Graco Trabon Modu-Flo System User Manual

Modu-Flo® System

LUBRIQUIP

Operation and Service Instructions

Bulletin 42000

Modular

Pumping Packages

Revised November 2005

TABLE OF CONTENTS

42000Modu-Flo® System

Section/Para Page

1 INTRODUCTION .............................................. 1-1

1.1 GENERAL ............................................................. 1-1

1.2 GENERAL SYSTEM OPERA TION......................... 1-2

2 RESERVOIRS AND TANKS............................. 2-1

2.1 DESCRIPTION...................................................... 2-1

2.2 MOUNTING INSTRUCTIONS ............................... 2-1

2.3 PREPARATION FOR USE.....................................2-2

2.4 GREASE RESERVOIR MAINTENANCE (OPTIONS GP1 THROUGH GP5 AND GM1

THROUGH GM4) .................................................. 2-3

2.5 OIL RESERVOIR MAINTENANCE

(OPTIONS OP1 THROUGH OP4) ........................ 2-7

2.6 OIL T ANK MAINTENANCE

(OPTIONS T1, T2 and T3) .................................. 2-11

3 PUMPS............................................................ 3-1

3.1 DESCRIPTION...................................................... 3-1

3.2 PREPARATION FOR USE.....................................3-3

3.3 PNEUMATIC PUMP MAINTENANCE

(OPTIONS A1 THROUGH A6) .............................. 3-3

3.4 HYDRAULIC PUMP MAINTENANCE

(OPTIONS H1 AND H3) ........................................ 3-9

3.5 HYDRAULIC PUMP MAINTENANCE

(OPTION H2)....................................................... 3-13

Section/Para Page

5.3 OIL T ANK AND RESERVOIR 15 AMP LOW-LEVEL ASSEMBL Y MAINTENANCE

(OPTIONS L1, L2 and L3) .................................... 5-2

5.4 OIL T ANK RESERVOIR 10-WA TT LOW-LEVEL ASSEMBLY MAINTENANCE (OPTIONS L5, L6

AND L7) ................................................................5-4

5.5 GREASE RESERVOIR LOW-LEVEL ASSEMBL Y

MAINTENANCE (OPTION L4)............................... 5-5

6 HIGH-PRESSURE AND BLOWOUT

SWITCHES...................................................... 6-1

6.1 DESCRIPTION...................................................... 6-1

6.2 HIGH-PRESSURE SWITCH ADJUSTMENT ........ 6-2

6.3 MOUNTING INSTRUCTIONS ............................... 6-3

6.4 HIGH-PRESSURE SWITCH MAINTENANCE

(OPTION P1) ......................................................... 6-3

6.5 RESERVOIR BLOWOUT SWITCH MAINTE-

NANCE (OPTIONS P2 and P3) ............................6-4

6.6 TANK BLOWOUT SWITCH MAINTENANCE

(OPTION P4) ......................................................... 6-6

7 PNEUMA TIC SOLENOID OPTIONS ................ 7-1

8 CONTROLLERS .............................................. 8-1

8.1 DESCRIPTION...................................................... 8-1

8.2 WIRING ................................................................. 8-2

4 MANIFOLDS.................................................... 4-1

4.1 DESCRIPTION...................................................... 4-1

4.2 PREPARATION FOR USE.....................................4-1

4.3 MAINTENANCE ..................................................... 4-1

5 LOW-LEVEL SWITCHES ................................ 5-1

5.1 DESCRIPTION...................................................... 5-1

5.2. MOUNTING INSTRUCTIONS ............................... 5-1

LIST OF ILLUSTRATIONS

Number Title Page

1-1. Modu-Flo Functional Schematic ......................... 1-3

2-1. Grease Reservoir - Exploded View.....................2- 5

2-2. Oil Reservoir - Exploded View ............................ 2-9

2-3. Oil Tank - Exploded View ..................................2-13

3-1. Typical Pump Operation ...................................... 3-2

3-2. Pneumatic Pump, Exploded View ...................... 3 -7

3-3. Hydraulic Pump Options H1 and H3 -

Exploded View................................................... 3 -11

3-4. Hydraulic Pump Option H2 - Exploded View .... 3-15

4-1. Typical Manifold Assembly.................................. 4 -3

5-1. Oil Tank and Reservoir 15 Amp Low-Level

Assembly ............................................................5-3

9 SYSTEM OPERA TION ..................................... 9-1

9.1 GENERAL ............................................................. 9-1

9.2 SYSTEM INFORMATION ....................................... 9-1

9.3 OPERATING TIPS ................................................. 9-1

9.4 MATERIAL CONSIDERATIONS............................. 9-2

10 TROUBLESHOOTING ................................... 10-1

10.1 GENERAL ........................................................... 10-1

Number Title Page

5-2. Oil Tank and Reservoir 10-Watt

Low-Level Assembly ........................................... 5-5

5-3. Grease Reservoir Low-Level Assembly ............. 5-6

6-1. High-Pressure Switch ......................................... 6-2

6-2. High-Pressure Switch (Rear View) ..................... 6 -4

6-3. Reservoir Blowout Switch Assembly (Front

View)....................................................................6-5

6-4. Tank Blowout Switch Assembly .......................... 6- 7

7-1. Pneumatic Solenoid ........................................... 7-1

8-1. DC Timer Wiring Schematic ............................... 8 -2

8-2. AC Timer Wiring Schematic................................ 8- 2

8-3. TC1000 Timer/Counter Wiring Schematic ......... 8 -3

8-4. WMP Maxi-Monitor Wiring Schematic .................8-3

Modu-Flo® System 42000

LIST OF TABLES

Number Title Page

2-1. Reservoirs and Tanks ......................................... 2-2

2-2. Grease Reservoir Parts List ............................... 2-4

2-3. Oil Reservoir Parts Lists ..................................... 2- 8

2-4. Oil Tank Parts List ............................................. 2-12

3-1. Pumps................................................................. 3-2

