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CIMA GROUP CHAP. 4: OPERATION

MOTOR PUMP MP7 720 CV 49

OPERATION

CHAP. 4: OPERATION CIMA GROUP


FORESEEN USE OF THE MACHINE The MP7 motor pump was designed for professional use. This means that, when the machine is delivered the operator needs to be appropriately instructed by the yard foreman or the person di-rectly in charge. Our product comes under the category of yard or building site machines and is used for JET - GROUTING and solidification operations where water injections or cement mixes are requested, up to 400-450 bars with a delivery of up to 500 l/min. The motor pump, fed with a mixture of water and cement, enables, by means of an alternating 3-piston movement, that the mixture is pumped under high pressure into a pipe that supplies the ce-ment feed head and the drilling rod battery.

1) Silos 2) Batching plant 3) High pressure jet pump METAX MP7 4) Air compressor 5) Equipment or drilling probes with rod battery for jet grouting. The motor pump can also be used for: - shear, pumping water only - emptying.

CAUTION Do not use the pump without liquid inside and under no circumstance pump only air or colloidal substances; failure to observe these rules could cause serious damage to the machine.

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HANDLING AND POSITIONING THE MACHINE

) NOTE Prior to leave the factory, it's possible that the container is treated with a protective paraffinic wax, in order to protect the varnished surfaces against atmospheric agents and dirt (bugs, salt, etc.). In this case, before positioning the container, remove the protective wax from the surfaces using the proper dewaxer for paraffin supplied with the container. To remove the protective wax please act as follows: 1 Run a dewaxer soaked rag on the surface to be treated 2 Wait 5 minutes and remove the most part of the wax from the surface by means of a plastic

palette knife without damaging the paint. 3 Run again the dewaxer soaked rag on the surface and remove the wax completely. 4 Wash the container with a steam cleaner and detergent to remove the possible wax residue.

To hoist the motor pump, a lift truck and skilled personnel are needed. This is so that the motor pump can be unloaded from its means of transport then positioned in the operating area. 4 lugs are used to hoist the motor pump container. This lugs are 2 couple equal, one is 3200 mm long and is to be positioned on the pump side and the other is 4200 mm long (engine side). Having fixed the 4 lugs to the mullions of the container you must control that the container is hoisted cor-rectly (it must hold its horizontal position). Remember that on the mullions of the container it is marked the weight of the whole machine.

WARNING

During hoisting operation, never stand or pass under the motor pump.

When positioning the machine on site, make sure that the ground is solid and that the motor pump is rested on a flat area as this gives good cross head lubrication even at slow engine speeds and stops the motor pump from sinking or moving during the pumping phases. The suction pipes between the pump and the cement bath must be without curves, without bottle-necks and the inner diameter must never be less than 100 mm. The cement tank must be placed as close as possible to the pump and the height of the suction mouth must be 300 mm higher than the pump collector. It is very important to check that inside the suction pipes there are no leakages, since these, letting the air into the pipe, would cause a volumetric loss in the performance of the pump and the suction valve would become very noisy. It is important that the suction pipe is regularly washed with water to prevent the cement that gets stuck to the inside walls blocks or reduces the flow through the suction and causes cavitation in the pump.



With this is in mind you are strongly advised to connect the water suction pipe as close as possible to the cement suction mouth so that the pipe is thoroughly washed during drilling phases. All the MP7 motor pumps must be washed with an over feed pump connected to the deliv-ery. Furthermore connect the fittings of the cooling coil for the piston lubrication oil to the external water socket.



INSTRUMENT / CONTROL PANEL

1) Acceleration lever MIN MAX . It enables to increase or decrease the motor revolutions. 2) Engine control panel 3) Pumping unit control panel 4) Service indicator reset key. By pressing it the service indicator switches off (5) 5) Service indicator. It lights up after 250 operating hours to indicate that the service operations

which are foreseen for the machine, must be carried out. 6) Illumination knob

Pos. 0 = OFF Pos. 1 = Pump compartment light THE LIGHTS WORK ALSO WITH KEY NOT INSERTED Pos. 2 = Engine compartment light Pos. 3 = ON

