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Allied Construction Products, LLC www.alliedcp.com

BreakerLube

CML Series

Electric Grease Pump

Safety, Installation, Operation, Maintenance and Parts

This manual was prepared to assist qualified personnel with the information necessary to
install, operate and maintain the Allied BreakerLube. Read, understand and follow the
information contained in the safety messages. Keep for future reference.

TM102783

-MAX-

-MIN-

BreakerLube

Содержание BreakerLube CML Series

Страница 1: ...lation Operation Maintenance and Parts This manual was prepared to assist qualified personnel with the information necessary to install operate and maintain the Allied BreakerLube Read understand and follow the information contained in the safety messages Keep for future reference TM102783 MAX MIN BreakerLube ...

Страница 2: ...sion History Effective Date Page Summary of Change 15 Jul 17 18 19 40 41 42 43 44 45 46 47 48 Update figures for black and gray connectors Update breaker models installation kits Revise electrical diagrams Revise parts tables and figures for 2 3 element adapter kits Add figures for items used in electrical kits 09 Jan 6 Technical Data Table revise lubricant output 08 May Model change over 07 Apr 1...

Страница 3: ...Fig S1 Safety Alert Symbol The Safety Alert Symbol Fig S1 either used alone or in conjunction with a signal word is used to draw attention to the presence of potential safety hazards Signal Words DANGER WARNING and CAUTION are signal words used to express severity of consequences should a hazard be encountered DANGER Indicates an imminent hazard which if not avoided will result in death or serious...

Страница 4: ... for grease type re lubrication schedules procedures and precautions that must be observed to prevent risk of equipment damage if instructions are not followed or through unapproved methods L4 Maximum Fill Line Decal indicates the maximum fill line when refilling the cartridge with lubricant The decal also calls attention to hazard if overfilled L5 Grease Refill Decal identifies the location of th...

Страница 5: ...kerLube CML_15jul Safety Information cont d Fig L11 Label Positions Identified Table S 1 Labels Item Part Name Part No Qty Description L2 Crush Point 576737 1 L7 Rotation Arrow 1 L8 Allied 676652 1 L9 BreakerLube 679967 1 L10 Product ID Tag 1 MAX MIN BreakerLube Front ...

Страница 6: ...ve key before servicing Personnel maintain a safe distance Falling object Unsupported loads Personal Protection Equipment Hearing protection Safety eyewear Gloves Safety shoes Falling part Moving part in direction indicated by arrow Crush point Crush Entanglement Moving Parts Crush Pinch point Leaking fluid under pressure Hot surfaces Gas Oil under pressure Electric Shock Hazard Prohibited actions...

Страница 7: ...afety information become tool specific and operation specific Allied has made every effort to provide information as complete and accurate as possible for this document Allied cannot anticipate every possible circumstance that might involve a potential hazard The warnings in this manual and labels affixed to the Allied attachment are therefore not all inclusive General Construction Safety Always f...

Страница 8: ... access to danger areas Guards are fitted to the Allied equipment to protect against unsafe situations that could not be eliminated through design measures Guards are only effective when properly installed and in place Guards shall not be removed unless for the purpose of inspection and service of components Reinstall all guards after service or adjustments are completed Where it was not possible ...

Страница 9: ... 15 6 6 Instructions for Installing Pump Element 15 6 7 Set up and Adjustments 16 6 8 Adjustable Type Element Option 16 6 9 Electrical Installation General 17 6 10 Black Connector Identified 17 Section Page 6 11 Gray Connector Identified 18 6 12 6 13 Examples of Various Wiring Diagrams 19 6 14 Install Instructions Using Auxiliary Valve 24 6 15 System Start up Check List 24 6 16 Set up and Adjustme...

Страница 10: ...ressure Switch 3 Way Valve 18 6 18 Black Connector 43 Identified 18 6 19 Top View Markings on Black Connector 18 6 20 Gray Connector 26 Identified 18 6 21 Gray Connector 3 Poles Plus Ground 19 6 22 Basic Wiring for Motor 19 6 23 Plug 41 2 Pole with Ground 19 6 24 Electrical Diagram 2E 20 6 25 Electrical Diagram 3E 21 6 26 Electrical Diagram 3E Relay 1 2 Detail 22 6 27 Electrical Diagram 4E 23 6 28...

