E.C. HOPKINS LTD PGO4 PEANUT GRINDER OPERATORS MANUAL AND PARTS LIST

Transcription

1 E.C. HOPKINS LTD PGO4 PEANUT GRINDER OPERATORS MANUAL AND PARTS LIST E.C. HOPKINS LTD UNIT 1, 82 KETTLES WOOD DRIVE, WOODGATE BUSINESS PARK, WOODGATE VALLEY, BIRMINGHAM B32 3DB TEL NO. +44 (0) FAX NO. +44 (0) Version 1 (Amendment )

2 Contents Page Specification 2 Maintenance 2 Operation 3 Disassembly 4 Assembly 4 Bearing Removal 5 Illustration / Parts List 6 Hydraulic Motor 7 Troubleshooting 8 Warranty 9 CE Certificate 10 SAFETY! ALL OPERATORS OF THIS GRINDER MUST READ THIS MANUAL AND FULLY FAMILIARISE THEMSELVES WITH THE OPERATION OF THE GRINDER BEFORE USE. ENSURE THE HYDRAULIC POWER SOURCE IS COMPATABLE FOR USE WITH THIS GRINDER (e.g. FLOW AND PRES- SURE). ALL PERSONAL PROTECTION EQUIPMENT (PPE) MUST BE WORN DURING OPERATION OF THIS GRINDER. IF IN DOUBT ASK! TECHNICAL HELPLINE +44 (0)

3 SPECIFICATION SPEED MAX. 40lpm EHTMA Category E 30lpm EHTMA Category D 20lpm EHTMA Category C CHUCK / ARBOR 6mm Collet Nut 1 A/F ROTATION CCW (viewed from chuck end) FLOW RANGE 20 to 40 Litres Per Minute MAXIMUM FLOW 40 Litres Per Minute HYDRAULIC OIL ISO 32 Mineral Oil OIL IN HANDLE 15W/40 30ml PRESSURE RELIEF 138 Bar (2000 psi) MOTOR POWER 6.4 KW / 38lpm SYSTEM TYPE Open Centre (OC) PORTS -8SAE O-ring HOSE WHIPS 1mtr Long CONNECTION Flat Face Couplers LENGTH 350mm DIAMETER (Nose) 56mm DIAMETER (Body) 90mm WEIGHT 4Kgs (without hoses) VIBRATION LEVEL 1.37m/s 2 Maintenance Before use:- 1. Check hose whips for damage or exposed wire braid and replace as necessary. 2. Check the tightness of all fasteners. 3. Check the trigger safety catch and trigger moves freely. 4. Remove filler plug (22) and make sure the handle / bearing housing is full of oil. After use:- 1. Ensure any faults with grinder are reported. 2. Wash the grinder off with clean water and work a light oil to the moving parts e.g. valve spool, trigger, safety catch and collet. 3. Store away in a clean environment. Page 2

4 Running the peanut grinder Connect the peanut grinder to a suitable hydraulic power source. Run the grinder for 15 seconds and check for leaks. Should it require a longer test, submerge the front end of the grinder in a bucket of water so as not to overheat the rotary seal. Operation 1. Make sure that the power pack has a maximum output flow of 40 Litres Per Minute and that the maximum system pressure is no more than 138 Bar (2000 psi). 2. Ensure the hydraulic circuit is of the open centre (OC) type. 3. Wipe the flat face couplings with a clean cloth. 4. Connect the return hose first to the power pack and then the pressure hose. When disconnecting, uncouple the pressure hose first and the return hose last so as to minimize any pressure being trapped in the grinder. If the couplings will not connect due to pressure within the grinder, slowly loosen off one of the couplings allowing some oil to leak out. Re-tighten the coupling and connect to the power pack. 5. Start the power pack and move the ON/OFF lever to the ON position. 6. Operate the trigger and ensure the chuck rotation is correct (CCW if viewed from the chuck end) and there are no leaks. Do not run the peanut grinder out of water for more than 2 minutes as it will overheat and potentially damage the rotary seal. 7. Do not start the grinder with the cutting tool in contact with the work surface. Page 3

