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LINCOLN HELIOS (INDIA) LIMITED

OPERATION & MAINTENANCE MANUAL


CUSTOMER : M/S Telco Construction equipment co. Ltd.
EQUIPMENT MODEL : EX-1200 Excavator.

Contact Address:

LINCOLN HELIOS (INDIA) LTD


BG-II,

Devanhalli Road, Off Old Madras Road

BANGALORE - 560 049 INDIA

PH.NO. : 080 30710015

FAX NO. : 080 30710001


E-MAIL : mktg@lincolnindia.com

URL : www.lincolnindia.com

Manual is subjected to revision please contact manufacturer for any clarifications


CONTENTS

SECTION 1.0
1. INTRODUCTION

SECTION 2.0
2. REFERENCE DRAWINGS & CATALOGUES

SECTION 3.0
3. INSTALLATION & COMMISSIONING OF CENTRALISED LUBRICATION SYSTEM

SECTION 4.0
4. GENERAL INSTRUCTIONS

SECTION 5.0
5. TROUBLE SHOOTING

SECTION 6.0
6. SCHEDULE FOR CHECKS

SECTION 7.0
7. LIST OF RECOMMENDED SPARES
SECTION 1.0

INTRODUCTION

The system is connected inline with the enclosed schematic drawing no. 22337BH-100. The
system comprises of a pump suitable to be mounted on 200 liters standard barrel, Injectors,
timer, tubing and fittings.

The Lincoln Rotary Hydraulic Pump is fully hydraulically operated grease pump. Grease
Output is proportional to the Hydraulic Input Flow. An integrated Pump Control Manifold is
incorporated with motor to control input flow & pressure. A 24 V DC Solenoid Valve is also
incorporated to turn the pump on or off. This is controlled in the system by means of a Timer
provided in the Control Panel circuit.

Pump is driven by Hydraulic Motor. Rotary motion is converted to reciprocating motion by an


eccentric crank mechanism. The reciprocating motion causes the pump cylinder to reciprocate.
The Pump is a double acting pump as grease output occurs on both upward and downward
stroke of the pump.

The pump operates as long as the solenoid valve is in open position allowing the hydraulic
motor to run. Once the solenoid valve is cut off the oil flow to the hydraulic motor is also cut.
This causes the pump to stop and the grease in the line to relieve back to the reservoir through
vent valve assembly. Once the grease line pressure relieves, the injectors will dispense the
lubricant to the points and get ready for charging for the next cycle.

The system is monitored by means of the Pressure Switch provided in the line and this signal
is used for solenoid switching action to control the pump run and off times.

Additionally we have offered Hose Reel with Grease Gun, for manual Lubrication for points
covered in the Manual Lubrication as in Swing Circle points.
SECTION 2.0

REFERENCE DRAWING AND CATALOGUES.


SYSTEM FOR EX-1200 SHOVEL
S.No. LHIL Part No. Description Qty Unit

CENTRALISED LUBRICATION
1 21642-000394 CONNECTOR TUBE ASSLY FOR LH-IMINJECTOR 2 EA
2 22337-000223 LIFTING TACKLE FOR 200 LTR. STANDARD BAR 1 EA
3 22337-000043 TIE ROD FOR 200 LITRES BARREL 2 EA
4 22337-000083 4 WAY MANIFOLD WITH MOUNTING H 1 EA
5 22337-000153 PUMPSTATION ASSY 1 EA

TYPE OF SYSTEM: CENTROMATIC


6 2435-00005-4 ELECTRICAL CABLES AND ACCESSORIES 1 EA
7 2435-00006-4 ELECTRICAL CABLES AND ACCESSORIES 1 EA
8 6097-00503-4 TIMER MODEL GN 50A 1 EA
9 623-25461-2 PR SWITCH DW -400 1 EA
10 6640-01020-3 TWO INJECTORS WITH MANIFOLD 1 EA
11 6640-01040-3 FOUR INJECTORS WITH MANIFOLD 4 EA
12 6980-01000-1 HOSE REEL ASSEMBLY 1 EA
13 7013-03561-4 MALE CONNECTOR 8 EA
14 7013-03581-4 MALE ELBOW CONNECTOR 1 EA
15 7013-03591-4 FEMALE CONNECTOR 1 EA
16 7013-03605-4 UNION TEE FLARE TUBE ENDS 2 EA
17 7013-03648-4 HOSE ENDS - RE-USABLE SCREW NON MANDREL 20 EA
18 E74-000001-9 BAND SELF TIE 4.7X200X1.6T 20 EA
19 H07-700708-9 STAUFF CLAMP ASSY DIA.16MM 5 EA
20 H19-151422-9 ELBOW FTG#WE 06L,1/8"BSPT,GAL. BLUE 10 EA
21 H19-151822-9 ELBOW FTG#WE 06L, 1/8"NPT,GAL.BLUE 24 EA
22 H20-150834-9 STRAIGHT FTG #GE 10S,3/8"BSP,GALV.BLUE 4 EA

Devanahalli Road, Off old Madras Road, Bangalore- 560049.


23 H20-150844-9 STR FTG #GE 16S, 1/2" BSP, GALV.BLUE 4 EA

LINCOLN HELIOS (INDIA) Ltd


24 H20-151234-9 STRAIGHT FTG #GE 10S,3/8"NPT,GALV.BLUE 6 EA
25 H20-153241-9 MAV 10S, 1/2"BSP, PR.GG.CONN. GALV.BLUE 1 EA

CHKD
PRPD

APRD
26 H20-154134-9 EVGE 10S,3/8"BSP,STRAIGHT STUD STANDPIPE 1 EA
27 H20-155312-9 ADAPTER #3/8"BSP(M)X1/2"BSP(F)GALV.BLUE 2 EA
28 H20-155712-9 ADAPTER #3/8"NPT(M)X1/2"BSP(F)GALV.BLUE 2 EA
29 H20-155811-9 ADAPTER #3/8"BSP(M)X3/8"NPT(F)GALV.BLUE 6 EA
30 H20-155816-9 ADAPTER #3/8"NPT(F)X1/2"BSP(M)GALV.BLUE 2 EA
31 H20-155916-9 ADAPTER #1/2"NPT(M) X 3/8"NPT(F)GALV.BLU 2 EA
32 H20-156011-9 ADAPTER 3/8"NPT(M)X3/8"NPT(M)GALV.BLUE 6 EA
33 H20-156916-9 ADAPTER #1/2"NPT(M) X 3/8"BSP(M)GAL.BLUE 2 EA
34 H22-241704-1 PR GAUGE, DIAL:100MM, RANGE :O-600KG/CM2 1 EA
35 H60-190903-7 BALL VALVE 3/8" 2 EA
36 H63-1000306-9AP SEAMLESS CS TUBE #6X1.0 AFTER PLATING 40 M
37 H63-1000516-9AP SEAMLESS CS TUBE #16X2.0 AFTER PLATING 11 M Alteration
38 H63-1000410-9AP SEAMLESS CS TUBE#10X1.5 AFTER PLATING 8 M
39 H84-150834-9 STRAIGHT FTG#XGE 10S,3/8"BSP GALV.BLUE 1 EA
40 H99-999019-9 HEX LOCK NUT, M20, GAL YELLOW 4 EA
41 M06-103019-7 MTG. BRACKET FOR SSV 12. 1 EA
42 M07-103093-2 TUBE CLAMP TC-1-6-WEL-MS 10 EA
43 M99-105032-1 SEAT A FOR INJECTOR 12 EA
44 M99-105032-2 SEAT B FOR CLAMP. 6 EA
Index