Страница 11: ...sible for future reference 1 2 Content Includes Safety Section Equipment Identification Operating Principle Configurations Equipment Options Installation Guidelines Maintenance Care Recommended Lubricants Priming Pre filling Lines Troubleshooting Removal Storage Technical Data General specifications Parts Information Spare Replacement The publication identified in Table 1 1 was created solely for ...

Страница 12: ...ler requires complete information about the equipment to better assist you with questions regarding parts warranty operation maintenance or repair Copy the Model and Series Number from the Equipment Identification Tag to the space provided below Indicate the date in which the Allied equipment was placed into service Fill out the Warranty Registration form and return to Allied Construction Products...

Страница 13: ...ity includes Ensure that personnel entrusted with installation operation and maintenance of the Allied equipment adhere to the following Read and fully understand the information included in this manual Recognize that operating this equipment in conditional applications such as working underwater requires modifications to the standard breaker and additional training for the operator maintenance an...

Страница 14: ...Calibration Carelessness Incorrect operating methods Inattention to re lubrication and other maintenance requirements Misuse Unapproved applications Inadequate or Absence of Training Use of non genuine Allied replacement parts Unapproved modifications Use of grease which is not or is only conditionally Pumpable The use of a lubricant type that is unsuitable for the application Allied Chisel Paste ...

Страница 15: ...ety is improved as operators are not required to lubricate in hazardous areas Increase service life of components Lubrication occurs while the breaker is in operation when it is of the most benefit Will dispense the precise amount to maintain sufficient lubrication while reducing costs from excessive consumption with less waste and environmental pollution With proper delivery the constant replenis...

Страница 16: ...th special pump elements for use with Chisel Paste Delivery of grease up to NLGI No 2 at temperatures from 25C to 70C System activation works with both electrically operated and pilot operated controls for breaker valve Note Additional parts required for pilot operated control not included in standard installation kit Custom designed install kits facilitate quick installations Kits include a basic...

Страница 17: ...low capacity pump The pump s discharge rate is purposely metered for small quantities only 4 4 Operation of Low level Control The basic pump assembly comes standard equipped with a low level control When wired to a light or alarm the operator is signaled that the grease level inside the reservoir has fallen below the minimum mark Fig 4 6 Low level Control 1 Magnetic switch 2 Electromagnetic switch...

Страница 18: ...ent Specify 12VDC or 24VDC 3 Re fillable Reservoir Specify Size 1 or 2 Gallon 21 Pump Element Qty 1 included Order additional elements separately 24 Adapter 25 Pressure Relief Valve Qty 1 included Order additional relief valves separately 26 Gray Connector Pre wired with 4 conductor wire Cord for Low Level Control 43 Black Connector Pre wired with 4 conductor Cord Power Supply to Motor Mounting Ha...

Страница 19: ...1 2 Basic Pump Assembly A1 A2 A3 A The basic pump assembly includes items shown in Fig 5 1 Begin configuration with the basic pump Select from A1 A2 or A3 B Identify the supply voltage of the carrier and match it with the correct basic pump assembly Fig B Match Carrier s Supply Voltage C Choose size of reservoir 1 or 2 gallon Mounting considerations should include easy access for re filling and pr...

Страница 20: ...lube lines and relief valves Fig E Breaker with Two Grease Ports Bushings With Independent Grease Passages CAUTION Each separate pump line must have a relief valve installed F Follow configuration F for breakers designed with a single grease passage to both the upper and lower bushings will this Fig F1 Lube Line Kit Item 70 Determined By Carrier Reach Fig F2 Single Feed Passage Lubricates Both Bus...

Страница 21: ...y before installing Do not modify disable or interfere with any existing safety equipment already fitted to the carrier Mount the BreakerLube CML away from sources of heat Refer to Table in Technical Data section for operating temperatures Do not run any lube lines through the operator s cab they may leak or even burst injuring the operator 6 1 2 Safety Precautions Welding WARNING Electric shock h...

