K93100 / K93190

Four Ball Wear and EP Tester

Operation and Instruction Manual

Koehler Instrument Company, Inc.

1595 Sycamore Avenue • Bohemia, New York 11716-1796 • USA
Toll Free: 1-800-878-9070 (US only) • Tel: +1 631 589 3800 • Fax: +1 631 589 3815
http://www.koehlerinstrument.com • e-mail: info@koehlerinstrument.com
Petroleum Testing & Analysis Instrumentation • Custom Design & Manufacturing
IMPORTANT:

1. Always keep this manual near the equipment for ready reference.

2. The manual was considered to be complete and accurate at the time of

publication. However due to our drive for constant improvement in
our product quality and specifications it may be subjected to
modification and or changes.

3. If a new manual is required please contact KOEHLER office with

equipment name, work order number

NOTE:
Input voltage to machine is to be 3 Phase, 220V, 60 Hz, 1.5kW.

A voltage stabilizer is necessary if this machine is used in situations,

where the input voltage fluctuations are more than 10% of the rated
voltage.

2
 PREFACE

We greatly appreciate you selection of Four-ball tester TR-30L for your

laboratory. This testing equipment is capable of conducting tests for
wear, extreme pressure and co-efficient of friction according to ASTM &
IP standards. It is capable of operating at high load with precision
and good repeatability

This manual provides essential information & instructions necessary for

operation, maintenance, installation and safety of the machine.

Please read this manual carefully & thoroughly prior to handling and
operation of this tester to ensure the safety, efficiency and reliable
performance for several years.

In case of any doubt or need any clarification contact KOEHLER.

DO NOT OPERATE THE MACHINE WITHOUT GETTING THOROUGHLY ACQUAINTED WITH THE
CAPABILITIES, FUNCTIONS AND SAFETY PROVISIONS OF THE MACHINE.

3
 1. WARRANTY & COMMITMENT TO CUSTOMER
1.1 Warranty
The equipment is warranted against defects in materials and workmanship
for a period of 15 months from date of delivery or 12 months after installation
whichever is earlier. Warranty certificate has been enclosed along with commercial
documents.

1.2 Pre-installation preparation

As soon as the consignment reaches destination, user is required to
unpack and verify delivery of items as per the packing list. Kindly fax any
shortage or transit damage noticed within 48 hours of delivery and mail detailed
report. This is necessary to enable the service / installation engineer to arrange
proper replacement and tools as needed. It is also needed for insurance claim.
Utilities and services like unloading and unpacking of consignment, civil work,
lifting and shifting as required are to be arranged by the user in advance before
the arrival of installation personnel at the location to facilitate smooth and
speedy installation.

1.3 Koehler’s commitment to our customers

Providing quality testing instrumentation and technical support services for
research and testing laboratories has been our specialty for more than 50 years.
At Koehler, the primary focus of our business is providing you with the full
support of your laboratory testing needs. Our products are backed by our staff of
technically knowledgeable, trained specialists who are experienced in both
petroleum products testing and instrument service to better understand your
requirements and provide you with the best solutions. You can depend on Koehler
for a full range of accurate and reliable instrumentation as well as support for
your laboratory testing programs. Please do not hesitate to contact us at any time
with your inquiries about equipment, tests, or technical support.

1.4 Contact Information

KOEHLER INSTRUMENT COMPANY, INC.
1595 Sycamore Avenue • Bohemia, • e-mail: info@koehlerinstrument.com
New York 11716-1796 • USA Petroleum Testing & Analysis Instrumentation
Toll Free: 1-800-878-9070 (US only) • Custom Design & Manufacturing
• Tel: +1 631 589 3800 • Fax: +1 631 589 3815 http://www.koehlerinstrument.com

4
 2. SAFETY PRECAUTIONS
SYMBOLS & DESIGNATIONS CONNECTED WITH SAFETY

Ignoring a “Danger Ignoring a “warning Ignoring a “Caution

Symbol” could result in precaution” could result Designation” could
death. in serious injury and result in injury and /or
/or major damage to damage to machine
machine.
2.1 Mechanical
2.1.1 For Safe Operation
To ensure proper and appropriate machine operation, follow the instructions given
below
a) Carefully read the technical manual and make sure you understand the contents
This technical manual describes correct instructions about correct
operation and servicing with warnings at crucial points. Read this
manual before operating the machine and fully understand the
contents. Never attempt to use the machine in any way not described
in the manual.

b) Only personal trained for operation are authorized to handle the machine
Only personnel who are trained for proper operation and handling of
the machine and are having sufficient knowledge should be authorized
by your supervisor to operate the machine. For maintenance and
servicing of electrical components/equipment, only personnel
qualified officially must be authorized to handle. We suggest a
qualification system to be prescribed in your shop regulations.
KOEHLER shall not be responsible for any direct, incidental or consequential damages
on person or property if operators are not knowledgeable about operation and proper
practice to use the machine.

c) Always keep this instruction manual near the machine

Keep this instruction manual safely in a designated place easily accessible to you.
If the manual is damaged or lost, please intimate the machine model number and the
work order number to M/s. KOEHLER Instruments Pvt. Ltd. for obtaining one such at
your cost.

d) The machine has to be switched ‘OFF’ before opening the electrical cabinet. But
input power supply will be present in the incoming supply terminals. Hence
maintenance or service personnel must be very careful while removing or replacing
components from electrical cabinet when necessary.

e) All personnel must be aware of the location of EMERGENCY STOP BUTTON

All personnel concerned with operation and of maintenance must know the
location of emergency stop button; its location and how to use it under
emergency conditions, so that it can be operated at any time without
looking at it. Unauthorized persons should not operate the machine

f) Never use journal to clean inside the work zone:

Use only tissue paper & solvent to clean the work zone i.e. spindle, bearing and
surrounding areas either before or after test. Do not blow air for cleaning.

5
2.1.2 Hazardous Area On The Machine
2.1.2.1 High Voltage Area
Opening of electrical cabinet and touching the devices inside will result in
serious personnel injury or death from electrical shock
The power input to the machine is 220V, 3 phase and 50Hz. Necessary
safety measures are provided to protect the operator due to shock in
electric motors and other electrical components, electrical cabinet
and wiring through which high voltage runs. Hazardous areas are
located inside the electrical cabinet.
Touching these devices could result in serious personal injury or death to electric
shock.

2.1.2.2 Machine Movable Area

Always keep away from the following areas during operation, as they
are extremely dangerous.
Position: Weights with loading pan

2.1.3 Never operate the machine without ensuring that machine guard is in place.

Except during machine operation, turn off the main power, before
entering the work zone for maintenance or other reasons.

2.1.4 Machine Operation

Never operate the machine without ensuring the following.
 Without tightening the ball pot to the required torque value of 50ft
lbs or 68 Nm.
 Applying normal load while spindle is switched ON.
 Do not apply normal load without placing ball pot beneath spindle
If the above measures are not taken, it will result in damage to
machine or personnel.
2.1.5 Slippery Surfaces
In the event of operating/maintenance personnel entering in the
working zone of the machine, they should understand that presence of
oil, coolant or grease etc may make surfaces slippery, leading to
sliding or slipping or skidding. Hence to prevent such accidents, the
working area in and around the machine must be maintained neat &
clean.
The concerned personnel should adopt precautionary measures like wearing of
suitable footwear, goggles and gloves, whichever is necessary.
2.1.6 During Operation

Never attempt to open any guard or cover while machine is running.

2.1.7 Parameter setting

Do not change parameters such as pressing zero button of normal load, frictional
force, adjustments in machine parts or electrical parameters such as
current limit of motor protection circuit breakers under machine
operation.
If such changes are unavoidable record values prior to changes so that
they can be reverted to their original values if necessary.

6
2.1.8 Interrupting a cycle
Do press ‘TEST STOP’ button to interrupt a cycle. Sort out the problem
and fix it before proceeding next test.
Never attempt to hold back or restrain any machine parts during
operation with intention of avoiding abnormality. Always use proper
procedure to stop the machine.

2.1.9 Completion of Operation

Make sure that you switch off the electrical power supply to the
machine after completion of the day’s operation before leaving. Clean
up the machine and the working area too.

2.2 Electrical.
2.2.1 High voltage Area
Electrical drive power voltage level to the machine is 220 VAC, 3Phase, 50 Hz.
Necessary safety measures are provided to protect the operator from electric shock
due to electrical components.
However proper care must be observed while working in and around the machine.
Touching or getting direct contact with electrical components such as motors and
wiring cables would result in a serious personal injury or death.
The following are the hazardous devices/areas that must be carefully dealt with,
 Electrical Cabinet and  Controller
Wiring  Electrical motor

Only qualified and trained personnel are permitted to open the door
of electrical cabinet, controller box cover and motor terminal
protective cover in case of servicing or maintenance. Unqualified
personnel must not access to any of these areas.

2.2.2 Protective devices

For safety reasons protective devices are provided in the machine,
 Never damage, remove or relocate any parts of safety devices. Doing so without
KOEHLER’s permission would result in serious personnel injury/loss
of property.
 Before operation, check out that all safety devices are working
properly. If not immediately contact KOEHLER with machine type and
work order number. Unauthorized personnel are strictly prohibited
from opening electrical cabinet door or any cover with protective
device for open/close.
 Do not meddle with any proximity & load cell settings unless you are authorized
to do so.

