ASSALUB FL User manual

ASSALUB AB, Prästängsvägen 15, Box 240, SE-597 26 ÅTVIDABERG, SWEDEN
Tel. [phone], E-mail: [e-mail], URL: www.assalub.se
I
I2108-E-20.11
INSTRUCTION MANUAL
ÅSSA LUBRICATORS
TYPE FL & TYPE FE

Original instructions
Thank you for choosing an Assalub lubricator.
It is a high-quality Swedish product. Every lubricator is
subjected to comprehensive testing before delivery.
Read the instruction manual carefully to ensure correct
use of the lubricator.

CONTENTS
1. Presentation
2. Safety regulations
3. Technical description
4. Assembly and installation
5. Initial start-up, setting discharge rate
6. Maintenance and repair
7. Spare parts
8. Guarantees,
9. EU Declaration

1. PRESENTATION
•ÅSSA lubricators Type FL and FE are intended for automatic grease lubrication
of machinery. They can also be used for dispensing high-viscosity lubricants
and lubricating pastes.
•When electrically driven lubricators (Model FLM and FEM) are to be used in an
explosive environment an electric motor of the correct type and safety class
must be used.
2. SAFETY REGULATIONS
•Read the instruction manual carefully before starting the lubricator.
•These lubricators may only be used for the media for which they are intended.
•All components used together with the lubricators must be capable of
withstanding their flows and pressures.
•Do not exceed the maximum permissible continuous back-pressure.
•Make sure that the lubricator drive is disconnected before any dismantling or
servicing.
•Note that leaks or other fine jets of liquid under high pressure can cut the skin.
It is especially important to be careful with oil systems that operate under high
pressure.
•Inspect the equipment for wear at regular intervals, paying particular attention
to link systems in the case of ratchet drive.
•Be careful when in the neighbourhood of rotating drive shaft couplings, hand
cranks and ratchet drive systems.

3.1
3. TECHNICAL DESCRIPTION
GENERAL
The two types of lubricator are of similar design and consist of:
Top section I –lubricant reservoir with pre-feeder
Intermediate section II –pump mechanism
Bottom section III –drive unit
MODE OF OPERATION
Type FL
When the central shaft 10 rotates, driven by shaft 17, the
pre-feeder (consisting of vane 1, pre-feed roller 2and
angled pin 3) feeds lubricant from the reservoir down
through the strainer 4to the cylinder pump 13 via the inlet
passages 11 in the pump body 16. The figure shows the
situation when the pump cylinder is being filled with
lubricant. When the central shaft continues to rotate, the
pump plunger pressure ball 8presses the pump plunger
upwards when it passes the pressure ball of the
respective outlet. At the same time, the orifice 12 of the
cylinder passage also passes one of the outlet passages
5in the pump body and the lubricant is forced out into
the line to the lubricating point via outlet 6. The pump
plunger then gets its suction movement from pin 9when
the guiding ball 15 in the central shaft engages with the
setting screw 14. Each outlet has a pressure ball 7, a
setting screw 14, an inlet passage 11 and an outlet
passage 5. The setting screws 14 adjust the length of the
pump plunger stroke and thus the lubricant discharge.
The lubricant discharge rate set for each outlet is
completely independent of those of the other outlets.
Type FE
When the central shaft 21 rotates, driven by shaft 24,
the pre-feeder 2–6feeds lubricant from the reservoir
through the strainer 8to the inlet 30 of the respective
pump unit 10. At the same time, the eccentric on the
central shaft and the guide plate 19 impart a plane-
parallel circular motion to the pump disc 20. By this
means the pressure studs 27 give the pump plungers
28 their axial suction and pressure motion, with the
rotational motion at dead centre which places the pump
unit cylinder 26 alternately in communication with the
intake opening 30 and the discharge connection 17 via
passages 13 and 16.
The central shaft drives the pre-feeder via the driver 9.
The pre-feeder homogenizes the grease and renders it
free from air.
The discharge rate is set individually for each pump unit
by adjusting the stroke of the pump plunger with the
setting screw 31. The setting screws are accessible
after removal of the protective plugs 32.
The pump units are readily accessible for replacement
after removal of the top section.

