SETUP & INSTALLATION MANUAL FOR
Contents
1. SETUP amp INSTALLATION MANUAL FOR DOOSAN DL 200 TC TOOL CARRIER BY INTERLUBE ATIMKEN Brand IM 005 ISSUE 1 05 04 2012 Page 1 of 27 2012 Interlube Systems Lid UK Table of Contents Ports Bearings Fitting and Lubrication Charts cccccecccseeeeseeeeseseeseeeeseeeeeeeeesees 3 HDI System Installation 8 6 HISEOT POD did aet audae ue Indo ua dU 7 Doosan DL 200 TC Tool Carrier System 8 8 System Insrallauorn CUlcle er een ere eee 9 An Overview Vehicle Layout and etie e a eeu ea ues ones eaten een o Suede nodis 22 ovstem InsiallaUton ACC CS SOC MERE MEDIE 25 PUOL NIO EET 26 Components Layout Description 27 IM 005 ISSUE 1 05 04 2012 Page 2 of 27 Ports Bearings Fitting and Lubrication Charts Primary Divider Valve Section Output Port No Feeds Valve No SPLO6K Primary Divider Valve Port 2 To SPL12 Divider Valve Port 5 To SPL10 Divider Valve steering Section Output Port No Feeds Bearing No SPL10 Secondary Valve Valve 12. 9 Rear Axle Pivot Side IM 005 ISSUE 1 05 04 2012 Page 3 of 27 Bucket Section Output Port No Feeds Bearing No SPL12 Secondary Valve Valve 3 Pont Lift Ram R H Side Ponz 6 Lift Ram LH Side Pott Ponte Pon3 8 Bucket Pin RH Side Bucket Pin LH Side Pons 9 Bucket Pin R H Side Lift Section Output Port No Feeds Bearing No SPL12 Secondary Valve Valve 2 IM 005 ISSUE 1 05 04 2012 Page 4 of 27 Note 1 Caution switch off the vehicle engine and remove the ignition key before starting work on the machine installation This will prevent accidents occurring on site 2 Before commencing installation of this lubrication system it is important that the owner operator ensures that all the bearings are pre filled with the correct lubricant 3 It is important to use recommended grease for the vehicle DO NOT mix different types of grease together in Pump System Keep them separate Acknowledge Grade 2 grease is recommended for use in HDI Pump IM 005 ISSUE 1 05 04 2012 Page 5 of 27 HDI System Installation Layout oi L Primary Valve a 6 ttem 2 1 ry RN icona E cm s alve alve alve mes pii 10 9 8 7 6 5 4 3 2 12 13 24 2 1 14 23 25 3 10 15 22 26 3 4 9 16 2 2 30 5 8 17 20 28 29 6 18 19 IM 005 ISSUE 1 05 04 2012 Page 6 of 27 IM 005 ISSUE 1 List of Abbreviations HDI Pump 24Vdc
3. Secondary Valve 1 e Bearing points 25 lubricated from Secondary Valve 1 e Bearing points 32 lubricated from Secondary Valve 1 IM 005 ISSUE 1 05 04 2012 Page 14 of 27 Bearing points 31 lubricated from Secondary Valve 1 Quick Hitch Bracket is used to split pipes when the vehicle is under maintenance so the operator user is able to remove front steering from the vehicle body without cutting off the pipe linkage Furthermore it s also used to connect with different pipe size connector Lubricant Lubricated from SPL10 Secondary Valve 1 Y Bearing point Y Bearing point Bearing points 21 lubricated from SPL12 Secondary Valve 2 IM 005 ISSUE 1 05 04 2012 Page 15 of 27 Remote Connection Splitter Bracket SPL12 Secondary Divider Valve 2 Lift section Wiring Method Protective Helix Plastic will wrap the loose pipe together v Tube Support come in handy to hold the tube in position Bearing points 13 lubricated from Secondary Valve 2 Bearing points 26 and 27 lubricated from Secondary Valve 1 e Detail view of bearing points 13 lubricated from Secondary Valve 2 IM 005 ISSUE 1 05 04 2012 Page 16 of 27 e Bearing points 21 lubricated from Secondary Valve 2 e Articulated Vehicle Lift Section Lift Arm Ram Linkage Centre Arm Ram Linkage Lift Arm Linkage Lift Ram Push Ram e Articulated Vehicle Bucket Section F Bucket Pin G T Bar Linkage IM 005 IS
