Lincoln FlowMaster A, FlowMaster 85486 Instruction Manual

FlowMaster™ Single Action Rotary Driven Hydraulic Pump

For 5 Gallon Pail/Container

Model: 85486 Series “A”

U. S. Patent No. 6,102,676

Foreign Patent Pending

This pump conforms to the European Directive for Product Safety

7.5A-18110-J00 Form 403566JUNE 2005

To order call 1-800-548-1191 or visit www.partdeal.com - [e-mail]

Section

- A21 - 6H

Page

FlowMaster™ Rotary Driven Hydraulic Pump

Table of Contents

Page

Safety ….…………………….....................................................2

Description..................................................................................2

Appropriate Use................................................................2

Pump Performance and Specifications..............................3

Installing the Pump.....................................................................3

Operation.....................................................................................4

Maintenance and Repair...........................................................4

Pump Dimensions.............................................................5

Repair Parts List............................................................................7

Trouble Shooting.........................................................................8

Safety

Read and carefully observe these operating instructions before
unpacking and operating the pump! The pump must be oper­ated, maintained and repaired exclusively by
persons familiar with the operating instructions. Local safety
regulations regarding installation, operation and maintenance
must be followed.

Operate this pump only after safety instructions and this ser­vice manual are fully understood.

Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
Indicates a potentially hazardous situation which, if not

Specialized equipment and knowledge is required for repair
of this pump. Contact the factory authorized warranty and
service center nearest you for repair or adjustments other than
maintenance specified in this manual.

Annual inspection by the factory authorized warranty and ser­vice center nearest you is recommended.

A list of factory authorized warranty and service centers is
available upon request.

Damaged Pumps

Any pump that appears to be damaged in any way, is badly
worn or operates abnormally, shall be removed from use until
repairs are made. Contact the factory authorized warranty and
service center nearest to you for repairs.

Description

General Description

The Lincoln Industrial FlowMaster Pump Model 85486 is a fully
hydraulically operated grease pump. Grease output is
proportional to the hydraulic input flow. The pump is
primarily designed for use in a 5 gallon pail or small
container.

The pump is driven by the rotary motion of the hydraulic motor.
Rotary motion is converted to reciprocating motion through an
eccentric crank mechanism. The reciprocating action causes
the pump cylinder to move up and down. The pump is a posi
tive displacement single acting pump. Grease output occurs
during the up stroke of the pump.

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avoided, may result in minor or moderate injury.

Safety Instructions

This equipment generates very high grease pressure. Ex­treme caution should be used when operating this equipment
as material leaks from loose or ruptured
components can inject fluid through the skin and into the body
causing serious bodily injury. Adequate protection is recom
mended to prevent splashing of material onto the skin or into
the eyes.
If any fluid appears to penetrate the skin, get emergency
medical care immediately. Do not treat as a simple cut. Tell

attending physical exactly what fluid was injected.

-

Inspection

If overpressurizing of the equipment is believed to have oc­curred, contact the factory authorized warranty and service
center nearest you for inspection of the pump.

During the down stroke, the pump cylinder is extended into
the grease. Through the combination of shovel action and
vacuum generated in the pump cylinder chamber, the grease
is forced into the pump cylinder. During the upstroke, the inlet
check closes, and the grease taken in during the previous
stroke is transferred through the outlet check and discharged
to the outlet port. Typical output of the pump is shown on page
3, under Pump Performance and Specifications.

Appropriate Use

• The pump is exclusively designed to pump and dispense
lubricants using hydraulic power.

• The maximum specification ratings should not be
exceeded.

• Any other use not in accordance with instructions will
result in loss of claims for warranty and liability.
Do not exceed 450 PSIG (32 bar) maximum supply inlet hy­draulic pressure. Exceeding the rated pressure may result in

damage to system components and personal injury.

