Graco LubeMaster Instructions Manual

Instructions
®
LubeMaster
Floor
Mount or Wall Mount
3A2781A
Pump Package
Maximum Working Pressure: 5000 psi (340 bar, 34.0 MPa)
The LubeMaster Pump Package includes the following components:
Reservoir
Oil or Grease Pump
EN
See page 6 for part number information.
Important Safety Instructions
Read all warnings and instructions in this manual. Save these instructions.
Table of Contents
Table of Contents
Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
System Identification . . . . . . . . . . . . . . . . . . . . . . . 6
Component Identification . . . . . . . . . . . . . . . . . . . . 7
Reservoirs - Oil or Grease . . . . . . . . . . . . . . . . . 7
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Motors and Drives . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation Instructions . . . . . . . . . . . . . . . . . . . . . 8
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pressure Relief Valves . . . . . . . . . . . . . . . . . . . . 8
Choosing an Installation Location . . . . . . . . . . . . 8
Pump Installation Procedure . . . . . . . . . . . . . . . . 8
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Filling the Reservoir . . . . . . . . . . . . . . . . . . . . . . 9
System Filling . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Manifold Bleeding . . . . . . . . . . . . . . . . . . . . . . . 11
Adjusting the Clutch Drive . . . . . . . . . . . . . . . . . 11
Standard Pump Adjustment . . . . . . . . . . . . . . . 12
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure Relief Procedure . . . . . . . . . . . . . . . . 13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Maintenance and Repair . . . . . . . . . . . . . . . . . . . . 17
Pumps: Oil and Grease Models . . . . . . . . . . . . 17
Grease Reservoirs . . . . . . . . . . . . . . . . . . . . . . 18
Low-Level Switch Assemblies . . . . . . . . . . . . . . 19
Oil Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation After Maintenance . . . . . . . . . . . . . . 24
Drive and Motor . . . . . . . . . . . . . . . . . . . . . . . . . 24
Recommended Lubricants for Enclosed Gear
Reducers . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Alternative AGMA Lubricants . . . . . . . . . . . . . . 24
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Grease Reservoirs . . . . . . . . . . . . . . . . . . . . . . . 25
Oil Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Overhead Supply Adapter Assembly . . . . . . . . . 27
Pump Body Assembly . . . . . . . . . . . . . . . . . . . . 28
Clutch Drive Assembly . . . . . . . . . . . . . . . . . . . 29
LubeMaster Pump . . . . . . . . . . . . . . . . . . . . . . . 30
Motorized LubeMaster Pump with Gear Reducer
and Motor (Up to 20 lbs):
Floor Mounting . . . . . . . . . . . . . . . . . . . . . . 31
Motorized LubeMaster Pump with Gear Reducer
and Motor (Up to 20 lbs):
Wall Mounting . . . . . . . . . . . . . . . . . . . . . . . 32
Oil Reservoir 15 Amp Low-Level Assemblies . . 33 Oil Reservoir 10-Watt Low-Level Assemblies . . 33
Grease Reservoir Low-Level Assembly . . . . . . . 34
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Clutch Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Clutch Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Motorized LubeMaster (Up to 20lbs):
Wall Mounting . . . . . . . . . . . . . . . . . . . . . . . 41
Motorized LubeMaster (Up to 20lbs):
Floor Mounting . . . . . . . . . . . . . . . . . . . . . . 42
Motorized LubeMaster (Up to 20lbs) . . . . . . . . . 43
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 44
2 3A2781A
Part Number
Part Number
Use the Part Number Key provided below to identify each component included in your LubeMaster Pumping System Part Number. The Codes associated with each Option (A-D) that make up the Part Number are provided in the tables below. For example, Part Number - LM1321 is a LubeMaster pump system with a 12 pint plastic oil reservoir. It has a 10:1 reduction ratio and is floor mounted. It is powered with a 115/230V, 1/2 hp, 1 PH, 60 hz, 1725 RPM motor and does not have a low level switch.
NOTE: Some part number configurations are not available. Contact Graco Customer Service or your local Graco distributor for assistance.
