system pressurised bleed the
brakes.
With system de-pressurised refill oil
if necessary.
2.3.5 Bleeding and flushing the hydraulic
power unit
To meet the demands of NAS 1638 Class 8
or ISO 4406 Class 19/17/14 the hydraulic
power units supplied from Twiflex Ltd have
been flushed before leaving the factory.
Despite the above, the hydraulic system
must always be flushed and bled again
before commissioning.
Flushing of the system will remove minor
particles and potential dirt in the system and
prevent damage to the unit.
After flushing, the hydraulic power unit must
be bled in order to remove any air in the
system.
If the hydraulic power unit is not properly
bled potential damage to the seals may
occur.
The hydraulic power unit must always be
bled in conjunction with assembly, repair or
when making changes in the system.
Failure to bleed the hydraulic system will
allow air to remain in the brake lines which
could prevent the brake system from
reacting fast enough. This might, for
example, cause the linings to remain in
contact with the brake disc and excess
heating of the brake pads and brake disc
could occur.
Air in the system could also destroy the
seals (diesel effect) within the hydraulic
system.
Make a functional check of the system by
checking the pressure, and the hydraulic
settings.
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3. Description of the
hydraulic system
3.1 General
The LCS hydraulic units have been
developed to be used together with active
(pressure applied) and passive (spring
applied) brake calipers from Twiflex Ltd.
The pump can be connected to one or more
brakes.
The hydraulic power unit typically consists of
2 main items:
Base unit (including tank, manifold,
motor and pump)
Optional junction box (including
terminal rail, mounting plate and
lifting eye)
Except for the dimensional drawing and
mounting/handling instructions this manual
contains no further information about the
cabinet.
The power unit is described in detail
including functionality, assembly/mounting,
pressure settings, spare parts, description of
main parts, maintenance, trouble shooting,
and hydraulic fluids, etc.
The junction box is illustrated in the
electrical diagram (see Appendix D) and is
installed in order to simplify the electrical
connection.
3.2 Function
(See the hydraulic diagram section 3.3)
3.2.1 System energy
In the hydraulic system an electric motor (4)
and a pump (2) convert electrical power into
oil pressure and oil flow.
Pressure is limited by:
The pressure switch (40) that turns
off the motor when the preset
pressure is reached.
A system relief valve (16).
Pressure is monitored by a pressure switch
(40). If pressure drops below the pre-set
value the motor will restart to increase
pressure.
The check valve (17) prevents pressure
from returning to tank when the motor stops.
The accumulator (A1) provides an additional
volume of pressurised oil to minimise the
number of motor starts.
3.2.2 Applying the brakes.
Operating the motor (4) (on) and closing of
valve (23) (off), transfers the oil from the
pump to the brakes.
3.2.3 Releasing the brakes
When opening valve (23) (on) and stopping
the motor (4) (off) this will dump the oil to
tank, which immediately releases the
brakes.
3.2.4Monitoring
Pressure switch (40) monitors the system
pressure (see 3.2.1).
When there is a need to re-pressurise the
system it will restart the motor (providing a
signal for a maximum of 5 seconds)
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3.3 Hydraulic diagram
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4. Maintenance
Maintenance is important for the ability of
the hydraulic power unit to control the
brakes at any time.
Maintenance consists of inspection and
service.
All pressure control valves, flow control
valves, pump regulators and signalling
devices such as pressure switches are
adjusted during the initial manufacture
and subsequent commissioning.
The settings must be monitored
continuously during the initial stages of
operation and then subsequently at
reasonable intervals.
4.1 Inspection
Initial commissioning inspection is done to
check if adjustment of the pump unit is
necessary.
Later inspection is done on a regular
basis.
CAUTION
IMPORTANT (safety information)
Be aware that the system is equipped
with a hydraulic accumulator, and before
any maintenance work it should be
ensured that the system is completely
without hydraulic pressure by opening the
valve (23).
4.2 Adjustment
A number of components demand the
correct setting or charging in order to
make the braking system work properly.
The correct setting and adjustment
procedures can be found in Appendix C.
All components in the pump unit are pre-
set to the stated pressure from the
factory, but may need adjustment during
initial commissioning.
4.3 Checks
By remaining alert and paying close
attention to detail it is possible to detect
faults in their early stages and so prevent
them from developing into more serious
malfunctions. This is particular important
during the early stages, but also remains
important throughout the service life of the
pump unit.
A constant attention should be kept for:
External leaks
Dirt
Damage, especially to hoses and
pipes
Unusual noises from pump,
electric motor, valves etc.
Proper functioning of instruments
and gauges
A maintenance log should be established
to ensure the equipment is kept in
operating condition.
Caution
System contains
Accumulator
Depressurize system
Before maintenance
FIGURE 4.1
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