Pump Performance and Specification

Maximum Output Pressure,

Page Number - 2

7.5A-18110-J00 Form 403566

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FlowMaster™ Rotary Driven Hydraulic Pump

5

1

3

8

2

7

Typical Installation

PSIG (BAR) 4,500 (320)
Supply inlet hydraulic pressure,
maximum,PSIG (bar) -
Hydraulic Inlet Flow,
GPM (l/min) - Up to 7 (28)
Pump Ratio - 10:1
Operating Temperature,ºF (ºC)- -20 to +150 (-10 to 65)
Hydraulic Inlet Port, In - 7/8-14 UNF-2B (SAE-10)
Tank Return Port, In - 7/8-14 UNF-2B (SAE-10)
Pump Outlets, In - 1/4 NPTF
Maximum Pump Output - 22 in³/min. *

(244 grams/min)

Maximum Hydraulic
Fluid Temperature, ºF, (ºC) - 250 (121)
Weight, Lbs (Kg) - 36 (16)
Crankcase oil- 10 oz of API 10W30

motor oilSF-SC

* Tested with NLGI #2 grease and 1,000 PSI (68 bar)
backpressure at 5 gpm (19 l/pm)

450 (32)

6

4

1. Pump Model 85486

2. Plug, unused outlet

3. Hose Reel

4. Follower, Model 252725

5. Control Valve

6. Shut-off Valve

7. Hydraulic Power Supply
and Return

8. Swivel

Installing the Pump

Typical installation is shown only as a guide for selecting and
installing system components. Contact your Lincoln
Industrial representative for assistance in designing a
system to suit your specific needs.

The pump was tested in light weight oil which was left in to pro
tect the pump from corrosion. Flush the pump before
connecting it to the system to prevent contamination of the
grease with residual oil.

Use follower plate 252725 for a 35 lb (5 gallon) pail.

1. Mount the pump securely on the drum cover so that is
cannot move or vibrate during operation.

2. Attach hydraulic supply line and return line to the motor
ports. The pump will work in either direction.

3. Connect hose reel inlet line to the pump outlet. Plug the
unused outlet on the opposite side of the pump.

-

Assembling the Manifold

The pump is shipped without the manifold (33), manifold
mounting screws (32) and O-rings (34) assembled to the
hydraulic motor (36). Assemble these parts to the motor (36)
as shown in Illustration #1 on page 6. Torque screws to 20-25
ft. lbs.

Form 403566

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7.5A-18110-J00

Mount the pump securely on the drum cover. Failure to do so
could result in personal injury and equipment damage.

Page Number - 3

FlowMaster™ Rotary Driven Hydraulic Pump

3. Remove six self-threading Screws (29) and remove the
Housing Cover (30) and the Cover Gasket (31).

Do not exceed 450 PSIG (32 bar) working hydraulic pressure.
Use high pressure components to reduce risk of serious injury
including fluid injection and splashing in the eyes or on the skin.
All accessories connected to the pump outlet must have a work
ing pressure rating of at least 5,000 PSIG (345 bar).

Operation

Connect one port of the pump to a hydraulic power supply and
the other to the tank line. The pump motor will run in either
direction, so it makes no difference which port
connects to the power supply.

1. Slowly turn on the hydraulic flow until the pump begins to
run.

2. Prime the pump by slowly operating the pump until
lubricant begins to flow. Make sure that all air has been
expelled from the pump and even lubricant flow is achieved.

3. Adjust the pump pressure to the desired application
requirements. Do not exceed pump operating pressure of
450 PSIG (32 bar).

4. Always use the lowest pump output pressure to obtain the
desired results. This will reduce the pump wear.

Do not exceed maximum operating temperture of the hydraulic
fluid (200° F (93° C)). Recommended minimum hydraulic fluid
viscosity is 50 SUS. Never allow the pump to run dry of lubri
cant. A dry pump quickly speeds up,creating friction heat, which
can damage the seals. Monitor the supply lubricant level and
refill when necessary.