Par t Key: LM A - B - C - D Part Example: LM 1 3 2 1
LM = LubeMaster
Option A: Reservoir Options
Code
Code
Reservoir Size:
pints (liters)
1 12 (5.68) Oil Plastic 2 20 (9.46) Oil Plastic 3 12 (5.68) Oil Metal 4 20 (9.46) Oil Metal
Reservoir Size:
pounds (kg)
5 12 (5.44) Grease Plastic 6 20 (9.07) Grease Plastic 7 12 (5.44) Grease Metal 8 20 (9.46 L) Grease Metal 9 No Reservoir, Overhead Supply
Oil or Grease
Oil or Grease
Plastic or
Metal
Plastic or
Metal
Option B: Drive Options
Code
1None 2 Clutch Drive With Arm 3 10:1 Floor Mounting 4 10:1 Wall Mounting 5 60:1 Floor Mounting 6 60:1 Wall Mounting
Reduction Ratio Mounting Option
Description
Option C: Motor Options
Code Voltage Horsepower PH Hz RPM
1None 2 115/230 1/2 1 60 1725 3 230/460 1/2 3 60 1725 4 115/230 1/2 1 60 1140 5 230/460 1/2 3 60 1140
Option D: Low Level Switch Options
Code Size
1 2 12 (5.68 L) Oil X 15 3 20 (9.46 L) Oil X 15
12 and 20 pounds
4
(5.44 and 9.07 kg)
5 12 (5.68 L) Oil X 10 6 20 (9.46 L) Oil X
Oil or
Grease
No low level switch
Grease
SPDT Amps Watts
10
3A2781A 3
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama­tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause elec­tric shock.
Turn off and disconnect power at main switch before disconnecting any cables and before servicing or installing equipment.
Connect only to grounded power source.
All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical
treatment.
Do not point dispensing device at anyone or at any part of the body.
Do not put your hand over the fluid outlet.
Do not stop or deflect leaks with your hand, body, glove, or rag.
Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or servicing equipment.
Tighten all fluid connections before operating the equipment.
Check hoses and couplings daily. Replace worn or damaged parts immediately.
FIRE AND EXPLOSION HAZARD
When flammable fluids are present in the work area, such as gasoline and windshield wiper fluid, be aware that flammable fumes can ignite or explode. To help prevent fire and explosion:
Use equipment only in well ventilated area.
Eliminate all ignition sources, such as cigarettes and portable electric lamps.
Ground all equipment in the work area.
Keep work area free of debris, including rags and spilled or open containers of solvent and gasoline.
Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
Use only grounded hoses.
Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until you identify and correct the problem.
Keep a working fire extinguisher in the work area.
4 3A2781A
Warnings
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
Do not operate the unit when fatigued or under the influence of drugs or alcohol.
Do not exceed the maximum working pressure or temperature rating of the lowest rated system com­ponent. See Technical Data in all equipment manuals.
Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request Safety Data Sheet (SDS) from distributor or retailer.
Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu­facturer’s replacement parts only.
Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards.
Make sure all equipment is rated and approved for the environment in which you are using it.
Use equipment only for its intended purpose. Call your distributor for information.
Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
Do not kink or over bend hoses or use hoses to pull equipment.
Keep children and animals away from work area.
Comply with all applicable safety regulations.
ENTANGLEMENT HAZARD
Rotating parts can cause serious injury.
Keep clear of moving parts.
Do not operate equipment with protective guards or covers removed.
Do not wear loose clothing, jewelry or long hair while operating equipment.
Equipment can start without warning. Before checking, moving, or servicing equipment, follow the
Pressure Relief Procedure and disconnect all power sources.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. Protective equipment includes but is not limited to:
Protective eyewear, and hearing protection.
Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
3A2781A 5
System Identification
11
Oil Model
Grease Model
A
D
B
30
31
C
101
E
F
E
13
12
Side View
System Identification
(Floor Mount Model Shown)
FIG. 1
A Pump Adjustment Nut B Pump Inlet CDrive Shaft D Pressure Gauge E Drain and Drain Plug (Oil Models: one on each side of
base); (Grease Models: one on the opposite side of the base from the fill stud (13)
F Pump Outlet
11 Reservoir Assembly (Oil or Grease) 12 Fill Cap (Grease Only) 13 Fill Stud (Grease Only) 30 Fill Cap (Oil Only) 31 Filter Screen (Oil Only) 101 Pump Body
6 3A2781A
Component Identification
31
30
13
Component Identification
All LubeMaster Pump Packages include the following components:
A reservoir (11) for holding the lubricant.
A standard pump (101).
Reservoirs (11) - Oil or Grease
Container for holding oil or grease.
