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21

V. MAINTENANCE AND REPAIR

DANGER

FAILURE TO OBSERVE ALL SAFETY RULES, WRITTEN AND IMPLIED, AND THOSE

SUGGESTED BY COMMON SENSE, CAN RESULT IN DEATH, SERIOUS INJURY, AND /OR
EQUIPMENT DAMAGE. LOCKOUT POWER BEFORE PERFORMING ANY MAINTENANCE.

5.1 General Maintenance

A good maintenance program involves thorough general housekeeping, adequate periodic re-lubrication, and
replacement of worn or damaged components.

5.2 Periodic Inspection

At regularly scheduled intervals, while observing all safety precautions observe the equipment as it operates. Inspect
for:

A.   Loose or missing hardware.

B.   Proper hydraulic oil level.

C.   Noisy motors or motor bearings.

D.   Structural damage.

E.   Rust or corrosion.

F.   Damaged wiring, including exposed conductors and connections.

G.  Hydraulic leaks, damaged hydraulic lines and components, hoses that are kinked, chaffed or that are

binding

H.   Excessive dirt accumulation in the hydraulic power unit, vacuum unit, boom pivot and telescoping joints.

I.   Vacuum hoses that are kinked or chaffed. Vacuum leaks.

J.   Make sure that all guards are in place and that all warning labels are in place and legible. Section I,

GENERAL SAFETY INFORMATION, explains the purpose and intended location of the warning signs.
Warning signs are an important part of any safety program; replace any missing signs IMMEDIATELY!

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Summary of Contents for InterSystems STP

Page 1: ...ETY NSTALLA OPERATIO MAINTENA M A N ATION ON ANCE U A L L Mod ww TRUC del TP N R 9575 N Omaha Nebra 402 ww intersys CK PR P and No PC 5 Revised 20 109th Ave aska 68142 2 330 1500 tems net ROBE d STP 29834J 17 02 15 ...

Page 2: ...OTOR OFF ON Switch S 2 15 4 1 3 PROBE MOVEMENT Push button Switches S 3 thru S 10 Old Style Control 15 4 1 4 PROBE MOVEMENT Joy stick Switches S 3 S 4 Standard JS Control 15 4 1 5 Main Fuse 15 4 1 6 Terminal Strip 15 4 1 7 Vacuum Motor s Relay 15 4 2 Electrical Components 16 4 2 1 Hydraulic Pump Motor 16 4 2 2 Pump Motor Starter Thermal Overload 16 4 2 3 Hydraulic Oil Heater 16 4 2 4 Vacuum Motor ...

Page 3: ...s Troubleshooting 26 6 3 1 Cylinder Leaking 26 VII REPLACEMENT PARTS 27 7 1 Scope 27 7 2 Ordering Parts 27 7 3 Replacement Parts 27 7 4 Repair Kits 27 7 4 1 Truck Probe Parts Listing 28 VIII WARRANTY 39 List of Illustrations Drawings FIGURE 1 1 TRUCK PROBE SAFETY LABEL LOCATIONS 4 FIGURE 2 1 TYPICAL INSTALLATION TRUCK PROBE SYSTEM 5 FIGURE 3 1 HOSE REUSABLE FITTING ASSEMBLY INSTRUCTIONS 9 FIGURE 3...

Page 4: ...or its operating environment Careless changes could result in death or serious injury to people and reduce the performance and service life of the equipment Never perform any service on this equipment or any other powered equipment until all power has been shut off and locked out so that it cannot be restored without the consent and knowledge of the person who interrupted power Power includes elec...

Page 5: ...4 FIGURE 1 1 TRUCK PROBE SAFETY LABEL LOCATIONS ...

Page 6: ...ion The vacuum system is turned on and then the probe tip is inserted down into the hopper truck with the sampling ports closed The sampling ports are opened to receive a sample and then closed to dump the sample in the vacuum conveying chamber of the probe tip The probe tip is raised and re inserted into the material in a different location This is repeated as required by the FGIS or other regula...