45 M99-105077-0 ADAPTER# (1/8"NPT(M)X1/8"NPT(F)) 3 EA


46 T01-310016-9 HEX.HD.SCREW M10x16 AS PER DRG105-007 6 EA
47 T01-310050-9 HEX.HD.BOLT M10X50 AS PER DRG105-007 12 EA
48 T32-130010-9 HEX.NUT M10 AS PER DRGNO. 105-008. 20 EA
49 T32-130020-9 HEX.NUT M20, GALV.YELLOW 4 EA
50 T37-130206-9 PUNCHED WASHER A6.6, IS-2016,GALV.YELLOW 4 EA
51 T37-130210-9 PUNCHED WASHER A11,IS-2016,GALV.YELLOW 30 EA
52 T37-130218-9 PUNCHED WASHER A20,IS-2016, GALV.YELLOW 4 EA
53 T37-830406-9 SPRING WASHER B6.1, GALV YELLOW 4 EA
54 T37-830410-9 SPRING WASHER B10.2 10 EA
55 T40-120030-9 EYE BOLT M20X30, GR 8.8, GALV. YELLOW 2 EA
56 H25-999918-9 HOSE#SAE 100R2-8, AT, 1/2""ID 40 EA
57 H20-150822-9 STRAIGHT FTG #GE 06S, 1/8"BSP,GALV.BLUE 18 EA
58 H20-156022-9 ADAPTER(3/4"NPT(M)X3/8"NPT(M))GALV.BLUE 2 EA
59 H20-156324-9 ELBOW #3/4"NPT(F), GALV.BLUE 1 EA
60 22337-300200 FITTINGS FOR FABRICATION 1 EA
61 H20-150825-9 STR. FTG #GE 06S,1/4 "BSP ,GAL.BLUE 10 EA
62 H20-157219-9 TEE RED UNION #TR 16/10/16S GALV.BLUE 2 EA
63 H25-299054-9 HOSE#SAE100R2,1/4""ID,D06,2000MM LG 2 EA
FlowMaster™ Rotary Driven Hydraulic Pump
Models: 85480, 85481, 85482 and 85483
Series “B”

Foreign and U.S. Patent Pending

This pump conforms to the European Directive for Product Safety

7.5A-18100-D00 June 2000 Form 402971 Section - C8 Page - 269E


FlowMaster™ Rotary Driven Hydraulic Pump

Table of Contents service center nearest you for repair or adjustments other
than maintenance specified in this manual.
Page
Safety ….……………………................................................................2
Annual inspection by the factory authorized warranty and
Description....................................................................................2
service center nearest you is recommended.
Appropriate Use................................................................2
Pump Performance and Specifications..............................3
A list of factory authorized warranty and service centers is
Installing the Pump.....................................................................4
available upon request.
Operation.....................................................................................5
Maintenance and Repair...........................................................5
Pump Dimensions.............................................................7 Damaged Pumps
Repair Parts List................................................................................9 Any pump that appears to be damaged in any way, is badly
Trouble Shooting.........................................................................10 worn or operates abnormally, shall be removed from use
until repairs are made. Contact the factory authorized
Safety warranty and service center nearest to you for repairs.
Read and carefully observe these operating instructions
before unpacking and operating the pump! The pump must
Description
be operated, maintained and repaired exclusively by per- 85480 - Pump for 120 pound drum (16 gallon)
sons familiar with the operating instructions. Local safety 85481 - Pump for 60 pound drum
regulations regarding installation, operation and 85482 - Pump for 400 pound drum (55 gallon)
maintenance must be followed. 85483 - Pump for 5 gallon pail

Operate this pump only after safety instructions and this General Description
service manual are fully understood. The Lincoln Industrial rotary Hydraulic Pump is a fully
hydraulically operated grease pump. Grease output is
proportional to the hydraulic input flow. The pump is
primarily designed for centralized lubrication systems such
as the Single Line Parallel, Single Line Progressive and
Indicates a potentially hazardous situation which, if not Two Line systems. An integrated pump control manifold is
avoided, could result in death or serious injury. incorporated with the motor to control input flow and
pressure. A 24 volt DC solenoid valve is also incorporated
as a method to turn the pump on and off.

The pump is driven by the rotary motion of the hydraulic


Indicates a potentially hazardous situation which, if not motor. Rotary motion is converted to reciprocating motion
avoided, may result in minor or moderate injury. through an eccentric crank mechanism. The reciprocating
action causes the pump cylinder to move up and down. The
Safety Instructions pump is a positive displacement double acting pump as
This equipment generates very high grease pressure. grease output occurs during both the up and down stroke of
Extreme caution should be used when operating this the pump.
equipment as material leaks from loose or ruptured
components can inject fluid through the skin and into the During the down stroke, the pump cylinder is extended into
body causing serious bodily injury. Adequate protection is the grease. Through the combination of shovel action and
recommended to prevent splashing of material onto the vacuum generated in the pump cylinder chamber, the
skin or into the eyes. grease is forced into the pump cylinder. Simultaneously,
grease is discharged through the outlet of the pump. The
volume of grease during intake is twice the amount of
grease output during one cycle. During the upstroke, the
inlet check closes, and one half of the grease taken in
If any fluid appears to penetrate the skin, get emergency during the previous stroke is transferred through the outlet
medical care immediately. Do not treat as a simple cut. check and discharged to the outlet port. Typical output of the
Tell attending physical exactly what fluid was injected. pump is shown on page 4.

Inspection Appropriate Use


If overpressurizing of the equipment is believed to have • All pump models are exclusively designed to pump and
occurred, contact the factory authorized warranty and service dispense lubricants using hydraulic power.
center nearest you for inspection of the pump. • The maximum specification ratings should not be
exceeded.
Specialized equipment and knowledge is required for repair • Any other use not in accordance with instructions will
of this pump. Contact the factory authorized warranty and result in loss of claims for warranty and liability.