Grease models include a follower plate.
The reservoir mounts directly to LubeMaster pump.
Oil Reservoirs
Reservoirs for oil models have a fill cap (30) and screen (31), located on top (F
IG. 2).
Pump (101)
The pump can be driven by an electric motor or by a rotating or oscillating machine motion.
The pump must always be installed with the reser­voir (11) in a vertical position to ensure proper oper­ation.
Always use lockwashers with mounting bolts and make certain that the bolts are properly torqued.
Motors and Drives
Gear Reducer
NOTICE
Gear reducer units are shipped without lubricant. Before operating, always check lubricant level and fill per manufacturers instructions. Operation without lubri­cant will damage the gear reducer. A table of sug­gested lubricants is provided on page 24.
Gear reducers have either a 10:1 or 60:1 reduction or an oscillating clutch drive that can be activated by a machine motion.
FIG. 2
Grease Reservoirs
FIG. 3
Grease reservoirs require an external air-free sup­ply source connected to the fill stud (13).
ENTANGLEMENT HAZARD
An exposed drive shaft must be guarded to enclose the shaft.
A shaft guard is included if the pump is configured with a gear reducer.
The user must provide a guard for any other config­uration.
Low-Level Switch
Low-level switches protect the system against excessive pressure and low lubricant levels. The switch provides an electrical signal when the lubricant level in the reser­voir is low.
3A2781A 7
Installation Instructions
Installation Instructions
The reference letters and numbers used in the following sections, refer to F
Components are completely assembled when you first receive the LubeMaster Pump Package from the factory. Reassembly instructions for these components are pro­vided in the Maintenance and Repair section of this manual, beginning on page 17.
IG. 1.
Grounding
The equipment must be grounded to reduce the risk of static sparking and electric shock. Electric or static sparking can cause fumes to ignite or explode. Improper grounding can cause electric shock. Grounding provides an escape wire for the electric current.
Install a 12 gauge (1.5 mm) minimum ground wire between the LubeMaster pump package and a true earth ground.
Pressure Relief Valves
Pressure Relief Valves
Choosing an Installation Location
AUTOMATIC SYSTEM ACTIVATION HAZARD
The system is equipped with an automatic timer that activates the pump lubrication system. Unexpected activation of the system could occur and result in serious injury, including skin injection and amputa­tion.
Before you install or remove the lubrication pump from the system, disconnect and isolate all power supplies and relieve all pressure.
Select a location that will adequately support the weight of the pump and lubricant, as well as all plumbing and electrical connections.
Refer to the mounting hole layouts provided in the Dimensions section of this manual begin­ning on page 37. No other installation configura­tion should be used.
Use designated mounting holes and provided configurations only.
Use fasteners that are strong enough to support the weight of the pump and lubricant when securing the pump to the mounting surface.
To prevent over-pressurization, which can result in equipment rupture and serious injury, a pressure relief valve appropriate for the lubrication system must be installed close to every pump outlet to allevi­ate unintended pressure rises in the system and pro­tect the pump from damage.
Only use a pressure relief valve that is rated for no more than the working pressure of any component installed in the system. See Technical Data, page
35.
Install a pressure relief valve close to every pump outlet and before any auxiliary fitting.
8 3A2781A
Pump Installation Procedure
1. Secure with attaching hardware to installation loca­tion. Make certain all fasteners are tightened to the proper torque.
2. Install all guards and mechanical linkages or con­nections removed at the pump drive shaft.
3. Install the reservoir.
4. Electrically reconnect the pump drive.
5. Fill system with lubricant. See Filling the Reservoir instructions, beginning on page 9.
Setup
31
30
Setup
Filling the Reservoir
Material Cleanliness
Make sure that lubricant used to fill the system is clean. If there is doubt about cleanliness, lubricant should be filtered before being introduced into the system. System life and consistent operation will both be improved by using clean lubricant.
After filtering the lubricant, make sure the lubricant sup­ply is protected from debris.
On all pumps, the lube piston diameter is very close to the diameter of the chamber in the pump body. Contam­inants in the lubricant could cause scoring in this area, resulting in erratic pump operation and costly parts replacement.
Temperature Effects
Flow characteristics of the lubricant may change if the area the unit is used in goes through drastic tempera­ture changes. Choose a lubricant that will flow properly at all temperatures expected in the system environment.