Page 7: ...ll of the following items A Traffic control lights B Intercom system C Aluminum sample conveying tubing 2 3 Material Sampled Most material from light to heavy density powders granules flakes and pellets 2 4 Truck Probe Construction Standard Truck Probe construction is of painted carbon steel this includes the base stand booms probe etc Other materials and or finishes appropriate to the operating e...

Page 8: ... securely anchored to a reinforced concrete base constructed as specified by the certified drawing s The Truck Probe requires no bracing but it was not designed to support other equipment Separate support must be provided for any accessory equipment The user or installer is advised to retain a civil or architectural engineer to plan the overall installation and more specifically the reinforced con...

Page 9: ... and sample lab as in Figure 2 1 Locate the Truck Probe and associated equipment for ease of access and maintenance The Truck Probe operator should have an unobstructed view of the entire area of boom movement The Truck Probe is to be installed only as shown on the certified drawing s If an alternate mounting arrangement is desired contact InterSystems prior to installation for proper guidance The...

Page 10: ...tall the head to the m he hardware t assembly n e foundation d UNIT IS SH OF FLUID I wing in the hy talled The h o fit CE VALVE T REUSABL r clockwise u berally se into the so meter boom p ugh for the b pivot shaft t om the cylinde e cylinder piv e end of the 1 8 diamete main stand a kit to fasten in near the base drawing s IPPED WITH S FURNISHE ydraulic fitting oses from the TO WORK PR LE FITTING ...

Page 11: ...f other obstructions such as buildings poles etc are nearby First lightly tack weld the stops to the plate on top of the probe stand Then swing the Probe through the entire range of travel to verify that it does not hit any obstruction When proper stop placement is determined weld the stops in their permanent position NOTE WHEN WELDING THE STOPS CAREFULLY SHIELD THE DRIVE SPROCKET AND OTHER DRIVE ...

Page 12: ...lation pads when mounting the control enclosure or mount the controller in a vibration free location B Unless ordered for severe duty locate controller so it is protected from water and dust C Unless an explosion proof rated controller was specifically ordered DO NOT locate the controller in a hazardous area D Most applications require that the Truck Probe be in easy view of the controller 3 7 Sys...

Page 13: ...nk Heater Optional 120 VAC 50 60 Hz Single Phase 500 Watts 3 7 1 4 Hydraulic Pump Motor Hydraulic Power Unit Horsepower Voltage Phase 60 HZ Amps 3 HP TP Comp Core 230 1PH 14 0 3 HP TP Comp Core 230 460 3PH 8 29 4 14 3 HP TP Comp Core 575 3PH 3 32 5 HP STP Comp Core 230 1PH 21 5 5 HP STP Comp Core 230 460 3PH 13 2 6 6 5 HP STP Comp Core 575 3PH 5 28 NOTE THE MOTOR CHART AMPERAGES SHOWN ARE FOR REFE...

Page 14: ...T TEFLON T FIG ed and tested le federal sta solenoid valv hoses and fitt hoses to the aulic lines CA AY CAUSE TAPE OR P GURE 3 2 HY before it left ate and local ves and mani tings for conn e hydraulic p AUTION MINOR INJ PIPE SEALA YDRAULIC S the factory T codes and re fold were mo necting the hy power unit e N JURY CLAM ANT ON O SCHEMATIC The final insta egulations ounted on the ydraulic powe exer...

Page 15: ...N SENSE CAN RESULT IN DEATH SERIOUS INJURY AND OR EQUIPMENT DAMAGE LOCKOUT POWER BEFORE PERFORMING ANY MAINTENANCE 4 1 Operators Control Components And Their Functions FIGURE 4 1 STANDARD NEMA 12 OPERATORS CONTROL PANEL DETAIL Refer to the certified electrical drawing s for dimensions on control panels with optional features ...

Page 16: ... solenoids controlled by each joy stick can be energized at a given time As a consequence two boom probe motions can be initiated simultaneously However if two boom motions are initiated simultaneously both will occur at a slower rate because of the limited pump capacity It is much harder to accurately control two boom motions simultaneously 4 1 5 Main Fuse This fuse located in a fuse block within...