Page Number - 2 7.5A-18100-D00 Form 402971


FlowMaster™ Rotary Driven Hydraulic Pump

Hydraulic Motor
Hydraulic Manifold
(Item 42)

Hydraulic Material
Fluid Return Outlet
to Tank

Hydraulic
Fluid Inlet

Flow Control
Valve (Item 39)
Solenoid Valve
(Items 34 & 35)
Pressure Gauge
Pressure Reducing
Vent (Item 32)
Valve (Item 38)
Valve
Illustration 1

Pump Performance and Specification


Supply inlet hydraulic pressure, Operating Temperature, ºF (ºC)- -20 to +150 (-10 to 65)
maximum, PSIG (bar) - 3,000 (200) Operating Voltage, VDC - 24
Operating working hydraulic Hydraulic Inlet Port, In - SAE 4
pressure , PSIG (bar) - 300 to 450 (20 to 32). Tank Return Port, In - SAE 6
Hydraulic Inlet Flow, Pump Outlets, In - 1/4 NPTF
GPM (l/min) - Up to 7 (28) Maximum Hydraulic
Pump Ratio with manifold - 9:1 at low inlet pressure Fluid Temperature, ºF, (ºC) - 200 (93)
(300 to 350 psi [20 to 25 Weight, Lbs (Kg) - 36 (16)
bar]) and low inlet flow
(below 2 gpm [7 lpm])
Pump ratio approaches
11.0:1 ratio at higher
inlet pressure and flow. Do not exceed 3,000 PSIG (200 bar) maximum supply inlet
hydraulic pressure. Exceeding the rated pressure may result
in damage to system components and personal injury.
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Form 402971 7.5A-18100-D00 Page Number - 3


FlowMaster™ Rotary Driven Hydraulic Pump

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24VDC Connections Installing the Pump


No Connection to Typical installation is shown only as a guide for selecting
Center Lug and installing system components. Contact your Lincoln
Solenoid Valve Industrial representative for assistance in designing a
Illustration 2 system to suit your specific needs.
F
E The pump was tested in light weight oil which was left in to
protect the pump from corrosion. Flush the pump before
D G connecting it to the system to prevent contamination of the
H grease with residual oil.
C
J
B The pump has flow and pressure controls integrated into
the manifold (37). A normally closed ON/OFF Solenoid Valve
(35) is also integrated into the manifold and will start or
A
stop the pump operation.
K L 1. Mount the pump securely on the drum cover so that it
cannot move or vibrate during operation.
2. Attach hydraulic supply line to the Inlet and return line to
the Tank ports.
3. Connect material supply line to the pump outlet. Plug
the unused outlet on opposite side of the pump.
4. Install high pressure shut-off valve in the material supply
line. (Required)
5. Connect 24 VDC power supply to the solenoid valve (35).
See Illustration #1. Use connector plug (36) supplied
with the pump.

NOTE: To install the pump Model 85481 as a replacement


Illustration 3 pump for 84961 used on Model 84944, use adapter/spacer
A - Pump Outlet Plug
p/n 249616 with bolts p/n 50014, included in the pump
B - Hydraulic Supply Line
package (see illustration #4).
C - Hydraulic Return to Tank
line (3/4” ID min.)
D - Supply Line Shut-off Valve
E - 24 VDC from Controller
F - Return Line Shut-off Valve
(3/4” ID min.)
G - Vent Valve Port with Restrictor
H- Outlet Shut-off Valve
J - Material Supply Line
K - Follower Plate (85492 for 120 lb. drum only)
L - Drum Cover (83115 for 400 lbs., 84616 for 120 lbs.)

Page Number - 4 7.5A-18100-D00 Form 402971


FlowMaster™ Rotary Driven Hydraulic Pump

Do not exceed maximum operating temperature of the


hydraulic fluid (200º F/93º C) . Never allow the pump to run dry
of lubricant. A dry pump quickly speeds up, creating friction
heat, which can damage the seals. Monitor the supply
lubricant level and refill when necessary.

Setting the Pump Manifold Pressure and


Flow Controls
The pressure must first be adjusted to insure the desired flow
Illustration 4 setting is achieved.

Pressure Control Valve Adjustment


- Loosen the lock nut on the Pressure control by turning the
Mount the pump securely on the drum cover. Failure to do nut COUNTERCLOCKWISE.
so could result in personal injury and equipment damage. - Turn the valve stem COUNTERCLOCKWISE until it no
longer turns. The valve stem will unscrew until it reaches
the stop. It will not come off. This is the minimum pressure
setting, which is about 170 psi (12 bar).
- With the pump stalled against pressure, turn the Pressure
Do not exceed 450 PSIG (32 bar) working hydraulic Control Valve stem CLOCKWISE until the desired pressure
pressure. Use high pressure components to reduce risk of is attained on the manifold Pressure Gage. (Do not exceed
serious injury including fluid injection and splashing in the 450 PSI.
eyes or on the skin. All accessories connected to the pump - Tighten the lock nut by turning CLOCKWISE.
outlet must have at least 5,000 PSIG (350 bar) minimum
hydraulic pressure. All accessories connected to the pump Flow Control Valve Adjustment
inlet must have at least 3,000 PSIG (200 bar) minimum - Loosen the lock nut on the Flow Control Valve by turning the
working pressure. nut COUNTERCLOCKWISE.
- Adjust the flow by turning the valve stem CLOCKWISE to
reduce the flow and COUNTERCLOCKWISE to increase it.
Operation The Flow Control Valve can be turned in until the valve is
All pumps are factory set at 350 PSIG (24 bar) working inlet completely closed, and out a maximum of 2 1/2 turns. The
hydraulic pressure with a flow rate of 2.5 GPM (9.5 l/min). valve stem will not come out when fully open (unscrewed)
Do not change the settings for the pump until after the as there is a stop at this position.
start up procedure. - After adjusting the flow to the desired setting, tighten the
lock nut by turning it CLOCKWISE.
1. Shut off the material supply line valve.
2. Turn on the hydraulic pressure.
3. Energize the solenoid On/Off valve. Maintenance and Repair
4. Prime the pump by slowly opening the shut-off lubricant Relieve pressure from the pump and supply lines before
supply line valve. Make sure that all air has been servicing or repairing the pump, to reduce the risk of an
expelled from the pump and even lubricant flow is injury from injection, splashing fluid or moving parts.
achieved.
© 5. Adjust the pump pressure and flow to the desired
application requirements. See Pressure and Flow
Control Valve Adjustment for instructions to adjust
pressure and flow, Do not exceed pump operating Always use Lincoln Industrial parts for service and repair.
pressure of 450 PSIG (32 bar).
6. Always use the lowest pump output pressure and
hydraulic fluid flow to obtain the desired results. This
will reduce the pump wear.

