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GSi InterSystems TP Manual

Truck probe
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S
AFETY
IN
NSTALLA
ATION
OPERATIO
O
ON
MAINTENA
M
ANCE
M A N
M
U A L L
TRUC
Mod
del TP
 
CK PR
ROBE 
P and
d STP 
No. PC 5
N
29834J 
Revised 20
R
17‐02‐15 
th
9575 N
. 109
 Ave. 
Omaha, Nebra
aska 68142 
(402
2) 330‐1500 
ww
ww.intersys
tems.net 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

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  • Page 1       AFETY   NSTALLA ATION   OPERATIO   MAINTENA ANCE   M A N U A L L   TRUC CK PR ROBE  del TP P and d STP            No. PC 5 29834J  Revised 20 17‐02‐15      9575 N . 109  Ave. ...

  • Page 2: Table Of Contents

    Table of Contents   I. GENERAL SAFETY INFORMATION ...................... 3   II. GENERAL INFORMATION .......................... 5     2.1 System Description  ..............................  5   2.2 Optional Features ..............................  6   2.3 Material Sampled ..............................  6   2.4 Truck Probe Construction ............................  6 III. GENERAL INSTALLATION REQUIREMENTS .................. 7  ...
  • Page 3 V. MAINTENANCE AND REPAIR ........................21     5.1 General Maintenance .............................  2 1   5.2 Periodic Inspection ..............................  2 1   5.3 Lubrication  ................................  2 2   5.3.1 Boom Pivoting And Sliding Joints, Monthly .....................  2 2   5.3.2 Boom Rotation Drive Chain & Sprockets, Every 6 Months ................  2 2  ...

  • Page 4: General Safety Information

    I. GENERAL SAFETY INFORMATION SAFETY FIRST! The symbols shown identify examples of the safety labels and signs to be found on InterSystems equipment. They are affixed to the equipment to warn of danger to persons and of possible equipment damage. These signs must never be removed, tampered with, painted over or obscured in any way.
  • Page 5 FIGURE 1-1, TRUCK PROBE SAFETY LABEL LOCATIONS...

  • Page 6: General Information

    II. GENERAL INFORMATION 2.1 System Description The Truck Probe is designed to collect a representative sample of granular, pellet, chip, flake or other materials from an open top hopper truck. Figure 2-1 illustrates a typical Truck Probe installation. Sample collection is initiated in response to the operator's manual command generated by controller logic. A sample cycle begins when the operator positions the probe tip for insertion into the truck by rotating the boom and stroking it in or out to the desired sampling position.

  • Page 7: Optional Features

    2.2 Optional Features The certified drawings indicate which, if any, optional features are included with a Truck Probe System. Some of the more frequently specified optional features are briefly described in the following list. Additional optional items that may be furnished if described in the Equipment Quotation and if specifically ordered, may include some or all of the following items: A.

  • Page 8: General Installation Requirements

    III. GENERAL INSTALLATION REQUIREMENTS 3.1 Receiving Inspection Carefully inspect the equipment for damage as soon as it is received. Also, verify that the quantity of parts or packages actually received corresponds to the quantity shown on the packing slip. Report any damage or shortage to the delivering carrier as soon as possible.

  • Page 9: Location

    F. Plan the location of the Sample Collection Cabinet. Most often the desired site is at the beginning of the sample grading process in the grain inspection area. If the material other than grain is being sampled, other criteria may apply. G.
  • Page 10 C. Loosen n the bearing set screws o on the 1” diam meter boom p pivot shaft at t the top of th he main base e assembly, remove e cotter pin a and pull the s shaft out eno ugh for the b boom to be p positioned in...

  • Page 11: Initial Startup

    Compartmentized Probe only: Cut & install one 5’-0” length of vacuum hose between the probe tip & the inner telescoping vacuum tube. Clamp in place using the worm screw clamps provided in the hardware package. J. Core Probe only: Install the core vacuum tube kit provided. Refer to the kit installation drawing and the already installed vacuum tube assembly for proper placement.

  • Page 12: Controller Location

    WARNING HYDRAULIC LINES UNDER HIGH PRESSURE, FLUID CAN ESCAPE WITH GREAT VELOCITY! EYE AND SKIN INJURY MAY RESULT. USE EYE & HAND PROTECTION WHEN BLEEDING HYDRAULIC LINES. C. While operating the Probe, make sure that the hydraulic and vacuum hoses do not become pinched and are not pulled tight.

