20081031 service & repair guide dyna 345.11.pdf

8/10/2019 20081031 Service & Repair Guide Dyna 345.11.pdf

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Doc: 345.11 Rev: 01 Page 1/7

Copyright 2011, Proceq SA, CH-8603 Schwerzenbach Working copy if printed

Filename: 20081031 Service & Repair Guide Dyna 345.11

DYNA Z 6, Z16Refill of Oil including Dismantling and Mounting of the necessary Parts as well asChecking of all Pull-off and Extraction testers

Issue for sales representatives and authorized calibration stations

Service Manual & Repair Guide

This document is part of the ASPO Service & Repair set for Dyna and describes the procedurehow to adjust, repair and calibrate the instruments.

Key Words: Pull-off-tester, Repair, Service, Calibration, Upgrade, Manual, ASPO

Document Number : 345.11

Document Revision: 01

Revision Date: 31-Oct-2008

Document State: released

Author: Rudolf Bhend [email protected]

Company: Proceq SA

Bahnstrasse 23

CH-8603 Schwerzenbach

Switzerland

Classification: for internal use only
mailto:[email protected]:[email protected]


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Table of Contents

1 Scope and Application

2 Aim of Instructions

3 Means for the Refill

4 Description of the Checking and Refill with Oil

4.1 Preparation and Repairs

4.2 Refill with Oil, Pump in vertical Position

4.3 Assembling and first Testing of Instrument4.4 Refill with Oil, Pump in inclined Position

4.5 Final Checks

4.6 Figures

4.7 Control of Path Measuring Device

5 Applying Documents
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Dyna Z Refill, Dismantling and Mounting Service Manual & Repair Guide

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4.2 Refill with Oil, Pump in vertical Position

Turn the pump rod (62) anticlockwise back to the start position and check the position of the piston(4) at the soffit of the device plate (5).The lower edge of the piston (4) must be 1.0 to 1.5 mm higheras the soffit of the device plate (5). If necessary move the piston (4) manually to the right position.

Refill the oil via the opening of the interlocking vent screw (63) using a syringe with needle (64).Constantly refill oil to keep a constant oil level (see figure 2) until the top level is reached. Some of theold oil may escape via the vent screw (66) opening.

Close vent screw (66). Insert interlocking/vent screw (63) and remove excess oil with cloth. Close ventscrew (61) of manometer (2) / pressure sensor (8).

For information: In case of new instruments with LEO1 manometer or if a new manometer must beinstalled, the lower part of the manometer is filled with oil by means of the syringe (64). Themanometer (2) is mounted and the vent screw (61) inserted simultaneously.

4.3 Assembling and first Testing of Instrument

In case the pin (to prevent the turning of the draw spindle (14)) is loose or even removed install it andlock it with a centre punch and a hammer.

Mount the draw spindle (14), the wheel (13), ((13.1) in case of the extraction tester) and the crank(12).

Fix the instrument on the calibration unit.

Load instrument up to the nominal load with the load rate of 100 N/s (as set in the calibration unit) byturning the pump crank (12) at the speed that the flow bar follows the pace maker on the display of thecalibration unit with the same speed.

Leave the instrument loaded for about two minutes. The load will decrease, at the beginning fastertowards the end slower. The drop of load after two minutes may be up to 10 % of the nominal load.Increase load again up to the nominal load and leave the instrument for another five to seven minutes.With this the whole hydraulic systems gets stabilized.

Turn pump crank (12) anticlockwise back to the start position.

4.4 Refill with Oil, Pump in inclined Position

Clamp the instrument with one of the legs (protect it with a cloth) in the vice with the vent screw (66) ofthe plate on the top (see figure 3).

Undo vent screw (66) on the device plate (5).

Exit the oil slightly by pushing carefully onto the piston (4), check at the vent screw (66) opening if anyair bubbles are trapped in the oil, if necessary remove some oil by pressing several times smoothlyonto the piston (4).

Fill up emerging hollows immediately with oil from the syringe (64) with immersed needle through the

vent screw (66) opening(see figure 3).

Leave the instrument open. Repeat the procedure of the previous two points after approx. five

minutes. Fix the vent screw (66). Only little oil should come out. Check the start position of the piston (4) at the soffit of the device plate (5).The lower edge of the

piston (4) must be 1.0 to 1.5 mm higher as the soffit of the device plate (5).

