Graco Inc. TRI-LUBE GREASE PUMP PACKAGE User Manual

Tri-Lube Grease Pump Package User Manual

Tri-Lube

Grease Pump

Package

Tri-Lube Grease Pump Package User Manual L42255

TABLE OF CONTENTS

SECTION/PARAGRAPH PAGE

1.0 INTRODUCTION

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

1.2 SAFETY INSTRUCTIONS .............................................. 1-1

1.3 DESCRIPTION ............................................................. 1-1

1.4 OPERATION ................................................................ 1-2

2.0 INSTALLATION

2.1 MOUNTING ................................................................. 2-1

2.2 WIRING ....................................................................... 2-1

2.3 FILLING RESERVOIR .................................................... 2-2

2.4 PURGING AIR FROM PUMP .......................................... 2-2

2.5 ADDING PUMP ELEMENTS .......................................... 2-3

2.6 PUMP ADJUSTMENTS ................................................. 2-3

LIST OF ILLUSTRATIONS

NUMBER TITLE PAGE

1-1 PUMP OPERATION ..................................................... 1-2

2-1 PUMP DIMENSIONS .................................................. 2-1

2-2 ELECTRICAL DIAGRAMS ............................................ 2-1

2-3 TYPICAL PUMP PACKAGE .......................................... 2-2

2-4 ADD PUMP ELEMENTS .............................................. 2-2

2-5 RELIEF VALVE ADJUSTMENT ...................................... 2-3

2-6 OUTPUT ADJUSTMENT .............................................. 2-3

3-1 RESERVOIR COVER.................................................... 3-1

3-2 RESERVOIR & FOLLOWER ......................................... 3-1

3-3 RESERVOIR & PADDLE .............................................. 3-2

3-4 RESERVOIR & BEARING ............................................. 3-2

SECTION/PARAGRAPH PAGE

3.0 SERVICE AND REPAIR

3.1 REQUIRED TOOLS ....................................................... 3-1

3.2 REPLACING COVER, LL & FOLLOWER .......................... 3-1

3.3 REPLACING RESERVOIR .............................................. 3-2

3.4 REPLACING ECCENTRIC SHAFT BEARING .................... 3-2

3.5 REPLACING CAM ASSEMBLY ....................................... 3-2

3.6 REPLACING DC GEARMOTOR ...................................... 3-3

3.7 REPLACING AC MOTOR ............................................... 3-4

4.0 PARTS LISTS ............................................4-1 THRU 4-3

5.0 TROUBLESHOOTING ................................................. 5-1

NUMBER TITLE PAGE

3-5 ECCENTRIC ............................................................... 3-2

3-6 DC MOTOR COVER .................................................... 3-3

3-7 DC MOTOR LEADS .................................................... 3-3

3-8 MOTOR ATTACH SCREWS .......................................... 3-3

3-9 PUMP DISASSEMBLED .............................................. 3-3

3-10 AC MOTOR & REDUCER ............................................ 3-4

3-11 AC MOTOR ................................................................ 3-4

4-1 DC PUMP PARTS ....................................................... 4-1

4-2 AC PUMP PARTS ....................................................... 4-2

4-3 11 LB RESERVOIR PARTS .......................................... 4-3

LIST OF TABLES

NUMBER DESCRIPTION PAGE

2-1 OUTPUT ADJUSTMENT .............................................. 2-3

4-1 DC PUMP PARTS LIST ............................................... 4-1

NUMBER DESCRIPTION PAGE

4-2 AC PUMP PARTS LIST ............................................... 4-2

4-3 11 LB RES. PARTS LIST ............................................. 4-3

Tri-Lube Grease Pump Package User Manual L42255

OPERATION AND SERVICE INSTRUCTIONS

SECTION 1

INTRODUCTION

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

1.2 SAFETY INSTRUCTIONS ..................................................................1-1

1.3 DESCRIPTION ..................................................................................1-1

1.4 OPERATION .....................................................................................1-2

1.1 GENERAL

1.1.1 This User Manual is intended to familiarize the user with

the Tri-Lube grease pump and its various features. It contains important information for safe, correct and economical operation of the grease pump. Following the instructions will help avoid hazards, reduce downtime and repair costs, increase the reliability and prolong the service life of the entire system.

1.1.2 This User Manual must be read and used by those who will work with the complete lubrication system.

1.1.3 Other useful Graco/Trabon Bulletins are:

Bulletin 40000 – Series Progressive System a. Installation Guide.

Bulletin 30103 – How to Remove Air from a Series b. Progressive System.

Bulletin 30101 – How to locate Blockage in a Series c. Progressive System.

1.2 SAFETY INSTRUCTIONS

Read all of the applicable instructions before a. operating your lubrication system.

Keep all operating instructions near system for b. future reference.

Incorrect use or unauthorized system changes may c. result in bearing damage caused by under or over lubrication.

Any existing safety equipment must not be modiﬁed d. when attaching the lubrication pump and system to the machine.

If any safety equipment is removed to allow e. mounting of the lubrication pump or system, it must be re-assembled prior to machine and/or lubrication system operation.

Keep lubrication system away from any high heat f. source.

Disconnect and lock out electrical power source g. before attempting any repairs to the Tri-Lube Pump Package.

1-1

Use only original replacement parts. h.

1-1

Tri-Lube Grease Pump Package User Manual L42255

1.3 DESCRIPTION

1.3.1 All Tri-Lube Pump Packages consist of the following

components:

A reservoir for holding the lubricant. Reservoirs are a. cylindrical in shape and are made from transparent plastic or metal depending on the speciﬁc model. Each reservoir is equipped with a low level switch activated by the follower assembly and a rotating paddle to assist priming of the pump.