TECHNICAL DATA
Noise level
The noise level is less than 70 dB(A)
Lubricants
Lubricators of types FL and FE are capable of pumping grease with penetration up to NLGI-4.
They can also be used for pumping highly viscous oils and pastes with lubricating properties.
Grease with a stringy or fibrous consistency should not be used. Do not mix different kinds of grease or
grease with oil. Different lubricants may slide on each other, which disturbs the pre-feed. More than
90% of all operating problems are due to contaminated lubricants or central lubrication with unsuitable
grease.
Performance
Type
FL
FE
Number of outlets
1 –6
1 –12
Max. feed per pump stroke, cm3
0.10
0.25
Max. continuous back-pressure, MPa
5.0
25.0
Max. intermittent back-pressure, MPa
10.0
45.0
Type/model
FLP
FLR
FLM
FEM
Ratchet lever stroke
6 –60°
–––
–––
–––
Max. ratchet pulses/min
450
–––
–––
–––
Max. drive shaft rpm
–––
450
–––
–––
Discharge/outlet and min
0.25 –10
0.25 –10
0.7 1.4 2.8 5.6 (50 Hz)
4. ASSEMBLY AND INSTALLATION
•Make sure when unpacking that no items are missing from the delivery.
•Before assembling, make sure that all pipes and hoses are clean inside.
•The lubricator must be installed on a level surface. Use shims to eliminate any unevenness.
This is important in order to avoid stresses that might give rise to cracking. Fix the lubricator in
place with three M8 bolts
•In the case of rotary drive it is advisable to connect the drive shafts together with a flexible
coupling.
•With ratchet or rotary drive a guard must be fitted over moving parts in order to prevent
accidents.
•Electric motors must only be connected to the mains power supply by an authorized electrician.
Note the direction of rotation of the motor as indicated by an arrow on the motor.
•Choose the diameters of piping between the lubricator and the lubrication points so as to
minimize pressure drops. The following table can be used as a guide:
In choosing pipe sizes, account must be taken of:
-Temperature
-Lubricant consistency and pumpability
-Number of bends
-Number and type of connections and valves, if any.
Always use seamless cold-drawn precision steel pipes according to DIN 2391/C,
Note that there must be no branches in the lubricating lines. The lubricant will always take the branch
with least resistance. If it is necessary to branch the lubricating lines this must always be done by fitting
a suitable progressive distributor such as ASSALUB Type PF or PFS.
Pipe length
Pipe size
0 –8m
Ø8 x 1mm
8 –15m
Ø10 x 1mm
15 –25m
Ø12 x 1mm
> 25m
Ø15 x 1,5mm

5. INITIAL START-UP
•Fill the reservoir with clean lubricant of the correct grade in accordance with the maker's
recommendations for the machine. See further under Lubricants.
•Fill the gear housing to the middle of the level gauge, models FLM and FEM, with gearbox oil
of EP type, viscosity ISO VG 150-320.
•Screw the setting screws 14 (FL) and 31 (FE) (fig. p. 3) all the way in for maximum discharge.
Run the lubricator until lubricant is discharged uniformly and without air bubbles from all
outlets. Connect the lubricating lines and run the lubricator until oil emerges at the pipe
orifices. Then connect the pipes to the lubrication-point connectors on the machine. Filling of
the lubricating pipes can be expedited by use of a separate oil pump.
•After a time in operation, check all connections, pipes and hoses for leaks.
Setting discharge rate
The discharge rate can be reduced by screwing the setting screws counter-clockwise. On type FE the
setting screw has 6 detent positions. On type FL adjustment is continuous. If the setting screw is
unscrewed completely the discharge ceases. The discharge rate can be calculated and adjusted with
the aid of the following table. One pump stroke corresponds to one revolution of the center shaft or the
pre-feed vane in the reservoir. The pre-feed vane should always rotate clockwise, seen from above.
Discharge / pump stroke, (nominal)
Type FL
Type FE
Max.
0.10 cm3
0.25 cm3
One turn of setting screw =
0.03 cm3
–––
One notch of setting screw =
–––
0.05 cm3
When calculating and making settings, account must be taken of unavoidable internal leakage. This
varies with the flow resistance in the piping and the backpressure at the lubricating point and is normally
about 15%. After long use the internal leakage may be somewhat larger. These lubricators work best
with a setting that gives a fairly large discharge per pump stroke at a low rotational speed. For very
small discharge rates we recommend that the lubricators should be driven intermittently through a
separate control unit. The discharge rates can only be finely adjusted by measuring / weighing the
quantity discharged at the end of the lubricating lines per unit of time.
Plugging or unplugging unused outlets
Type FL
Unused outlets can be plugged by replacing the
outlet connection with plug 900153 and gasket
900742. It is important that screw 903337 with
gasket F1172 should be removed; otherwise the
lubricator may be damaged. The complete control
unit LF317 should be replaced by plug F1167.
Plugged outlets can be taken into service by
replacing the plugs with the above-mentioned parts.
Make sure not to forget to install screw 903337 and
gasket F1172, otherwise there will be no discharge.
Type FE
Unused outlets must not be plugged. Any pump units that are not used must be removed and the
space filled with grease. The outlet may then be plugged with plug 900153 and gasket 900742.

