Allied AutoLube III User manual

AutoLube III
Automated
Lubrication
System
Construction Products, LLC
TECHNICAL
MANUAL
Manual Part No. 102782
November 11, 2002

Allied AutoLube III
Allied AutoLube III
Document Change Notice
Date Page Change

Allied AutoLube III
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TABLE OF CONTENTS
Section Page
SECTION 1.0 INTRODUCTION .............................1
SECTION 2.0 OVERVIEW.................................3
SECTION 3.0 GENERAL CONSTRUCTION SAFETY .................4
3.1 Operator Safety Recommendations ........................4
SECTION 4.0 AUTOLUBE III TECHNICAL SPECIFICATIONS ...........5
SECTION 5.0 THEORY OF OPERATION ........................6
SECTION 6.0 AUTOLUBE III INSTALLATION ....................7
6.1 Installation .....................................7
6.2 Installing the Reservoir Retainer .........................8
SECTION 7.0 AUTOLUBE III OPERATION ......................10
7.1 Follower Seal ...................................10
7.2 Filling Pump with Grease ............................10
7.2.1 Remove Empty Cartridge .........................10
7.2.2 Install Grease Cartridge ..........................11
7.2.3 Air Purging .................................11
7.2.4 Prefill Lubricant Line ...........................11
7.2.5 Manual Bulk Filling .............................11
7.2.6 Manual Filling with Hand Pump .....................12
7.3 Maintenance Before Operation..........................12
7.4 Operation .....................................12
7.4.1 Working In High/Low Temperatures ...................12
7.4.2 Working Underwater ...........................13
SECTION 8.0 TROUBLESHOOTING ..........................14
AutoLube III Inoperable ...............................14
SECTION 9.0 REMOVAL AND STORAGE OF AUTOLUBE III............16
9.1 Mechanical Removal Of AutoLube III ......................16
9.2 Removing Hoses .................................16
9.3 Reattaching AutoLube III After Idle Periods ..................16
SECTION 10.0 PARTS INFORMATION ........................17

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SECTION 1.0
INTRODUCTION
This manual contains important informa-
tion for the safe use and maintenance of the
Allied AutoLube III. Read this manual
thoroughly before installing, operating or
servicing the AutoLube III. The AutoLube
III must be operated, maintained and re-
paired exclusively by persons familiar with
the operating instructions. Operate the
AutoLube III only after safety instructions
and this manual are fully understood. This
manual must be easily accessible to opera-
tors and service personnel. Store this man-
ual in a convenient location.
~Instructions identified with this sym-
bol are important for personnel safety and
full service life of the AutoLube III. Follow
them carefully.
~WARNING
Instructions given inside a WARNING
box emphasize a potentially dangerous
procedure which may result in injury or
death to the operator or any bystanders
in the work area. Please read and fol-
low these instructions carefully and
heed all decals.
~CAUTION
Instructions given inside a CAUTION box
emphasize a procedure that may cause
damage to the equipment if not per-
formed properly. Read these instruc-
tions carefully before performing the
procedure on the Allied AutoLube III
Lubrication System.
This technical manual describes in detail
the procedures needed to operate the Allied
AutoLube III Lubrication System on site.
Pay careful attention to all instructions
and follow all governing regulations. This
pump is exclusively designed to dispense
grease in Hydraulic Hammer applications
and should be operated only with hydraulic
power. Any other use not in accordance
with the instructions will result in loss of
claims for warranty and liability. Opera-
tion or service other than in accordance
with these instructions may subject the
AutoLube III to conditions beyond its de-
sign capability. Improper operation, ser-
vice or the use of non-Allied parts may
result in AutoLube III failure or personnel
injury.
Responsibility for operation and safety lies
at all times with the operator of the carrier.
Allied takes no responsibility for the fol-
lowing:
·Incorrect usage of the AutoLube III.
·Exceeding maximum ratings as pro-
vided in Section 4.0 Specifications.
·Inadequate maintenance of the
AutoLube III.
·Use of non-Allied spare parts.
·Damages due to the use of grease which
is not or is only conditionally pumpable
in a centralized lubrication system.
Allied Chisel Paste is recommended.
·Damage caused by unauthorized modi-
fication of the system components. Con-
tact Allied Technical Service Depart-
ment if modification is necessary.
Allied AutoLube III
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·Damage caused by insufficient lubri-
cant or irregular pump refilling.
·Damage caused by contaminated lubri-
cants.
·Damage caused by improper disposal of
used or contaminated lubricants.
Allied provides no warranty for the follow-
ing wear parts:
·All seals
·O-rings
·Hoses
Allied AutoLube III
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SECTION 2.0
OVERVIEW
The Allied AutoLube III Lubrication Sys-
tem (AutoLube III) is designed to provide a
simple and effective, inexpensive method
of lubricating hydraulic hammers.
The AutoLube III is a fully automated sys-
tem with lubricant supplied by a hydraulic
pump. The AutoLube III is installed and
works integrally with the carrier and ham-
mer, pumping lubricant to the hammer
bushings and demolition tool every time
the hammer is activated. Costly downtime
is eliminated because the right amount of
lubricant is delivered at the right time. The
Allied AutoLube III is the proven solution
for lubricating hydraulic hammers.
The Allied AutoLube III Lubrication Sys-
tem provides the following advantages:
·Simple design
·Compact size - mounts on hammer.
·Supplied with all mounting hardware
and adapter fittings.
·Replaceable or refillable, standard 12
ounce grease cartridge. Bulk filling of
cartridge canbe complete
·No tools required to change grease
cartridge.
·Primer releif valve.
·Adjustable output by changing meter-
ing plug.
·Used with Allied Chisel Paste.
·Lubricant level can be monitored from
operator’s cab.
Figure 2-1 illustrates the AutoLube III
main components and Figure 2-2 shows
typical mounting locations of the
AutoLube III on a hammer. The mounting
location varies with the hammer model.
Allied AutoLube III
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PUMP
HOUSING
GREASE
Figure 2-1. AutoLube III Main Components
Figure 2-2. Typical AutoLube III Mounting