2.2.3 List of protective devices

NAME LOCATION
Emergency Stop Button Equipment body
Mains power Switch Electrical cabinet
Tripping limit of frictional Mechanical stopper on load cell bracket & trip
force load cell value setting on PC
Mechanical locknuts On spindle assembly
Safety guard On front of equipment with interlock
MCB Electrical cabinet
Line filter Electrical cabinet & controller
Belt guard Equipment body
Fuse Controller

7
2.2.4 Thermal Risk
Any personnel likely to come into contact with these parts should take precaution to
allow them to cool down before attending with bare hands.
 Motors in the machine are likely to be hot during operation and
hence possibility of burns.
 Ball pot is hot to handle immediately after the test.
 Spindle is HOT to handle immediately after test.
Use of safety leather gloves is recommended.
Safety Labels
Safety labels, caution markings must be observed and understood before operation.
When they get damaged or become illegible, please replace it or contact KOEHLER.
Do not scratch/soil or remove any safety markings/labels from machine.
2.2.5 Noise
Noise level produced by the machine is within permissible limits
(85Dba). This test is done at our works during final stage running
tests using noise level measuring instruments.
However, the machine may produce excessive noise during its operation,
which can cross beyond safe limits under abnormal conditions. If this
is encountered, operating personnel should take required precautions to
avoid hearing impairment by using earplugs.
2.2.6 Control equipment:
The control system of the m/c employs a ‘FUSE’ design. In the event of tripping they
need only to be replaced after ascertaining and eliminating the cause for the fault.
Refer to the ‘spare parts list’ for specification and ordering details of protection
devices used on the machine.
The control equipment of the machine is housed in
1. A controller cabinet with IP55 degree protection, inside it with the following
items mounted:
i. Transformer. vii. Toggle switch for supplying power
ii. Line filter. to controller
iii. 2ch display card viii. Display of wear, frictional
iv. Data acquisition card torque, normal load & timer
v. Instrumentation card. ix. PID
vi. Power supply card

2.2.7 In case of emergency

Emergency stop, which arrests all dangerous machine movement, may be
brought about either by operating the EMERGENCY STOP push button on
the machine body or the MCB provided on the electrical cabinet.
2.2.8 Checkpoints before operation
 Electric supply voltage to the machine for 220V AC and availability of 3 phases.
 Damaged cable or wire anywhere in or near the machine visually.
 Ensure proper earth connection.
 LED indicators for operation status.
 Remove all not required items on the working area, especially at the work zone.
 All guards, covers and doors are placed in proper position.
 Safety shoes, goggles, gloves etc
 Lighting for proper illumination of working area.
 Manual operation of all mechanisms for desirous results

8
2.3 Safety Instructions
Read carefully instruction manual before installing or operating the machine.
Partial understanding may cause serious injury.
Read all safety instructions and observe strictly all instructions.
Never make modifications or changes to machine.
a) Ensure that only qualified and trained personnel operate the machine.
b) Read and understand the manual thoroughly before operating the machine. Please
contact KOEHLER for doubts and clarifications, if any. Partial understanding may
cause serious injury to personnel or damage to machinery.
c) Read all safety and maintenance instructions
d) Ensure that working area is free of obstructions and suitable bin for collection
of test discard.
e) Keep hands away /off from the work zone area, while test is under process.
f) Ensure spindle is in Stop condition before changing ball pot.
g) Close all doors and covers before switching ON machine.
h) Never touch the ball pot or try to make adjustments with bare hands when machine
is working.
i) Do not operate the machine with safety devices, interlocks, doors and guards
removed or bypassed.
j) Switch off the mains electrical supply during maintenance or repair.
k) Do not attempt to touch any electrical device with wet hands as it may result in
shock
l) Provide sufficient working space to avoid hazard
m) User is responsible for safe handling and operating of the machine by observing
safety precautions provided in the instruction manual and caution, warning a
danger labels displayed on the machine.
n) Ensure servicing of the machine by only trained personnel using the maintenance
manual
Strictly observe the above instructions to avoid serious injury or machine damage.
It is the employer’s responsibility to comply with the above and also to provide
necessary safety measures for proper use of the machine.
The electrical cabinet consists of MAINS ON/OFF switch of 10 amperes
capacity. This is used to cut off the mains supply from your works to
machine. Since this involves 3-phase voltage level of 220VAC, it is
extremely dangerous to life of personnel if happen to get in contact
or touch with. Extreme care should be taken when cabinet door is
opened for any maintenance purpose.

NOTE:
If power fails during operation, please switch off supply to the machine by turning
the Toggle switch ‘OFF’ position. After power resumption, switch on the supply to
machine by turning the MCB to ‘ON’ position.
Any maintenance or repair work on the electrical part of the
installation must be carried out by a duly qualified technician. To
protect the operator of the machine, the machine must be connected to
earth. The earth point must be as close to the machine as possible.
Each machine must be connected to its own line. The Electric supply
mains must be led into the electrical cabinet through the inlet
passage provided.
The cable should be or copper conductor having a minimum cross section of 2.5 Sq.
mm, with insulation grade of 650 / 1100 volts.
When all these connections have been properly made, the machine can be powered up
by operating the main switch.

9
 3 FUNCTIONS & FIELD OF APPLICATION
1.2 Functions:
This testing equipment is a Four ball tester the consisting of parts explained
under machine construction. It is fully guarded for operator safety.
It covers the determination of the wear preventive characteristic of lubricating
oil in sliding steel on steel application. It is not intended to predict wear
characteristics with metal combinations other than steel on steel.

On this equipment steel ball is rotated under load against three stationery ball
immersed in lubricating oil. The load, speed and duration of test are selected
according to either ASTM or IP standards. The diameter of wear scars on the
stationery ball are measured after compilation of tests.

3.1 Field of application:

This equipment is suitable for evaluating the wear & extreme pressure properties of
lubricating oil. It is also used for evaluating the co-efficient of oils.

4.3 Features and benefits:

 Confirms to ASTM D 4172, D2783, D2266, D2596, and IP 239.
 Tester suitable for Wear, EP and co-efficient of friction tests.
 Acquire and display of frictional force, normal load & speed.
 Microscope for measuring wear scar.
 Setting of exact test duration.
 Infinitely varying spindle speed between min & max range.
 Same ball pot for Wear, EP & co-efficient of friction test with heating
provision.

THIS TESTING EQUIPMENT IS NOT SUITABLE FOR CONDUCTING TEST WITHOUT OIL
IN BALL POT.

DO NOT USE OIL WITH CORROSIVE PROPERTY FOR TESTING.

In case of any doubt manufacturer has to be consulted regarding

applications.

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 4 TECHNICAL DATA & SPECIFICATION
4.1 Technical Data
SL NO DESCRIPTION REMARKS
Rated supply
1 220 V  10% 3Ø
voltage
Rated supply
2 6 A  1%
current
Rated supply
3 60 Hz  2%
frequency
Not > 10% of the total RMS Phase to Phase to voltage
for the sum of 2nd & 5th harmonic. And additional 2% max
4 Harmonics
of total RMS Phase to phase voltage for the sum of 6th
through 30th harmonic.
Not > 20% of peak supply voltage for more than 1cycle.
5 Dip in voltage There should be more than one sec between successive
dips.
Neither the voltage of the negative sequence component
Voltage & nor the voltage of the zero sequence components shall
6
unbalance exceed 2% of the positive sequence component.

Supplies interrupted are zero voltage for not more than

Voltage 3msec, at any random time in the supply cycle. There
7
interruption shall be more than 1 sec between successive
interruptions.
Operating
8 Between +5 & +400C
temperature
9 Humidity Up to 50% @ 400C
10 Altitude Not exceeding 1000mt above MSL
11 Vibration Rubber mat provided for isolating vibration
12 Radiation Do not keep any other radiation equipment near it
Transportation Protection is provided to against failure while
13
temperature transporting between -250C&550C
14 Handling 2no’s of eye bolt are provided to lift equipment

4.2 Connection of equipment to Electric supply main:

Cross sectional of the
mains cable
Rating of MCB at source
of supply
2.5 Sq mm copper conductor having insulation grade of
650 / 1100V
16 A, type C / Indo kupp,3 Pole

4.3 Customer specification

SL NO TEST PARAMETERS SPECIFICATION
1 Speed Min: 300 rpm, max: 3000 rpm
2 Max axial load 10,000N
3 Temperature Ambient to 100°C
3 Test ball dia 12.7mm
4 Power 220V / 60 Hz / 3 Ph
5 Scar dia 0.01 to 4mm

11
4.4 Mechanical specifications:
SL NO PART DETAIL RANGE
1 Collet diameter 12.7mm
2 Base plate height from floor 920 mm
3 Loading arm height from floor 1030 mm
4 Ball pot height from floor 1250 mm
5 Loading arm length 1305 mm
6 Loading arm ratio 1:15
7 Maximum load 9999 N
Minimum load (Move rider to extreme
8 60 N
position)
9 Dead weights In steps of 1, 2 & 5kg
10 Motor height from floor 1580 mm
Minimum speed 300 rpm
11 Spindle speed
Maximum speed 3000 rpm
12 Pulley ratio for speed 1:1
Over all size of the machine L x W
13 660 x 1305 x 1650 mm
x H
Weight of the machine including
14 388 kg
dead wt’s
15 Floor size L x W 2500 x 1500mm
16 Controller 10 Kg
17 Dead weight’s + tool box 35 Kg
18 Packing box 150 Kg
19 Gross weight 425 Kg
Magnification 100x & 40x
Optical 100x – upto 1mm scar dia, 40x – above 1mm & upto 4mm
20
microscope Input supply Input - 220V, 50Hz x 1Ø
Make Radical microscope
4.5 Electrical specification:
SL NO PART DETAIL RANGE
AC induction Make SIEMENS
1 motor 3.3A, 2 hp, 1415 rpm, foot mounted,
Specification
Motor 1.5Kw
Input supply 220 V, 60Hz, 3ph
Make Commander SK
Variable
2 Input supply 220 V, 3Ø, 2Hp, 1.5Kw
frequency drive
Specification 2hp, 4.7 A
3 Power required Machine 1.5Kw
Size  10 x 50 mm long
4 Heater Capacity 150 W
Voltage 24 V
Input voltage 220 V
5 Controller Input current 2A
Size lxbxh 540 x 300 x 170mm
6 Electricity Machine 220V x 3Ø x 60Hz & 6A
Make OMRON, E5CZ
7 PID
Input supply 220V, 50Hz, 1 Ph, 10Va