Maintenance & Repair

Relieve pressure from the pump and supply lines before
serviceing or repairing the pump, to reduce the risk of an
injury from injection, splashing fluid or moving parts.
Always use Lincoln Industrial parts for service and repair.

Disassembly Procedure (See illustration #1)

Tools Required:

- Hex Bit Socket Wrenches (3/8” square drive) with 3/8” hex,
5/32” hex, 1/4” hex.

- 3/8” O.D. Steel Rod, 8” long

- 12” Crescent Wrench

- Spanner Wrench (for 3/8” diameter tube, 1/8” pin)

- 1/2” to 3/8” square drive adapter

- Torque wrench (1/2” square drive, 0 - 50 ft-lb capacity)

- Torque wrench (3/8” square drive, 0 - 120 in-lb capacity)

- 1/4” nut driver

- Screwdriver (flat blade, 1/8” blade width)

1. Remove the four Socket Head Screws (32) and separate
Connection Manifold (33) from the Hydraulic Motor (36).

2. Remove Pipe Plug (39) and drain the crankcase oil from
the Pump Housing (40).

4. Remove Retaining Ring (51) and pull the Shovel Plug
(50) from the Housing Tube (49).

5. Remove two Socket Head Screws (38) and separate the
Hydraulic Motor (36) from the Pump Housing (40).

-

6. Remove two Outlet Pin Nuts (44) from the Pump Housing
(40).

7. Remove the Pump Subassembly (1 through 28) from
the Pump Housing (40). Pushing the subassembly up
with a wooden or plastic rod 3/4 O.D. against the Check
Seat Housing (28) is helpful.

8. Remove the Housing Tube (49) from the Pump Housing
(40) by inserting a 3/8” rod through the inlet holes at the
bottom of the Housing Tube (49) and unscrewing it.

9. Remove the Bronze Bearing (45), the O-Ring (46), and
the Backup Washer (47) from the Housing Tube (49).

10. Remove the Crankrod Assembly (1 through 8) from the
pump by unscrewing the Button Head Screws (12) and
then pulling out the Wrist Pin Bushings (13).

11. Remove the Check Seat Housing (28) from the
Reciprocating Tube (21). There is a 3/8 Allen Head
socket in the throat of the Check Seat Housing (28) to
facilitate removal.

12. Unscrew the Wrist Pin Anchor (14) from the
Reciprocating Tube (21) and pull the Plunger Assembly
(9 through 20) from the tube.

13. Using a 1/2” dia. wooden or plastic rod, push the Cup

­ Seal (22) and the Pump Cylinder (24) from the

Reciprocating Tube (21).

14. Remove the Pump Plunger (20) from the Plunger Link
Rod (17). A spanner wrench, which uses the holes in
the Pump Plunger, is required.

15. Unscrew the Plunger Link Rod (17) from the Plunger
Tube (11) and slide off the Cup Seal (16), the Backup
Washer (15) and the Wrist Pin Anchor (14).

16. Unscrew the Plunger Tube (11) from the Outlet Pin (9).

17. To dismantle the Crankrod Assembly (1 through 8),
remove Flat Head Screws (1) and the Counter
Weights (2).

18. Remove the Retaining Rings (6) and press the Ball
Bearing Assembly (6, 7, 8) out of the Crank Rod (5). Be
sure to press the Ball Bearing (8) on the outer race.

Pump Assembly Procedure

1. When the pump is dissembled, it is recommended to
replace all seals and gaskets, which are included in the
repair kit.

2. In the process of disassembly, examine the following
components and replace if excessive wear is indicated:
Ball Bearing (8), Crank Eccentric (7), Crankrod (5), Wrist
Pin Bushings (13), Plunger Tube (11), Pump Plunger and
Upper Check Parts (20, 19 and 18), Pump Cylinder (24),
Check Seat Housing and Lower Check Ball and seat (28
and 26), upper Bronze Bushing (45), Housing Tube (49),
Shovel Plug (50), and Reciprocating Tube (21).