3-2. Pneumatic Pump Parts List ................................ 3 -5

3-3. Hydraulic Pump Options H1 and H3

Parts List ........................................................... 3-10

3-4 Hydraulic Pump Option H2 Parts List...............3-14

4-1. Operating Ports on Modu-Flo Manifolds ............. 4-2

4-2. Manifolds and Manifold Accessories .................. 4 -2

5-1. Low-Level Switch Assemblies ........................... 5-2

5-2. Oil Tank and Reservoir 15 Amp Low-Level

Assemblies Parts List ........................................5-3

Number Title Page 5-3. Oil Tank and Reservoir 10-Watt Low-Level

Assemblies Parts List ........................................5-5

5-4. Grease Reservoir Low-Level Assembly

Parts List ............................................................. 5-6

6-1. Blowout Discs and Kits ....................................... 6 -1

6-2. High-Pressure and Blowout Switch

Assemblies......................................................... 6-2

6-3. Pressure Switch Settings ...................................6-3

6-4. High-Pressure Switch Parts List ........................6-4

6-5. Reservoir Blowout Switch Parts List .................. 6-5

6-6. Tank Blowout Switch Parts List ........................... 6- 6

7-1. Pneumatic Solenoid Parts List ........................... 7-1

10-1. Modu-Flo Troubleshooting ...............................10-1

42000Modu-Flo® System

OPERATION AND

SERVICE INSTRUCTIONS

SECTION 1

INTRODUCTION

1.1 GENERAL................................................................... 1-1

1.1.1 Standard Components ...................................1-1

1.1.2 Modu-Flo Options ........................................... 1-1

1.2 GENERAL SYSTEM OPERA TION .............................. 1-1

1.1 GENERAL

1.1.1 Standard Components. A wide choice of modular

components may be assembled to meet a given application.

1.1.1.1 All Modu-Flo systems consist of the following components:

a. A reservoir or tank for holding the lubricant. Reservoirs

are cylindrical units for grease or oil and are equipped with a spring-loaded follower for grease applications. Tanks are rectangular and are used for applications using oil. Further information on reservoirs may be found in Section 2.

b. A pump for dispensing a specific volume of lubricant.

Pumps may be pneumatically or hydraulically operated. A selection of power ratios and displacement ranges are available. Further information on pumps may be found in Section 3.

c. A manifold attached to the base of the reservoir to

provide a mounting base for any pump. The manifold has all the necessary porting to allow lubricant to flow from the reservoir to the pump and from the pump to the lubricant lines. Ports are also provided for pneumatic or hydraulic inputs to operate the pump. Accessories such as gauges and blowout assemblies are available and may be connected to the manifold. If the pump is to be located some distance from the reservoir, a wallmounted manifold is available. Further information on manifolds is contained in Section 4.

Modu–Flo®

System

1.1.2 Modu-Flo Options.

1.1.2.1 Options which are available for any system include

the following: a. Low-level switches which mount to the reservoir or tank

and provide a low-level fault signal to a customerdesignated component. Level switch options are described in Section 5.

b. High-pressure indicators which are installed into the

pump outlet circuit and provide an over-pressure signal to external components. Pressure switch options are discussed in Section 6.

c. A pneumatic solenoid valve which mounts directly to the

manifold. The solenoid valve is a three-way, normallyclosed type. Use of the solenoid allows the pump to be cycled by various controller options. The solenoid is equipped with a manual override button which may be used to simplify system testing, line filling and line bleeding.

d. Several types of controllers are used which can be

adapted to the system. Controller options are discussed in Section 8. Controllers available are as follows:

(1) Timers which may be set to cycle the pump at given

intervals. Both AC and DC models are available.

(2) A TC-1000 timer can operate the lube system on

either a time or machine cycle basis. It is available in 12 or 24 VDC or 115 or 230 VAC.

1-1

(3) A WMP Maxi-Monitor which provides a dispense

signal on either a time or machine cycle basis. The WMP also monitors and displays the status of the lube system it is controlling. The Maxi-Monitor is available in either 115 or 230 VAC.

Modu-Flo® System 42000

1.2 GENERAL SYSTEM OPERATION

1.2.1 Figure 1-1 shows a functional schematic of a Modu-

Flo system.

1.2.1.1 The following steps outline the operating sequence of a Modu-Flo system:

a. Lubricant stored in the reservoir or tank flows to the

manifold. The manifold may be mounted directly to the reservoir or tank, or it may be mounted on a wall.

b. The manifold directs lubricant into the pump to fill the

pump chamber.

c. A controller energizes a solenoid valve to dispense and

the solenoid sends air or hydraulic fluid to the manifold. Porting in the manifold directs the air or hydraulic fluid to the pump, causing the pump to dispense lube to the manifold outlet port.

d. When the controller releases the solenoid, air or

hydraulic fluid is redirected, causing the pump to retract. On single-acting pneumatic pumps a spring pushes the pump to the retracted position.

e. Lubricant from the reservoir flows through the manifold

and refills the empty chamber in the pump.

f. A pressure gauge, blowout disc, and high-pressure

switch are options which may be connected to the output lube on the manifold. A signal from the pressure switch can be used to actuate an alarm or warning light.

g. Low-level switch options are available for all tanks or

reservoirs. The switch provides an electrical signal when lubricant level is low.