Страница 22: ... to breaker s Operating Manual Location of the G port can vary Typical location is on the valve housing or back head The port is marked G 6 3 2 G Two Elements Into Single Lube Line Fig 6 4 Add 2 nd Pump Bridge into 1 Lube Line 1 If not already installed refer to the pump element instructions in Section 6 6 Refer to above figure for assembly of 2 element adapter kit 2 Route lube lines along the exi...

Страница 23: ...ulic hoses Allow for proper slack at pivot joints Wrap any hose susceptible to damage from rubbing IMPORTANT Route hoses avoiding sharp bends Wrap any hose susceptible to damage from rubbing Before cutting hose check for proper length to both termination points knowing where each component mounts 4 Measure cut and assemble connectors to lube lines according to figure 6 3 Quick disconnect couplers ...

Страница 24: ... 6 6 Refer to above figure for assembly of 3 element adapter kit 2 Route lube lines along the existing hydraulic hoses Allow for proper slack at pivot joints IMPORTANT Route hoses avoiding sharp bends Wrap any hose susceptible to damage from rubbing Before cutting hose check for proper length to both termination points knowing where each component mounts 3 Measure cut and assemble connectors to lu...

Страница 25: ...nd removal of the breaker Fig 6 9 Assemble Fitting to Plain Hose End 3 Secure lube lines with supplied nylon ties 4 For the location of port G refer to breaker s Operating Manual Location of the G port can vary Typical location is on the valve housing or back head The port is marked G 6 5 Install Re usable Fittings to Plain End of Hose 1 Thread hose nut item 76 onto hose 2 Insert stem end of item ...

Страница 26: ...lement Adjusting may take several attempts to reach proper delivery Every application is different the variety of operating conditions is unlimited and other factors need to be taken into account such as the size of breaker and wear of bushings and tool 1 Loosen locking nut 2 while holding the pump element body 3 in position with a second wrench 2 Change the position of the adjusting spindle 1 3 R...

Страница 27: ...kerLube Wiring diagrams shown here 1E thru 4E are generic Fig 6 15 Electrical Connections on Pump Housing 20 6 10 Black Connector 43 Identified The Basic Pump Assembly is provided with one black and one gray connector The black connector 43 is pre wired to a 4 conductor cable and used to power the motor Fig 6 16 Black Connector The black connector is keyed the pole positions to fit the plug 41 tha...

Страница 28: ...e brown wire to negative side of battery Fig 6 19 Plug 41 2 Pole Plus Ground 6 11 Gray Connector 26 Identified The gray connector is keyed to fit the plug 28 located on the right side of the pump housing It is pre wired with a 4 conductor cable and used to wire the low level control to an alarm Fig 6 20 Gray Connector Fig 6 21 Low Level Control Wired to Dash Lamp One option is to use the low level...

Страница 29: ...n switch is turned off 6 12 1 Electrical Diagram 2E Warning Light Breaker Shut Down 1 Install the fuse holder in a location that s accessible for service 2 Find a protected location for installing the relay 3 Install the dash lamp in a position inside the cab so it s visible to the operator while the breaker is in operation 6 12 2 Gray Connector 26 with Pre wired Cord RD 1 Red BK 3 Black BN 2 Brow...

Страница 30: ... alliedcp com 20 TM102783_BreakerLube CML_15jul 6 0 Installation cont d Fig 6 23 Electrical Diagram 2E M 1 2 3 3 2 1 2 3 1 2 3 1 43 37 26 20 6 8 5 7 1 3 2 4 7 8 5 6 1 3 4 2 Brown Red Yellow Green Black Not Used 7 8 5 6 1 3 4 2 3 1 37 2E R ...

Страница 31: ...allation cont d Fig 6 24 Electrical Diagram 3E 6 13 Diagram 3E LLC Enabled and 2 Relays Wire per Fig 6 24 diagram 3E Part Name Part Number Relay 24V 102598 Relay Socket 102599 Fuse Holder Fuse 679342 815641 Dash Lamp 24V Lens 102122 102597 Hour Meter 3E R M 1 2 3 3 2 1 2 3 1 2 3 1 43 26 20 37 ...

Страница 32: ...roducts LLC www alliedcp com 22 TM102783_BreakerLube CML_15jul 6 0 Installation cont d Fig 6 25 Electrical Diagram 3E Detail View Relay 1 2 37 6 8 5 7 1 3 2 4 7 8 5 6 1 3 4 2 3 1 6 8 5 7 1 3 2 4 7 8 5 6 1 3 4 2 M 2 1 M 3E R ...