SECTION 3.0
GENERAL CONSTRUCTION SAFETY
Always follow procedures that promote
safe conditions for workers and by-
standers. This includes, but is not limited
to: locating existing underground utility
services, establishing pedestrian barriers
and wearing personal protective equip-
ment.
~CAUTION
Read and follow all equipment and
machinery instructions.
Comply with all federal and local regula-
tions regarding construction practices and
public safety. Identification of and compli-
ance to governing regulations are the re-
sponsibility of the owner and operator.
In the United States, comply with the rec-
ommendations of the Occupational Safety
and Health Administration standards of
the U.S. Department of Labor. For OSHA
construction guidelines contact your local
federal government office or write:
U.S. Government Printing Office
Superintendent of Documents
P.O. Box 371954
Pittsburgh, Pa. 15250
Ask for Construction Industry OSHA
Standards Stock #869-034-00107-6.
3.1 Operator Safety Recommendations
·This equipment generates very high
grease pressure. Use extreme caution
when operating this equipment as ma-
terial leaks from loose or ruptured com-
ponents can inject fluid through the
skin and into the body causing serious
bodily injury.
·Use adequate protection to prevent
splashing of material onto the skin or
into the eyes.
·If any fluid appears to penetrate the
skin, get emergency medical attention
immediately. Do not treat as a simple
cut. Tell attending physician exactly
what fluid was injected.
·Do not run any hydraulic lines through
the operator’s cab; they may leak or
even burst, injuring the operator.
·Relieve hydraulic oil pressure before
disconnecting or removing existing
lines on the carrier.
·Collect any oil which spills out and dis-
pose of it properly.
When welding as needed to mount the
AutoLube III, the following instructions
must be observed:
·Disconnect all battery cables from the
carrier battery.
·Protect all hydraulic hoses in the imme-
diate vicinity of the point being welded
to prevent danger of fire or damage to
hoses from heat.
To avoid damage to the carrier and/or the
AutoLube III, perform the following daily
inspections.
·Before starting, visually inspect all
hoses, fittings and fasteners for wear
and looseness.
·Check lubricant level inside the car-
tridge. Refer to Section 6.4.
Allied AutoLube III
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SECTION 4.0
AUTOLUBE III TECHNICAL SPECIFICATIONS
Weight Empty 16.3 lbs. (7.4kg)
Full 17.3 lbs. (7.8kg)
Hydraulic Inlet Pressure (max.) 5000 psi (345 bar)
Max Inlet Back Pressure 200 psi (13.8 bar)*
Output Pressure (max.) 6500 psi (450 bar)
Output per Stroke 0.018 in3(0.3 cm3)*
Pump Ratio 1.3:1
Grease Reservoir Volume 14.5 oz.
Operating Temperature -10oF to +180oF (-23oCto+80
oC)
*Pressure Relief Valve required if back pressure is higher than 200 psi.
**Pump output can be increased up to 0.072 in.3(1.2 cm3)byreplacingthe
metering plug; refer to Section 7.4.
Metering Plugs
0.018 in.3(0.3 cm3) Part No. 103057 0.060 in.3(1.0 cm3) Part No. 103060
0.036 in.3(0.6 cm3) Part No. 103508 0.072 in.3(1.2 cm3) Part No. 103061
0.048 in.3(0.8 cm3) Part No. 103059
Hose Inside Diameters:
Hydraulic Line 3/8-inch (9.53mm)
Lubricant Line 1/4-inch (6.35mm)
Connecting Threads:
Hydraulic Line SAE #4 (7/16-20 UNF)
Lubricant Line SAE #4 (7/16-20 UNF)
Cartridge: Allied Chisel Paste
See Section 9.0 for ordering information
Allied AutoLube III
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Allied AutoLube III
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Table 4-2. Dimensions of AutoLube III
Letter Dimension
in. (mm)
Decscription
A 14.91 (379) Overall Height
B 8.69 (221) Overall Width
C 3.00 (76) Overall Depth
D 3.00 (76) Cylinder Block Height
E 8.39 (213) Cylinder Block Width
F 5.64 (143) Mounting Hole Location
G 1.50 (38 Low Level Indicator Cap extended
H 1.40 (36) Hydraulic Inlet Location
J .50 (13)
.56 (14)
Lube Outlet Location
K