1-2

RESERVOIR

OR TANK

42000Modu-Flo® System

LOW LEVEL SWITCH

CONTROLLER

PNEUMATIC/

HYDRAULIC SUPPLY

MANIFOLD

PUMP

SYSTEM FILL

CHECK

GAUGE

TEST/AIR PURGE PORT

PRESSURE

SWITCH

LUBE OUTLET CHECK

SOLENOID

BLOWOUT ASSEMBLY

LUBE LINES

PNEUMATIC/HYDRAULIC LINES

ELECTRICAL LINES

1-3/(1-4 Blank)

Figure 1-1. Modu-Flo Functional Schematic

42000Modu-Flo® System

OPERATION AND

SERVICE INSTRUCTIONS

SECTION 2

RESERVOIRS AND TANKS

2.1 DESCRIPTION .......................................................... 2-1

2.1.1 Reservoir Description ................................... 2-1

2.1.2 Tank Description ........................................... 2-1

2.1.3 Reservoirs and Tanks Available ................... 2-1

2.2 MOUNTING INSTRUCTIONS ................................... 2-1

2.3 PREP ARATION FOR USE ......................................... 2-2

2.3.1 Filling Oil Reservoirs and Tanks ................... 2- 2

2.3.2 Filling Grease Reservoirs ............................. 2-2

2.4 GREASE RESERVOIR MAINTENANCE (OPTIONS GP1 THROUGH GP5 AND GM1 THROUGH

GM4) .......................................................................... 2-3

2.4.1 General..........................................................2-3

2.4.2 Grease Reservoir Maintenance .................... 2-3

2.4.3 Disassembly of Grease Reservoirs ............. 2-3

2.4.4 Assembly of Grease Reservoirs................... 2-3

Modu–Flo®

System

2.4.5 Grease Reservoir Parts Lists ....................... 2-3

2.5 OIL RESERVOIR MAINTENANCE

(OPTIONS OP1 THROUGH OP4)............................. 2-7

2.5.1 General..........................................................2-7

2.5.2 Oil Reservoir Maintenance ............................ 2 -7

2.5.3 Disassembly of Oil Reservoir ....................... 2-7

2.5.4 Assembly of Oil Reservoir ............................. 2- 7

2.5.5 Oil Reservoir Parts Lists ............................... 2-7

2.6 OIL T ANK MAINTENANCE

(OPTIONS T1, T2 and T3)....................................... 2-11

2.6.1 General........................................................ 2-11

2.6.2 Oil Tank Maintenance .................................. 2-11

2.6.3 Disassembly of Oil Tanks........................... 2-11

2.6.4 Assembly of Oil Tanks ................................. 2 -11

2.6.5 Oil Tank Parts List ....................................... 2 -11

2.1 DESCRIPTION

2.1.1 Reservoir Description. Reservoirs are cylindrical in

shape and are used for either grease or oil lubricants. If a reservoir is to be used for grease it will be equipped with a spring-loaded follower which will apply pressure on the grease to force it into the pump. Reservoirs use cylinders made of metal or plastic. If a metal cylinder is used, the reservoir will be equipped with a level indicator to allow a visual check of lubricant level. Plastic cylinders are clear, allowing personnel to actually see the amount of lubricant present. The base of all reservoirs has the necessary tapped holes for either direct mounting of a manifold or for installing hose or tubing to a remote-located manifold.

2.1.2 Tank Description. Tanks are rectangular weldments used for holding oil. All tanks are equipped with a sight glass to allow personnel to easily check the lubricant level. A pad mounted to the tank base provides the necessary tapped holes for either direct mounting of a manifold or for installing hose or tubing to a remote-located manifold.

2.1.3 Reservoirs and Tanks Available. Table 2-1 lists the tanks and reservoirs available for use. Listings in the option column are used to identify the reservoir or tank selected when a Modu-Flo system is ordered. The option used is

designated by the entry in the ordering code as shown below:

MPP - XXX - XXX - XX - XX - XX - XX - XX - XXX - XX

Reservoir Option

2.2 MOUNTING INSTRUCTIONS

2.2.1 Reservoirs and tanks may be mounted to any

vertical surface. All units have 7/16 inch holes for attaching bolts or screws. Cylindrical reservoirs have two holes, six inches apart, drilled in the base bracket. All tanks have four holes drilled in flanges according to the following rectangular dimensions:

9-7/8 wide by 7 inches high for T1 tanks 11-1/8 wide by 7 inches high for T2 tanks 16-3/8 wide by 7 inches high for T3 tanks

2.2.1.1 Make sure the mounting location allows clearance

for any accessories attached to the tank or reservoir. Oil reservoirs and all tanks have a fill cup on the top. Make sure there is enough room above the fill cup to permit personnel to perform a filling operation without difficulty. Drill the required holes and attach the reservoir or tank to the vertical surface. Securely tighten all attaching hardware. Make sure that the reservoir or tank is level.