Overhead Supply Adapter Assemblies Only
Filling Oil Reservoirs
Oil reservoirs have a fill cap (30) and filter (31).
FIG. 4
1. Wipe the area around the fill cup to avoid contami­nation during filling.
2. Open the fill cap (30) and slowly pour oil into the reservoir (11) through the filter screen (31).
NOTE: The filter screen (31) will remove large parti­cles which may be present in the oil.
The recommended inlet pressure is 15 psi (0.103 MPa,
1.03 bar) or less.
3. When filling is complete, close fill cap (30) and wipe any spillage.
3A2781A 9
Setup
12
E
13
E
Filling Grease Reservoirs
OVER PRESSURIZATION HAZARD
Over pressurization can result in equipment rupture and serious injury. Fill slowly to avoid over pressuriz­ing the reservoir.
FIG. 5
Filling grease reservoirs requires an external, air-free supply source be connected to the fill stud (13).
To avoid introducing air into the system, make sure there is enough grease in the supply source to fill the reservoir without being disconnected.
Operate the supply source at a steady speed to allow air-free filling of the reservoir. Filling the reser­voir too fast may result in air pockets.
1. Remove cover (12)
2. Connect grease supply source to fill stud (13).
3. Loosen the drain plug (E) (located on the opposite side of the base from the fill stud (13) (F
IG. 6).
FIG. 6
4. Slowly begin to fill the reservoir, allowing air trapped under follower to exhaust out the open drain plug.
5. When grease free of air flows from the drain, tighten the plug (E) and continue to fill the reservoir until fol­lower is at the vent hole in reservoir tube (any remaining air and small amount of grease will exit drain).
6. When filling is complete, turn off the supply source and disconnect if from the fill stud (13). Replace the cover (12).
NOTE: A check valve in the fill stud will prevent lubricant from being forced back out.
The level of grease is checked by visual means.
- In reservoirs with plastic cylinders, the grease level can be viewed through the cylinder.
10 3A2781A
7. Loosen system mainline connection at pump outlet.
8. Operate pump until lubricant free of air flows from outlet port.
9. Tighten mainline connection at pump. Pump is now free of air.
NOTE: If the pump will not take a prime, it may be helpful to inject several ounces of heavy oil through the fill stud. The pump will then prime on oil pulling the grease behind it. If it becomes necessary to use this method, all injected oil should be discharged at the loosened system mainline connection along with any air.
Setup
System Filling
After the reservoir is filled as described in Filling the Reservoir, page 9, fill the remainder of the system by attaching a hand pump to the system downstream from the pump manifold block assembly and cycle the hand pump until the system is filled.
Manifold Bleeding
Proper filling of the system will reduce the chance of air entrapment. The pump block manifold assembly (117, page 28) must be bled to remove air which will be trapped inside the pump. Cycle the pump several times until air-free lubricant is dispensed.
NOTE: Manual air bleeding procedures are necessary in the event any system components are loosened, dis­connected or otherwise removed after their initial instal­lation.
Adjusting the Clutch Drive
The degrees of throw of the clutch lever is adjustable from 12 to 60 degrees. Table 1 (page 12) provides the minimum/maximum pump outputs. The actual pump output for your installation may be computed by using the Calculating Pump Output procedure (page 12).
Using the clutch lever diagram provided in F mine the anticipated clutch lever throw angle.
IG. 7 deter-
FIG. 7
3A2781A 11
Setup
Clutch Drive - Calculating Pump Output
The standard pump output can be varied, from 0.010 to 0.050 cubic inches (0.1639 to 0.8195 cu. cm) per cycle, by changing the position of the pump adjustment sleeve (2) (F high volume pump has a fixed output.
To calculate the pump output per hour, use the following formulas:
IG. 1, page 6) located below the pressure gauge (3). The
360°
Degrees of Throw
* Degrees of Throw can be found by using clutch lever diagram (F
IMPULSES/HOUR
RATIO
Pump strokes per hour x 0.010 = Minimum Pump Output per Hour Pump strokes per hour x 0.050 = Maximum Pump Output per Hour
= Effective Ratio
IG. 7, page 11)
PUMP STROKE PER HOUR
=
Table 1: Minimum / Maximum Pump Output
Degrees of Throw
Effective Ratio Impulses Per
Minute
Output Per Hour Pump Strokes Per
Cubic Inches (Cubic Centimeters)/hour Minimum Maximum
Hour 12 30:1 5 Minimum 10 0.100 (1.639) 0.500 (8.195) 60 6:1 150 Maximum 1500 15.00 (245.8) 75.00 (1229)
Standard Pump Adjustment
Table 2: Standard Output/Stroke Adjustment
Percent of
Output
100 0.050 (0.820) Max.
