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ABB ZSD 2020, Overhaul Instructions

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ABB ZSD 2020 Overhaul Instructions Download Page 2

Date: 2021-01-13

Version: 1.2

Overhaul instructions

Central lubrication unit

Scope

Page 2 of 50

Scope

Assembly:

Central lubrication unit dosing unit ZSD 2020 ABB

Product Version:

ZSD 2020

Item Number:

3HDA10100097017

Drawing Number:

80003300-013

© 2021 ABB Automation GmbH |

en

Summary of Contents for ZSD 2020

Page 1: ...on GmbH Grüner Weg 6 61169 Friedberg Germany Phone 49 6031 85307 Fax 49 6031 85227 E Mail Internet TRANSLATION OF ORIGINAL en Overhaul instructions Keep for future use Version 1 2 ZSD 2020 Central lubrication unit ...

Page 2: ...aul instructions Central lubrication unit Scope Page 2 of 50 Scope Assembly Central lubrication unit dosing unit ZSD 2020 ABB Product Version ZSD 2020 Item Number 3HDA10100097017 Drawing Number 80003300 013 2021 ABB Automation GmbH en ...

Page 3: ...ty Measures 12 1 9 Position numbers 12 2 Tools and accessories 13 3 Removing 14 3 1 Notes 14 3 2 Removing of the container 15 3 3 Removing the filling strainer 19 3 4 Removing the oil filter 22 3 5 Removing the diaphragm pump 24 3 6 Removing the solenoid valve 27 3 7 Removing the local control switch 30 4 Cleaning and assembly preparation 33 5 Installation 34 5 1 Fitting the container 34 5 2 Fitti...

Page 4: ...ving the solenoid valve 29 Figure 16 Removing the local control switch 30 Figure 17 Removing the switch mounting screws 31 Figure 18 Removing the local control switch 32 Figure 19 Screwing on the filling strainer 34 Figure 20 Fitting the container 35 Figure 21 Fitting the lid 36 Figure 22 Closing the clamp fasteners 37 Figure 23 Screwing on the filling strainer 38 Figure 24 Insert the filter unit ...

Page 5: ...1 2 Overhaul instructions Central lubrication unit Indexes Page 5 of 50 List of tables Table 1 Personnel skills requirements 6 Table 2 Personnel and their activities 7 Table 3 Tightening torques 33 2021 ABB Automation GmbH en ...

Page 6: ...t our Customer Service or the manufacturers directly 1 2 Target readership of these instructions These instructions must be observed and used by maintenance and repair personnel Persons working with the assembly must have been suitably trained by the manufacturer or plant owner The repair personnel must be suitably trained Personnel Prerequisites Briefed personnel Operating personnel are people wh...

Page 7: ...rameters disregarding the conditions specified in the order and without prior consent of the manufacturer The content of the technical documentation has been prepared with the utmost care However no liability is assumed for possible errors or incompleteness This also applies to the content of the technical documentation of all sub contractors The documentation contains information that is protecte...

Page 8: ...gerous situation Unless prevented this situation can cause minor injury or material damage IMPORTANT This box indicates a potentially dangerous situation Unless avoided this situation can lead to material or product damage NOTE This box contains important notes that require special attention Notes without a specific sequence are given with bullet points If a specific order is necessary these notes...

Page 9: ...The operating company of the system is responsible for implementing these provi sions 4 Only trained and instructed expert staff may undertake conversion of the component 5 For work on the assembly the personnel has to have access to personal protective equipment such as protective work wear safety gloves helmet and safety goggles 6 In the event of a fault the assembly has to be switched off and a...

Page 10: ...the energy supply after an interruption the plant can unexpect edly restart This can cause severe injuries During maintenance work switch off the plant and secure it against restarting main switches and shut off valves Observe the safety instructions in the plant documen tation The plat operating personnel must receive regular training in operation and handling of the plant and its components WARN...

Page 11: ... in structor the personnel All work on the material supply lines and adjacent components must be carried out only by trained briefed specialists and with sufficient ventilation Within the area of the plant eating drinking smoking snuffing tobacco etc is pro hibited Dispose of spilt or escaped material immediately and according to regula tions The specified protective clothing must be worn when wor...

Page 12: ... gloves when working on the material and hydraulic system When working on the material compressed air and hydraulic system al so wear protective goggles When working within the machine wearing a head protection protection against bumping is required NOTE Check your protective clothing before each use 1 9 Position numbers The position numbers are specified in this document as follows Position numbe...

Page 13: ... Tools and accessories Page 13 of 50 2 Tools and accessories The following tools and accessories are required for installation uninstallation maintenance and repair of the assembly Set of Allen keys Set of open end spanners Oil filter spanner 93 45 2021 ABB Automation GmbH en ...

Page 14: ...carried out at a standstill The system must be secured against restarting The safety and accident prevention regulations given in these documentations must also be observed Assembly work must be carried out by the manufacturer by specially briefed personnel or by trained personnel NOTE If you have any questions contact our customer service ABB Automation GmbH Grüner Weg 6 61169 Friedberg Germany T...