Страница 33: ...jul 6 0 Installation cont d Fig 6 26 Electrical Diagram 4E Part Name Part Number Part Name Part Number Relay 24V 102598 Fuse Holder Fuse 679342 815641 Relay Socket 102599 Dash Lamp 24V Lens 102122 102597 Hour Meter 3 way Valve 571327 Terminal Strip Key Switch 2 3 1 4E R M 1 2 3 41 ...

Страница 34: ...rect rotation is verified Operation of the Low Level Control should be verified before reservoir is filled Reservoir filled with clean grease Test low level control prior to filling The carrier has been operated through a complete range of motion to check lube lines for unrestricted movement without rubbing excessive sag or kinking Lube line connections are made at all connection points from pump ...

Страница 35: ...icient lubrication 1 Pre fill all lines and passages leading to the bushings and tool 2 If a new tool is installed apply a liberal amount of lubricate to the shank of the tool before inserting into front head Fig 6 29 3 Procedure 2 applies to tools and related parts that are wiped clean for purposes of inspection These parts include retainers for tool Fig 6 29 Pre Lube Tool Shank Before Installing...

Страница 36: ...o skin IMPORTANT Before components are disassembled take steps to prevent spills Have a suitable container available to collect fluids Comply with local regulations for fluid disposal 7 2 Grease Level Inside the Reservoir CAUTION Make regular checks of the grease level in reservoir and re fill when nears the minimum mark Always refill reservoir as soon as low level signal is triggered If the greas...

Страница 37: ...by removing the reservoir lid Store unused portions of Chisel Paste in a clean dry area Do not use grease that has change consistency over time Fig 7 2 Unapproved Re fill Method The recommended method for refilling the reservoir is thru the grease nipple located on the front of the pump housing 1 Use a hand operated grease gun manual lever or power type Wipe debris from grease nipple Attach the gr...

Страница 38: ...ut bubbles is seen at open end of hose 4 Re attach lube line to breaker Fig 7 5 Grease Fitting 25a On Relief Valve IMPORTANT Before components are disassembled take steps to prevent spills Have a suitable container available to collect fluids Comply with local regulations for fluid disposal 7 6 By pass BreakerLube Grease By Hand CAUTION When servicing this equipment use personal protection equipme...

Страница 39: ...ol When Horizontal Fig 7 8 Tool Unseated Risk of Seal Damage CAUTION Use the BreakerLube only for dispensing grease Allied recommends the use of Chisel Paste CAUTION If the breaker is removed from the carrier or lube line is disconnected power to the BreakerLube must be switched off If power is not cut off grease will continue to pump from open line or relief valve IMPORTANT Use benzene or petrole...

Страница 40: ...be to avoid loss or damage Prevent contamination from entering the system Plug openings to keep out dirt and debris 8 4 Re attach After Idle Period Grease may change its characteristics and deteriorate during periods of storage The rate and degree in which grease may deteriorate can vary Some grease may undergo change in consistency becoming firmer and forming a putty like condition that can impai...

Страница 41: ...at the open end of lube line at the G port Line then re installed The breaker s bushings and tool have been filled with grease according to procedure found in the Breaker s Operator s Manual If a new tool was installed proper procedures were followed and pre greasing was completed before insertion into front head These instructions can be found in the Operator s Manual The operator must confirm op...

Страница 42: ...perature Check NLGI number of grease Pumpability of selected grease is too high At cold temperatures lubricant it may take up to 10 minutes of operation before the pump elements reach their full output Restriction in line Clear impurities Locate source of contamination and eliminate Line size is too small Kinked or crushed hose By pass Bypass at relief valve or piston Check valve inside pump eleme...

Страница 43: ...ricants Greases up to NLGI grade 2 Motor Voltage 12Vdc or 24Vdc Motor Connection Type 2 Pole Plus Ground Black Connector Pre Wired With 4 Conductor Cord Input Current 3 A Fuse 5 A 250V 5A Bussman Pump Operating Time 30 minutes max Motor Max Power Input Speed D C gear interference suppressed 24VDC 3 A 12VDC 6 5 A 17 RPM approximate Low level Control Switched current 3 A LLC Connection Type 3 Pole P...