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ENGINE CONTROL PANEL

1) Emergency stop 2) Engine ignition / stop key 3) EngiMeter multifunctional display It allows the displaying of the engine parameters in real

time (engine revolutions, engine coolant temperature, fuel level, engine oil pressure, gearbox oil temperature and engine operating hours) as well as of possible error and/or warning mes-sages detected by the engine control unit

4) Engine warning buzzer 5) Warning light (red). It indicates a generic engine failure detected by the EngiMeter (3). At the

same time the buzzer is activated (4) 6) Warning light (red). It indicates a generic engine failure detected by the engine control unit. At

the same time the buzzer is activated (4) 7) Engine diagnostic warning light (orange). It indicates the presence of an active failure by

means of flashing codes. For more information about the engine diagnostics and the flashing code please read in the chapter "Operating" the paragraph "Engine diagnostics" in the "C18 industrial engine operating and service handbook" given by the manufacturer and delivered together with this manual.

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PUMPING UNIT CONTROL PANEL

1) Gearbox emergency buzzer 2) Delivery pressure pressure gauge 3) Capacity display 4) Gearbox selector with display 5) Pressure gauge for pneumatic system air pressure 6) Oil gearbox low pressure warning light 7) Pressure gauge for box / cross head lubrication system oil 8) Oil gearbox high temperature warning light 9) Pressure gauge for piston lubrication system oil 10) Gearbox emergency light 11) Emergency light activated

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BATTERY CUT OUT (1) This element consents the electrical power supply to the plant to be cut off. At the end of a working day and during normal maintenance you always need to use this battery cut out to ensure that the electrical supply is completely disconnected from the plant.

INSTRUCTIONS FOR USE Before being sold, the motor pump is tested in a special testing ground where all the data relative to performance are read and all the settings are made (see Spare parts catalogue).

WARNING: To avoid faulty functioning and to safeguard the health of those who work near the machine, these settings must not be altered.

The motor pump can be used by personnel normally present in the work yard or site once they have been given sufficient training from the people responsible for machine delivery on specific re-quest of the user. The machine has a few simple controls on the instrument panel, which are needed for motor pump start-up and stop.

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OMRON H7CX-AUD 1 COUNTER SETTING 1) Open the back panel of the switchboard,

make sure that the white switch on the display is on the position K/P - OFF.

2) Press MODE for a few seconds, then

make sure that all numeric data turn into 0, now only one 0 will appear on the very right in the red field. This operation always allows to exit the setting func-tion.

3) Press MODE + the button on the very right until the first variable FUnC appears in the red field, now press the numeric but-ton on the very right until tAC appears in the green field.



4) Press MODE again for a few seconds, then 0 will appear in the red field on the display.

5) Keep MODE pressed and keep pressing

the button on the very right until ttn ap-pears in the red field and HLL in the green field.

6) Press MODE only, the writing Cnt5 will appear in the red field and the figure 30H on the numeric display (green field).



7) Press the button on the very right until the writing turns into 10 H.

8) Press MODE again until the writing dP appears (red field).

9) Press MODE again, scroll down until the writing P5CL appears (indicating 1000 in the green field).



10) Change the 5 figure item according to the following chart by pressing the buttons 1 to 6 to set the respective figures:

MOTORPUMP

MODEL PLUNGER DIAME-

TER FLOW RATE

FACTOR NR RPM FACTOR

MP5-430 88,9 36400 13000 MP5-430 100 46000 13000 MP7-600 88,9 45100 13000 MP7-600 100 57000 13000 MP7-600 108 67800 13000 MP7-600 115 76900 13000 MP7-680 115 76900 13000 MP7-720 108 67800 13000 MP7-720 115 76900 13000

11) Press MODE again for a few seconds un-

til 0 appears in the red field to exit the setting function.

12) Set again the white button in the ON po-sition.