12
4.6 Sensor specification

PART DETAIL UNIT MIN MAX

Sensor Proximity sensor APS-8, Make: TAP
Range Rpm 300 3,000
Speed
Least count Rpm 1
Accuracy Rpm (1 ± 2% measured rpm)
Beam type Load Make: Sensortronics, Capacity: 1100
Kg
cell kg
Normal load Range N 0 9999
Least count N 1
Accuracy N (1±1% measured load) N
Beam type load
kg Make: IPA Capacity: 20 kg
cell
Frictional Range Nm 0 16
torque Least count Nm 0.01
(0.1±1% measured frictional force)
Accuracy Nm
Nm
Sensor Deg C RTD
Range Deg C 0 300
Temperature
Least count Deg C 1°C
Accuracy Deg C (1±1% measured temperature)

13
 5 SERVICE REQUIREMENTS
5.1 Site Area

Size of machine 660 x 1305 x 1650 mm

Size of controller 350 x 480 x 150 mm
Total area required 2400 x 1300 mm
Weight of equipment (all together) 388 kg

5.2 Electrical Power Supply System

Power supply for main switch 3 phase, 220V, 50Hz
Current rating required 6A
Power rating required 2.5 kw
220V x 3ph x 50hz, 15 A :-1 for m/c
No of points required
230V x 1ph x 50hz , 5 A:- 3 no’s for computer

Plug for electrical chord 4sq mm , Plug suiting the electrical point at customer
5core. place from which the power supply is drawn

5.3 Miscellaneous Items Required

A cpu having following configuration, Pentium
4 processor, 80GB HDD , DVD RW , 512 MB RAM,
2.8GHz with windows XP Operating system .
Computer having following
An optical mouse
configuration
A 17” color monitor
Computer table & chair

5.4 Consumables Required At Site

Cotton waste 5kg for cleaning equipment before & after test
Ball 12.7mm dia, AISI E-52100 steel ball EP
Test specimen
polished and hardened to 64-66 HRc

14
 6 INSTALLATION
6.1 Transportation:
The equipment is packed inside a wooden container of air and road worthy class. The
entire equipment and spares are covered inside the packing box by using Insta- pak
solution, which protects equipment against variation in temperature, shock &
vibration.
The size packing box size lxbxh : 1300 x 900 x 1110 mm
The weight of packing box : 125 kg

Carry ropes of suitable size to be used for lifting the equipment

while transportation, so that no parts of the equipment are damaged.
The equipment and spares are protected by wooden packing and packing
material.
For moving on ground surfaces use a pallet trolley.

6.2 Environment:
For long life of tester with accuracy, select an installation site, which satisfies
the following conditions.
 No vibration source to be near the equipment, no roads with heavy traffic should
be located in the vicinity.
 Place equipment on firm, vibration less floor. It is placed over rubber mat to
absorb low vibration.
 Ambient temperature and humidity around the equipment should be kept with in the
following degrees. This influences accuracy.
 No direct sunlight to fall on controller box.
 Temperature in the factory 200 C - - +450 C.
 Humidity in the factory 45%-75% with dew condition.
 Heart sources, which generates local rise in heat in temperature of machine to be
away from the machine.
 The machine should not be exposed to direct sun light.
 Ambient atmosphere should not include organic or corrosion gases or
mist.
 The installation site should be free from dust, mist, salt,
corrosive gases & other elements, which could damage the machine.

6.3 Temporary Storage:

If the machine is not installed immediately after arrival, it must be stored in an
enclosed space and make sure that no dust or moisture enters the equipment.
The suggested ambient temperature of the enclosed storage space should be in the
range of -250 C to 550 C.

6.4 Unpacking and Cleaning:

Before packing all non- painted / plated surfaces are coated with rust preventive
oil. After the equipment is unpacked, the entire consignment to be checked to ensure
that it is complete and has not been damaged in transit. Do not dispose of packing
material until after inspection. Any damage or defects are to be reported
immediately.
Remove the five wooden side panels of packing box by removing the bolts, remove
insta-pak packing materials and cut out all shrink-wraps from around the body of the
equipment.
The rust preventive oil must be removed with a dry cloth or cloth wetted with
petrol.

15
Four ball tester TR-30L is packed along with weights stand in a wooden pallet.
The weights stand is kept at bottom of structure and anchored to the frame. The
tester is bolted to the wooden base from below.
The total weight of tester and weights stand is about 388Kgs. Remove weight and
weight stand from structure bottom and bolt it on side of structure on the side of
loading pan.
Proper electrical power supply with good electrical grounding is to be provided.
To release the loading arm, unscrew the locking bolt; bring it to horizontal
position and lock again with same screw. Insert loading pan through the eyebolt
provided at the bottom end of loading arm.
A tool-kit with commonly used tools for normal operation of the equipment is
provided along with the equipment.

Never operate the machines before cleaning

Never use compressed air like air gun for cleaning.

6.5 Hoisting:
When hoisting the machine, be sure to lift the equipment properly.
 Only qualified personnel are authorized to lift the equipment by using crane &
forklift.
 Never put yourself under the lifted equipment in any event.
 Use wire, rope, and shackle or lifting jig of the specified size without damage,
which can sufficiently withstand the equipment weight while using a crane.
 Use pallet trolley or truck to move it inside the laboratory.

6.6 Disposal after Installation:

After installing the machine, collect and classify packing materials (Eg: Wood
board, carton, plastic sheet etc.) and ask quality waste disposal organization for
disposal, so that wastes shall not cause environmental pollution.

6.7 Installation of equipment

Move the equipment to the pre-determined place where proper electrical power supply
with good electrical grounding is to be provided. Spread rubber mat provided over
this place.
Ensure that the loading arm movement is free about its axis support
Connect power cable to power supply socket. Which is protected though an ELCB of
220V, 30mA rating
A tool-kit with commonly used tools for normal operation of the equipment is
provided along with the equipment for all activities.

Fig 1

Fig

16
 Tester section

6.8 Installation of controller

Place TR-30L controller on a table and connect it to tester section (fig 2) using
control and signal input cables provided.
Set RPM knob on controller in extreme counter clockwise position.

6.9 PC connection to controller:

Ensure that computer power is disconnected and TR–30L controller is switched off.
Use Data acquisition cable to connect it with the controller back
panel and “COM1” serial port of the PC. Refer to Tribodata 2010
software manual for installation and operation of software.

Sensors are already fixed at right places do not disturb them.

7 DESCRIPTION
7.1 Description of equipment

17
Four-ball tester TR-30L model is versatile equipment combining the features of both
Four Ball Extreme Pressure and four balls wear test machines.
The selection of proper materials and machining process of the mechanical
components ensure a high degree of accuracy and smooth operation of all moving /
rotating / stationary components with minimum vibrations and noise levels.
This tester is used to determine load carrying, co-efficient of friction and anti-
wear properties of lubricating oils and greases. It is compatible for both ASTM &
IP standards.
In this tester three 12.7 mm diameter steel balls are clamped together and covered
with lubricant to be evaluated, a fourth ball of same dia referred to as top ball
is held in a special collet inside spindle, rotated by AC motor . The top ball is
rotated in contact with three fixed bearing balls, which are immersed in sample
oil. Inside the ball pot the balls are held in position against each other by a
clamping ring and force applied by tightening lock nut, additional provision to
heat and control temperature of oil sample is also provided at bottom of ball pot.
Normal load is applied on the balls by loading lever and dead weights placed on
loading pan. The ball pot is supported above the loading lever on a thrust bearing
& plunger and beneath plunger a load cell is fixed to loading lever to measure
normal load. The frictional torque exerted on the three balls is measured by
frictional force load cell.
The tester portion is placed over a structure (fig 3) made up of mild steel
material. All spares and tools required for operation & maintenance are placed
inside pull down drawers provided in the structure, provision is made on all three
bottom drawers for placing used balls after test. A base plate is mounted on
structure top and all test assemblies mounted over it, A depression on base plate
top (fig 4) is for placing ball pot over it to clamp 3 balls inside at 68Nm torque
and unclamp balls after test.
The tester unit consisting of cylindrical main body is mounted over base plate,
inside at center of the body a spindle assembly is mounted to rotate the fourth
ball, spindle is driven by a AC motor through a flat belt drive. The AC motor is
mounted on the rear portion of outer body with a flat crowned pulley fixed on its
shaft, the pulley height is leveled with spindle pulley height to prevent belt
slipping, the pulley ratio is maintained at 1:1, a idler pulley is fixed between
pulleys to increase belt tension, the belt drive is covered by a guard for safety.