  • Page 13: Controller

    3.7.1.1 Controller Refer to the certified electrical drawing(s) for specific wiring requirements. 3.7.1.2 Solenoid Valve Coils 110/120 VAC, 50/60 Hz, Single Phase, 50 Watts. Optional - 220/240 VAC, 50/60 Hz, Single Phase, 90 Watts. 3.7.1.3 Hydraulic Tank Heater (Optional) 120 VAC, 50/60 Hz, Single Phase, 500 Watts. 3.7.1.4 Hydraulic Pump Motor Hydraulic Power Unit Voltage &...

  • Page 14: System Plumbing

    8 System Plumbing he hydraulic p power unit wa s pre-plumbe ed and tested before it left the factory. T The final insta allation must c comply with SHA Regulati ons and all ot ther applicab le federal, sta ate, and local codes and re egulations.

  • Page 15: Operations And Adjustments

    IV. OPERATIONS AND ADJUSTMENTS 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. 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: Power Off/On Switch S-1 & Light

    4.1.1 POWER OFF/ON Switch S-1 & Light This illuminated selector switch controls electrical power to the controller, valve solenoid coils, vacuum motor relay coil and the hydraulic motor starter coil. The light is illuminated as long as power is available to the controller and the POWER switch is set to ON.

  • Page 17: Electrical Components

    4.2 Electrical Components 4.2.1 Hydraulic Pump Motor This motor is coupled to the hydraulic pump via flexible shaft coupling and a pump adapter that bolts to the motor. The motor runs at fixed speed of ~1800 RPM. A label is located on the pump mount designating the correct direction of rotation (reference Figure 1-1).

  • Page 18: Hydraulic Components

    4.3 Hydraulic Components 4.3.1 Solenoid Valves V-1, V-2, V-3, & V-4 These valves are 4-way, 3-position, double-solenoid operated, spring-centered directional control valves. When both solenoids of a valve are de-energized, the valve spool is spring-centered and hydraulic fluid is routed directly into the manifold's return passage.

  • Page 19: Boom Left/Right Valve

    4.3.1.3 Boom LEFT/RIGHT Valve V-2 This solenoid-operated directional control valve alternately pressurizes opposing ports of the rotational motor to swing the boom left and right. When the valve's "A" solenoid is energized, the valve spool shifts, pressurizing the port that swings the boom to the left. When the "B" solenoid is energized, the valve spool shifts, pressurizing the port that swings the boom to the right.

  • Page 20: Boom Left/Right Flow Control Valves

    To adjust the relief valve setting, remove the protective cap- nut and loosen the lock-nut on the valve stem. Use a 1/8" hex key to turn the valve stem clockwise to increase pressure or counter-clockwise reduce pressure. Make valve adjustments in small increments and observe the gauge while doing so.

  • Page 21: Rotational Motor

    4.3.6 Rotational Motor FIGURE 4-3, ROTATIONAL MOTOR & DRIVE CHAIN The hydraulic torque motor swings the boom left or right by means of a pair of sprockets & roller chain. The motor is mounted to an adjustment plate located under the chain drive guards. The adjustment plate along with a pair of jack screws allow for tightening the drive chain.

  • Page 22: Maintenance And Repair

    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.

  • Page 23: Lubrication

    5.3 Lubrication 5.3.1 Boom Pivoting And Sliding Joints, Monthly Lubricate all shafts and bearings with a liberal amount of multi-purpose grease. Bearings and shafts should be re- greased monthly. All boom motions should be smooth and constant. Jerky operation may indicate mechanical damage to the boom, to a cylinder, or the rotation motor.

  • Page 24: Breather Cap Cleaning, Every 3 Months

    5.4.2 Breather Cap Cleaning, Every 3 Months Remove the breather cap. Wash it thoroughly and blow it dry. Replace the cap. 5.4.3 Hydraulic Filter Replacement, Every 3 Months Remove & replace the filter canister. A check valve between the filter & the oil reservoir prevents excessive oil spillage during replacement.

  • Page 25: Compartmentized Probe Tip Inspection

    5.5 Compartmentized Probe Tip Inspection This inspection is best done with the probe lowered near ground level. A. While keeping the hands clear of the Probe, have someone OPEN and CLOSE the probe tip through several cycles. The inner tube should rotate smoothly and evenly within the outer tube. B.