Page 15: ... Central lubrication unit Removing Page 15 of 50 3 2 Removing of the container Release the clamp fasteners 51 on either side of the container Figure 1 Releasing the clamp fasteners Item number Designation 51 Clamp fastener 2021 ABB Automation GmbH en ...

Page 16: ...haul instructions Central lubrication unit Removing Page 16 of 50 Remove the square container 22 with the Mesamoll to be replaced Figure 2 Removing the container Item number Designation 22 Square container 2021 ABB Automation GmbH en ...

Page 17: ...tructions Central lubrication unit Removing Page 17 of 50 Remove the plate 4 from the container and hang the plate on the provided support plate 2 Figure 3 Taking off the lid Item number Designation 4 Plate 2 Plate 2021 ABB Automation GmbH en ...

Page 18: ...ation 1 Filling strainer 5 Lid DANGER Danger through electric current Risk of serious or fatal injury through incorrect handling Only qualified electricians must operate or work on the electrical installation The plant must be isolated from mains power and secured against restarting during this work Observe all information about machine parts that remain live when the plant is switched off at the ...

Page 19: ...erhaul instructions Central lubrication unit Removing Page 19 of 50 3 3 Removing the filling strainer Unscrew the two thumb screws 40 Figure 5 Removing thumb screws Item number Designation 40 Thumb screw 2021 ABB Automation GmbH en ...

Page 20: ...Overhaul instructions Central lubrication unit Removing Page 20 of 50 Take the filling strainer complete with its lid 5 out of the plate Figure 6 Taking out the filter unit Item number Designation 5 Lid 2021 ABB Automation GmbH en ...

Page 21: ...signation 1 Filling strainer DANGER Danger through electric current Risk of serious or fatal injury through incorrect handling Only qualified electricians must operate or work on the electrical installation The plant must be isolated from mains power and secured against restarting during this work Observe all information about machine parts that remain live when the plant is switched off at the ma...

Page 22: ... 2 Overhaul instructions Central lubrication unit Removing Page 22 of 50 3 4 Removing the oil filter Unscrew the oil filter 19 Figure 8 Unscrewing the oil filter Item number Designation 19 Oil filter 2021 ABB Automation GmbH en ...

Page 23: ...ugh electric current Risk of serious or fatal injury through incorrect handling Only qualified electricians must operate or work on the electrical installation The plant must be isolated from mains power and secured against restarting during this work Observe all information about machine parts that remain live when the plant is switched off at the main switch 2021 ABB Automation GmbH en ...

Page 24: ... Central lubrication unit Removing Page 24 of 50 3 5 Removing the diaphragm pump Disconnect all plastic hoses 33 from the diaphragm pump Figure 10 Disconnecting hoses Item number Designation 33 Plastic tubing PLN 8x1 25 NT 2021 ABB Automation GmbH en ...

Page 25: ...ul instructions Central lubrication unit Removing Page 25 of 50 Extract the screws 79 of the double diaphragm pump 60 Figure 11 Release screws Item number Designation 79 M5x12 screws 60 Double diaphragm pump 2021 ABB Automation GmbH en ...

Page 26: ... through electric current Risk of serious or fatal injury through incorrect handling Only qualified electricians must operate or work on the electrical installation The plant must be isolated from mains power and secured against restarting during this work Observe all information about machine parts that remain live when the plant is switched off at the main switch 2021 ABB Automation GmbH en ...

Page 27: ...tions Central lubrication unit Removing Page 27 of 50 3 6 Removing the solenoid valve Disconnect all plugs 37 and connected lines Figure 13 Removing the solenoid valve Item number Designation 34 Solenoid Valve 37 Plug 2021 ABB Automation GmbH en ...

Page 28: ... 1 2 Overhaul instructions Central lubrication unit Removing Page 28 of 50 Release and remove the screws 78 Figure 14 Removing solenoid valve mounting screws Item number Designation 78 M3x14 screw 2021 ABB Automation GmbH en ...

Page 29: ... DANGER Danger through electric current Risk of serious or fatal injury through incorrect handling Only qualified electricians must operate or work on the electrical installation The plant must be isolated from mains power and secured against restarting during this work Observe all information about machine parts that remain live when the plant is switched off at the main switch 2021 ABB Automatio...

Page 30: ... lubrication unit Removing Page 30 of 50 3 7 Removing the local control switch Remove the connectors 43 and 47 Figure 16 Removing the local control switch Item number Designation 43 Sensor actuator plug 47 Sensor actuator connector 2021 ABB Automation GmbH en ...

Page 31: ...sion 1 2 Overhaul instructions Central lubrication unit Removing Page 31 of 50 Remove the 4 screws 87 Figure 17 Removing the switch mounting screws Item number Designation 87 Socket head screw 2021 ABB Automation GmbH en ...

Page 32: ...l switch DANGER Danger through electric current Risk of serious or fatal injury through incorrect handling Only qualified electricians must operate or work on the electrical installation The plant must be isolated from mains power and secured against restarting during this work Observe all information about machine parts that remain live when the plant is switched off at the main switch 2021 ABB A...