Do not remove belt guard and run the spindle.

Pull down
drawer for
tools

Pull down
Fig 3 Fig 1 Fig 4 drawer for
used balls
Fig Fig

Beneath motor a electrical cabinet is fixed to outer body , inside it a variable

frequency drive, line filter , transformer and many other electrical items are
mounted. The input supply is given to VF drive from there it is distributed to
motor and controller, For this a 5pin plug socket & a MCB is mounted on electrical
box, supply status (fig 6)is indicated by three lamps fixed beside it.

18
 Spindle

Top ball with

collet

Fig 5 Fig 6

Fig Spindle
Fig
housing is firmly fixed on the body in vertical direction , so that the fourth ball
can be inserted into it from bottom . The spindle (fig 5) is mounted between two
high precision ball bearings inside the housing to take maximum load & speed with
out heating and also to rotate with no run out on spindle inside taper, a slot is
provided to insert drift to remove collet during ball change.
Below collet, 3 balls required to conduct test is clamped on a ball pot and placed
over anti-friction disc, this disc is moved up & down by a plunger sliding freely
inside LM bush. Up & down movement to plunger is given by a loading lever fixed
beneath the plunger, the loading lever is pivoted on base plate away from the center
of plunger to give 1:15 loading ratio, on the shorter length of loading lever a load
cell is fixed and over it a roller is fixed, on this roller the plunger rests freely
and it moves up when loading arm is pulled down. On the end of longer arm a loading
pan is suspended to place dead weight’s for applying normal load, the arm length
ratio from pivot point is fixed to get load ration of 1:15, for every 1kg of dead
weight placed on loading pan, 15kgf force is applied on top ball. A rider
arrangement moves over the lever to increment the weight applied. The loading arm is
folded at end while transporting.
7.2 Ball pot: -
The function of ball pot is to clamp three balls firmly to prevent rotation when
subjected to high load & speed and the handle of it is used to measure the
frictional force. The Ball pot assembly (fig 7) is made up of three parts ball pot,
ball pot race and lock nut. Ball pot has a hollow portion for filling sample oil and
inside it balls are tightened against each other and retained by ball pot race. The
ball race retains balls in position and force is exerted against balls while
tightening lock nut using torque wrench set to required torque (68 Nm or 50 ft lbs).
Two heater cartridges housed beneath ball pot heat it to the required temperature
and a RTD sensor provided between the heaters to measure oil temperature. A PID
provided on the controller controls heating and
required oil temperature is set on the PID.FrontOncover to Locking support
the ball pot handle a taper bush is fixed, during
3 balls pressed prevent oil splash
test due to rotation of spindle it presses
against
against the frictional each other
force during test
load cell button Loading arm
to measure frictional force.

Socket for heater

Handle

19
 7.3 Controller box:
The machine operation is controlled by an electronics controller, the controller
parts are housed inside a metal box which makes it highly mobile, it can be placed
near the machine at a convenient position for operation. For receiving its power and
signals, it is connected to machine through control cable and signal input cable. It
transmits the signals after processing to PC for data storing. For easy operation
of machine all switches are mounted on the front panel of controller. Front panel of
Fig 7
controller has four displays (fig 9), normalFigload, 8 frictional torque, and
temperature, speed and time. A PID is fixed to control and display oil temperature;
Fig Loading
utton a toggle switch for powerpan
to controller ON/OFF & 2 zero push button for initializing
the display on normal load and frictional torque to zero before start of test. Test
start/ stop push buttons for begin and end test, a potentiometer knob called SET RPM
for setting spindle speed. A toggle switch for activating test mode either in time

Fig 9
Fig 10

Fig Fig

or revolution mode, timer or rev values is entered by using two push button
switches, SET & ENTER.
Similarly on the back panel (fig 10) of the controller following are fixed, a MS
shell connector socket for receiving control cable, fuse 2A and D-type connectors
for signal input and data acquisition.

7.4 Working of controller:

When MCB on the machine panel is switched ON, the input supply is sent to AC drive,
heater transformer and controller. When controller is switched ON, the input supply
goes to step down transformer inside controller, where the voltage gets stepped down
to 15-0-15V and 0-10V, both these voltages are sent to power supply card for
rectification and the regulated output from it is in three components + / - 15v,
+ / - 5V and 5V . The voltage + /- 15V is sent to IC’s on instrumentation card,+ /
-5V is sent to Normal and frictional force load cell and 5V is sent to proximity
switch.
When timer is set and START button on controller is pressed, the signal from timer
card is sent to AC drive and according to setting on SET rpm potentiometer the
required voltage is sent to motor. If timer is not set, the default value being
10secs the motor will run for only 10secs.
In heater transformer the input voltage is step down to 24V and sent to heater fixed
at bottom of ball pot through a SSR. The SSR is controlled by PID. On PID the
required temperature is set, when set temperature value is greater than measured
temperature the PID gives signal to SSR to
close, to allow current to flow into
heaters and vice versa.

Data acquisition card

FB Instrumentation card

20
 Transformer

Fig 11
7.5 Sensor:
The instrumentation used on this machine consists of 4 Fig
sensors normal load cell,
frictional force load cell , temperature sensor & proximity sensor, the instruments
used is explained in detail below:
7.5.1 Normal load cell:
One beam type load cell of capacity 1100 kg is mounted inside the loading arm firmly
and over it an roller arrangement is fixed to exert pressure on the plunger (fig 12)
in line contact. When dead weights are placed on loading pan for applying normal
load, the loading arm being hinged moves down lifting the load cell portion of lever
arm vertically upwards. This movement lifts the plunger & ball pot till it touches
top ball, and further movement exerts pressure on the contact area. This exerted
pressure is measured by the load cell and
signal sent to controller for processing and Load
Plunger
display.
7.5.1.1 The construction and working of
load cell;
This is a strain gauge type of load cell; it is Roller
primarily a column of corrosion resistant super arrangement
alloy of high tensile strength steel that
deforms very minutely under load. This
deformation is sensed by foil type strain
gauges bonded on to the column and connected to
form a balanced wheatstones bridge. The
electrical output from Wheatstones Bridge is proportional to the load acting on
column. The extremely rugged and hermetically sealed construction makes them the
ideal choice for this application.
Fig load
7.5.2 Frictional torque: Frictional torque is measured by a 20 kg beam type 12
cell fitted at a distance of 80 mm from the center of spindle, the load cell is
Fig
fixed vertically on a bracket, with the load cell button engaging the ball pot
handle(fig 13) . The handle side of ball pot is fitted with a taper bush to press
the load cell button when test started, the force applied is measured as frictional
force and converted to frictional torque by multiplying by 0.08. A projection on
bracket leaves a 1mm gap from the rear of load cell, to protect bending of load
cell, this is a mechanical protection further load cell is protected by variable
frequency drive when torque value exceeds 14Nm.
The construction and working of this load cell is the same as explained in
normal load cell.

Frictional force sensor

Step for over load

protection

Load cell button

Fig 13 Fig 14
7.5.3 Temperature sensor: A RTD sensor is used to measure the temperature of oil
Fig Fig

21
inside the ball pot , it is mounted at bottom part of ball pot between the two
heaters. A PID fixed on controller box is connected to both heaters and sensor .The
temperature sensed is transmitted to PID, which checks these values against the
already set temperature values on PID, accordingly power is either sent or cut off
to heaters by PID.
7.5.4 Proximity sensor:
The proximity sensor is used to measure spindle speed, the Least count of
measurement is 1rpm, for this an rpm sensor disc (indexing plate) with slots on
circumference (fig 15) is fixed to top of spindle and rotates along with it.
Proximity sensor is mounted perpendicular to it on a bracket with equal gap for all
slots on disc circumference; signal is generated when sensor disc approaches the
active surface with in the specified switching distance. This sensor functions in
contact less fashion and do not require any sensing mechanisms.
An inductive proximity sensor is selected as it has excellent means of detecting the
presence of a wide range of metallic targets. This
detection is accomplished without contacting target Proximity sensor
and is mechanically wear free. It is comprised of a
high frequency oscillator circuit followed by level
detector, a post amplification signal circuit and
drives a buffered solid-state output.
In effect when the sensor disc is brought with in
effective range of the emitted field of the
oscillator, a damping action results which reduces
the amplitude of oscillator. This amplitude shift is
converted to digital signal by the level detector,
which drives a buffer stage. When the object is
removed, the oscillator and digital output is turned to its former state.
Sensor disc Fig 15
7.6 Cables
Following cables are used on this equipment: Fig
Power input cable: To transfer 220V, 3 phase, 50 Hz, 10A power from external source
to machine. Connect suitable socket at other end of cable.
19 pin control cable: It is made of 19-pin MS connector on either ends of cable, to
transfer power & signal from machine to controller.
A B & C :- Phase, Neutral and N & U :- SSR out put
earth. P V & T :- Proximity
D & H :- Start and stop R & S :- PT 100
E, F & G :- Potentiometer
Signal input cable: It is made of 15-pin D type connector fixed on either end of
cable to transfer signal from sensors to controller.
Data acquisition cable: It is made of 15 pins D type connector on either ends of
cables to transfer data from controller to computer using RS 232 port.