3. Assembly Procedure is the reverse of the Disassembly
Procedure except for the following:

Page Number - 4

7.5A-18110-J00 Form 403566

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FlowMaster™ Rotary Driven Hydraulic Pump

4. Install parts (22) through (28) into the Reciprocating Tube
(21) after the plunger assembly (9 through 20) is
installed.

5. Install the Pump Subassembly (1 through 28) into the
pump Housing (40) before tightening the Housing Tube
(49) to the Pump Housing (40). Be sure the
Reciprocating Tube (21) is inserted through both
bushings before tightening the Housing Tube (49).

6. Use loctite 242 (or similar product) medium strength
thread lock on all torqued threaded connections. Extreme
care must be exercised to prevent excess compound
from flowing into critical areas such as clearance fits and
ball check. Allow a minimum of 30 minutes cure time
before operating the pump.

7. Fill cranckcase with 10W30 motor oil up to the bottom off
the pipe plug (39).

8. Torque Specifications:
A. Plunger Tube (11) to Outlet Pin (9) - 100 to 110 In.-Lbs.
B. Button Head Screws (12) to Wrist Pin Anchor (14) 100
to 110 In.-Lbs.

5 13/16”

(148.5 mm)

C. Plunger Tube (11) to Plunger Link Rod (17) - 100 to
110 In.-Lbs.
D. Plunger Link Rod (17) to Pump Plunger (20) - 100 to
110 In.-Lbs.
E. Flat Head Screws (1) to Counter Weight (2) - 100 - 110
In.-Lbs.
F. Wrist Pin Anchor (14) to Reciprocating Tube (21) - 20 to
25 Ft.-Lbs.
G. Check Seat Housing (28) to Reciprocating Tube (21) ­ 20 to 25 Ft.-Lbs.
H. Outlet Pin Nut (44) to Pump Housing (40) - 30 to 35 Ft.­ Lbs.
I. Housing Tube (49) to Pump housing (40) - 20 to 25 Ft.­ Lbs.

9. Fill crankcase with oil up to pipe plug (39) before
fastening housing cover (30) and housing gasket (31)

8 1/2”

(216 mm)

6 9/16”

(167 mm)

2 13/16

(71.5 mm)

2 1/4”

(57 mm)

1. SAE10© Inlet Port/Tank Port

2. 1/4 NPTF Pump Outlets

2.25”
(57 mm)

1/4-20 THD

2.25”
(57 mm)

5 3/16

(132 mm)

21 3/4”

(552 mm)

13 11/16”
(348 mm)

Form 403566

7.5A-18110-J00

To order call 1-800-548-1191 or visit www.partdeal.com - [e-mail]

Page Number - 5

FlowMaster™ Rotary Driven Hydraulic Pump

Page Number - 6

Illustration #1

53

52

55

54

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252725 Follower Plate

Illustration #2

7.5A-18110-J00 Form 403566

56

FlowMaster™ Rotary Driven Hydraulic Pump

Repair Parts List

(Common to all Models)