A pump element is available with either a ﬁxed or b. adjustable output. All pump elements are equipped with an adjustable relief valve that relieves to atmosphere. A second or third pump element can be added in the ﬁeld to supply additional output volume or additional lube points where required.

A gearmotor (12 or 24 VDC) or a motor and gear c. reducer (115 or 230 VAC, 1 ph, or 230/460 VAC, 3 ph) which drives the pump.

A pump body which houses the pump drive d. eccentric and to which all other components are attached.

1.4 OPERATION

1.4.1 Figure 1-1 shows the general relationship of the pump

element and the drive eccentric. The following steps outline the operating sequence:

Grease in the reservoir keeps the pump body full a. during normal operation and maintains a head pressure to accomplish two objectives.

Provide constant lubrication to the moving • pump components.

Supply lubricant to the piston chamber in the • pump cylinder.

A rotating cam (Item 1) forces the pump piston b. (Item 2) forward displacing lubricant from the pump cylinder, past an internal discharge check valve and out of the pump outlet.

As the cam (Item 1) continues to rotate, the pull-c. back ring (Item 3) pulls the pump piston (Item

2) back to the prime position allowing grease to re-prime the piston chamber for the next stroke. Also attached to the eccentric shaft is a paddle (not shown) with an angled surface that forces grease into the pump chamber as it rotates and also aids in dispersing any small air pockets that might be present in the grease.

Fixed Pump Element

Lube Outlet

Figure 1-1

1-2

Tri-Lube Grease Pump Package User Manual L42255

U2 V2

FA N

SHAFT

OPERATION AND SERVICE INSTRUCTIONS

SECTION 2

INSTALLATION

2.1 MOUNTING .....................................................................................2-1

2.2 WIRING ...........................................................................................2-1

2.3 FILLING RESERVOIR ........................................................................2-2

2.4 PURGING AIR FROM PUMP ..............................................................2-2

2.5 ADDING PUMP ELEMENTS ..............................................................2-3

2.6 PUMP ADJUSTMENTS .....................................................................2-3

2.1 MOUNTING THE PUMP

2.1.1 The pump should be mounted in a vertical position with

the reservoir at the top and in a protected location, but where it is accessible for ﬁlling and routine maintenance.

DC Motor, Front View

DC Motor, Side View

2.1.2 The pump is mounted using two 5/16” or two 8 mm bolts (furnished by user) that pass through the mounting feet on the pump body. The mounting bolt length will depend on the thickness of the mounting surface and whether the holes are to be tapped for the bolts or locked in place with nuts and washers. Mounting dimensions are shown in Figure 2-1

2.2 WIRING THE PUMP

2.2.1 Electrical connections are shown in Figure 2-2

2.2.2 Wiring to the AC motors should be 16 AWG stranded

wire with insulation rated for 300 V max and 105ºC.

2.2.3 The DC pump motors and all low level switches may be wired with 18 AWG stranded wire cable.

Figure 2-2b(AC)

Cantoni & ABB Motors

FAN

CAPACITOR

GND

Figure 2-2c (DC)

Moto Technica 1ph Motors

Z2 U1

AC Motor, Front View AC Motor, Side View

Figure 2-2a (DC)

Figure 2-2d (AC & DC)

COMMON

Top View, DC and AC

Figure 2-1

2-1

LOW LEVEL SWITCH WIRING SCHEMATIC

Figure 2-2

Tri-Lube Grease Pump Package User Manual L42255

2.3 FILLING THE RESERVOIR

2.3.1 The reservoir should be ﬁlled with clean air

free grease of the type recommended by the machine builder and having an NLGI grade number consistent with the ambient operating temperature of the equipment (grease must be pumpable at the lowest anticipated

operating temperature).

CAUTION

Do not ﬁll the reservoir with grease heavier than NLGI #2. For temperatures below -5OF (-20OC), use NLGI #1 or lighter grease.

2.3.2 Filling is accomplished by connecting a suitable transfer

pump to the ﬁll ﬁtting in the front of the pump housing (See Figure 2-3). Before connecting the transfer pump, make sure that both the lube ﬁtting and the coupler are clean and that the hose and transfer pump are full of clean grease that is free of air.

2.3.4 For subsequent re-ﬁlling, unless the reservoir has been allowed to run dry or air was pumped into the reservoir, it will not be necessary to remove the yellow plug or ﬁll above the vent hole.

2.4 PURGING THE PUMP AND SYSTEM OF AIR

2.4.1 Operate the pump with the main line

disconnected until grease free of air is seen at the pump outlet.

2.4.2 Fill and purge system lines and divider valves

following the procedures outlined in Trabon Bulletin L30103.

2.4.3 Once all lines and dividers have been purged free

of air, reconnect pump to mainline.

Vent Hole

Fill Fitting

Pump Position

Plug

Figure 2-3

2.3.3 For the initial ﬁlling, or if the reservoir has been allowed

to run dry, removing one of the pump position yellow plugs from the pump body will facilitate expelling air from the body and reservoir. Slowly start to ﬁll the reservoir until grease free of air ﬂows from the open pump position. At this point, stop the transfer pump and re-install the yellow plug. After the plug is installed, ﬁll slowly until the follower seal is slightly above the vent hole in the reservoir tube. This will allow air remaining below the follower to escape. When grease free of air is seen at the vent, stop ﬁlling.

Figure 2-4a

Figure 2-4b

Figure 2-4c

Figure 2-4

2-2

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