  • Page 26: Troubleshooting

    VI. TROUBLESHOOTING 6.1 General Truck Probe Troubleshooting DANGER CARELESS OR ACCIDENTAL RESTORATION OF POWER CAN RESULT IN DEATH OR SERIOUS INJURY. MAKE CERTAIN AREA IS CLEAR BEFORE REMOVING LOCKOUTS. SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION Truck Probe does not operate Power switch OFF. Turn power switch ON.

  • Page 27: Directional Solenoid Valve Troubleshooting

    6.2 Directional Solenoid Valve Troubleshooting SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION Valve does not shift but full line No or low hydraulic pressure. Check. voltage signal is present at the Faulty field wiring. Check for full line voltage at the terminal strip inside the control. solenoid.

  • Page 28: Replacement Parts

    VII. REPLACEMENT PARTS 7.1 Scope The certified drawings list the non-standard components that have been incorporated into the equipment. InterSystems normally stocks non-fabricated parts and non-custom OEM parts. Replacement parts for any other components, including fabricated parts and custom OEM components can be supplied upon request. 7.2 Ordering Parts Direct parts orders or requests for technical assistance to your sales representative or to: InterSystems...

  • Page 29: Truck Probe Parts Listing

    7.4.1 Truck Probe Parts Listing ITEM NO. DESC PART NO PART NO MAIN STAND WELDMENT 531748 531749 CHAIN GUARD SMALL HALF 531750 531752 CHAIN GUARD LARGE HALF 531751 531753 DRIVE SPROCKET 35688 35688 PIVOT TUBE WELDMENT 531900 543931 RYERTEX TEE BUSHING 518911 529628 ZERK BOLT ½-13UNC (1/2 TP &...
  • Page 30 ITEM NO. PART NO DESCRIPTION 530288 URETHANE PROBE TIP REPLACEMENT KIT 531904 RAIN COVER TOP COMP PROBE 531905 RAIN COVER FRONT COMP PROBE 35702 COUPLING ACTUATOR 35686 HYD ROTARY ACTUATOR 180 DEG 35611 VACUUM HOSE 1-1/2” ID COLLECTION CABINET COMPONENTS 35790 COLLECTION BOX FRAME 512871...
  • Page 31 ITEM NO. PART NO DESCRIPTION 35547 PIPE NIPPLE ADAPTER ¼ MPT TO ½ MPT 35789 BLACK PIPE NIPPLE ½ X 1-1/2 LG 36440 BLACK PIPE NIPPLE ¾ X 1-1/2 LG 35737 BLACK PIPE BUSHING 1 MNPT TO ½ FNPT 35742 7/8 MSAE O-RING X ½...
  • Page 32 FIGURE 7-1, MAIN STAND ASSEMBLY...
  • Page 33 FIGURE 7-2, TELESCOPING BOOM ASSEMBLY FIGURE 7-3, COMPARTMENTIZED & CORE PROBES...
  • Page 34 FIGURE 7-4, SAMPLE CABINETS...
  • Page 35 FIGURE 7-5, VACUUM MOTOR UNITS...
  • Page 36 FIGURE 7 7-6, HYDRAU U LIC POWER R UNIT ASSEMBLY...
  • Page 37 FIGURE 7-7, HYDRAULIC POWER UNIT FITTINGS& HOSES...
  • Page 38 FIGURE 7-8, HYDRAULIC HOSES & FITTINGS...
  • Page 39 TOMATIC T TRUCK PRO OBE MAINT TENANCE C CHECK LIST Firm ________ ____________ ____________ ________ City _________ ____________ ___ State ____ ________ Name ________ _____________ ____________ ________ Date _________ _____________ ____________ ________ Manager _____ ____________ _____________ _______ Machine Type an nd Size _______ __ Serial No.

  • Page 40: Warranty

    VIII. WARRANTY InterSystems reserves the right to make changes in design or in construction of equipment and components without obligation to incorporate such changes in equipment and components previously ordered. WARRANTY, LIMITATION OF LIABILITY, DISCLAIMER OF IMPLIED WARRANTIES: InterSystems manufactured equipment and components are guaranteed against defects in workmanship or materials for one year from date of shipment.

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