7.7 Data acquisition system TRIBODATA 2010:

This rig has PCB based sequence programmable control & data acquisition. This
provided by an integrated PCB circuits inside the controller, the output of sensor
is acquired by Tribodata 2010 software running on PC, operating under windows Xp.
Data is stored to hard disc in standard spread sheet compatible file formats.
Tests are defined by a sequence of steps, each step containing set point, recording
rates & alarm levels information. Set points may be adjusted by step change or
ramp. The test sequence is followed unless interrupted by the operator or an alarm.
The signals from sensors after processing in controller are transmitted to PC
through data acquisition cable, there it is displayed on ACQUIRE screen in software.

22
The software used for acquiring data is Lab view based and it is installed inside PC
as Tribodata 2010. The software has three screens one for acquiring & displaying
data during test and other two screens are for post- evaluation of result. On the
acquire screen the acquired test parameters are displayed in graph form with X
axis as Data points Vs Y axis the current value of parameter , graph displayed are
normal load ,frictional torque and temperature graphs. Two other screens are used
for post processing of test data , WEAR & EP screen, wear screen display graphs of
4 tests in normal scale with X axis have time and Y axis frictional torque, the
graph displayed is each parameter independently, this helps to
evaluate the results of same parameter in four tests. EP screen
display in log scale with load on X axis and frictional torque on Y
axis, the results of four tests are compared.
7.8 Ball inserter / remover
To insert top ball inside collet and also to remove from it a ball inserter/remover
is used. It is mounted next to main body and easily accessible for operation, it is
made of a top and bottom brackets hinged at middle. The top bracket has a boss with
recess to insert collet and inside boss a spring-loaded pin is fixed. The spring
loaded pin protrudes from either ends and is used to push ball out of collet. The
handle is used to apply pressure for inserting ball and also while removal of ball.
The ball is seated at a recess provided at bottom bracket.

During EP test when balls get welded, the collet holding top ball is removed using
tongs.

7.8.1 Procedure for ball insertion

Place ball to be inserted at bottom as shown in fig (fig 16), insert collet into
recess at top, bring down the lever and press down handle to lock, a click sound
will be uttered to indicate ball is locked. Handle

7.8.2 Procedure for ball removal

Insert collet into the recess on top, press Recess for collet
handle till the bottom spring loaded pin
Spring loaded
presses against the bracket. This action
releases the ball from collet.

Top bracket

Fig 16 Hinge

Fig Ball

Collet

7.9 Safety measures

The machine consists of built in safety
Bottom bracket
measures given below:

23
 Fig 18 Fig 19 Mechanical stopper
 Motor stops automatically when overloaded or the balls are welded (fig 17)

Fig Fig
Mechanical stopper prevents over-loading of frictional torque load cell (fig 19)
 Emergency switch, to switch off the controller power if situation demands (fig18)
 Front cover to protect user from oil splash during the test (Fig 8).

8 OPERATION
8.1 Check points before operation
 Check electric voltage 220V, 3 Phase, 50 Hz.
 Check for damaged cables and wires; it can cause electric leakage or shocks.
Double check to ascertain there is no damage on cable. Failure to observe this
warning result in a serious personal injury or death by electric shock.
 Check all electrical wires including grounding wires are connected properly.
 Clean the machine of oil spillage, dust, etc. before starting the operation.
 Check the front guard is closed.
 Use safety shoes, safety gloves & earplugs to be used when necessary.
 Check the work area light is in operation, and is adequate.
 After inserting collet, make a trial run.
 Tools & other items must not be placed on base plate of the equipment.
 Store new & used balls, oils in designated place.
 Check whether switches & levers operate smoothly

The following points are to be checked visually at least once a shift to keep the
equipment in good condition.
Check Points Check them Method
Antifriction Cleanliness Check visually
disc
Guard No dust accumulated. Check visually
Spindle Cleanliness Check visually
Collet seating Cleanliness Clean it thoroughly with
area waste
Electric cabinet Door closed, no damage to external Check visually
wiring / cable.
General Machine environment clean. No loose Check visually
of bolt on cover, wheel guard etc.

8.2 Wear Test Procedure (ASTM 4172)

8.2.1 Selection of test balls
Test balls should be chrome alloy steel, made from AISI E-52100, with dia 12.7mm,
Grade 25 EP (extra polish) and Rockwell C hardness 64 to 66.
8.2.2 Preparation of tester
 First clean four new test balls, ball pot and collet thoroughly using solvent
(hexane).
 Insert a clean ball in collet by using ball inserter / extractor (fig16) mounted
on the base plate of the machine and insert it into the spindle.

24
 Place the ball pot assembly in the slot on base plate. Remove the lock nut, lift
the ball race by about 5 mm, insert three cleaned balls inside the cavity, and
lower the ball race to retain balls in position.
 Set torque wrench (fig 20) to the required torque value (68 Nm or 50 ft lbs) by
pulling out the lever from the arm and rotating in the required direction (a
graduated scale in lb-ft / Nm / Kgm are given on the arm), push back the lever to
lock the torque wrench.
 Torque wrench is having an arrow mark on both sides of the handle. Make sure that
while tightening, torque is applied in clockwise direction and while loosening it
is in anti -clock wise direction.
 Place lock nut over ball pot and rotate by hand till it touches the tip of ball,
further tighten it with the torque wrench set at the recommended value.

Fig 20

 FigEnsure that the thrust bearing ball ring is in its position over the plunger.
Apply a thin layer of EP grade oil on the anti-friction disc surface.
 Fill the ball pot assembly with sample lubricant / grease
up to 3 mm above the tip of ball.
 Lift the loading arm up and lock it (fig 21). Place the
ball pot assembly over the anti - friction disc. Connect
heater cable to the ball pot.
8.2.3 Preparing controller for test Fig 21
 Switch on the Main power. This will illuminate the
controller displays. Fig
 Allow 5 minutes for warm up of electronics.
 Set the duration of test with the timer (fig 22). The timer can be set for
 Maximum duration of 99 hours, 59 minutes and 59 seconds in steps of 1 Second.
 Default value of timer is 10 seconds. Press ENTER to go to the
 Desired blinking digit. Press SET to increment the digit.
 ENTER push button is used to shift flashing display on time window on controller
from last digit to 2nd last digit, 3rd, 4th digit and so on.
 SET button is used to increase display value by pressing once.

8.2.3.1 Procedure for entering test duration.

Initially last digit timer display will be flashing.
Press once ENTER button to shift flashing display to next
digit.
Press once SET button to increase the displayed value.

Default display value is

00 00 10
TO SET VALUES 99 59 59
Initially all display values are zero and last digit on
display will be flashing.

Press SET button till display shows

00 00 09 Fig 22
Press ENTER button, flash from last digit display shifts to
2nd last digit. Fig

00 00 59

25
Press SET button till display shows

Similarly repeat till values

99 59 59 are set.

The timer is configured to work in following modes

1. Initialize the normal load and frictional torque indicators to zero by pressing
the corresponding ZERO push buttons Fig 23

8.2.3.2 Setting of spindle speed: Fig 23

Ensure free the spindle is free to rotate by hand and the loading arm is in locked
position. Fig
On controller press on START button (fig 23) and rotate the SET RPM knob
(potentiometer) clockwise till the display indicates the required speed.
Press STOP to halt the spindle.
8.2.3.3 Oil temperature setting:
At bottom of ball pot assembly two electrical heaters and a temperature sensor is
fixed, sensor measures the oil temperature inside the ball pot.
A PID module (fig 24) controls the heating and display the measured temperature, for
this initially the temperature required is entered into the PID using soft keys, the
entered value is displayed at bottom screen.
Soft keys on PID
If specimen heating is required then temperature has to be entered on PID

Click on this key to enter numerals in ascending order

Click on this key to enter numerals in descending order

Initially the display blinks on 1st digit, press this key to move blinking to
2nd or 3rd position to enter numerals

To store the entered value

Procedure for entering value

Click on to move the blinking of numerals

to 1st digit

Press key till required value is displayed

Fig 24
Repeat the same operation for all other 3 digits
Fig
Press to store the data
Allow delay of 1 minute, the PID saves the data, and it is displayed on bottom
screen
The value measured by temperature sensor is displayed on top screen on PID
After the value is entered & stored, the system starts to operate immediately.
Initially PID compares the sensor display with set value, if set value is higher
than sensor display, PID gives signal to SSR to allow current to heater till the set
value is reached, later by constant switching ON & OFF, the temperature is

26
controlled with in the set value.
8.2.4 Applying normal load
Normal load is either 147 N or 392 N ( 15 or 40 Kgf)
Place ball pot assembly over anti-friction disc and slowly unlock the loading arm
till the top ball sits over the bottom balls,
Rotate spindle to ensure it is at center.
Apply the normal load by placing dead weights on the loading pan and moving rider on
loading arm till the required load is displayed.
Avoid impact loading of the spindle. Run continuously
8.2.5 Prepare PC for test.
Open Tribodata 2010 software
Click run continuously icon to activate screen
Select
Fig 25
screen to receive &
display test parameters
Fig
Enter a file name to save data and in remarks
column fill in details
Enter load value in the window
On Acquire control select timer by moving the
switch to top position, enter 60 in
samples/min (60 samples will be stored/min).

Click to receive & display test data, at bottom of

normal load & frictional torque screen the existing values are displayed on windows,
these values are identical to display on controller.