© Indicates change

Form 402971 7.5A-18100-D00 Page Number - 5


FlowMaster™ Rotary Driven Hydraulic Pump

Disassembly Procedure (See illustration #6) Pump Assembly Procedure

Tools Required: 1. When the pump is dissembled, it is recommended to


- Hex Bit Socket Wrenches (3/8” square drive) with 3/8” hex, replace all seals and gaskets, which are included in the
5/32” hex, 1/4” hex. 270663 repair kit.
- 3/8” O.D. Steel Rod 2. In the process of disassembly, examine the following
- 12” Crescent Wrench components and replace if excessive wear is indicated:
- Spanner Wrench (for 3/8” diameter tube, 1/8” pin) Ball Bearing (8), Crank Eccentric (7), Crankrod (5), Wrist
- 1/2” to 3/8” square drive adapter Pin Bushings (13), Plunger Tube (11), Pump Plunger and
- Torque wrench (1/2” square drive, 0 - 50 ft-lb capacity) Upper Check Parts (20, 19 and 18), Pump Cylinder (24),
- Torque wrench (3/8” square drive, 0 - 120 in-lb capacity) Check Seat Housing and Lower Check Ball (28 and 26),
- 1/4” nut driver upper Bronze Bushing (51), Housing Tube (55), Shovel
- Screwdriver (flat blade, 1/8” blade width) Plug (56), and Reciprocating Tube (21).
1. Remove the four Socket Head Screws (33) and separate 3. Assembly Procedure is the reverse of the Disassembly
Manifold from the Hydraulic Motor (42). Procedure except for the following:
2. Remove Pipe Plug (45) and drain the crankcase oil from 4. Install parts (22) through (28) into the Reciprocating Tube
the Pump Housing (46). (21) after the plunger assembly (9 through 20) is
3. Remove six self-threading Screws (29) and remove the installed.
Housing Cover (30) and the Cover Gasket (31). 5. Install the Pump Subassembly (1 through 28) into the
4. Remove Retaining Ring (57) and pull the Shovel Plug pump Housing (46) before tightening the Housing Tube
(56) from the Housing Tube (55). (55) to the Pump Housing (46). Be sure the
5. Remove two Socket Head Screws (44) and separate the Reciprocating Tube (21) is inserted through both
Hydraulic Motor (42) from the Pump Housing (46). bushings before tightening the Housing Tube (55).
6. Remove two Outlet Pin Nuts (50) from the Pump Housing 6. Use loctite 242 (or similar product) medium strength
(46). thread lock on all torqued threaded connections. Extreme
7. Remove the Pump Subassembly (1 through 28) from care must be exercised to prevent excess compound from
the Pump Housing (46). Pushing the subassembly up flowing into critical areas such as clearance fits and ball
with a wooden or plastic rod 3/4 O.D. against the Check check. Allow a minimum of 30 minutes cure time before
Seat Housing (28) is helpful. operating the pump.
8. Remove the Housing Tube (55) from the Pump Housing 7. Torque Specifications:
(46) by inserting a 3/4 rod through the inlet holes at the A. Plunger Tube (11) to Outlet Pin (9) - 100 to 110 In.-Lbs.
bottom of the Housing Tube (55) and unscrewing it. B. Button Head Screws (12) to Wrist Pin Anchor (14) 100
9. Remove the Bronze Bearing (51), the O-Ring (52), and to 110 In.-Lbs.
the Backup Washer (53) from the Housing Tube (55). C. Plunger Tube (11) to Plunger Link Rod (17) - 100 to 110
10. Remove the Crankrod Assembly (1 through 8) from the In.-Lbs.
pump by unscrewing the Button Head Screws (12) and D. Plunger Link Rod (17) to Pump Plunger (20) - 100 to
then pulling out the Wrist Pin Bushings (13). 110 In.-Lbs.
11. Remove the Check Seat Housing (28) from the E. Flat Head Screws (1) to Outer Weight (2) - 100 - 110
Reciprocating Tube (21). There is a 3/8 Allen Head In.-Lbs.
socket in the throat of the Check Seat Housing (28) to F. Wrist Pin Anchor (14) to Reciprocating Tube (21) - 20 to
facilitate removal. 25 Ft.-Lbs.
12. Unscrew the Wrist Pin Anchor (14) from the G. Check Seat Housing (28) to Reciprocating Tube (21) -
Reciprocating Tube (21) and pull the Plunger Assembly 20 to 25 Ft.-Lbs.
(9 through 20) from the tube. H. Outlet Pin Nut (50) to Pump Housing (47) - 30 to 35 Ft.-
13. Using a 1/2” wooden or plastic rod, push the Cup Seal Lbs.
(22) and the Pump Cylinder (24) from the Reciprocating I. Housing Tube (55) to Pump housing (47) - 20 to 25 Ft.-
Tube (21). Lbs.
14. Remove the Pump Plunger (20) from the Plunger Link © 8. Fill cranckcase with oil up to pipe plug (39) before
Rod (17). A spanner wrench, which uses the holes in fastening housing cover (30) and housing gasket (31).
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 Inner and Outer
Weights (2 & 3).
18. Remove the Retaining Rings (6) and press the Crank
Eccentric (7) out of the Ball Bearing (8). Be sure to
support the Ball Bearing (8) on the inner race. © indicates change

Page Number - 6 7.5A-18100-D00 Form 402971


FlowMaster™ Rotary Driven Hydraulic Pump

11.46 9.08
(291) (231)
4.61
9.54
(117)
(242) 8
1.5
3.125 (38)
(79)

5.025
2 (128)

1. 1/4 NPTF Pump Outlets


© 2. SAE 4 Inlet Port
© 3. SAE 6 Tank Port
A 4. 1/4 NPTF Orifice fitting for
Vent Valve Port
5. Solenoid Valve
6. Pressure Reducing Valve
7. Flow Control Valve
8. Pressure Gauge

ø 1.25
(32)

4
02'(/ ',0$LQ PP ',0%LQ PP
    
     2.25
(57)
     7
    

1/4-20 THD 2.25


(57)
Illustration #5
© indicates change

Form 402971 7.5A-18100-D00 Page Number - 7


FlowMaster™ Rotary Driven Hydraulic Pump

2
3 1
4
29 5
6
7
32 30
8
6
31
34 33 4
3
2 9
58
35
1 10

36 60 11

37 12
59
45 13
38 14
39 46
61 15
40 41 47
48 16
42 49
17
43
50
44 51
52
53
54 18
19
20