Page 17: ... if and overload occurs If the overload trips it will be necessary to determine the cause and manually reset the overload module inside the starter enclosure 4 2 3 Hydraulic Oil Heater The immersion heater is mounted in the side of the oil reservoir to heat the oil to a suitable operating temperature The heater is rated at 500 watts and has in internal thermostat to shut it off at when the oil has...

Page 18: ...entered so that all ports are blocked and movement is inhibited 4 3 1 2 Counter Balance Valve V 12 When at rest the probe s weight causes static hydraulic pressure The purpose of the Counter Balance Valve is to prevent the probe from free falling slightly when the probe is initially powered down The counter balance valve also prevents the probe from drifting down If the probe drifts down the count...

Page 19: ...te the sample ports to collect and dump samples When the valve s A solenoid is energized the valve spool shifts pressurizing the port of the actuator that opens the sample ports When the B solenoid is energized the valve spool shifts pressurizing the port of the actuator that closes the sample ports Note when neither A nor B solenoid is energized the valve is spring centered so that all ports are ...

Page 20: ...boom swing to the right The flow controls will need to be adjusted upon initial start up To adjust first loosen the small set screw on the metering screw Turn clockwise to decrease boom swing speed and counter clockwise to increase boom swing speed After desired speed is achieved re tighten the set screw to lock setting NOTE AVOID EXCESSIVE BOOM SWING SPEED WHICH WILL RESULT IN UNCONTROLLABLE BOOM...

Page 21: ...h a pair of jack screws allow for tightening the drive chain Solenoid valve V 2 controls left right movement 4 3 7 Hydraulic Pump The hydraulic pump is a fixed displacement gear pump that produces a flow of 5 6 GPM at 1800 RPM The probe speed can be decreased by adding flow controls to any of the cylinders actuators but cannot be increased Maximum speeds for troubleshooting are as follows Probe Fu...

Page 22: ... A Loose or missing hardware B Proper hydraulic oil level C Noisy motors or motor bearings D Structural damage E Rust or corrosion F Damaged wiring including exposed conductors and connections G Hydraulic leaks damaged hydraulic lines and components hoses that are kinked chaffed or that are binding H Excessive dirt accumulation in the hydraulic power unit vacuum unit boom pivot and telescoping joi...

Page 23: ...IN AND FLUSH THE SYSTEM COMPONENTS WHEN CHANGING THE HYDRAULIC OIL 5 4 1 Hydraulic Oil Inspection Daily A Check the reservoir fluid level with the probe operating The level must be above the RED Low Oil Level bar on the sight gage Replenish reservoir as necessary to maintain minimum level B Check fluid temperature after the truck probe has operated for a time Fluid temperature should stabilize bet...

Page 24: ...connect the pressure and suction hoses at the pump to drain any remaining fluid and solvent Then reconnect the hoses E Make sure the hoses to the Truck Probe are labeled where they connect to the fittings on the end of the power unit Disconnect the hoses to drain them of fluid Then reconnect the hoses F Replace the return line filter cartridge G Temporarily remove the suction strainer Wash it with...

Page 25: ... D The probe tip should pivot freely on the end of the boom without side play 5 6 Core Probe Vacuum Pressure Equalization The Core Probe is designed to be a balanced system such that air is neither being pulled into or pushed out of the sampling end of the tip Check for correct air balance as follows A Turn the vacuum motor on B Place a three inch square piece of paper over the sample opening C Th...

Page 26: ...e switch Truck Probe does not operate Power light On Faulty system wiring Correct Refer to certified electrical schematic Starter overloads tripped Reset Refer to Section 4 2 2 Pump motor power off Turn motor power on No or low hydraulic pressure Check pressure gauge Defective control valve Refer to Section 6 2 Truck Probe sluggish Relief valve set too low Reset Refer to Section 4 3 2 Operates too...

Page 27: ...damaged seals Examine the piston rod for wear or damage Replace the rod and seals if rod s surface is rough or worn out of round B Internal Leakage 1 The lip seal piston seals are virtually leak free unless they are worn or damaged Replace defective seals 2 Contaminants in the hydraulic supply can lead to scored cylinder walls resulting in rapid seal wear If such is the case check to see if the fi...