8.2.6 Test start

Close the front acrylic door, an interlock is provided unless door is closed test
does not begin.
Press the “START” switch to run the test. Allow the machine to run the test period,
motor will automatically stop after elapse of preset duration in the timer.
Motor will also stop if frictional torque exceeds the trip value. Data acquisition
also stops after the elapse of preset time.
WEAR test mode: (Timer set for any duration equal or more than 2 minute) On
actuation of START only the heater is powered ON. PID module controls the ball pot
temperature. When ball pot temperature is achieved for the first time the spindle
and data acquisition is initiated. After test duration is over the heater is OFF.

8.2.7 Test end

Ball pot assembly and collet removal
After completion of test, remove the dead weights, lift up and lock the loading arm.
Open the acrylic door. Disconnect the heater cable.
Remove ball pot & place over base plate allow it to cool to room temperature.
Insert collet remover into spindle & apply pressure to release collet from spindle.
Separate ball from collet using ball extractor.
When ball pot is cool to room temperature measure wear scar either using image
acquisition system or microscope.

8.2.8 Measure scar diameter with microscope.

Wear scar is measured using a microscope after removing the balls from ball pot.
Procedure to measure wear scar:
 Using permanent marker pen circle the wear portion on each ball,
 Un clamp test balls from ball pot using torque spanner.
 Clean the balls with hexane, wipe dry with a soft cloth.

27
 Place the individual ball below microscope lens on stand.
 Raise or lower eyepiece-using knob till scar image is clear.
 Move the ball scar using micrometer till the cross line on eyepiece coincides
with edge of scar, record micrometer reading.
 Looking through microscope, rotate micrometer till the other edge of scar
coincides with cross line.
 The difference between the initial & final reading is the wear scar dia along one
axis.
 Similarly using other axis micrometer, measure the scar dia.
 Replace with second ball & measure wear scar diameter, similarly repeat for the
third ball.
 Add all the six scar dia values& find the average.
 The average value is taken as scar dia for that run.
Eye piece

Knob for raising or

lowering

Magnification lens
Fig 26

Fig

 Hold the base and tilt the arm to an angle for

convenient observation. Locking through
the eyepiece rotate & switch ON the LED lamp until a bright illumination is
obtained.
 Lower the body tube help of focus adjustment knob until the objective lens stops
just above the specimen.
 Looking through the eyepiece raise the main tube by turning the adjustment knobs
until the microscope slide gets focused.
 All the objectives are made par-focal, so that one focusing is made with one
objective lens, slight adjustment of focus will be necessary when changing to any
other objective lens on the revolving no piece.
 The arm serves as support to the body tube, its lens system and to hold the
microscope while carrying.
Precaution While Handling The Microscope
 Do not force down movement of rack and pinion assembly when it comes to a stop.
 Check that the eyepiece and objectives are clean.
 Do not open out optical lenses of the objectives for cleaning from inside as they
require expert handling.
 Keep the microscope covered with a dust proof cover, when not use.

8.2.9 Test evaluation

For test evaluation open wear screen, the screen
displays 4 windows (File 1 , 2, 3,& 4).
Fig 27
Click on file 1 a drop box open, select a file &
Fig

28
click open to display on screen.
Similarly repeat for file 2,3, 4.
Click refresh button to display all four graphs, each file is identified by
different colors.
Select either of normal load, frictional torque, co-efficient of friction for
comparing the graphs of different files.
8.3 Test Procedure For Weld Load Test (EP test ASTM 2783)
8.3.1 Selection of test ball :- Follow procedure in 9.2.1
8.3.2 Preparation of tester :- Follow procedure 9.2.2
8.3.3 9.3.3 Preparation of controller:- Follow procedure 9.2.3, while setting test
duration enter 10 seconds & speed 1770 rpm.
8.3.4 Applying normal load:- Follow procedure 9.2.4
8.3.5 Prepare PC for test:- Follow procedure 9.2.5, on screen acq control select
actual for EP test
8.3.6 Test start :- Follow procedure 9.2.6.
EP test mode: (Timer set for less than 2 minutes) On actuation of START the spindle
rotation and data acquisition is initiated immediately. Heater is OFF always.
8.3.7 Test end :- Follow procedure 9.2.7, the test ends before test duration if
welding has occurred, in the event of no welding test runs the entire test duration
of 10 sec. In case of welding not occurred ,wear scar of 4 mm & above is considered
to be weld load.
The step load below this weld load is considered as pass load.
When welding has occurred (fig 27), ball pot will remain attached to the collet.
Insert the collet extractor into the slot on the spindle.
Hold the ball pot and press extractor
Downwards to release the collet.
Disconnect the heater cable and place the ball pot assembly on the recess on base
plate. Allow it to cool.
Pull out the collet with pliers / tongs.
Release the lock nut & remove the ball pot.
Clean with solvent to remove sample lubricant / grease and clean the ball pot for
next test.
Whenever welding takes place the motor stops and AC drive displays fault. In such an
event the “MOTOR DRIVE” is to be reset by switching off the main power for minimum
2 minutes.

Fig 25

Fig 28 Fig 29

Fig Fig

If welding has not taken place, remove the ball pot assembly
after disconnecting the heater cable.
Place ball pot assembly on recess of base plate and allow it to cool.
Insert the collet extractor and remove the collet.
Place the collet in the ball extractor / inserter and press the lever backward to
seperate the ball.
After ball pot is cooled to room
temperature measure scar using either image
acquisition system or microscope.
Measure wear scar :- Follow procedure in
9.2.9
8.3.8 Test evaluation
Open screen EP test , on the x-axis the Fig 30

Fig

29
normal load is displayed in logarithm scale.
On the screen display four windows file 1,2,3, &4 is seen, Follow procedure 9.2.10
for display of graph.

8.4 Test Procedure For Grease:- Weld Test (EP test ASTM 2266)
8.4.1 Selection of test ball :- Follow procedure in 9.2.1
8.4.2 Preparation of tester :- Follow procedure 9.2.2
Filling grease inside ball pot;
Place a small amount of grease in the ball pot
Insert three balls in the ball pot with centering ring; lock the balls in position
by tightening the lock nut
Coat the test balls located inside ball pot and chuck thoroughly with grease , fill
the ball pot with grease and level off with the top surface of the lock nut
8.4.3 Preparation of controller: - Follow procedure 9.2.3, while setting test
duration enter 10 seconds & speed 1770 rpm.
8.4.4 Applying normal load:- Follow procedure 9.2.4
8.4.5 Prepare PC for test:- Follow procedure 9.2.5, on screen acq control select
actual for EP test
8.4.6 Test start: - Follow procedure 9.2.6
EP test mode: (Timer set for less than 2 minutes) on actuation of START the spindle
rotation and data acquisition is initiated immediately. Heater is OFF always.
8.4.7 Test end :- Follow procedure mentioned 9.2.7

8.5 Test Procedure For Grease:- Wear test (ASTM 2596)

8.5.1 Selection of test ball :- Follow procedure in 9.2.1
8.5.2 Preparation of tester :- Follow procedure 9.2.2
Filling grease inside ball pot;
Place a small amount of grease in the ball pot
Insert three balls in the ball pot with centering ring; lock the balls in position
by tightening the lock nut
Coat the test balls located inside ball pot and chuck thoroughly with grease, fill
the ball pot with grease & level off with the top surface of the lock nut
8.5.3 Preparation of controller: - Follow procedure 9.2.3,
8.5.4 Applying normal load:- Follow procedure 9.2.4
8.5.5 Prepare PC for test:- Follow procedure 9.2.5, on screen acq control select
timer & enter 60 to acquire 60data /min
8.5.6 Test start: - Follow procedure 9.2.6
8.5.7 Test end :- Follow procedure mentioned 9.2.7

8.6 Test Procedure For Weld Load Test (IP 239)

Normal load for IP 239 testing is at series of loads in 10Kg steps up to 100Kg,
then in 25Kg steps up to 300Kg and finally in 50 Kg steps up to 800Kg.
8.6.1 Selection of test ball :- Follow procedure in 9.2.1
8.6.2 Preparation of tester :- Follow procedure 9.2.2
8.6.3 Prepare PC for test:- Follow procedure 9.2.3, on screen acq control select
actual for EP test
8.6.4 Test start :- Follow procedure 9.2.4.
EP test mode: (Timer set for less than 2 minutes) On actuation of START the spindle
rotation and data acquisition is initiated immediately. Heater is OFF always.
8.6.5 Test end :- Follow procedure 9.2.5, the test ends before test duration if
welding has occurred, in the event of no welding test runs the entire test

30
 duration of 10 sec. In case of welding not occurred ,wear scar of 4 mm & above
is considered to be weld load.
8.6.6 Measure wear scar :- Follow procedure in 9.2.6
8.6.7 Test evaluation
Open screen EP test , on the x-axis the normal load is displayed in logarithm
scale.
On the screen display four windows file 1,2,3, &4 is seen, Follow procedure 9.2.7
for display of graph

9 CALIBRATION
This procedure is to be followed once in a year and in case of replacement of sensor
or display module.
9.1 Normal load sensor
Unload the loading arm. Adjust the “ZERO” push switch on the controller front panel
to display “000.0 N”. Place a calibrated load cell in place of the ball pot. Apply a
load and measure it by the calibrated load cell. Compare it with the normal load
display on the controller. Adjust the corresponding “DAS” trim pot (fig 33) on the
main card inside the controller to display correct reading (refer card below for its
identification).

Calibrated load cell

Display unit of
calibrated load cell

Fig 31

Fig

Procedure for normal load calibration;

 Switch ON controller and ensure the loading lever is lifted & supported on stand,
initialize the controller normal load reading to zero
 Remove ball pot and replace with calibrated load cell (fig 28)
 Connect the calibrated load cell to its display unit (indicator)
 Switch On the display unit and initialize the display to zero
 Slowly bring the loading lever to horizontal position, move rider over the arm
till the normal load display on indicator and controller are zero.

