Crane STEP1042L, Installation And Operation Manual

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SECTION F: SERVICE AND REPAIR
NOTE: All item numbers in ( ) refer to Figures 9 & 10.
WARNING !
ELECTRICAL POWER TO THE PUMP MOTORS MUST
BE DISCONNECTED AND LOCKED OUT TO PREVENT
ANY DANGEROUS ELECTRICAL HAZARDS OR
PERSONNEL DANGER BEFORE ANY SERVICE WORK
IS DONE TO THE PUMP.
CAUTION !
OPERATING PUMP BUILDS UP HEAT AND
PRESSURE; ALLOW TIME FOR PUMP TO COOL TO
ROOM TEMPERATURE BEFORE HANDLING OR
SERVICING.
F-1) Lubrication:
Anytime the pump is removed from operation, the cooling oil
in the motor housing (5) should be checked visually for oil level
and contamination.
F-1.1) Checking Oil:
Motor Housing-
To check oil, set unit upright. Remove pipe
plug (31). With a flashlight, visually inspect the oil in the motor
housing (5) to make sure it is clean and clear, light amber in
color and free from suspended particles. Milky white oil
indicates the presence of water. Oil level should be to the
midpoint of capacitor (2), see Fig. 9, when pump is in vertical
position.
F-1.2) Testing Oil:
1.
Place pump on it’s side, remove pipe plug (31), from
motor housing (5) and drain oil into a clean, dry container.
2. Check oil for contamination using an oil tester with a range
to 30 Kilovolts breakdown.
3. If oil is found to be clean and uncontaminated (measure at
or above 15 KV. breakdown), refill the motor housing
as per section F-1.3.
4. If oil is found to be dirty or contaminated (or measures
below 15 KV. breakdown), the pump must be carefully
inspected for leaks at the shaft seal (10), cable assembly
(29), and pipe plug (31), O-rings (7) and pipe plug (19),
before refilling with oil. To locate the leak, perform a
pressure test as per section F-1.4. After leak is repaired,
refill with new oil as per section F-1.3.
F-1.3) Replacing Oil:
Motor Housing-
Drain all oil from motor housing and dispose
of properly. Set unit upright and refill with (see parts list for
amount) new cooling oil as per Table 1. Fill to the midpoint of
capacitor (2) as an air space must remain in the top of the motor
housing to compensate for oil expansion (see Cross-section
Fig. 9). Apply pipe thread compound to threads of pipe plug
(31) then assemble to motor housing (5).
Seal Chamber- Set unit on its side with fill plug (19) downward,
remove plug (19) and drain all oil from seal chamber. Set unit
on its side, with plug (19) upward, and refill completely with
(see parts list for amount) new oil as per Table 1. Apply pipe
thread compound to threads of pipe plug (19) and assemble to
spacer (9).
WARNING !
DO NOT OVERFILL OIL
OVERFILLING OF MOTOR HOUSING WITH OIL CAN
CREATE EXCESSIVE AND DANGEROUS HYDRAULIC
PRESSURE WHICH CAN DESTROY THE PUMP AND
CREATE A HAZARD. OVERFILLING OIL VOIDS
WARRANTY.
F-1.4) Pressure Test:
Motor Housing-
Before checking the pump for leaks around
the shaft seal, square rings, and cord inlet, the oil level should
be full as described in section F-1.3. Remove pipe plug (19)
from motor housing (5). Apply pipe sealant to pressure gauge
assembly and tighten into hole (see Fig. 2). Pressurize motor
housing to 10 P.S.I. Use a soap solution around the sealed
areas and inspect joints for "air bubbles". If, after five minutes,
the pressure is still holding constant, and no "bubbles" are
observed, slowly bleed the pressure and remove the gauge
assembly. Replace the pipe plug (19) using a sealant. If the
pressure does not hold, then the leak must be located and
repaired.
Seal Chamber- Remove pipe plug (19) from Intermediate
Coupling (9) and check that the seal chamber is full of oil. Apply
pipe sealant to pressure gauge assembly and tighten into hole
in Intermediate Coupling (9). Pressurize seal chamber to 10
P.S.I. and check for leaks as outlined above.
10 PSI
AIR
⇓
Pressure Gauge Ass’y
(See Parts List)
Fig. 2
Remove Plug
10 PSI AIR
⇒
8