2-1

Modu-Flo® System 42000

T able 2-1. Reservoirs and Tanks

Part Number Type (Use) Reservoir Capacity Option 521-001-060 Tank (oil) 12 pint (5.68 liters) T1

521-001-070 Tank (oil) 24 pint (11.4 liters) T2 521-001-080 Tank (oil) 40 pint (18.9 liters) T3 185-100-080 Reservoir, Plastic (oil) 5 pint (2.37 liters) OP1 185-100-060 Reservoir, Plastic (oil) 12 pint (5.68 liters) OP2 185-100-070 Reservoir, Plastic (oil) 20 pint (9.46 liters) OP3 185-100-750 Reservoir, Plastic (oil) 6 pint (2.84 liters) OP4 185-100-040 Reservoir, Plastic (grease) 5 lbs (2.27 kg) GP1 185-100-000 Reservoir, Plastic (grease) 12 lbs (5.44 kg) GP2 185-100-010 Reservoir, Plastic (grease) 20 lbs (9.07 kg) GP3 185-100-760 Reservoir, Plastic (grease) 6 lbs (2.72 kg) GP4 185-101-080 Reservoir, Plastic (grease) 3 lbs (1.36 kg) GP5 185-100-050 Reservoir, Metal (grease) 5 lbs (2.27 kg) GM1 185-100-020 Reservoir, Metal (grease) 12 lbs (5.44 kg) GM2 185-100-030 Reservoir, Metal (grease) 20 lbs (9.07 kg) GM3 185-100-770 Reservoir, Metal (grease) 6 lbs (2.72 kg) GM4 185-101-100 Reservoir, Plastic (grease) 40 lbs (18.14 kg) -185- 101- 110 Reservoir, Plastic (grease) w/low level indicator 40 lbs (18.14 kg) -185-100-120 Reservoir, Plastic (grease) w/low level micro switch 40 lbs (18.14 kg) --

* These assemblies are not available through the normal MPP system, only by ordering the full part number.

* *

2.3 PREPARATION FOR USE

NOTE

Before filling any reservoir or tank, a manifold should be attached to the base. The manifold has a check valve built into it which will prevent the lubricant from dripping out of the reservoir or tank. If the system has a remote-located manifold, make sure there is hose or tubing connected from the bottom of the reservoir or tank to the remote manifold.

2.3.1 Filling Oil Reservoirs and T anks. Reservoirs and tanks for oil have a fill cup mounted on top. Wipe the area around the fill cup to avoid contamination during filling. Open the fill cup cap and slowly pour the oil into the fill cup. A strainer attached to the fill cup will remove large particles which may be present in the oil. When filling is complete, close fillcup cap and wipe any spillage.

2.3.2 Filling Grease Reservoirs. WARNING

If a high-pressure, high-volume supply pump is used to fill grease reservoirs, excess pressure may not be completely released by the bleed hole in the reservoir wall. This could cause the reservoir to fracture, exposing personnel to flying particles and lubricant. Safety glasses must be worn during filling operations and the supply pump must be turned off and disconnected when filling is complete.

2.3.2.1 Filling of grease reservoirs requires that an external

supply source be connected to the fill stud located in the base of the reservoir. 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. Too fast of a fill speed may result in air pockets. The level of grease is checked by visual means. In reservoirs with plastic cylinders, the grease level may be seen through the cylinder. Reservoirs with metal cylinders have a levelindicator rod mounted on the cap which will indicate when the fill is complete.

NOTE

Excess lube forced into the reservoir after it has reached full level will be vented from a bleed hole in the reservoir tube. (See Warning above.)

2.3.2.2 When filling is complete, turn off the supply source and disconnect it from the fill stud. A check valve in the fill stud will prevent lubricant from being forced back out. A plastic dust cap is attached to the fill stud and should be installed over the fill stud to keep dirt from entering the system.

NOTE

For first time grease filling, or if the grease reservoir has been allowed to go empty, open the petcock in the bottom right side of the reservoir. Slowly begin to fill the reservoir, allowing air trapped under follower to exhaust out the open petcock. When grease free of air flows from the petcock, close petcock and continue to fill the reservoir until follower is at vent hole in reservoir tube (any remaining air and small amount of grease will exit vent).

Loosen system mainline connection at pump outlet. Operate pump until lubricant free of air flows from outlet port. Tighten mainline connection at pump. Pump is now free of air.

Note, for extreme cases where the pump will not take a prime, it may be helpful to inject serveral

2-2

42000Modu-Flo® System

ounces of heavy oil through the grease fill quick disconnect. 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 supply connection along with any air.

Refer to bulletin 12411 (Portable Filler-Pak) for manual operated fill pump.

2.4 GREASE RESERVOIR MAINTENANCE (OPTIONS GP1 THROUGH GP5 AND GM1 THROUGH GM4)

2.4.1 General. Maintenance tips, disassembly, and as-

sembly procedures for grease reservoirs are discussed in Paragraphs 2.4.2, 2.4.3 and 2.4.4. An exploded view of a typical grease reservoir is shown in Figure 2-1 and should be referred to during the discussion.

2.4.2 Grease Reservoir Maintenance.

2.4.2.1 Maintenance on the grease reservoir consists of the

steps described below: a. Visually inspect the reservoir for lubricant leaking

between reservoir tube (8, Figure 2-1) and base (10). This may indicate a bad gasket (9) or that the hex nuts (12) are not tight. Torque the nuts to 5 ft lbs. If the leakage continues, replace gasket (9). Check for cracks and nicks in tube (8). Replace the tube as required.

b. Visually inspect the reservoir tube (8) for dents which

may restrict the movement of the follower cups (6 and 7). Replace the tube as required.

WARNING

Disconnect and lock out power before opening electrical enclosures or conduit connections. Serious injury may result from electrical shock.