55

21

56
57
22
23
24
25
26
27
28

Illustration #6

Page Number - 8 7.5A-18100-D00 Form 402971


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 32. 1 Pressure Gauge 270768
(1/4 x 1-3/4) 270635 33. 4 Socket Head
2. 2 Outer Weight 270606 Screw (5/16 x 1-1/4) 270680
3. 2 Inner Weight 270605 34. 1 Solenoid Valve
4. 2 Retaining Ring 270609 Cartridge (Note #2) 270690
5. 1 Crankrod 270665 35. 1 Solenoid Valve
6. 2 Retaining Ring 270608 Coil (24 VDC) 270691
7. 1 Crank Eccentric 270666 36. 1 Solenoid Connector 242209
8. 1 Ball Bearing 270607 © 37. 1 Manifold 270771
9. 1 Outlet Pin 270670 38. 1 Pressure Reducing
10. 1 O-Ring (Nitrile) * Valve (Note #3) 270692
11. 1 Plunger Tube 270667 39. 1 Flow Control Valve
12. 2 Button Head Screw (Note #4) 270693
(1/4 x 1/2) 270634 40. 2 O-Ring (Nitrile) *
13. 2 Wrist Pin Bushing 270668 41. 1 Motor Gasket *
14. 1 Wrist Pin Anchor 270669 42. 1 Hydraulic Motor
15. 1 Backup Washer * (Note #1) 270676
16. 1 Cup Seal 43. 2 Washer 48548
(Polyurethane) * 44. 2 Socket Head
17. 1 Plunger Link Rod See Chart Below Screw (1/2 x 1-1/4) 270658
18 1 Spring 270616 45. 1 Pipe Plug (3/8 NPTF) 67417
19. 1 Ball 66010 46. 1 Pump Housing 270673
20. 1 Pump Plunger 270671 © 47. 2 Backup Ring (Polyurethane) *
21. 1 Reciprocating Tube See Chart Below © 48. 2 O-Ring (Polyurethane) *
22. 1 Cup Seal 49. 2 O-Ring (Nitrile) *
(Polyurethane) * 50. 2 Outlet Pin Nut 270619
23. 1 O-Ring 51. 1 Bronze Bearing 270674
(Polyurethane) * © 52. 1 O-Ring (Polyurethane) *
24. 1 Pump Cylinder 270672 53. 1 Backup Washer *
25. 1 Ball Cage 270675 54. 1 O-Ring (Nitrile) *
26. 1 Ball 66001 55. 1 Housing Tube See Chart Below
27. 1 O-Ring (Nitrile) * 56. 1 Shovel Plug 270707
28. 1 Check Seat 270664 57. 1 Retaining Ring 270705
29. 6 Self-Threading 58. 1 Seal Kit (Nitrile) 270687
Screw (8 x 1/2) 270633 59. 1 Seal Kit (Nitrile) 270688
30. 1 Housing Cover 270629 60. 1 Seal Kit (Nitrile) 270689
31. 1 Cover Gasket 61. 1 Orifice Fitting 270735
(Nitrile) * Soft parts Kit 270663

Repair Parts List


(Non-common items)

Item Qty. Description Model Model Model Model


No. 85480 85481 85482 85483
17 1 Plunger Link Rod 270648 270614 270645 270641
21 1 Reciprocating Tube 270649 270617 270646 270642
55 1 Housing Tube 270659 270660 270661 270662

* Included in 270663 Soft Parts Kit.


1. Includes Gasket (Item 41) and O-Rings (Item 40).
2. Includes Seal Kit (Item 58).
3. Includes Seal Kit (Item 59).
4. Includes Seal Kit (Item 60).
© indicates change

Form 402971 7.5A-18100-D00 Page Number - 9


FlowMaster™ Rotary Driven Hydraulic Pump

Troubleshooting
Condition Possible Cause Corrective Action

Pump does not run. No pressure on gauge (32):


- Closed Supply line shut off valve. Open shut-off valve.
- No power to solenoid valve (34). Correct electrical fault.
- Faulty Solenoid (35). Replace solenoid (35).
- Pressure Reducing Valve (38) is Reset Pressure Reducing Valve (38).
set too low.
- Insufficient Hydraulic Fluid supply. Check hydraulic supply for proper
pressure and flow.

Pressure is shown on gauge (32):


- Closed fluid outlet line. Check outlet line and clear
obstructions.
- Flow Control Valve is fully closed. Readjust valve to 3/4 turn open.
- Pump is stalled due to grease Check vent valve in system.
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.
Copyright 1999

Pump runs, but output is low. Insufficient hydraulic fluid supply. Check hydraulic supply and adjust
flow using valve 39.

Inlet pressure too low. Increase pressure using valve 38.

Faulty inlet (25, 26, 27) or discharge Replace faulty components.


check valve (18, 19, 20).

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

Pump becomes noisy. No crank case oil. Add crank case oil. Remove Pipe
Plug (45) from Pump Housing (46).
Oil level should be at the bottom of
the Pipe Plug opening. Add 10W30
Printed in the U.S.A.

motor oil until the crankcase is full.

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

Lincoln Industrial Lincoln GmbH Lincoln Industrial


One Lincoln Way 69190 Walldorf 25 International Business Park
St. Louis, MO 63120-1578 Heinrich-Hertz Strasse 2-8 #01-68 German Centre
(+1) 314 679 4200 (+49) 6227 33-0 Singapore 609916
www.lincolnindustrial.com (+65) 562-7960

Page Number - 10 7.5A-18100-D00 Form 402971


MODEL 84990
VENT VALVE ASSEMBLY
FOR OFF-HIGHWAY TYPE MINING MACHINERY 120 LB. DRUM

84980

242631
(PART OF
HYDRAULIC
PUMP)

ASSEMBLY INSTRUCTIONS

1 ) Bolt the 361104 Bracket to drum cover with 66246


Lockwashers and 50000 (5/8" long) Screws as
illustrated (see DETAIL "A").

2 ) Screw 12213 Adapter, 81938 Outlet Check and


14727 Nipple together. Screw assembly into pump
236874
outlet. Assemble 84980 Vent Valve to nipple, in
position as illustrated, so that material return outlet can
be connected to vent tube with 236874 Hose.

3 ) Bring drum cover onto pump tube and align vent valve
to bracket. Secure with 66246 Lockwashers and
50034 (1/2" long) Screws, and bolt drum cover to
pump.

4 ) Assemble 12538 Nut, 360580 Bracket and 48415 Washers to


67290 Vent Tube. Slide bracket onto pump tube, and insert vent tube
through drum cover. Place 31010 Washers onto vent tube and secure
with 81753 Elbow Union Assembly (hand tight). Tighten 12538 Nut
securely against bracket.
5 ) Assemble 236874 Hose to vent valve and assemble 67034 Coupling to
hose.