CHECKS BEFORE STARTING At the start of each working day, apart from reconnecting the batteries to the system, the following operations must be carried out: a) Check the area under and around the motor for oil, diesel and coolant leaks; b) Check the correct clamping of the gearbox oil circuit fittings and verify also the integrity of the

factory-applied sealing paint

c) Check the engine coolant level; d) Check the engine oil level; e) Check the gearbox oil level; f) Check the fuel level; g) Check the piston lubrication oil level; h) Fill the cylinders with water to expel any air contained in them; i) Make sure that the intake nut is locked tightly; j) Grease the threads on the threaded plugs (P5-0056) and lock them tightly; k) Check the lock on the stuffing box nuts; l) Make sure that the emergency devices work properly; m) Check that the hatches and casing of the pump are assembled and fixed correctly; n) Check that the water inlet tap is opened in the cooling coil for the piston lubrication oil; o) Having started the machine, let it run at slow speed for a few minutes and check that the pres-

sures in the various circuits are correct.



STARTING The following operations must be carried out to start the engine: 1) Set the accelerator lever at the minimum

(1). 2) Rotate the ignition/stop key (3) toward

right (first click); the following warning lamps light up: engine emergency (red) (7), oil gearbox low pressure (red) (6), motor diagnostics (orange) (8) and en-gine service (orange) (9). Besides, the multifunctional display (2) and the flow rate indicator (4) are fed. On the gearbox selector display (5) the writing CH ap-pears.

3) Wait about 5 seconds until the following warning lights switch off: engine emer-gency (7), engine diagnostics (8) and engine service (9) and in order to start the engine rotate further the ignition/stop key (3) toward right.

4) Let go of the key that returns in the previous position (first click); on the display of the gearbox selector (5) the writing N appears and the oil gearbox low pressure warning light (6) switches off.

5) Press the red button D on the gearbox selector (5); on the display the number 3 appears to indicate the inserted gear and the oil gearbox low pressure warning lamp(6) lights up: it will switch off when the engine revs will be increased.

) NOTE On starting work, the machine must be run at slow speed for a few minutes to bring the motor pump engine up to temperature.

6) By moving the accelerator lever (1), it is possible to increase the engine revs, while pressing the buttons (up arrow) and (down arrow) on the gearbox selector (5), the operator can change respectively to a higher gear (up to the sixth) or lower gear (up to the third).

WARNING

The gear change is forbidden when the engine revs are higher than 1000 rpm.

) NOTE During the gear change the gearbox control unit decreases the revs per minute and then it accelerates again bringing the engine revs to the value previously set.

) NOTE Independent of the gear engaged, it is always possible to press the button N (=NEUTRAL) placed on the gear selector (5) to disengage the gear and also the pump from the engine. Then to engage the gear press D (=DRIVE).

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If during the motor pump running a fault of the engine electrical system should occur (e. g. low or high engine coolant tempera-ture, low engine oil pressure, etc.), the elec-tronic control unit will stop the engine and the engine emergency light (7) and warning light (11) as well as the buzzer (9) will be activated at the same time. Through the engine diagnostics light (8) it is then possible to collect information about the fault occurred with the engine. The di-agnostic light (8) indicates the presence of an active failure by means of a flashing di-agnostics code. For more information about the engine diagnostics and the flashing code please read in the chapter "Operating" the paragraph "Engine diagnostics" in the "C18 industrial engine operating and service handbook" given by the manufacturer and delivered together with this manual. The type of fault can be also read on the EngiMeter multifunctional display (10). Also the gearbox electronic control unit is able to save the possible faults of the gearbox electric system that are occurred during the machine running and to display them by a flashing code. The following procedure must be carried out to read the fault codes:

- Press the button "N" on the gearbox selector (5) - Press the button (up arrow) on the gearbox selector (5) for about 5-10 seconds - Keeping the button (up arrow) pressed, the fault codes will be displayed on the gearbox selec-

tor display (5). For the list of the flashing codes or more information please contact the company CIMA S.p.A..

USE OF THE MACHINE While the machine is running, the operator must always remain near the control panel, since it is from here that he can lock, slow down, accelerate or modify the functioning of the machine and keep a check on its performance.

CAUTION During the injection work, engage the gear on the gearbox that permits to keep the

engine always at a speed equal or higher than 1700 rpm



Check: 1) The engine water temperature, the engine oil pressure and the gearbox oil temperature indi-

cated on the multifunctional display (1). If the gearbox temperature should increase over 70 - 80 C, an acoustic warning signal is released and a warning lamps (2) and (3) light up. In this case it is possible to finish the current work by monitoring the temperature of the gearbox that must not exceed 90 C.

