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.
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.
43A2781A
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.
3A2781A5
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
APump Adjustment Nut
BPump Inlet
CDrive Shaft
DPressure Gauge
EDrain 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)
FPump 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
63A2781A
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.
3A2781A7
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.
83A2781A
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.
3A2781A9
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.
103A2781A
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
3A2781A11
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
* All marks are counting clockwise from the maximum
setting.
FIG. 8
Output Per Stroke Cubic
Inches (Cubic Centimeters)
Adjustment
Mark
123A2781A
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
isproperly 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.
3A2781A13
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.
ProblemCauseSolution
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 keyReplace 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 offTurn 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.
143A2781A
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