6 ) Remove 10724 Union Nut, 11907 Union Nipple & 34049 Washer intact
trom 81753 Elbow Union Assembly and install into coupling. Reassemble
elbow union.

7 ) Screw the straight end of the 241963 Hose into the 242631 Orifice
Assembly which is assembled into the bottom side of the Valve Assembly.
Screw the other end of the hose assembly into the top of the vent valve.

© IMPORTANT NOTE: Maximum allowable hydraulic re-


turn line pressure NOT TO EXCEED 30 PSI for proper
venting of SL-1 injectors (15 psi for SL-11).
8 ) Screw 10160 Elbow & 90942 Safety Unloader into vent valve. © Indicates Change

One Lincoln Way


Copyright 1996
Printed in U.S.A.
Section-C8
St. Louis, Missouri 63120-1578
(314) 679-4200 Page -246E

MAY - 96 FORM 402689


1/4" 84980 VENT VALVE
NPTF
241807
Series "B"

244652

244653

14722

239330

14723

31047

3/4"
NPTF
3/4"
NPTF
239336

SERVICE PARTS
Part Qty. Description Part Qty. Description

10160 1 Elbow 66246 4 Lockwasher


10724 1 Union nut 67034 1 Coupling
11907 1 Union nipple 67290 1 Vent tube
12213 1 Adapter 81753 1 Elbow union assembly
12538 1 Nut 81938 1 Outlet check
14722 1 Needl e 90942 1 Safety unloader
14723 1 Valve seat 236874 1 Hose
14727 1 Nipple 239330 1 Packing assembly
16377 1 Check housing 239336 1 Valve body
31010 2 Washer (copper) 241807 1 Cylinder
31047 1 Check seat gasket 241963 1 Hose assembly
34049 1 Washer 244652 1 U-cup (Buna N)
48415 3 Washer (steel) 244653 1 Piston
50000 2 Screw 360580 1 Bracket
50034 2 Screw 361104 1 Bracket
51026 2 Nut

RETAIN THIS INFORMATION FOR FUTURE REFERENCE


When ordering replacement parts, list: Part Number, Description, Model Number, and Series Letter.

LINCOLN provides a Distributor Network that stocks equipment and replacement parts.
PDD-OM-C-014 Nov 04

INJECTOR
LH-IR-100

OWNER’S MANUAL
page1 of 8

Lincoln Helios (India) Ltd, Devanahalli Road, Off Old Madras Road, Bangalore – 560 049 Tel: 080-8472727, 8472424
E-Mail: mktg@lincolnindia.com www.lincolnindia.com
PDD-OM-C-014 Nov 04

Table of contents
Sl. No. Contents Page No.
1 Introduction 2
2 Specifications 2
3 Operation 3-4
4 Manifold Assembly 5
5 Service Parts List 6-7
6 Trouble Shooting 8

1. INTRODUCTION

Centromatic Injector LH-IR incorporated in the lubrication system measures out and
provides required quantity of grease to each bearing under high pressure.

2. SPECIFICATION

Maximum operating pressure 240 Bar (3500 psi)

Minimum operating pressure 130 Bar (1850 psi)

Recommended operating pressure 170 Bar (2500 psi)

Maximum vent (Recharge) pressure 41 Bar (600 psi)

Lubricant output is adjustable from 0.131-1.31 cc (0.008-0.08 cu. in)


Subject to improvements without notice

Injectors can be mounted in any position and can be used in circuits with SL-32 and / or
SL-33 injectors for dispensing grease up to N.L.G.I. # 2

page2 of 8

Lincoln Helios (India) Ltd, Devanahalli Road, Off Old Madras Road, Bangalore – 560 049 Tel: 080-8472727, 8472424
E-Mail: mktg@lincolnindia.com www.lincolnindia.com
PDD-OM-C-014 Nov 04

3. OPERATION:

MEASURING
CHAMBER

INJECTOR
PISTON

DISCHARGE
CHAMBER
PASSAGE

SLIDE
VALVE

LUBRICANT
SUPPLY

STAGE 1 STAGE 2
Subject to improvements without notice

The injector piston is in its normal or rest When the slide valve uncovers the passage,
position. The discharge chamber is filled lubricant is admitted to the measuring
with lubricant from the previous cycle. chamber above the piston which forces
Under the pressure of incoming lubricant lubricant from the discharge chamber
the slide valve is about to open the passage through the outlet port to bearing.
leading to the measuring chamber above
the injector piston.

page3 of 8

Lincoln Helios (India) Ltd, Devanahalli Road, Off Old Madras Road, Bangalore – 560 049 Tel: 080-8472727, 8472424
E-Mail: mktg@lincolnindia.com www.lincolnindia.com
PDD-OM-C-014 Nov 04
Subject to improvements without notice

STAGE 3 STAGE 4
As the injector piston completes its stroke, it After venting, the injector spring expands,
pushes the slide valve past the passage, cutting causing the slide valve to move, so that the
off further admission of lubricant to the passage passage and discharge chamber are
and measuring chamber. The injector piston connected by a valve port. Further
and slide valve remain in this position until expansion of the spring causes the piston to
pressure in the supply line is vented (relieved at move upward, forcing the lubricant in the
the pump). measuring chamber through the passage and
valve port to refill the discharge chamber.
page4 of 8

Lincoln Helios (India) Ltd, Devanahalli Road, Off Old Madras Road, Bangalore – 560 049 Tel: 080-8472727, 8472424
E-Mail: mktg@lincolnindia.com www.lincolnindia.com
PDD-OM-C-014 Nov 04

4. INJECTOR MANIFOLD ASSEMBLY:

40NM±10%

LH-IR-100 LH-IR-100 LH-IR-100


~189

1/8"NPTF
OUTLET

REPLACEMENT
INJECTOR
LH-IR-100
41

NXØ10

MANIFOLD
41

3/8"NPTF 3/8"NPTF
INLET INLET

TIGHTEN TO TORQUE
38 31.70
80NM±10%
22.25 31.75 31.75
Subject to improvements without notice