Page 28: ... do wear out and fail It is InterSystems recommendation that a small supply of spare parts be kept on hand to cover any minor breakdowns A separate priced Spare Parts List will be sent identifying the suggested spare parts It is also necessary to check the certified drawings which will list any special or custom components utilized on this equipment 7 4 Repair Kits The following chart lists repair...

Page 29: ...DESCRIPTION QTY STAND PIVOT TUBE COMPONENTS 16 35684 CYLINDER HYD 3 BORE X 24 STROKE 1 17 34029 CHAIN ROLLER NO 60 H A R 18 34758 CHAIN LINK NO 60 H CONNECTOR 1 19 34033 CHAIN LINK NO 60 H OFFSET A R 20 35687 HYD TORQUE MOTOR W 1 00 SHAFT 1 21 531754 TP STP HYD MOTOR SLIDE PLATE 1 22 35628 ELBOW 90 M F MPT x FPT STL 2 23 35623 PIPE NIPPLE NPT X 2 LG BLACK 2 24 35629 ADJ FLOW CONTROL NPT 15 GPM 2 2...

Page 30: ...L DISCHARGE 1 DUAL VAC UNIT COMPONENTS 76 35607 VAC GASKET 9 7X 9 7 X 1 2 77 34498 HOSE 2 0 ID PLASTIFLEX A R 78 35212 VAC HOSE ADAPTER 2 0 OD 1 79 35605 VAC HOSE ADAPTER 1 5 OD 1 80 34069 PANEL LOCK W KEY 1 81 515495 VAC HOUSING DUAL 2 OR 3 STAGE 1 82A 35940 VAC OUTLET 1 50 OD 90 DEG 1 82B VAC OUTLET 2 38 OD 90 DEG 1 83A 35532 2 STAGE VAC MOTOR W TANGENTIAL DISCHARGE 2 83B 529239 3 STAGE VAC MOTO...

Page 31: ...PTER 1 126 35781 COUPLING SPIDER RUBBER L100 1 127 35782 COUPLING HALF BORE L100 1 128 35783 COUPLING HALF 1 1 8 BORE L100 1 129 TEFC C FACE FT MT ELECTRIC MOTOR 1 35792 3 HP 1 PH 115 230VAC 60 HZ 35791 3 HP 3 PH 230 460VAC 60 HZ 190 380VAC 50 HZ 524368 3 HP 3 PH 575VAC 60 HZ 35794 5 HP 1 PH 115 230VAC 60 HZ 35770 5 HP 3 PH 230 460VAC 60 HZ 190 380VAC 50 HZ 130 523135 548404 5 HP 3 PH 575VAC 60 HZ...

Page 32: ...31 FIGURE 7 1 MAIN STAND ASSEMBLY ...

Page 33: ...32 FIGURE 7 2 TELESCOPING BOOM ASSEMBLY FIGURE 7 3 COMPARTMENTIZED CORE PROBES ...

Page 34: ...33 FIGURE 7 4 SAMPLE CABINETS ...

Page 35: ...34 FIGURE 7 5 VACUUM MOTOR UNITS ...

Page 36: ...FIGURE 7 7 6 HYDRAU ULIC POWER R UNIT ASSEMBLY 35 ...

Page 37: ...36 FIGURE 7 7 HYDRAULIC POWER UNIT FITTINGS HOSES ...

Page 38: ...37 FIGURE 7 8 HYDRAULIC HOSES FITTINGS ...

Page 39: ...s on probe bearings or or pump of oil change at n reservoir must vel ure relief valve HP HP line connections cartridge change ent suction filte fluid temperature s F TRUCK PRO ________ ________ ________ ________ _______ _________ III t are of play l motor least be if req d er OBE MAINT Control Box Ty YE _____ __ _____ __ _____ __ _____ __ IV Collecti YES NO _____ __ _____ __ _____ __ _____ __ ____...

Page 40: ... than by an Authorized Service Representative This warranty does not cover the replacement of parts inoperative because of wear occasioned by use the cost of replacing parts by a person other than an InterSystems employee or an Authorized Service Representative or the adjustment of a product where the product was improperly adjusted by the purchaser In addition this warranty does not cover compone...

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