2.4.3 Disassembly of Grease Reservoirs. Figure 2-1

shows a typical grease reservoir but does not include other Modu-Flo components which may be mounted to the reservoir. These components include the manifold, pump, level switches and high-pressure blowout switches. Disassembly of the reservoir may require that some of these components be removed. The manifold and pump do not normally require removal, but may be removed if desired. The level and blowout switches may or may not require removal, depending on the level of disassembly required. The electrical connections to the switches probably should be disconnected in order to remove various parts without restriction of movement by the electrical cord. The removal of these components is explained in other sections of the manual. Refer to the table of contents to find where the components are discussed.

2.4.3.1 The disassembly procedure may be performed with

the reservoir mounted to the mounting surface. However, some mounting locations may be too restrictive to provide access to all components. If your particular installation requires dismounting of the reservoir, make sure the reservoir is drained of lubricant before removing the attaching hardware. This will reduce the weight of the reservoir and reduce

the chance of spillage. The disassembly procedure is as follows:

WARNING

Do not attempt to remove retaining ring (2) or cable assembly (5) (Figure 2-1) (or retaining ring (25) or guide rod (5) for Option GP5). Injury could result from sudden expansion of spring (4).

a. Slowly open petcock (11) and allow lubricant to be forced

from the reservoir into a bucket or similar container. Remove fill stud (15) and petcock (11) if necessary. Properly dispose of emptied grease.

b. Remove hex nuts (12) and lockwashers (13) from tie

rods (1). Remove tie rods (1) from cap (3).

c. Lift reservoir tube (8) from base (10) keeping reservoir

cap (3) in position on top of the tube.

d. Slide reservoir tube (8) away from reservoir cap (3) until

it is free of follower cup (7). e. Remove gasket (9) from bottom of reservoir tube (8). f. Further disassembly is only possible at the factory. If

damage is apparent on the follower cups (6 and 7),

cable assembly or guide rod (5), spring (4) or reservoir

cap (3) the unit cannot be serviced and the reservoir

assembly must be replaced.

2.4.4 Assembly of Grease Reservoirs.

NOTE

Before assembly, lubricate followers and tube inner diameter with the lubricant which is used in the system.

2.4.4.1 Assemble the grease reservoir according to the following procedure:

a. Slide reservoir tube (8, Figure 2-1) over follower cup (7)

being careful not to distort the follower cup lips. Slide

reservoir tube (8) up until it contacts reservoir cap (3). b. Install new gasket (9) on bottom of reservoir tube (8). c. Place reservoir tube (8) with gasket (9) on base (10) and

rotate reservoir cap (3) until holes in the cap line up with

holes in the base (10). d. Install tie rods (1) through holes in reservoir cap (3) and

base (10). e. Install lockwashers (13) and hex nuts (12) on tie rods (1)

and torque to 5 ft lbs. f. Install fill stud (15), dust cap (14) and petcock (11) in

base. Make sure petcock (11) is in the closed position.

2.4.4.2 When the assembly steps listed in the above paragraph have been completed, any Modu-Flo components which were removed to ease disassembly should be reinstalled on the reservoir.

2.4.5 Grease Reservoir Parts Lists. Table 2-2 identifies the parts indexed in Figure 2-1.

2-3

Modu-Flo® System 42000

T able 2-2. Grease Reservoir Part s List

Item Number Part Number Description Quantity

185-100-040 RESERVOIR ASSEMBLY, 5 lbs (2.27 kg), plastic (GP1) -185-100-000 RESERVOIR ASSEMBL Y , 12 lbs (5.44 kg), plastic (GP2) -185-100-010 RESERVOIR ASSEMBL Y , 20 lbs (9.07 kg), plastic (GP3) -185-100-760 RESERVOIR ASSEMBLY, 6 lbs (2.72 kg), plastic (GP4) -185-101-080 RESERVOIR ASSEMBLY, 3 lbs (1.36 kg), plastic (GP5) -185-100-050 RESERVOIR ASSEMBLY, 5 lbs (2.27 kg), metal (GM1) -185-100-020 RESERVOIR ASSEMBL Y , 12 lbs (5.44 kg), metal (GM2) -185-100-030 RESERVOIR ASSEMBL Y , 20 lbs (9.07 kg), metal (GM3) -185-100-770 RESERVOIR ASSEMBLY, 6 lbs (2.72 kg), metal (GM4) --

1 415-700-272 BOLT, Tie (5 lb., 12 lb.) 3

415-700-271 BOLT, Tie (20 lb.) 3 415-700-273 BOLT, Tie (6 lb.) 3

2 RING, Retaining 1 3 CAP, Reservoir 1 4 SPRING 1 5 CABLE ASSEMBLY 1

6 GUIDE, Follower 1 7 CUP Seal 1 9 501-423-001 GASKET (6” Tube) (3,6,12, 20 lb.) 1

415-020-190 BOLT, Tie (3 lb.) 3

Items 2 through 7 are not serviceable

GUIDE ROD 1

by the user; replace entire reservoir.