INJECTOR MANIFOLD ASSEMBLY


LH-IM-101/102/103/104/105
LH-IM-105 171.4 95.2 2 5 FIVE INJECTORS WITH MANIFOLD 6640-01050-3 7513-03005-3
LH-IM-104 139.5 63.5 2 4 FOUR INJECTORS WITH MANIFOLD 6640-01040-3 7513-03004-3
LH-IM-103 108 31.7 3 THREE INJECTORS WITH MANIFOLD 6640-01030-3 7513-03003-3
LH-IM-102 76 -DIM 1 2 TWO INJECTORS WITH MANIFOLD 6640-01020-3 7513-03002-3
LH-IM-101 63.5 - 1 1 SINGLE INJECTOR WITH MANIFOLD 6640-01010-3 7513-03001-3
DIM N ASSLY MANIFOLD
MODEL NO. NO OF NO OF TITLE
B B INJECTOR PART/DRG.NO. PART/DRG.NO.
HOLES

page5 of 8

Lincoln Helios (India) Ltd, Devanahalli Road, Off Old Madras Road, Bangalore – 560 049 Tel: 080-8472727, 8472424
E-Mail: mktg@lincolnindia.com www.lincolnindia.com
PDD-OM-C-014 Nov 04

5. SPARE PARTS LIST:

19
3
22 4
17 2
10 1
14
15
18
20
7 5
16 13
6 8
9 12
11
21
Subject to improvements without notice

REPLACEMENT INJECTOR (6640-01000-3)


MODEL LH-IR-100

page6 of 8

Lincoln Helios (India) Ltd, Devanahalli Road, Off Old Madras Road, Bangalore – 560 049 Tel: 080-8472727, 8472424
E-Mail: mktg@lincolnindia.com www.lincolnindia.com
PDD-OM-C-014 Nov 04

ASSLY
SL.NO. TITLE QTY/SET
PART/DRG.NO.
@ 1 PISTON STOP PLUG - 1
2 PISTON ROD - 1
* 3 ADJSUTING SCREW - 1
@
@ 4 LOCK NUT - 1
5 SPRING SEAT - 1
* 6 INJECTOR BODY 7363-03009-3 1
7 PLUNGER - 1
*
8 INLET DISC - 1
*
9 ADAPTER BOLT 7013-03010-4 1
@ 10 GASKET - 1
* 11 ADAPTER GASKET 7315-22008-4 1
12 PACKING - 1
* 13 PACKING - 1
* 14 PACKING - 1
@*
15 O-RING - 1
* 16 WASHER - 1
* 17 WASHER - 1
@
* 18 COMPRESSION SPRING 7713-07008-3 1
@ 19 INJECTOR CAP - 1
20 FITTING ASSEMBLY 6641-01100-4 1
21 WASHER 7315-04002-4 1
@ 22 SEAL FOR CAP - 2

NOTE:

* INDICATES REPAIR KIT (PART.NO. 6641-01)


Subject to improvements without notice

@ INDICATES ADJUSTING SLEEVE KIT (PART.NO. 6640-01110-4)

Accessories:
1. Connecting Tubes
2. Fittings
3. Fittings Assembly

page7 of 8

Lincoln Helios (India) Ltd, Devanahalli Road, Off Old Madras Road, Bangalore – 560 049 Tel: 080-8472727, 8472424
E-Mail: mktg@lincolnindia.com www.lincolnindia.com
PDD-OM-C-014 Nov 04

6. TROUBLE SHOOTING

SL.NO TROUBLE CAUSE REMEDY


1. Grease leakage at ports of -Improper assembly of -Dismantle & reassemble.
manifold. injector manifold. -Replace manifold or
Worn-out threads. adapter bolt as applicable.
-Replace it.

-Gaskets not effective.

2. Restricted flow of -Worn-out packing. -Replace packing.


Lubricant through injector. -Slide valve damage. -Replace slide valve.
-Worn-out injector bore. -Replace injector body.
-Worn-out piston
packing. -Replace packing.

3. No injector output -Pressure in the line is -Attend to the problems in


inadequate. other parts of the system.
-Clean injector bore &
-No movement of slide slide valve. Clean bore &
valve. piston.
-Find out whether spring is
-No movement of piston. getting compressed if not ,
replace the spring.
-Slide valve port closed. -Clean the port.
-Spring failure. -Replace spring.
-Injector inlet blocked. -Clean the port.

4. No movement of the indicator -Spring failure -Replace the spring.


pin. -As explained in (2) & (3) -As explained in (2) & (3)
above. above.
Subject to improvements without notice

5. Erratic output & inconsistent -Internal leakage at slide -Check packing &replace
movement of indicator pin. valve packing & piston if required.
packing.

page8 of 8

Lincoln Helios (India) Ltd, Devanahalli Road, Off Old Madras Road, Bangalore – 560 049 Tel: 080-8472727, 8472424
E-Mail: mktg@lincolnindia.com www.lincolnindia.com
TIMER GN50A

TECHNICAL DATA

• Operating voltage : 24V DC


• Output current : 3.5A (max.)
• Protections : − short circuit
− overload (trip at 3.0A)
− reverse voltage
− spikes & surges
• Class of protection : IP 55
• Vibration level : 5G @ 4000 cpm

TIME SETTINGS

• RUN Time : 1 minute


• PAUSE Time : 30 minutes
• SUPERVISORY Time : − for supervisory 1: 1 minute
− for supervisory 2: 1 minute

LED INDICATORS ON TIMER

1. Power ON : red
2. Pump ON : green
3. Short circuit / overload trip : amber
4. Supervisory fault 1 : amber
5. Supervisory fault 2 : amber
6. Continuos lubrication : green
7. Start (ignition) : Red
SWITCH DETAILS
• For selecting operating timings : PCB mounted dip switches
• For auto / continuos lubrication : Green Push button on the enclosure
• For fault reset : Red Push button on the enclosure
SWITCH ARRANGEMENT FOR OPERATING TIME SELECTION

SWITCH SWITCH POSITION


DETAILS 1 2 3 4 5 6 7 8
SWITCH A
RUN TIME 1 2 4 ON - High speed mode
PAUSE TIME 15 30 45 60 OFF- Normal mode
SWITCH B
SUPERVISORY 1 1 2
SUPERVISORY 2 1 2
PAUSE TIME 90 120 240

INSTRUCTIONS FOR SETTING OPERATING TIMINGS


- For RUN and PAUSE time in normal mode: Put Switch A-8 OFF.
- for RUN time of 1 minute put Switch A-1 ON.
- for PAUSE time of 30 minutes put Switch A-5 ON.
- for SUPERVISORY 1 of 1 minute put Switch B-1 ON.
- for SUPERVISORY 2 of 1 minute put Switch B-3 ON.
- For RUN and PAUSE time in high speed mode: Put Switch A-8 ON.
- The time settings can be made by “adding-on” the switches as explained above.

CONNECTION (TERMINAL) DETAILS


1. BAT +VE : connect to battery terminal
2. GND : connect to battery –ve / chassis ground
3. START : connect to ignition / machine start switch
4. OUTPUT : connect to pump motor +ve
5. LS-1 : connect to pressure switch at the front left hand side
6. LS-2 : connect to limit switch at the rear
GENERAL ARRANGEMENT
SECTION 3.0
INSTALLATION & COMMISSIONING OF CENTRALISED LUBRICATION SYSTEM.