2) The pressure of the pneumatic circuit air (4). 3) The pressure (0.5-0.7 bar) of the cross head lubrication circuit (5). 4) The pressure (20 bar) of the pistons lubrication circuit (6). 5) The efficiency of the gaskets in the bushings; check that, owing to wear on the gaskets, there

is no leakage of cement which would pollute the piston lubrication oil. This can be avoided by replacing the gaskets frequently, or at least intervening immediately that cement or water is detecting coming from the return valves on the piston lubrication tank.

6) Keep a check on the return valves in the piston lubrication-cooling circuit, checking not only for any leakages of cement but also making sure that the oil flow is constant and the delivery cor-rect. In fact, if the normal oil recirculation become faulty, the piston would overheat causing excessive wear on piston, gaskets, stuffing box and bushings.



STOPPING THE MACHINE Rotate the ignition/stop key toward left to switch off the motor pump.

) NOTE After having stopped the engine, before starting it again it is recommended to wait some seconds to allow the engine control unit to carry out the self-diagnosis.

When work is over, it is essential to wash out the inside of the pump, leaving it to pump only water for about ten minutes. At the end of the working day, the batteries must be disconnected with the device (1) the accumulator box so that the current to the ignition key is cut off. Moreover it is ne-cessary to carry out the routine cleaning that means the careful removal of any in-crustations on: cement outlet screw (2) intake header (3) After the cleaning operations, make sure that no parts are worn, damaged or incor-rectly fixed. Always also check the integrity of the piping and the absence of leaks of oil, fuel or elec-trolyte from the batteries.

CAUTION If any of these faults are found, it is strictly forbidden to restart the machine before the fault has been rectified.

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To safeguard the efficiency of the machine and the health of the operators, fundamental standards must be respected: - Always use gloves to protect the hands

during maintenance operations. - The positioning of the machine must re-

spect the standards given in the relative chapter; this is to avoid faulty functioning or risk to persons.

- When the automatic emergency device in-

tervenes, it begins flashing and then the EMERGENCY lamp on the control panel lights up and remains on. The gearbox switches into N (= Neutral) and disen-gages the pump from the motive force. Before starting to pump again:

1) intervene on the accelerator lever (4) so that the engine is brought to minimum speed; 2) unscrew the cement discharge valve to stop the elimination of pressure accumulated in the

machine; 3) press button D on the gearbox selector (5): the gearbox engages the third gear auto-

matically. 4) intervene on the gearbox selector (5) to select the desired gear. 5) re-accelerate gradually.

This sequence must be respected to prevent damage to transmission elements.

WARNING: On starting work, always check that the cylinder caps and stuffing nuts are locked cor-rectly for avoiding both damage and danger to the operator.

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WARNING Never interfere on the pressure switch calibration (6) and (7) as it may cause machine stress due to over high pressure, which could result in damaging the cylinders and putting the operator in a danger. The pressure switch is a protective system that au-tomatically interacts when the machine surpasses the pressure limits set by the manu-facturer. The calibration of the pressure gauge (7) varies in accordance to the diameters of the pistons. Whenever it is really absolutely essential to interact on the calibration of the pressure switch you must get written authorization from the manufacturer (see calibration table P7-323 page 15 Chap. 2).

- Never intervene on the motor pump for inspections or maintenance purposes while the machine

is running. - Never let the machine run without the motor pump protections, without the inspection covers or

with the container doors (engine side) open.

- Never interfere with the piston lubricating circuit safety valve as it may cause stress piping. - Before starting up the machine, remember to mount the terminal part of the exhaust discharge

pipe (Pict. 1).

Pict. 1 USING THE MOTOR PUMP IN PARTICULAR ENVIRONMENTS

SANDY ENVIRONMENT If the motor pump has to work in a particularly sandy environment (desert), it must be fitted with container or cabin with special filters which keep out sand and other impurities which could pene-trate the air intake of the engine and damage it. HOT ENVIRONMENT In very hot environments, the temperature of the oil in the gears must be kept in check.



COLD ENVIRONMENT Antifreeze In particularly cold regions, if it is not already present, antifreeze must be added to the water in the radiator with a 50% mixture of clean water and antifreeze.