Страница 44: ...struction Products LLC www alliedcp com 34 TM102783_BreakerLube CML_15jul 10 0 Technical Data cont d Fig 10 2 BreakerLube CML Series General Dimensions Identified MIN MAX BreakerLube Front View Top View Rear View ...

Страница 45: ...d Left Side Plug 41 Motor 2 Poles Plus Ground Right Side Plug 28 LLC 3 Poles Plus Ground Left Side Black Connector 43 Motor Right Side Gray Connector 26 LLC Fig 10 3 Location of Electrical Plugs and Connectors Identified 1 2 3 MAX MIN BreakerLube 1 2 3 1 2 3 MAX MIN BreakerLube 1 2 3 M 1 2 3 1 2 3 2 3 1 1 2 3 ...

Страница 46: ...Allied Construction Products LLC www alliedcp com 36 TM102783_BreakerLube CML_15jul 11 0 Parts Basic Pump Assembly Fig 11 1 Basic Pump Assembly BreakerLube CML Series ...

Страница 47: ... Gallon 103830 1 2 2 2 Gallon 103768 3 1 Reservoir 2 Gallon 103769 1 3 2 1 Gallon 103829 4 Hose 103770 1 10 cm 5 Stirring Paddle 103771 1 6 O Ring 103772 1 210 x 5 7 Adapter Ring 103773 2 8 Control Cam 103774 1 9 Bearing Ring 103775 2 10 Bearing 103776 1 11 O Ring 102628 1 144 x 4 12 Intermediate Plate 102610 2 13 Shim A103777 1 10 mm x 16 mm x 1 2 mm 14 Snap Ring 103778 2 15 Pressure Ring 103779 ...

Страница 48: ...Allied Construction Products LLC www alliedcp com 38 TM102783_BreakerLube CML_15jul 11 0 Parts Basic Pump Assembly cont d Fig 11 1 Basic Pump Assembly BreakerLube CML Series ...

Страница 49: ...ound 4 Conductor Cord 26a Flat Packing 1 Gasket 27 Screw A103789 8 BZ 3 x 10 C 28 Plug LLC 103790 1 3 Pole Plus Ground 29 Cover 103791 1 From S N 9810010250 981000064C 30 Screw 103792 10 M3 x 25 mm 31 Drain Hose 103793 1 32 1 12Vdc Motor 103794 1 32 2 24Vdc Motor 103795 1 33 Plug Motor 103796 1 34 Woodruff Key 103797 1 3 x 5 35 Radial Seal A103798 1 BA 10 x 22 x 7 36 Lube Fitting A103799 1 37 Magn...

Страница 50: ...ck Disconnect Push Connector 102627 26 Gray Connector with 4 wire cord 103788 1 43 Black Connector with 4 wire cord 103806 1 Mounting Hardware 1 Set Bolts Washers Nuts Table 11 4 Configuration of Installation Kits Kit Number 576461 572063 572064 572065 572066 572067 Basic Pump A102472 Config F1 40 E 1 60 F 60 G H 80 G 80 Elements 1 2 1 2 3 2 2 Element Kit None None None 102602 570954 102602 Relief...

Страница 51: ...ammer Series Rammer Series Config Part No Description Remarks Notes 1533 2155 F 40 576461 1655 2166 2577 F 60 572064 3088 E 1 60 572063 Note E 1 E Kits Include the 2nd Lube Line 2nd Pump Element and the 2nd Relief Valve 4510 H 80 572066 7013 G 80 X 2 572067 Basic pump x2 each equipped with x2 pump elements MIN MAX BreakerLube E MIN MAX BreakerLube F MIN MAX G MIN MAX H ...

Страница 52: ...Notes AR85B AR95B AR110C AR120B AR130B F 60 572064 AR140B AR165 G 60 572065 Equipped with 2 pump elements AR175 AR180D H 80 572066 AR205 G 80 X 2 572067 Basic pump x2 each equipped with x2 pump elements Table 11 7 Installation Kits Hy Ram Series Hy Ram Series Config Part No Description Remarks Notes HR290 HR330 HR390 HR470 F 60 572064 HR560 HR600 G 60 572065 Equipped with 2 pump elements HR710 H 8...