31
 Place 30kg weight on loading pan; record the display on controller & indicator
 Adjust the corresponding trim pot (fig 30) on data acquisition card till the
display on controller and indicator are same.
 Repeat with 10,20,30,40,50 & 60kg weight to ascertain the calibration is Calibration
true for
all loads
unit
9.2 Frictional torque sensor
Suspend a loading pan on the frictional force
calibration wire (figure 31),
Switch ON controller and ensure the loading lever is
lifted & supported on stand, initialize the controller
frictional force reading to zero
Place 1 kg dead weight on the loading pan, check
frictional torque display on controller is 0.8 Nm
If not tune the trim pot of frictional force channel on
data acquisition card (fig 29) till display on
controller show 0.8.
Repeat for other loads of 2,3, 5 & 10 kg.
Wire rope for hanging
loading pan Fig 32
Trim pot for Normal Trim Pot of Frictional Force
Fig
load cell Load Cell

Instrumentation card
Fig 33

Fig

9.3 Temperature
 Switch On controller, remove ball pot and fill with oil,
the oil
 Dip the ball pot assembly till the tip in a calibrated bath fitted with a
indicating thermometer. Maintain bath temperature 50oC and compare with the
display on PID module (fig 24). If the temperature variation is more than ± 3°,
change the temperature sensor. (The sensor is resistance variable and the values
are preset).

9.4 Speed
 Use a calibrated tachometer to measure spindle speed, stick a white reflecting
sticker on spindle end (near collet).
 Switch On controller ensure the loading arm is supported and ball pot is removed
, so that spindle is free to rotate
 Press START button, turn potentiometer knob on controller to set 100 rpm,
 Using tachometer measure spindle speed,
If there is difference between set speed and measured speed, increase/decrease the
gap between proximity sensor & sensor disc.
If the measured speed is less than the displayed speed, reduce the gap respectively
between the sensor and disc. For measured speed more than displayed speed increase
the gap between sensor and disc.

32
Repeat for other speed values of 200,500,1000,2000 & 3000 rpm.

Procedure for setting gap on sensor disc

Fig 35
Fig 34
Proximity sensor is clamped on bracket with 2 nuts.
Fig Fig
Measure gap between proximity sensor & sensor disc using a feeler gauge. If the
measured speed is less than the displayed speed, loosen nut and rotate sensor to
move near disc by 0.1mm, tighten nuts. Measure speed again using tachometer, if
required decrease gap further.
Similarly when measured speed is more increase the gap between the sensor disc and
proximity sensor.
9.5 Timer
Set the time on controller 10 sec, using a calibrated stopwatch measure time
elapsed. Similarly repeat for 60 sec’s, 2 min, 1 hr etc. If values are incorrect the
timer card has to be replaced.

9.6 Dead weight’s

Weights used on this machine are calibrated and their values are mentioned below.
SL.NO WEIGHT IN KG ACTUAL WT IN KG
1 1 1.007
2 1 1.006
3 1 1.003
4 1 998
5 2 2.002
6 2 2.004
7 2 2.005
8 2 2.005
9 2 2.005
10 2 2.005
11 5 5.014
12 5 5.014
13 5 5.012
14 5 5.013
15 5 5.013
16 5 5.017
17 5 5.017
18 5 5.017
19 5 5.012
20 5 5.013

33
 10 MAINTENANCE
10.1 General:
A regular and preventive maintenance is a must for the operational safely and life
of the equipment. A regular and careful cleaning of the equipment form dirt, oil
remainders dust increase the life and functional safety of the equipment. It reduces
malfunction leading to lower down time and maintains equipment accuracy and
precision.

Never air blast to clean the equipment.

To prevent anyone from turning power ON or touching the panel

accidentally during maintenance, place a tag saying.
“Maintenance-Do not touch the equipment” at a prominent place. Before
maintenance or servicing, turn Off the main power.
For maintenance of electrical cabinet, turn Off the main power. Failure to observe
these instructions may lead to serious injury or death from electric shock.
 Ensure connectors are secured properly. While not in use, the equipment is to be
well covered to keep it dust free.
 Handle sensors (RTD, load cells and proximity) carefully. Excessive force,
shocks, temperature, dirt, oil, water affect calibration and may cause damage.
 The RPM indicator measures period of one revolution. Period is then converted to
RPM for display. When equipment is stopped it waits up to 10 seconds looking for
signal from next revolution and as a consequence last display will be on for a
few seconds even after the motor has stopped.
 Care must be taken while experimenting with hot oil so that it does not spill out
on the sensors.
 Spindle is to rotate always in the clockwise direction as indicated by the arrow
mark on the belt guard. If the motor rotates in the opposite direction
interchange any two phases of input 3-phase supply.

10.2 Routine maintenance:

Check for belt tension if not adjust it as given in procedure below
Procedure for belt tension:

34
 Remove belt guard by loosening bolts
 Press belt near motor pulley with finger to feel its tightness
 Loosen Allen screws of idler pulley and press it against the belt till belt is
sufficiently tight, tighten screw firmly
 Again press belt near motor pulley by finger to feel the tightness.
 Insert ball inside collet and rotate ball by finger, if there is movement discard
collet.
 Speed is measured with a proximity sensor located near spindle. Rotate sensor
disc manually to check the lamp is ON when flat face of sensor disc passes near
the proximity sensor, if not rotate the nut of proximity sensor to adjust the gap
so that lamp illuminates.
 Inspect ball-locking ring of ball pot for any visual damages, discard it
immediately on deformation.
 Inspect bearing plate inside ball pot for wear, if scar is noticed replace it.
 Oil plunger body before use.
The microscope is to be cleaned regularly.
Special care should be taken to clean eyepiece & objectives. Clean the surface of
lens with gauze or soft rush. The lens of the objectives should not be touched with
fingertips. If fingerprints are left on the lenses it will affect the clarify and
sharpness of the image adversely.
In case there are fingerprints, stains or dirt left on the lenses, they should be
rubbed off by using tissue paper dipped in pure alcohol, xylol or any other soft
lens cleaning liquid.
The parts of microscope can be cleaned with a clean cloth or linen cloth regularly
for trouble free services and long life of the microscope

10.3 Annual maintenance:

 Calibrate normal load cell, frictional force load cell, temperature sensor and
proximity sensor, refer calibration chapter for details.
 Thoroughly clean the inside of controller with brush.
 Check for loose wires and re-tighten if required.

10.4 Replacing normal load sensors:

 Normal load cell is mounted inside loading lever, which is mounted on a support
on one base plate.
 Unscrew two Allen screws fixing u frame to base plate.
 Slowly move the loading arm assembly outside the body.
 Using a pin remove shaft.
 Unscrew and remove load cell.
 Replace load cell

10.5 Annual contract for maintenance: (AMC)

The annual contract for maintenance can be ordered along with purchase of your new
system and throughout the warranty period of your system. The AMC can also be
purchased after your original factory warranty expires. Significant discounts will
be applied if this agreement is ordered with your new system, and if ordered when
coverage is still current on your system and for plans of 2 years or more. Multiple
systems discounts are also available (pricing on request).

35
 11 SERVICE
11.1 Spares list for mechanical items
SL.NO PART DETAILS DRAWING NO QTY
A-LFB300-0100 SPINDLE ASSEMBLY
1 Spindle M-LFB300-0101 1
2 Spindle Housing M-LFB300-0102 1
3 Spindle Spacer-1 M-LFB300-0109 1
4 Collet M-LFB300-0111 1
5 Steel Ball Dia 12.7HRC-60 Gr24 MBX00-BS-12.7 1
6 Ang.ContBall Brg.No7207ETDULP4 MBA00-7207 CTRDUL P3 4
7 Lock Nut ZM (M30x1.5) MBZ00-LNUT-M30X1.5 2
A-LFB300-0200 BALL POT ASSEMBLY
8 Ball Pot M-LFB300-0201 1
9 Loading Button M-LFB300-0203 1
10 Ball Locking Ring M-LFB300-0206 1
11 Ball Pot Locking Nut M-LFB300-0207 1
12 Temperature Sensor Holder M-LFB300-0208 1
13 Steel Ball Dia 12.7HRC-60 Gr24 MBX00-BS-12.7 3
14 Heater 24V, 150W, Ø10x50lg. EAH01-24V150W10X50 2
15 PT 100 Sensor-3mmdia(28/500mm) EST03-PT100 1
A-LFB300-0300 LOADING UNIT ASSEMBLY
16 Anti Friction Disc M-LFB300-0301 1
17 Loading Lever Holder M-LFB300-0303 1
18 Bearing Holder M-LFB300-0307 1
19 Dowel Pin M-LFB300-0308 1
20 Pivot Pin M-LFB300-0310 1
21 Spacer M-LFB300-0311 1
22 Pivot Pin M-LFB300-0313 1
23 Plunger M-LFB300-0316 1
24 Top Flange M-LFB300-0317 1
25 Bottom Flange M-LFB300-0318 1
26 Thrust Ball Brg. No. 51206 MBH00-51206 1
27 Bearing Bush SMTEM40-W MBX00-BUSH-SMTEM40-W 1
28 Needle Roller Bearing NK15/20 MBN00-NK-15/20 2
29 Beam Load Cell 1100KG-65023 ESL05-1100KG-65023 1
A-LFB300-0600 IDLER PULLEY ASSEMBLY
30 Idler Pulley shaft M-LFB300-0601 1
31 Idler Pulley Base M-LFB300-0602 1
32 Idler Pulley Bearing Spacer M-LFB300-0603 1
33 Idler Pulley Housing M-LFB300-0604 1