501-414-000 GASKET (4” Tube) (5 lb.) 1

10 521-000-500 BASE, Aluminum (6” Tube) (6, 12, 20 lb.) 1

521-000-530 BASE (4” Tube) (5 lb.) 1

521-008-950 BASE, Black (6” Tube) (3 lb.) 1 11 501-970-000 PETCOCK 1 12 410-040-020 NUT, Hex, 5/16-18 3 13 421-010-020 LOCKWASHER, 5/16 inch 3 14 506-165-000 CAP, Dust 1 15 506-189-001 Reservoir Fill Stud 1 16 410-060-120 NUT, Hex, 5/16-18 1 17 511-041-000 PLATE, Backup 1 18 521-003-630 INDICATOR, Level (12 lb. Metal) 1

521-003-640 INDICAT OR, Level (20 lb. Metal) 1

521-004-310 INDICAT OR, Level (6 lb. Metal) 1

521-003-620 INDICAT OR, Level (5 lb. Metal) 1 19 185-100-720+ TUBE, Reservoir, plastic, 13 inches (330.2mm) x 1

185-100-730+ TUBE, Reservoir, plastic, 13 inches (330.2 mm) 1

185-100-740+ TUBE, Reservoir, plastic, 20 inches (508 mm) x 6.0 1

185-100-990+ TUBE, Reservoir, plastic, 8.5 inches (215.9 mm) x 6.0 1

185-100-191+ TUBE, Reservoir, plastic, 5 inches (127 mm) x 6.0 1

185-101-187+ TUBE, Reservoir, metal, 13 inches (330.2 mm) x 1

185-101-188+ TUBE, Reservoir, metal, 13 inches (330.2 mm) x 6.0 1

185-101-189+ TUBE, Reservoir, metal, 20 inches (508 mm) x 6.0 1

185-101-190+ TUBE, Reservoir, metal, 8.5 inches (215.9 mm) x 6.0 1

Mating fill coupler 506-322-000 (order separately)

4 inches (100 mm) outer diameter (5 lb.) x 6.0 inches (152.4 mm) outer diameter (12 lb.) inches (152.4 mm) outer diameter (20 lb.) inches (152.4 mm) outer diameter (6 lb.) inches (152.4 mm) outer diameter (3 lb.) 4 inches (100 mm) outer diameter (5 lb.) inches (152.4 mm) outer diameter (12 lb.) inches (152.4 mm) outer diameter (20 lb.) inches (152.4 mm) outer diameter ( 6 lb.)

+ Reservoir Tube Kit includes gasket (item 9).

2-4

T able 2-2. Grease Reservoir Part s List - Continued

Item Number Part Number Description Quantity

20 439-060-181 GASKET, T op V ent (3 lb.) 1 21 BUSHING, Follower 1 22 WASHER, Follower 1 23 WASHER, Support 1 24 NUT, Jam, 3/4-16 1 25 O-RING 1 26 RING, Retaining 1 27 527-000-230 PLUG, Low Level (3 lb.) 1 28 527-000-240 GASKET (3 lb.) 1

NOTE:

USED ON META L

RESERVOIRS ONL Y

Items 21 through 26 are not serviceable by the user; replace entire reservoir.

4 5

FOR OPTION GP5 ONL Y

WARNING

42000Modu-Flo® System

Do not attempt to remove retaining ring (2) or cable assembly (5),

19+

* Mating fill coupler 506-322-000 (order separately)

+ Reservoir Tube Kit includes gasket (item 9).

(Figure 2-1) (or retaining ring (26) or guide rod (5) for Option GP5). Injury could result from sudden expansion of spring (4).

DIMENSIONS

OPTION A B GP1, GM1, 7.25 inches 15 inches

GP2, GM2 (184 mm) (381 mm) GP3, GM3 7.25 inches 22 inches

(184 mm) (559 mm)

GP4, GM4 7.25 inches 10.5 inches

(184 mm) (267 mm)

GP5 7.25 inches 6.87 inches

(184 mm) (174 mm)

Figure 2-1. Grease Reservoir - Exploded View

2-5/(2-6 Blank)

42000Modu-Flo® System

2.5 OIL RESERVOIR MAINTENANCE (OPTIONS OP1 THROUGH OP4)

2.5.1 General. Maintenance tips, disassembly, and as-

sembly procedures for oil reservoirs are discussed in Paragraphs 2.5.2, 2.5.3 and 2.5.4. An exploded view of a typical oil reservoir is shown in Figure 2-2 and should be referred to during the discussion.

2.5.2 Oil Reservoir Maintenance.

2.5.2.1 Maintenance on the oil reservoir consists of the

following: a. Visually check for oil leakage between reservoir tube (6,

Figure 2-2) and base (8). Leakage may indicate that the gasket (7) is defective or that nuts (9) are not tight. Torque nuts (9) to 5 ft lbs. If leakage continues, replace gasket (7). Check for cracks and nicks on tube (6). Replace the tube as required.

b. Visually check screen (2) in fill cup (3) to make sure it is

not clogged. If necessary, remove the screen for cleaning.

c. Check reservoir bottom for debris. Clean as required.

WARNING

Disconnect and lock out power before opening electrical enclosures or conduit connections. Serious injury may result from electrical shock.

2.5.3 Disassembly of Oil Reservoir. Figure 2-2 shows a

typical oil reservoir but does not include other Modu-Flo components which may be mounted to the reservoir. These components include the manifold, pump, level switches and high-pressure blowout switches. Disassembly of the reservoir may require that some of these components be removed. The manifold and pump do not normally require removal, but may be removed if desired. The level and blowout switches may or may not require removal, depending on the level of disassembly required. The electrical connections to the switches should be disconnected in order to remove various parts without restriction of movement by the electrical cord. The removal of these components is explained in other sections of the manual. Refer to the table of contents to find where the components are discussed.