Страница 53: ... 1 Standard Fixed Delivery 24 Adapter 103476 1 25 Relief Valve Assembly 102625 1 70 2 Lube Line 60 572523 2 Hose 1 4 02MNPT Fitting x Plain End 71 72 Hose Fitting 572520 2 73 QD CPLR Plug 563617 2 74 QD CPLR Socket 563705 2 75 76 Hose Fitting 572519 2 77 Lube Line 20 572521 2 Hose 3 8 06MBSPP x Plain End 78 Bonded Seal 931102 2 79 Nylon Tie Strap 719073 50 Hex Cap 572874 2 Used to close the hose e...

Страница 54: ... 572522 1 Hose 1 4 02MNPT Fitting x Plain End 70 2 60 572523 Hose 1 4 02MNPT Fitting x Plain End 70 3 80 572524 Hose 1 4 02MNPT Fitting x Plain End 70 4 40 572522 Hose 1 4 02MNPT Fitting x Plain End 71 72 Hose Fitting 572520 1 Set Re usable 04MNPT For 1 4 Hose 73 QD Socket 563705 1 74 QD Plug 563617 1 75 76 Hose Fitting 572519 1 Set Re usable 04MNPT For 3 8 Hose 77 1 Lube Line 20 572521 1 Hose 3 8...

Страница 55: ...tes Two Element Adapter Kit w Element 102602 1 Includes all items listed in this Table 21b Pump Element 102623 1 Fixed Delivery Two Element Adapter Kit 102624 1 Includes 12 15 16 17 24 Adapter 103476 1 04FBSPT x 04MBSPT 50 Tee 102886 1 04FBPT X 04FBPT X 04MBPT 51 Hose 102887 1 HA 1 4 x 8 04BSPT x 04JSW90 52 Adapter 679791 1 04MBSP X 04MJIC Items 21a 25 a b are included with basic pump assembly A I...

Страница 56: ...his table 21b Pump Element 102623 1 Fixed Delivery 21c Pump Element 102623 1 Fixed Delivery Three Element Adapter Kit 570932 1 Includes 24 50 52 53 54 55 56 24 Adapter Extension 103476 1 04MBSPT X 04FBSPT 50 Tee 102886 1 04MBSPT X 04FBSPT X 04FBSPT 52 Adapter 679791 1 04MJ X 04MBSP 53 Tee 961820 1 04MJIC Union 54 Hose 274283 1 04BSPT X 04JSW 55 Hose 274282 1 04JSW X 04JSW EL90 56 Adapter w Swivel ...

Страница 57: ...889 14VDC 61 Indicator Lamp 102597 1 RED 1 35 28 VDC 62 1 Relay 102598 1 DPDT 24VDC 62 2 572623 DPDT 12VDC 63 Socket for Relay 102599 1 64 Fuse Holder 679342 1 Knob type inch 65 Fuse 815641 1 250V 5A Bussman Table 11 15 Components for Foot Treadle Operation Part Name Part No Description Remarks Notes Pressure Switch 054792 3 way valve 571327 24VDC Fig 11 9 Pressure Switch 3 way Valve 6 8 5 7 1 3 2...

Страница 58: ...unprotected Additionally the right type of grease must be able to withstand high temperatures The grease must have superior clinging ability to stay put at high temperatures otherwise it offers little protection if it melts and runs down the tool Many factors including operator technique determine whether the breaker will remain productive Everyday wear and tear is unavoidable and no other compone...

Страница 59: ...kerLube CML Series Series Model CML Serial No Please fill out completely Line Description Part Number Quantity Price 1 2 3 4 5 6 7 8 9 10 Contact information Your Name Company Name Phone Account Number Fax Purchase order Email Shipping method See note below Billing Address Shipping Address Note All backordered parts will be shipped when available via the same method as the original order unless in...

Страница 60: ...Allied Construction Products LLC www alliedcp com 50 TM102783_BreakerLube CML_15jul Notes ...

Страница 61: ...Allied Construction Products LLC www alliedcp com 51 TM102783_BreakerLube CML_15jul ...

Страница 62: ...TM102783_15jul_DRAFT R ...

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