90 0.045 (0.737) *1st 80 0.040 (0.656) *2nd 70 0.035 (0.574) *3rd 60 0.030 (0.492) *4th 50 0.025 (0.410) *5th 40 0.020 (0.328) *6th 30 0.015 (0.246) *7th 20 0.010 (0.164) Min.
* All marks are counting clockwise from the maximum
setting.
FIG. 8
Output Per Stroke Cubic
Inches (Cubic Centimeters)
Adjustment
Mark
12 3A2781A
Operation
a
Operation
Startup
Before attempting to operate any system, check the following:
Ensure the reservoir is securely fastened to the pump and that the fill cap or grease-fill fitting is eas­ily reached.
Check that the pump is securely fastened in place.
Check that gear reducer has been filled with proper lubricant.
Check all electrical connections to any controllers, level switches or pressure switches used on the sys­tem.
While the system is operating, periodically check the following components:
Check that the pump is cycling according to sched­ule.
Visually check the unit for leaks and loose fittings. Make sure that hoses do not become kinked and are not rubbing on anything.
If the reservoir is not equipped with a low-level switch, visually check the lubricant level and refill before all lubricant is used.
NOTE: If the reservoir is allowed to run dry, excess air will be introduced into the system, requiring that the system be bled.
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever you see this symbol.
Check that all accessories plumbed into the output manifold block assembly are secure.
Make sure all hose or tubing connections are tight.
Check that the reservoir is filled with lubricant. See Filling the Reservoir, page 9.
Check that all filling and bleeding steps have been completed.
Check the output of the lubricant pump. Adjust the output as described in the Clutch Drive - Calculating Pump Output, page 12.
If the pump is equipped with a clutch drive, verify it is properly adjusted as described in the Adjusting the Clutch Drive section, page 11.
The unit is now ready to run. The pump is cycled by an external source, such as a timer, counter, control pack­age, or customer-supplied drive. Once this external source is engaged, the unit will cycle as programmed.
This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Pro­cedure when you stop dispensing and before clean­ing, checking, or servicing the equipment.
1. Verify pump is stopped and disconnected from power source.
2. Using a wrench, slowly loosen the outlet fitting (a, F
IG. 9) connected to the pump block manifold
assembly until the fitting is loose and no more lubri­cant or air is leaking from the fitting.
3A2781A 13
FIG. 9
Troubleshooting
Troubleshooting
Many system problems may be caused by loose connections or trapped air in the system. Before removing system components, check all connections to make sure they are tight. Also make sure the system is properly bled.
Problem Cause Solution
No lubrication is dispensed from pump, but pump is rotating
Pump is Not Running or Requires Service
No lubrication is dispensed from pump and drive shaft is not rotating
Motor is Not Running
No Gear Reducer Output
Reservoir is empty
Check valve is defective
Adjustment sleeve seals are defec­tive
Problem is in the pump
Yoke connector pin and piston are defective
Sheared drive motor key Replace key.
Broken pump drive shaft
Piston is not engaged in sleeve
Motor is not running
No gear reducer output
Defective pump input shaft
Power is off Turn power on.
Electric connections to motor or timer are loose
Timer/controller is set incorrectly or defective
Key is sheared or missing at coupling Replace key.
Defective gearbox
Refill as required. See Filling The Reservoir, page 9.
Clean and install seal repair kit.
See Pump is Not Running or Requires Servicing section of this Troubleshooting Table.
Replace defective parts using Pump Drive Repair Kit.
Replace defective parts using Pump Drive Repair Kit.
Replace defective parts using Out­put Manifold Kit.
Refer to Motor is Not Running section of this Troubleshooting Table.
Refer to No Gear Reducer Output section of this Troubleshooting Table.
Replace defective parts using Pump Drive Repair Kit.
Check all connections and tighten securely.
Set timer/controller to correct setting. If unit is still not functioning, repair or replace timer/controller.
Gearbox must be replaced. For this repair unit must be returned to an authorized Graco repair facility.
14 3A2781A
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