4. Top v SPL10 Secondary Valve 1 Bottom e Detail side angle view of the divider valves Y High Pressure Grease Nipple s manually use to lubricated the system if the pump break down Optional Upon Customer Request v indicator pin has been fed to SPLO6 K primary valve inlet port 4 IM 005 ISSUE 1 05 04 2012 Page 11 of 27 Bearing points 29 and 30 lubricated from Secondary Valve 1 Lubricant Lubricated from SPL12 Secondary Valve 2 v Bearing points 16 and v Bearing points 14 and As shown in the following diagram Remote Connection Splitter bracket to bearing point 29 and Detail view of SPL10 Divider Valve 2 which the fitting connectors were made to lubricate single shot on each outlet point Note that v SPL divider valve lubrication systems See SPL Range Brochure for further Information SPL SB 190112 V1 for Progressive Divider Valves details There are 2 bearing points located at the back of vehicle wheel v Top bearing point is Rear Axle Pivot Left Hand Side of the vehicle v Bottom bearing point is Rear Axle Pivot Right Hand Side of the vehicle as shown in the diagram IM 005 ISSUE 1 05 04 2012 Page 12 of 27 SPL10 Secondary Valve 1 Steering Section v Output Port 2 to Bearing Point v Output Port 9 to Bearing Point e Bearing points 13 lubricated from Secondary Valve 2 IM 005 ISSUE 1 05 04 2012 Page 13 of 27 e Bearing points 26 and 27 lubricated from
5. HDI Pump PB SPLO6K Primary Valve Valve SPL10 Secondary Valve Valve 2 SPLI2 Secondary Valve 1 Valve 3 SPLI2 Secondary Valve 2 Output To Secondary Divider Valves Output Grease Flow Line 1 Vehicle Bearing Point 05 04 2012 Page 7 of 27 Doosan DL 200 TC Tool Carrier System Layout IM 005 ISSUE 1 05 04 2012 Page 8 of 27 System Installation Guide Side angle view of the vehicle where 24Vdc HDI pump s located on the mud guard above the whee adjacent to the engine cover Detail view of the vehicle where pump system s resting vertically on the external mounting L bracket attached above the mud guard Note that v 2 Litres electric pump mounted on DL 200 TC logo pump bracket oee HDI Set up Information ISF 294 Issue 12 09 for wiring and programming details IM 005 ISSUE 1 05 04 2012 Page 9 of 27 e Location of Pump override Ignition switch 24Vdc Green Push Button has been placed next to the driver seat Ignition Switch detail view can be found behind the manual ram joystick Note that v To operate override switch press button for approximately 5 seconds v When pump operates the light will be ON IM 005 ISSUE 1 05 04 2012 Page 10 of 27 Mounting positions of v SPLO6 K Primary Valve Top v SPL10 Secondary Valve 1 Bottom v SPL12 Secondary Valve 2 Right Next to DL 200 TC Steering Ram e Details view of SPLO6 K Primary Valve