Turn pump crank (12) clockwise to the end position and check the position of the lower piston edge. Itmust be 4.5 to 5.0 mm higher as the start position. Turn back the pump crank (12) anticlockwise to thestart position and check again the position.The instrument may has to be removed from the vice for easy turning of the crank (12) and clamedagain as shown in figure 3.

In case the positions of the piston (4) are correct,continue with chapter 4.5 Final check.

In case the positions of the piston (4) arenotcorrect:


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Exit the air left in the oil by turning the pump rod (62) clockwise and unscrewing the vent screw(66) simultaneously. The air will escape as bubbles at the opening of the vent screw (66).

Refill the oil using a syringe (64) with immersed needleand by simultaneously turning the pump

rod (62) anticlockwise, thus the pump piston in the pump body is pulled back and the oil suckedin. Constantly refill oil to keep a constant oil level.

If necessary unscrew also the vent screw (61) of the manometer (2) / pressure sensor (8) and fillup emerging hollows immediately with oil from the syringe (64) with immersed needle at theopening ofthe vent screw (61).

Fix vent screw (66) and possibly the vent screw (61). Only few oil should come out.

4.5 Final Checks

Fix the instrument on the calibration unit.

Load instrument up to 100% with the load rate of 100 N/s (as set in the calibration unit) by turningthe pump crank (12) at the speed that the flow bar follows the pace maker on the display of thecalibration unit with the same speed.

Leave the instrument loaded for about two minutes. The load will decrease, at the beginningfaster towards the end slower.

In case the drop is not more then 4% of the nominal load continue as follows:

For DYNATEST-Instruments mount the guide parts pos. 50, 51 und 52 (see figure 1)

Calibrate the instrument as explained in the instructions AW 345.05, respectively AW 345.13.For the model DYNA Z . Fs continue with chapter 4.7 Control of the Path Measuring Deviceon page 6/6.

In case the drop is more then 4% of the nominal load continue as follows:

Clamp the instrument with one of the legs (protect it with a cloth) in the vice with the vent screw(66) of the plate on the top (see figure 3)

Exit the air left in the oil by turning the pump rod (62) clockwise and unscrewing the vent screw(66) simultaneously. The air will escape as bubbles at the opening of the vent screw (66).

Refill the oil using a syringe (64) with immersed needle(4) and by simultaneously turning thepump rod (2) anticlockwise, thus the pump piston in the pump body is pulled back and the oilsucked in. Constantly refill oil to keep a constant oil level.

If necessary open also the vent screw (61) of the manometer (2) / pressure sensor (8) and fill upemerging hollows immediately with oil from the syringe (64) with immersed needle at theopening ofthe vent screw (61).

Fix vent screw (56) and possibly the vent screw (61). Only few oil should come out

Repeat the loading of the instrument, i.e. go back to the first point of this chapter 4.5.


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4.6 Figures

Wheel (13.1)Handle(13.2)

Piston (4)

O-rings

Device plate (5)

Guide parts (50),(51), (52)(For DYNATEST instruments only)

Figure 1 Vertical section through DYNA Z S

Interlocking/Vent Screw, (63)

Pressure sensor /El. measuring cell

(8)with vent screw

(61)

Device plate (5)

Figure 2

Syringe with needle (64)

Pump body (3)

Pump rod (62)


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Syringewith needle (64)

Figure 3

Vent Screw (66)

Pump body (3)

Piston (4)

4.7 Control of Path Measuring Device

The position of the path measuring device is checked as follows:

Turn the pump rod clockwise up to the end position of the pump piston inside of the pump body

Check if the finger of the path measuring device is touching the stop

If yes, instrument is functional, if not

Adjust the head piece of the finger accordingly

Calibrate the instrument as explained in the instructions AW 345.05.

5 Applying Documents

- Assembling drawings:

DYNA Z 16 4124 561

DYNA Z 16 S 4124 637

DYNA Z 16 analogue 4124 636

DYNA Z 6 4124 682

DYNA Z 6 S 4124 683

DYNA Z 16 E 4124 561

DYNA Z 16 SE 4124 637

DYNA Z 16 Fs 4124 637 4124 627

DYNA Z 6E 4124 682

DYNA Z 6 SE 4124 683

DYNA Z 6 Fs 4124 683 4124 627

- Operation instructions for the DYNA Z-Instruments