Page 33: ...re installed Seals and bearing surfaces must be lubricated with petroleum jelly or a high quality rolling bearing grease before assembly The bearing surfaces of the screw heads and threads are treated as well The following tightening torques must be observed M1 7 SMC SYJ3 0 12 Nm M8 12 9 25 Nm M3 SMC SYJ7 0 8 Nm M10 40 Nm M4 2 1 Nm M10 12 9 45 Nm M5 4 3 Nm M12 45 Nm M6 8 6 Nm M12 12 9 50 Nm M8 21 ...

Page 34: ...s Central lubrication unit Installation Page 34 of 50 5 Installation 5 1 Fitting the container Screw the filling strainer 1 onto the lid Figure 19 Screwing on the filling strainer Item number Designation 1 Filling strainer 2021 ABB Automation GmbH en ...

Page 35: ...uctions Central lubrication unit Installation Page 35 of 50 Place the square container 22 onto the central lubrication unit under the plate Figure 20 Fitting the container Item number Designation 22 Square container 2021 ABB Automation GmbH en ...

Page 36: ...1 2 Overhaul instructions Central lubrication unit Installation Page 36 of 50 Place the plate 4 with the coarse filter unit on the container Figure 21 Fitting the lid Item number Designation 4 Plate 2021 ABB Automation GmbH en ...

Page 37: ... the clamp fastener into the corresponding hooks Tighten the two clamp fasteners 51 so that the plate is firmly seated on the container Figure 22 Closing the clamp fasteners Item number Designation 51 Clamp fastener Start the system and check the correct function of each component 2021 ABB Automation GmbH en ...

Page 38: ...s Central lubrication unit Installation Page 38 of 50 5 2 Fitting the filling strainer Screw the filling strainer 1 onto the lid 5 Figure 23 Screwing on the filling strainer Item number Designation 1 Filling strainer 5 Lid 2021 ABB Automation GmbH en ...

Page 39: ...1 2 Overhaul instructions Central lubrication unit Installation Page 39 of 50 Insert the lid 5 with the filling strainer into the plate Figure 24 Insert the filter unit Item number Designation 5 Lid 2021 ABB Automation GmbH en ...

Page 40: ...lubrication unit Installation Page 40 of 50 Screw the two thumb screws 40 back into the cover Figure 25 Fastening thumb screws Item number Designation 40 Thumb screws Start the system and check the correct function of each component 2021 ABB Automation GmbH en ...

Page 41: ...the oil filter seal Fill the oil filter with Mesamoll up to its upper edge Screw the oil filter 19 onto the bracket using the oil filter spanner 93 45 tightening it to 20 to 25 Nm Figure 26 Screwing on the oil filter Item number Designation 19 Oil filter Start the system and check the correct function of each component 2021 ABB Automation GmbH en ...

Page 42: ...brication unit Installation Page 42 of 50 5 4 Fitting the diaphragm pump Place the double diaphragm pump 60 in the correct mounting position Figure 27 Fitting the double diaphragm pump Item number Designation 60 Double diaphragm pump 2021 ABB Automation GmbH en ...

Page 43: ...ructions Central lubrication unit Installation Page 43 of 50 Fasten the double diaphragm pump to the central lubrication unit with the four screws 79 Figure 28 Fitting screws Item number Designation 79 M5x12 screws 2021 ABB Automation GmbH en ...

Page 44: ...entral lubrication unit Installation Page 44 of 50 Connect all plastic tubes 33 Figure 29 Fitting tubes Item number Designation 33 Plastic tubing PLN 8x1 25 NT Start the system and check the correct function of each component 2021 ABB Automation GmbH en ...

Page 45: ... Central lubrication unit Installation Page 45 of 50 5 5 Fitting the solenoid valve Place the solenoid valve 34 in the correct mounting position Figure 30 Fitting the solenoid valve Item number Designation 34 Solenoid Valve 2021 ABB Automation GmbH en ...

Page 46: ...l instructions Central lubrication unit Installation Page 46 of 50 Screw the solenoid valve to the base plate with the screws 78 Figure 31 Securing of the solenoid valve Item number Designation 78 M3x14 screw 2021 ABB Automation GmbH en ...

Page 47: ...nit Installation Page 47 of 50 Connect all hoses and connectors 37 to the solenoid valve 34 Figure 32 Connecting hoses and plugs Item number Designation 34 Solenoid Valve 37 Plug Start the system and check the correct function of each component 2021 ABB Automation GmbH en ...

Page 48: ...tion unit Installation Page 48 of 50 5 6 Fitting the local control switch Position the local control switch 58 in its correct mounting position Figure 33 Positioning the local control switch Item number Designation 58 Local control switch 2021 ABB Automation GmbH en ...

Page 49: ...entral lubrication unit Installation Page 49 of 50 Screw the local control switch to the base plate with the 4 socket head screws 87 Figure 34 Screwing on the local control switch Item number Designation 87 Socket head screw 2021 ABB Automation GmbH en ...

Page 50: ... Installation Page 50 of 50 Reconnect all connectors 43 and 47 Figure 35 Fitting the local control switch Item number Designation 43 Sensor actuator connector 47 Sensor actuator plug Start the system and check the correct function of each component 2021 ABB Automation GmbH en ...

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