6. SUE 1 05 04 2012 Page 17 of 27 Details view of Lubricant Lubricated from SPL12 Secondary Valve 2 v Bearing points 22 and v Bearing points 18 and v Bearing points Side angle view of Bearing points 14 lubricated from Secondary Valve 2 Details view of e Bearing points 15 lubricated from Secondary Valve 2 IM 005 ISSUE 1 05 04 2012 Page 18 of 27 Mounting positions of SPL12 Secondary Valve 3 Located at DL 200 TC Cross Member Bar Lubricant Lubricated from SPL12 Secondary Valve 3 v Bearing points 1 and Y Bearing points 3 and Bearing points 4 and Bearing points 5 and Bearing points 6 and e Bearing points 6 and 7 lubricated from Secondary Valve 3 IM 005 ISSUE 1 05 04 2012 Page 19 of 27 e Lubricant Lubricated from SPL12 Secondary Valve 3 v Bearing points 1 and 12 v Bearing points 3 and 10 v Bearing points 4 and 9 Y Bearing points 5 and 8 e Bearing points 3 and 10 lubricated from Secondary Valve 3 Bearing points 1 and 12 lubricated from Secondary Valve 3 IM 005 ISSUE 1 05 04 2012 Page 20 of 27 IM 005 ISSUE 1 05 04 2012 Bearing points 4 and 9 lubricated from Secondary Valve 3 Bearing points 2 and 11 lubricated from Secondary Valve 3 Lubricant Lubricated from SPL12 Secondary Valve 3 v Bearing points 3 and 10 Y Bearing points 5 and 8 Page 21 of 27 An Overview Vehicle Layout Front Angle View of Steering Sectio
7. e Nipple 1 8 i I 12 13 6mm OD Check valve for divider valves blocks T 15 6mm OD Steel Olives for the SPL Check Valves 36 r 1 mm OD x 1 8 BSP M 18 6mm OD x 1 8 BSP M Elbow 30 19 6mm OD x 1 8 BSP Swivel Push Fit 20 21 1 8 BSP M x F Short Extension 23mm 25 22 HP Sleeve 8 6mm Pipe 23 HP Stud 8 6mm Pipe 24 HP Hose 8 6mm OD grease filled 50 25 6mm OD Nylon Pipe Grease Filled 100 27 Plastic Helix 12mm 25m coil 28 M6 Socket Head 12mm 20 29 M6 Socket Head 45mm 30 M6 Socket Head 70mm 31 6mm Spring Washer flat profile 32 Penny Washer 6mm bore 5 34 Threaded Weld Block M6 Thread 17 35 Protection Ring for Plant single slot circular 36 37 58 5 20 T lt IM 005 ISSUE 1 05 04 2012 Page 26 of 27 Components Layout Description uude Tareas T Grade 2 Grease Standard Nipple Filler Blanking Plug 1 Pumping Unit Quick Fill i Connection Electrical Supply Connector Configuration Panel Output Blanking Plug M10 Check Valve 1 8 B S P x 6MM Elbow Connector Fixing Holes L G 6 a Valve a if M11 Indicator Assy Steel Ball IM 005 ISSUE 1 05 04 2012 Page 27 of 27
8. n Lift Section Bucket Section Back Angle View of Steering Section 24Vdc HDI Pump IM 005 ISSUE 1 05 04 2012 Page 22 of 27 IM 005 ISSUE 1 05 04 2012 Side Angle View of Steering Section Lift Section Side Angle View of Lift Section Bucket Section Page 23 of 27 Steering Bracket is used to clip hold the high pressure pipe in position at Steering Ram Note 1 As a guide on these typical applications it is advisable that the pump default run time to be set to 5 minutes Each individual installations applications may require specific settings We recommend that new applications be initially monitored to ensure adequate lubrication of all bearings on the system being supplied IM 005 ISSUE 1 05 04 2012 Page 24 of 27 System Installation Accessories Stauff Clamp will be used most of the time during the installation period as a Tube Support in order to hold the tube in position HLX P 12 12mm Plastic Helix PC 6 10 6mm P Clip PC 13 10 13mm P Clip STP 6 1 6mm OD Steel Bundy Pipe Note Components as shown above were normally used during installation there are more component accessories will be included in Bill of Materials List on the following page IM 005 ISSUE 1 05 04 2012 Page 25 of 27 Bill of Materials OO ome v 1 HDI Pump with Moulded Reservoir 1 Element PRV 24V Push Button Green Pushbutton connectors SWA 28RFP 7 HP Greas
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