36
 34 Deep Groove Ball Brg. 6002Z MBD00-6002Z 2
A-LFB300-0700 LOAD CELL ASSEMBLY
35 Load Cell Holder M-LFB300-0701 1
36 Loading Button M-LFB300-0702 1
A-LFB300-0800 BODY ASSEMBLY
37 Body M-LFB300-0801 1
38 Bottom Flange M-LFB300-0802 1
39 Spindle Fixing Flange M-LFB300-0803 1
40 Plunger Housing M-LFB300-0806 1
41 Plunger Body M-LFB300-0807 1
A-LFB300-1000 BALL REMOVER ASSEMBLY
42 Jig Base M-LFB300-1001 1
43 Ball Base M-LFB300-1003 1
44 Pin M-LFB300-1004 1
45 Spring Lock Nut M-LFB300-1005 1
46 handle M-LFB300-1006 1
A-LFB300-1100 LOAD CELL ASSEMBLY
47 Load Cell Holder M-LFB300-1101 1
48 Loading Button M-LFB300-0702 1
49 Bellow Type Load Cell-20Kg ESL01-20KG 1
A-LFB300-1200 PLUNGER ASSEMBLY
50 Shaft M-LFB300-1201 1
51 Top Flange M-LFB300-1202 1
52 Bottom Flange M-LFB300-0318 1
53 SS Allen CSK Screw M03X10L XFS01-ACSK-M3X10 4
54 SS,CSK SCREW M03X15 XFS01-CSK-M03X15 4

11.2 Spares list for electrical items

SL NO PART DETAILS MAKE SPECIFICATION QTY

A-LFB300-5001 Four Ball Tester-TR30L
1 AC Motor-FM-1.5KW ,1500 RPM SIEMENS EMA02-220V1.5KW1500R 1
2 Beam Load Cell 1100KG-65023 SENSOTRONICS ESL05-1100KG-65023 1
3 Bellow Type Load Cell-20Kg IPA ESL01-20KG 1
Proximity Sensor-5mm -
4
150370 FESTO & TAP ESD01-5D 1
5 Heater 24V, 150W, Ø10x50lg. HOTSET EAH01-24V150W10X50 4
D Type Con.- 9 Pin-F-
6
M09S114 END01-09P-F 2
Emerg Stop Switch-1
7
NC,220V-5A EOS02-EM-1NC220V5A 1
8 Power Cable-4Core, 1.5Sqmm EWP01-4C1.5SQMM 1
9 USB Camera RADICAL EAO01-USB 1
10 Lense-PL4/0.6-160 EAO02-0.1/160 1
Power cont 220V, 5A,PS-
11
12,Sckt ENP01-220V5APS12 1
Power On/Off Switch-
12
250V5AMINI EPS02-MINI-250V5A 1
13 Power Cable plug in type 5A EWP03-PLUGIN3P5A 1
2Mtr Control Cable19 Pin
14
MsCon. EBC91-19P-2M 1
2 Mtr Signal Cable15 Pin
15
DCon. EBS91-D15P-2M 1
2Mtr Data Cable w9 Pin D
16
Con. EBD01-D9P-2M 1
17 MCB 2-Pole 16A INDOKUPP EPM01-2PC16 1
18 Line filter MF420 10A EMI EPF01-MF42010A 1

37
19 AC Drive 220V1P2HP GE EDA01-220V1P2HP 1
Trans Pri 220VSec:0-24-
20
48V6.5A GLASTRONICS EPT01-02448V6.5A 1
A-LFB300-6001 Four Ball Tester-TR30L
Power Supply Card-+ -
21
15(JAN2003) LCP91-15015 1
22 DAC Card / 101/2.1/Jan 04 LPB01-DAC CARD 1
23 Timer/RPM-Card LCY91-10TR 1
24 2Ch-Display Board 4/2001 LPB01-2 CH CARD 1
25 FB Instr-Normal&Frictional LCF91-FBI-N/F 1
26 Opto coupler Board LCI91-OCB 1
27 PID Controller – OMRON OMRON LDP01-OMRON-RELAY 1
28 Line Filter-3A ,220 V ,1Ph EMI EPF01-220V1PH3A 1
Trans. Pri 220V-15-0-15 0-
29
8V1A GLASTRONICS EPT01-15015-08V1A 1
30 Fuse-1A , Glass Catridge½ " EEF01-1A 1
31 Fuse Holder-FH1 EEH01-FH1 1
Potentiometer10KOhms.10Turn
32
s PAVAN EEP01-10KO10T 1
33 Knob-MK17 EOK01-MK17 1
34 Power On/Off Switch DPST EOS06-220V5A-GILLARD 1
35 Power Cable-5Core,1.5Sqmm EWP01-5C1.5SQMM 3
36 Resistor 100 Ohm ,1/2W MFR LSR01-100O-1/2W 2
37 IC-TIL 111 LSI01-TIL111 3
38 IC Base 6Pin LSX01-ICB-6P 3
39 General Purpose PCB-GEN LPB01-GEN 1

38
 12 TROUBLESHOOTING

PART TROUBLE CAUSE REMEDY

Loose belt Increase belt tension
Worn out belt. Replace belt & set correct belt
tension.
Spindle stalls Loose spindle Tighten the pulley screw.
during rotation. pulley.
Play on Pulley Replace pulley
Spindle
keyway
Replace belt
Belt slips from
Tighten pulley to lock spindle in
flat pulley
position
Anti clockwise Wrong motor phase Interchange any two-supply phase.
rotation. wiring
Loose connection. Check and tighten.
Burnt motor Rewind / replace the motor.
winding.
Check alarm number on drive, if
Motor Not running it is due to thermal or over load
Variable frequency trip, switch off machine for 15
drive tripped. minutes & restart.
If alarm is due to other defects,
refer manual of VFD
Cable damaged, Visually check for damage, if
socket not inserted required check continuity, &
properly insert socket properly & tighten
screw.
Normal Instrumentation/I- Check for power supply on card,
load/Fri das card failure connecting frictional force
No display
ctional sensor, if not replace card
force Sensor is saturated Loosen sensor-clamping screw till
(reached extreme display is seen & lock the
values) position.
Sensor damage Send to Koehler for repair or
replacement
File number & Run continuously Click On run continuously icon to
sample ID cannot icon not activated activate screen
be entered/
input parameters
is not accepted
Power icon on Click power icon, the color
software is not changes to green indicating the
clicked power is available on controller
Software
Run button Controller/machine
Switch On Toggle switch on
blinks power is not
controller & MCB of machine
switched ON
Sensor has come out Push sensor till the tip is
off position touching the heated surface
Set load value Released load value
Check MPPES for any change in set
not achieved does not reach
value
zero.

39
 13 PACKING LIST
SL.NO DESCRIPTION QTY ID NO

1 Basic Machine 1/42 1No

2 5183 Test Dead Weights 2/42 25Nos
3 Electronics Controller(K93114) 3/42 1No
4 Dust Cover For Controller 4/42 1No
5 Dust Cover For Machine 5/42 1No
6 Ball Pot Assembly(K93143) 6/42 2SET
7 Collet Master 7/42 1SET
8 Connecting Cable(K93140) 1SET
a) Power Cable 8/42 1No
b) Signal Input Cable 9/42 1No

c) Controller Cable 10/42 1No

d) Data Acquisition Cable 11/42 1No

9 Handle Tools(K93108)
a) Allen Key Set 12/42 1SET
b) Screw Driver Set 13/42 1SET
c) 18/19 Double Ended Spanner 14/42 1No
d) Cutting Plier 15/42 1No

e) 1/2” Adjustable Spanner 16/42 1No

f) Rachet Handle 17/42 1No

g) Torque Wrench(K93109) 18/42 1No
h) Tweeser 19/42 1No
Optical Microscope For Scar Size Measurement With
10 1SET
Ball Holder 20/42
11 Lock Nut Adopter 21/42 1No
12 Oil Splash Guard 22/42 1No
13 Steel Ball Dia12.7(Import)(K93105) 23/42 200Nos
14 Instruction Manual With Software Cd's 24/42 2SET

(K93900 & K93119)

15 Spares

40
a) 2 amps fuse(K93139) 25/42 5Nos

b) Heater (For Ball pot)(K93104) 26/42 2Nos

c) Pt-100 sensor(K93136) 27/42 1No
d) flat belt 900x30x2 28/42 1No
e) Antifriction Disc With Thrust Bearing-51206 29/42 2SET

16 Rubber Mat 37”x21”x10mm thk 30/42 1No

17 Loading Pan Calibration (f.f) 31/42 1No
18 Loading Pan 32/42 1No
19 Dead Weight(k93101)
a) 5kg 33/42 10Nos
b) 2kg 34/42 6Nos
c) 1kg 35/42 4Nos
20 Ball Chuck Collet Remover(K93144) 36/42 1No
21 DIA12.7mm Ball Chuck (collet)(K93124) 37/42 2Nos
22 Steel Bowl(K93145) 38/42 1No
23 Ball Remover Pin 39/42 1No
24 Dolly Assembly 40/42 4Nos

41