) NOTE Using other antifreezes, observe the manufacturers instructions.

) NOTE These operations are carried out at the end of the working day.

SAFETY DEVICES: CHECKS AND SETTINGS

As mentioned before, the safety elements are calibrated in testing phases and can only be modi-fied upon written authorization from the manufacturer. There are three machine parts that need to be calibrated: 1) Modular unit

The pressure in the air circuit can be regulated with the knob that is situated at the top of the unit (calibration ~7-8 bar).

2) Pressure switches You can reduce the emergency device pressure intervention by operating on the provided regulation screw (see calibration table P7-323 page 15).

WARNING Never interfere with the calibration of the pressure switch. Should this take place, CIMA S.p.A. wont be any longer responsible for the possible troubles to the motor pump and the warranty will become null and void. Whenever it is really absolutely essential to interact on the calibration of the pressure switch you must get written authorization from the CIMA S.p.A.

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3) Safety valve By turning a screw, it is possible to modify the pressure of the pistons lubricating circuit (cali-brated at 2530 bar).

In order to calibrate the safety valve, the follow-ing procedure must be carried out: 1) Start the motor and engage a gear. 2) By using a box wrench, completely close

the valves discharging the oil into the tank.

3) Unscrew and remove the plug covering the adjusting screw of the safety screw.

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4) Loosen the nut locking the adjusting screw, and, by using a socket wrench, turn the adjusting screw counter-clockwise, up to get the oil flowing out from the draining pipe in the oil case.

5) Speed up the motor to peak rpm. 6) Then, by using a socket wrench, turn the

adjusting screw clockwise, until the oil no longer flows out from the draining pipe in the oil case.

7) Further tighten, for another revolution, the adjusting screw, by turning it clockwise; on the pressure gauge, situated on the control panel and relevant to the pistons lubrica-tion circuit oil pressure, a value higher than 18 bar must be read.

CAUTION If the value read on the pressure gauge relevant to the pistons lubrication circuit oil pressure results to be higher than 28 bar, the pressure shall be reduced by progres-sively opening the valves discharging the oil into the tank, up to bring the pressure to a value lower than 28 bar.

8) Tighten the locking nut of the adjusting screw. 9) Reassemble the plug covering the adjusting screw of the safety screw. 10) Stop the motor. WARNING:

It is very important to always be sure that the emergency joint chamber is not faulty, otherwise, apart from not having the reading of the pressure on the panel, the emer-gency trip-out would not trigger. It is forbidden to use the machine with faulty cham-ber.

WARNING:

It is advisable to make frequent checks on the efficiency of the automatic emergency device. It is forbidden to work with broken devices.

WARNING: It is also extremely important to wash out the inside of the delivery fitting and the ce-ment outlet valve every day.

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INSTRUCTIONS FOR RESTARTING THE MACHINE IN THE EVENT OF AN EMER-

GENCY STOP

When the automatic emergency device intervenes, the first thing to do is to take the engine down to the minimum speed. At this point the cause of the emergency trip-out must be discovered. In the case that the emergency device intervened due to a blockage in the delivery pipe, turn off the machine and unscrew the cement discharge valve screw (1). This operation serves for expel-ling the excess pressure which has built up in the machine. At this point flush out the pipe, re-tighten the screw of the cement outlet valve, turn the machine on as described in the paragraph "STARTING" at page 62, press the button D on the gearbox selec-tor (2); (the gearbox engages the third gear automatically) and, by means of the accelerator lever (3), increase the engine speed gradually. In certain cases the emergency device may intervene because of an incorrect manoeuvre on the part of the operator. It can happen if the operator accelerates the machine too much and causes it to develop a delivery output pressure beyond the setting. In this case, after decelerating, press the button D on the gearbox selector (2); (the gearbox engages the third gear automatically), operate on gearbox selector (2) to select the desired gear and by means of the accelerator lever (3) in-crease the engine speed gradually.

) NOTE Should the customer require any further type of information, please contact directly Cima S.p.A.

) NOTE In the case of serious fault, on contacting assistance it is advisable to supply the construction date and the serial number written on the specific label so that the machine ca be identified immediately.

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090515-capitolo 04-en

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