2.5.3.1 The disassembly procedure may be performed with

is drained of lubricant before removing the attaching hardware. This will reduce the weight of the reservoir and reduce the chance of spillage. The disassembly procedure is as follows:

a. Remove pipe plug (4, Figure 2-2) from base (8) and

allow oil to drain from reservoir into bucket or similar container. Properly dispose of emptied oil.

b. Remove three hex nuts (9) and three lockwashers (10)

from tie rods (1). Remove tie rods (1) from reservoir cap

(5). c. Remove reservoir cap (5) from reservoir tube (6). d. Remove fill screen (2) from fill cup (3) and clean screen. e. Remove reservoir tube (6) from base (8). f. Remove and discard gasket (7) from reservoir tube (6).

2.5.4 Assembly of Oil Reservoir.

NOTE

Before assembly, lubricate followers and tube inner diameter with the lubricant which is used in the system.

2.5.4.1 Assemble the oil reservoir according to the following procedure:

a. Install screen (2, Figure 2-2) in fill cup (3). b. Install new gasket (7) on reservoir tube (6). c. Position reservoir tube (6) on base (8) and position

reservoir cap (5) on tube. d. Rotate reservoir cap (5) until tie rods (1) can be installed

through holes in cap and in base (8). The heads of tie

rods (1) must fit into the hexagon depressions on the

upper surface of the reservoir cap (5). e. Install lockwashers (10) and hex nuts (9) on tie rods (1).

Torque nuts to 5 ft lbs. f. Install pipe plug (4) in base (8).

2.5.4.2 When the assembly steps listed in the above paragraph have been completed, any Modu-Flo components which were removed to ease disassembly should be reinstalled on the reservoir.

2.5.5 Oil Reservoir Parts Lists. Table 2-3 identifies the parts indexed in Figure 2-2.

2-7

Modu-Flo® System 42000

T able 2-3. Oil Reservoir Parts List s

Item Number Part Number Description Quantity

185-100-080 RESERVOIR ASSEMBLY, 5 pint (2.37 liters), plastic (OP1) -185-100-060 RESERVOIR ASSEMBLY, 12 pin t (5 .68 l ite rs), plastic (OP2) -185-100-070 RESERVOIR ASSEMBLY, 20 pin t (9 .46 l ite rs), plastic (OP3) -185-100-750 RESERVOIR ASSEMBLY, 6 pint (2.84 liters), plastic (OP4) --

1 415-700-272 BOLT, Tie (5 pint, 12 pint) 3

415-700-273 BOLT, Tie (6 pint) 3

415-700-271 BOLT, Tie (20 pint) 3 2 534-304-003 SCREEN (40 Mesh) 1 3 534-147-000 CUP, Fill 1 4 508-975-000 PLUG, Pipe, 1/4 inch NPT 3 5 521-000-600 CAP, Reservoir (4” Tube) (5 pint) 1

501-474-029 CAP, Reservoir (6” Tube) (6,12, 20 pint) 1 6 185-100-720+ TUBE, Reservoir, 13 inches (330.2 mm) x 4 inches1

(100 mm) outer diameter (5 pint)

185-100-990+ TUBE, Reservoir, 8.5 inches (215.9 mm) x 6.0 inches 1

(152.4 mm) outer diameter (6 pint)

185-100-730+ TUBE, Reservoir, 13 inches (330.2 mm) x 6.0 inches 1

(152.4 mm) outer diameter (12 pint)

185-100-740+ TUBE, Reservoir, 20 inches (508 mm) x 6.0 inches1

(152.4 mm) outer diameter (20 pint)

7 501-414-000 GASKET (4” Tube) (5 pint) 1

501-423-001 GASKET (6” Tube) (6, 12, 20 pint) 1 8 521-000-530 BASE (4” Tube) (5 pint) 1

521-000-500 BASE (6” Tube) (6, 12, 20 pint) 1 9 410-040-020 NUT, Hexagon, 5/16-18 3 10 421-010-020 LOCKWASHER, 5/16 inch 3

+ Reservoir Tube Kit includes gasket (Item 7).

2-8

42000Modu-Flo® System

DIMENSIONS

OPTION A B OP1, OP2 7.25 inches 15 inches

OP3 7.25 inches 22 inches

(184 mm) (381 mm)

(184 mm) (559 mm)

OP4 7.25 inches 10.5 inches

(184 mm) (267 mm)

+ Reservoir Tube Kit includes gasket (Item 7).

Figure 2-2. Oil Reservoir - Exploded View

2-9/(2-10 Blank)

42000Modu-Flo® System

2.6 OIL TANK MAINTENANCE (OPTIONS T1, T2 and T3)

2.6.1 General. Maintenance tips, disassembly and as-

sembly procedures for oil tanks are discussed in Paragraphs 2.6.2, 2.6.3 and 2.6.4. An exploded view of a typical oil tank is shown in Figure 2-3 and should be referred to during the discussion.

2.6.2 Oil T ank Maintenance.

2.6.2.1 Maintenance on the oil tanks consists of the follow-

ing: a. Visually check for oil leakage between the tank (9, Figure

2-3), the pump mounting pad (12) and the level sight glass (11). Leakage in either of these areas indicates the components are loose or that gasket (10) or o-ring (13) is defective. The cover (1) will need to be removed to either tighten the components or replace defective seals.

b. Visually check fill screen (4) to make sure it is not

clogged. If necessary, remove the screen for cleaning.

c. Check that the tank is securely fastened to the wall or

supporting structures. Securely tighten any loose attaching hardware.

WARNING

Disconnect and lock out power before opening electrical enclosures or conduit connections. Serious injury may result from electrical shock.