5 Disassembly 1. Remove the hose whips and allow them to drain into a suitable container. 2. Remove the two filler plugs (22) and drain the oil from the handle / bearing housing (1). 3. Undo the button head screw (28) and remove the trigger (17). 4. To remove the valve spool (13) hold the spool with a spanner across the two flats and undo the button head screw (24). Remove the valve spring washer (15) and valve spring (14) and withdraw the valve spool out through the bottom of the valve block. 5. Remove the six button head screws (26) and pull the handle / bearing housing away from the motor case (10). At this stage the hydraulic motor is still attached and will come away with the handle / bearing assembly. 6. Undo the two cap screws (25) and withdraw the hydraulic motor from the handle / bearing assembly. 7. The two flow tubes (11) will either remain in the valve block (12) or hydraulic motor (9) and only require pulling out. 8. Remove the six cap screws (23) from the valve block (12) and pull away from the motor case (10). In either side of the valve block are two plugs, these should not be removed (unless leaking) as they only blank off cross drillings during machining. 9. Remove all the seals (items 30, 31, 32 & 34) and discard. Assembly 1. With the hydraulic motor shaft key (8) in position slide the motor into the end of the handle/bearing assembly and tighten the two cap screws (25). 2. Fit two new o-rings (31) into either end of the motor case (10). The tapped hole configuration at either end of the motor case differ, so ensure of correct alignment. Tighten the six button head screws (26) down equally. 3. Place four new o-rings (32) onto the two flow tubes (11) and smear with grease. Apply a smear of grease to the two hydraulic motor ports and the two ports in the valve block. Push the flow tubes into the ports of the hydraulic motor and then press the valve block into position on the motor ensuring the correct orientation. Tighten the six cap screws (23) down equally. 4. Fit two new seals (30) into the valve block (12) and smear with grease. Remove any score marks on the valve spool (13) with a fine abrasive paper. Apply a thin coat of grease to the valve spool and slide it into the bore from the bottom, giving it a twist as it encounters each seal. Fit the valve spring (14) and valve washer (15). Holding the spool with a spanner across the flats screw down the button head screw (24) and tighten. 5. Re-fit the trigger using the button head screw (28) and nyloc nut (29). 6. Fit new o-rings (34) onto the tail hoses. The tail hose with the female coupling (knurled sleeve) connects to the P port and the hose with the male coupling connects to the T port. 7. Lie the assembled grinder on it s side with the filler plugs (22) uppermost and pour in 30ml of 15W/40 oil. Re-fit the two filler plugs. Page 4

6 Replacing the rotary seal and bearing 1. Grip Service Tool PG on the hexagon in a vice and slide the shaft (2) in the handle/bearing assembly on to it. 2. Undo the tool chuck (5) and remove the rotating half of the rotary seal by gripping the spring and twisting it in a clockwise rotation whilst pulling it off the tool chuck. 3. The bearing (3) is a press fit. Place the remainder of the handle / bearing assembly and the service tool in a press. Apply heat to the housing around the area of the bearing whilst applying pressure from the press. The stationary half of the rotary seal will be pushed out along with the bearing and should be discarded. 4. Once the parts have cooled, use a bearing puller to remove the bearing off the shaft. Reassembly is basically the reverse procedure, but before doing so ensure there are no score marks in the surface where the o-ring of the stationary half of the rotary seal sits. If there should be any marks these can be removed (depending on their depth) by using a fine abrasive paper. 5. Fit a new bearing onto the shaft and screw on the tool chuck (5) along with the tool chuck nut (7). 6. Apply heat to the same area and place the shaft with the bearing in position. Ensuring it is lined up correctly tap the assembly down using a nylon mallet until it comes to a stop and allow to cool. 7. Unscrew the tool chuck and smear some grease on the shaft. 8. Take the rotating half of the new rotary seal and smear some grease on the o-ring located inside the spring. Engage the spring onto the end of the shaft of the tool chuck and twist it in a clockwise rotation whilst pushing it down to the shoulder. 9. Smear some silicon grease inside the housing in front of the bearing where the seal sits and on the o-ring on the stationary half of the rotary seal. Place the seal in position inside the housing with the mirrored finish uppermost. 10. Utilizing the piece of protecting card in with the rotary seal, cut a hole in the centre so it slips over the thread on the shaft and sits on the mirrored face. Using a piece of nylon bar or an equivalent material (25-30mm in diameter with a hole up the centre of 15mm diameter and 30mm deep) so as not to mark the seal face, place the bar over the end of the shaft onto the card and push down until the stationary seal half sits against the bearing. 11. Again grip the Service Tool in a vice and slide the shaft (2) within the handle / bearing housing onto it and screw on the tool chuck and tighten. Page 5

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9 Troubleshooting Below are various types of faults that may be encountered. Should a fault persist please call our technical helpline +44 (0) for assistance. Problem Probable cause Remedy Grinder runs slow Incorrect hydraulic flow Excessive back pressure Hydraulic oil viscosity too thick Flow test power pack Check return line for restrictions Raise oil temperature Change oil to a thinner viscosity Grinder gets hot Incorrect hydraulic flow Oil Cooler not working Oil Cooler matrix blocked Hydraulic Pump is worn Flow test power pack Check cooler electrics Clean with compressed air Replace pump Leaking oil around tool chuck Grinder runs in reverse Rotary seal worn Pressure and return hoses on the wrong way Fit new seal Check system for correct flow path and rectify Oil leaking from valve spool Grinder not working Seals worn Power pack not switched on Coupling blocked Mechanical failure Remove valve spool and replace seals Switch power pack on Check couplings and remove blockage Disassemble grinder and check for damage Page 8

10 WARRANTY This product is guaranteed (subject to normal wear and tear) against defective parts and faulty workmanship for a period of 12 months from date of purchase. It does not cover:- Parts already covered by original equipment manufacturers own warranties already in place Failure of parts due to lack of maintenance and services Any failure due to non-genuine parts fitted Rubber products Product subjected to misuse/abuse or being neglected in any way Being modified in any way without prior consent of E.C. Hopkins Ltd In case of disagreement between parties as to whether it is warranty or not, the failed part will be returned to the supplier for inspection at the customers cost. The findings by that supplier as to why the part failed will be binding. With an ongoing design and development program E.C. Hopkins Ltd reserve the right to alter the design or specification of any product without prior notice. Page 9