Item Qty Description All Item Qty Description All

No. Models No. Models

1 2 Flat Head Screw 30 1 Housing Cover 270629

(1/4 x 1-3/4) 270635 31 1 Cover Gasket

2 2 Counter Weight 272197 (Nitrile) *

4 2 Retaining Ring 270609 32 4 Socket Head

5 1 Crankrod 270665 Screw (5/16 x 1-1/4) 270680

6 2 Retaining Ring 270608 33 1 Manifold 270700

7 1 Crank Eccentric 270727 34 2 O-Ring (Viton) *

8 1 Ball Bearing 270607 35 1 Motor Gasket *

9 1 Outlet Pin 270670 36 1 Hydraulic Motor

10 1 O-Ring (Nitrile) * (Note #1) 274054©

11

1 Plunger Tube 270729 37 2 Washer 48548

12 2 Button Head Screw 38 2 Socket Head

(1/4 x 1/2) 270634 Screw (1/2 x 1-1/4) 270658

13 2 Wrist Pin Bushing 270668 39 1 Pipe Plug (3/8 NPTF) 67417

14 1 Wrist Pin Anchor 270731 40 1 Pump Housing 270673

15 1 Backup Washer * 41 2 Backup Ring (Polyurethane) *

16 1 Cup Seal 42 2 O-Ring (Polyurethane) *

(Polyurethane) * 43 2 O-Ring (Nitrile) *

17 1 Plunger Link Rod 270728 44 2 Outlet Pin Nut 270619

18 1 Spring 270616 45 1 Bronze Bearing 270674

19 1 Ball 66010 46 1 O-Ring (Polyurethane) *

20 1 Pump Plunger 270671 47 1 Backup Washer *

21 1 Reciprocating Tube 270642 48 1 O-Ring (Nitrile) *

22 1 Cup Seal 49 1 Housing Tube 270662

(Polyurethane) * 50 1 Shovel Plug 270730

23 1 O-Ring 51 1 Retaining Ring 270705

(Polyurethane) * 52 6 Nut 51412

24 1 Pump Cylinder 270672 53 1 O-Ring 249692

25 1 Ball Cage 270675 54 6 Bolts 249693

26 1 Ball 66001 55 1 Seal 249688

27 1 O-Ring (Nitrile) * 56 1 Seal 249687

28 1 Check Seat 270664 57 6 Gasket 252986

29 6 Self-Tapping© Soft parts Kit 249832

Screw (8 x 1/2) 270633

* Included in 249832 Soft Parts Kit.

1. Includes Gasket (Item 35) and O-Rings (Item 34).

© Indicates change

Form 403566

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7.5A-18110-J00

Page Number - 7

FlowMaster™ Rotary Driven Hydraulic Pump

Troubleshooting

Condition Possible Cause Corrective Action

Pump does not run. Closed supply line shut off valve. Open shut-off valve.

Insufficient Hydraulic Fluid supply. Check hydraulic supply for proper
pressure and flow.

Closed fluid outlet line. Check outlet line and clear
obstructions.

Pump is stalled due to grease Relieve grease backpressure.
backpressure.

Pump is seized or damaged. Dismantle the pump and repair
defective or seized component. See
disassembly and assembly
procedure.

Pump speeds up or runs erratically. Low level of grease or reservoir Refill reservoir.
is empty .

Follower plate is stuck and separated Check follower plate and container
from grease. for damage.

Pump piston or checks are worn. Disassemble the pump and repair.

Pump runs, but output is low. Insufficient hydraulic fluid supply. Check hydraulic supply and adjust
flow.

Inlet pressure too low. Increase pressure using valve 38.

Weepage from housing cover 30. Cup seal (16) or O-Ring (48) failure. Check the seals and replace if
necessary.

Pump becomes noisy. No crank case oil. Add crank case oil. Remove Pipe
Plug (39) from Pump Housing (40).
Oil level should be at the bottom of
the Pipe Plug opening. Add 10W30
motor oil until the crankcase is full.

Worn wrist pin bushing 13. Check the bushings and replace if
necessary.

Americas:

One Lincoln Way

St. Louis, MO 63120-1578

USA

Phone [phone]

Fax [phone]

Page Number - 8

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Europe/Africa:

Heinrich-Hertz-Str 2-8

D-69183 Walldorf

Germany

Phone [phone]

Fax [phone]

Asia/Pacific:

51 Changi Business Park

Central 2

#09-06 The Signature

Singapore 486066

Phone [phone]

Fax [phone]

© Copyright 2005 Printed in USA
Web site:
www.lincolnindustrial.com

7.5A-18110-J00 Form 403566