2.6.3 Disassembly of Oil Tanks. Figure 2-3 shows a

typical oil tank but does not include other Modu-Flo components which may be mounted to the tank. These components include the manifold, pump, level switches and blowout switches. Disassembly of tank may require that some of these components be removed. The manifold and pump do not normally require removal, but may be removed if desired. The level and blowout switches may or may not require removal, depending on the level of disassembly required. The electrical connections to the switches should be disconnected in order to remove various parts without restriction of movement by the electrical cord. The removal of these components is explained in other sections of the manual. Refer to the table of contents to find where these components are discussed.

2.6.3.1 The disassembly procedure may be performed with

the tank mounted to the mounting surface. However, some mounting locations may be too restrictive to provide access to all components. If your particular installation requires dismounting of the tank, make sure the tank is drained of lubricant before removing the attaching hardware. This will reduce the weight of the tank and reduce the chance of spillage. The disassembly procedure is as follows:

a. Remove pipe plug (3, Figure 2-3) from base of tank

weldment (9) and allow oil to drain into bucket or similar container. Properly dispose of emptied oil.

b. Remove self-threading screws (2) attaching cover (1) to

tank weldment (9) and remove cover and cover gasket

(6). c. Remove fill screen (4) from fill cup (5) and clean screen. d. Remove two screws (7) and aluminum gaskets (8) to

release pump mounting pad (12) from tank weldment

(9). Remove and discard o-ring (13) from pump mount-

ing pad (12).

NOTE

Step e should be performed only if the sight glass is dirty or leaking. Threads cut on nylon studs of sight glass may prevent the sight glass from being used.

e. Remove four self-threading nuts (14) and remove sight

glass (11) and gasket (10). Discard gasket (10) and

sight glass (11).

2.6.4 Assembly of Oil Tanks.

NOTE

Before assembly, lubricate all o-rings with the lubricant which is used in the system.

2.6.4.1 Assemble the oil tanks according to the following procedure:

a. Install one aluminum gasket (8, Figure 2-3) on each

screw (7) and insert threads of screws through holes in

bottom of tank weldment (9). b. Install new o-ring (13) in pump mounting pad (12) and

align threaded holes in pump mounting pad with screws

(7) protruding from bottom of tank weldment (9). Thread

screws (7) into pump mounting pad (12) until pump

mounting pad is snug against bottom of tank weldment

(9). Torque screws (7) to 10 ft lbs. c. Position new gasket (10) on sight glass (11) and install

sight glass on tank weldment (9). Secure sight glass

(11) with four self-threading nuts (14). d. Install screen (4) into fill cup (5). e. Position cover gasket (6) and cover (1) on tank

weldment (9) and secure with self-threading screws (2). f. Install pipe plug (3) in bottom of tank weldment (9).

2.6.4.2 When the assembly steps listed in the above paragraph have been completed, any Modu-Flo components which were removed to ease disassembly should be reinstalled on the tank.

2.6.5 Oil Tank Parts List. Table 2-4 identifies the parts indexed in Figure 2-3.

2-11

Modu-Flo® System 42000

T able 2-4. Oil Tank Parts List

Item Number Part Number Description Quantity

521-001-060 RESERVOIR ASSEMBLY, 12 pin t, ( 5.68 lit ers) (T1) -521-001-070 RESERVOIR ASSEMBL Y , 24 pint, (11.4 liters) (T2) -521-001-080 RESERVOIR ASSEMBLY, 40 pin t, ( 18.9 lit ers) (T3) --

1 521-000-810 COVER, (12 pint) 1

2 415-640-040 SCREW, Self-threading, 1/4-28 x 5/16 inch (12 pint) 6 3 508-975-000 PLUG, Pipe, 1/4 inch NPT 2

4 534-304-003 SCREEN (40 Mesh) 1 5 534-147-000 CU P, Fill 1

6 521-003-420 GASKET, Cover, (12 pint) 1

7 419-170-010 SCREW, Socket-head, 3/8-16 x 1/2 inch 2 8 439-050-060 GASKET, 3/8 stat-o-seal 2 9 WELDMENT, Reservoir 1

10 439-060-110 GASKET 1 11 438-028-283 SIGHT GLASS 1 12 521-000-921 PAD, Pump mounting 1 13 423-700-096 O-RING 1 14 410-701-986 NUT, Self-threading 4 15 421-010-010 Lockwasher, 1/4 inch (12 pint) 6

16 412-150-040+ Plug, 3/8 NPT 1

521-000-830 COVER, (24 pint) 1 521-000-850 COVER, (40 pint) 1

415-640-040 SCREW, Self-threading, 1/4-28 x 5/16 inch (24, 40 pint) 8

521-003-380 GASKET , Cover , (24 pint) 1 521-003-340 GASKET , Cover , (40 pint) 1

* *

Not available as a item replacement

* *

421-010-010 Lockwasher, 1/4 inch (24, 40 pint) 8

* Reservoirs with separate aluminum pump mounting pads

only. Steel pump mounting pads are welded in place and are not replaceable.

Used on reservoirs with front pressure-fill port only.

2-12

42000Modu-Flo® System

* Reservoirs with separate aluminum

pump mounting pads only. Steel pump mounting pads are welded in place and are not replaceable.

Used on reservoirs with front pressure-fill

port only.

16+

OPTION A B C T1 10.75 inches 7.25 inches 10.70 inches

12*

T2 12 inches 13.22 inches 10.59 inches

T3 17.25 inches 13.22 inches 10.59 inches

(273 mm) (184 mm) (272 mm)

(305 mm) (336mm) (269 mm)

(438 mm) (336 mm) (269 mm)

DIMENSIONS

2-13/(2-14 Blank)

Figure 2-3. Oil Tank - Exploded View

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