INSTALLATION

PRE-ASSEMBLY

• Mount the Pump Assembly and make the hydraulic oil -line connections with the hoses
as per the layout.

• Assemble the Injector manifolds as per the system layout.

INSTALLING THE FUNCTIONAL COMPONENTS

• Weld the seats for Injectors and clips to the chassis / deck / cabin of the equipment as
desirable.

• Mount the above functional components and secure them with bolts, nuts and washers
tightly.

• Assemble the Pressure Switch.

GREASE LINE CONNECTIONS

• Connect the main line Hoses / Steel Tube to the Pump outlet and to the Injector inlets /
outlets as per the standard layout.

• Connect the Hose Assemblies to the outlets of the Injectors and to the inlets of the
bearing points as per the standard layout.

• During the above assemblies, ensure proper crimping of the ferrules and secure the
coupling nuts of the fittings tightly.

ELECTRICAL CONNECTIONS

• Connect the Solenoid Valve / Pressure Switches


CLAMPING

• Clamp the Tube and Hoses to the seats welded on the body of the equipment and
secure them tightly.

COMMISSIONING

• Place the pump in a Grease Barrel with sufficient amount of grease for topping up of all
point.

• Set the hydraulic pressure and the flow as per site conditions

• Bleed the system

• Tighten the connections at all the outlets and inlets after grease is observed at all the
points.

PRECAUTIONS TO BE TAKEN DURING INSTALLATION & COMMISSIONING

• All components of the Centralized Lubrication Systems should be secured tightly to the
mounting brackets and proper clamping of all tubing’s / a hose has to be ensured.

• Sufficient loop of Hoses Assemblies should be allowed for the moving points.

• All fittings and connectors should be tightly connected such that no leakage is observed.

• The Pump reservoir / Barrel should be filled with grease before starting the system.

• The lube points should be free from any blockages.


SECTION 4.0
GENERAL INSTRUCTIONS

• Maintain the grease level in the reservoir and do not run the Pump when grease level is
low.

• Always bleed the Pump through the Vent hole before commissioning, re-commissioning.

• Always bleed the system during commissioning and also when old components / tubing
and hoses are replaced, to avoid air-lock in the system.

• Ensure that all fittings and connectors are secured properly and there is no leakage
from any joint / tubing / hoses / outlets / inlets of components.

• Always, strictly follow the procedures and precautions for commissioning the system
(refer preceding section).

• Refer succeeding sections on Troubleshooting and Schedules for Checks to ensure


satisfactory running of the system.

NOTE:

• Use only original LINCOLN spare parts for any repair.

• Contact LINCOLN HELIOS for any servicing / repair of the system.

• The manufacturer will not accept any liability for damage caused due to:

Insufficient lubricant in pump.


Use of contaminated grease / refilling from the top of the reservoir.
Blockage at the bearing inlets.
Mis-handling / tampering of any component.
Improper handling of the system.
SECTION 5.0
TROUBLE SHOOTING

1. SYMPTOM: Pump does not run / does not run at pre-set run time.

Possible cause Remedy

Repair / replace, if necessary


Fault in the combi valve
Inspect all connections and tighten / replace, as
Faulty oil connections
necessary

2. SYMPTOM: Pump does not deliver the lubricant / does not prime

Reservoir empty Refill


Air lock in the system Bleed and re-assemble
Follower spring cocked or hung up Remove, re-assemble / replace, if spring tension is
insufficient

Remove, clean and re-assemble / replace, if necessary


Outlet checks defective
Remove, clean and re-assemble / replace, if necessary
Vent Valve defective

3. SYMPTOM: Pump does not build up pressure

Check Combo Valve and Oil line connections, repair /


Insufficient pressure to the pump replace, if necessary
Air lock in the system
Bleed and re-assemble
Follower spring cocked or hung up Remove, re-assemble / replace, if spring tension is
insufficient

Outlet checks defective Remove, clean and re-assemble / replace, if necessary

Remove, clean and re-assemble / replace, if necessary


Vent Valve defective
Inspect and replace, if necessary
Plunger and bushing scored
Inspect all connections and tighten / replace, as
Leakage in the tubing’s / fittings
necessary
4. SYMPTOM: Injector indicator stem does not operate

Possible cause Remedy

Pump not running Refer point 2

Pump not building up pressure Refer point 3

Air pockets in the supply line Remove plug from Injector at the end of the
shortest supply line, bleed and re-assemble.
Repeat for each supply line.
Leakage in the supply line Inspect all connections and tighten / replace, as
necessary

Inspect and replace, if necessary


Plunger and bushing scored

5. SYMPTOM: Bearing heats up although the system appears to be operating properly

Insufficient grease supply to the bearings Refer points 1, 2, 3 & 4

Improper adjustment of Injector output Check and adjust the output with the Injector
adjusting stem.

6. SYMPTOM: Blockage in the system

Restriction in the lines Disconnect, bleed and re-assemble

Restriction at the lube point entry Clean / re-work the entry point and re-assemble

Air-lock in the system Bleed and re-assemble


SECTION 6.0
SCHEDULE FOR CHECKS

COMPONENT PARAMETERS CHECK SCHEDULE

Grease level Daily

Lubricant output Daily

Pump Operating pressure Daily

Oil line connections Daily

Outlet connections Every 3 days

Lubricant Output Daily

Operation of Indicator Pin Daily


Injectors
Caps Weekly

Outlet connections Every 3 days

Operation Every 3 days


Pressure Switch

Operation Daily

Combi Valve Solenoid Valve connections Daily

Oil line connections Daily

Leakage Every 3 days

Tubings & Hoses Fitment Every 3 days

Clamping Every 3 days

Leakage Weekly
Fittings
Fitment Weekly

For Solenoid Valve Weekly

Electrical connections For Pressure Switch Weekly


SECTION 7.0
LIST OF RECOMMENDED SPARES FOR STOCKING

Sl.No Part Number Description Qty

1 6640-01000-3 Replacement Injector LH-IR-100 3

2 6641-01 Repair Kit for Injectors 10

3 270663 Soft Parts Kits 1

4 270768 Pressure Gauge for pump 1

5 270692 Pressure Reducing Valve 1

6 270693 Flow Control Valve 1

7 270691 Solenoid Valve 1

8 270666 Crank Eccentric 1

9 111-35114-1 Polyimide Tube 15MTS

10 7013-03648-4 Hose Ends Reusable 10

11 H25-999918-9 Hose SAE 100R2-8, ½”ID 5MTS

12 X432-23031-1 Hose Sleeve 20

13 X432-24162-1 Hose Stud 20