S.C.R. WAGON WORK SHOP, GUNTUPALLI

          CTRB Greaseseal Press Machine

Procedure for replacement of Piston seals and chevron seals:

     1. Switch off the machine.
     2. Disconnect the hydraulic hoses from the power pack.
     3. Remove the lock nut and end plate of the cylinder.
     4. Remove the cylinder from the main frame and hold the cylinder safely.
     5. Remove the front cover using suitable tools by holding the cylinder rigidly with pipe vice.
     6. Remove the check nut with the help of C – clamp (or proper tool).
     7. Check the condition of the Chevron packing and 'O' - ring of the check nut. If damaged,
        replace with a new one.
     8. Gently remove the piston by holding the cylinder rigidly with pipe vice.
     9. Drain the oil in the cylinder.
    10. Clean the piston with soft cloth and never use cotton waste.

     Note:- Don’t use the cotton waste.

     11. Replace the PU seals if found damaged.
     12. Insert the piston in the cylinder gently.
     13. Lock the check nut and tighten properly by using C-clamp without damaging the chevron
         packing and O-ring of the check nut.
     14. Lock the cylinder by using end plate.
     15. Assemble cylinder in the frame.
     16. Connect the hydraulic hoses.
     17. Check the leakages from the cylinder by applying load.

     Overhauling procedure of the hydraulic Power pack:

          Hydraulic Power pack consist mainly the following items

     1. 5 HP Motor
     2. Solenoid operated Direction Control (DC) valve.
     3. Manifold block
     4. Pressure relief valve
     5. Hydraulic pump
     6. Pressure gauges

     Overhauling procedure:

      1. Switch off the machine.
      2. Disconnect the power connections.
      3. Disconnect the hydraulic hoses and pressure gauge from the power pack.
      4. Drain the oil in the power pack by removing drain plug.
      5. Dismantle the motor from power pack.
      6. Remove the coupling and check the condition if damaged, then replace.
      7. Remove the cover with suitable tool (Allen key/ spanner) and keep it in a clean tray.
      8. Disconnect the inlet and outlet steel pipes of the pump and check for any cracks or damages.
      9. Dismantle the pump and check the wear & tear of the Piston elements (5Nos. each located
         in two rows ie. A and F), washer, spring, steel ball, O- ring , bearing and replace if required.
     10. Clean the breather or air vent.
     11. Clean the power pack thoroughly with kerosene oil and soft cloth.
     12. Connect the inlet and outlet steel hoses.
     13. Assemble the pump and cover to the power pack.
     14. Fill the recommended viscosity grade oil (VG-68) in the power pack.
     15. Mount the motor on to the power pack and lock the screws.
     16. Connect the hydraulic hoses and pressure gauge.
     17. Switch on the machine and check the pressure developed in the system by applying the load
         ie. 10T at 70 bar.