6. MAINTENANCE AND REPAIR
PREVENTIVE MAINTENANCE
Make regular checks of the following:
•Lubricant level in reservoir. It must not run dry.
•Oil level in drive gear for types FLM and FEM.
When necessary, top up with oil of the correct grade. The recommended oil-change interval is
about 15,000 hours.
In the ratchet driven version (type FLP) the ratchet mechanism is filled with highly stable grease during
manufacture. We recommend the careful introduction of a multi-purpose NLGI-2 EP grease with a
grease gun through the drive ratchet housing grease nipple every 8,000 hours.
CORRECTIVE MAINTENANCE
TROUBLE-SHOOTING
Problem
Action
No discharge
Check that the drive is working. In the case of electrically driven
lubricators, make sure that the motor is running and rotating in
the direction of the arrow on the motor casing. The grease vane
in the reservoir should rotate clockwise.
If the grease vane does not rotate:
The driver F1120A or angled pin F1111 has probably broken
off. Check whether any of the lubricating lines is clogged or if
there is a foreign body in the reservoir.
If the grease vane rotates:
Pump mechanism worn out or broken. On type FL replace the
pump body LF338-2. On type FE replace the defective pump
units LF336. Screw plug 903337 with gasket F1172 is not fitted
in an outlet which is in use on type FL. See Plugging or
unplugging unused outlets, chapter 5.
Discharge rate too low
May be due to increased internal leakage or worn pump
mechanism. Increase discharge rate by screwing in the setting
screws completely. If this does not help, replace pump body
(FL) or pump unit (FE).
REPAIR
The procedure for disassembling and assembling these lubricators is clearly apparent from the spare
parts drawings. Always observe a maximum of cleanliness.
The pump body of FL pumps can only be repaired at the factory. The plungers in FE lubricators are
individually fitted to the respective pump body cylinder bores and they must therefore be reinstalled in
the correct pump unit.
The ratchet cross in the ratchet mechanism of type FLP must also be reinstalled in its original position,
otherwise the lubricator will not work, and the ratchet mechanism is liable to damage when restarted.
Repair and servicing are handled by our local agents or directly by our factory.

7.SPARE PARTS
General
When ordering spare parts always state lubricator type and serial number as on the nameplate
Definitions
Drive side
The right-hand or left-hand side of the lubricator is defined when the nameplate is not facing you.
Direction of rotation
The direction of shafts is defined looking towards the end of the shaft.

Lubricator type FL
Drive units type FLP & FLR
Art. No.
Designation
See
note
Art. No.
Designation
See
note
A 209
Ratchet arm
F1901-1
Spacer washer
B 127
Nut
F 1902
Stud
B 1065
Ratchet drive housing
F 1904
Bearing
B 1117
Tab washer
F 1904-2
Bearing
C 27
Spring
F 1910
Washer
C 1060
Key
F 2054-1
Gasket
C 1082
Plug
F 2055-1
Pipe
C 1399
Seal ring
F 2151
Lid, 4,8 & 16 litres
F 19-2
Grease vane, 4, 8 & 16 l
4
J 1118
Seal ring
F 40
Pin
4
Ö 1036
Grease nipple
F 47
Scraper
4
LF 317
Control unit
F 49
Pre-feed roll
2, 4
LF 338-2
Pump body
F 66
Pin
4
LF 346
Reservoir, 2 litres
4
F 1101-3
Housing
1
LF 346-1
Reservoir, 1.5 litres
4
F 1104
Washer
1
LF 347-1
Top section, 2 litres
F 1106
Plate
3, 4
OE 408
Nut
F 1107A
Pin
3, 4
TB 1494
Spring
1
F 1108
Strainer
4
100 734
Reservoir, 4 litres
4
F 1109A
Angled-pin plate
4
100 735
Reservoir, 8 litres
4
F 1110/I
Washer
4
100 736
Reservoir, 16 litres
4
F 1111
Angled pin
4
100 737
Lid, 4,8 & 16 litres
4
F 1113B
Lid, 2 litres
4
100 739
Top section, 4 litres
F 1118
Ball
1
100 740
Top section, 8 litres
F 1119A
Pin
1
100 741
Top section, 16 litres
F 1120A
Driver
120 165
Ratchet roller
F 1121-1
Grease vane, 2 litres
4
120 166
Wear plug
F 1142/I
Pump shaft
1
120 170
Ratchet cross
F 1153
Locking ring
4
120 171
Bushing
F 1154A
Setting screw
120 172
Ratchet cross washer
F 1155A
Setting sleeve
900 153
Plug
4
F 1156
Washer
900 194
Filter
F 1158-1
Pressure ring
900 557
Ratchet roller spring
F 1172
Gasket
900 558
Spring ring
F 1215
Gasket
900 742
Gasket
4
F 1216
Pin
1
903 337
Screw
4
F 1218/I
Plunger
1
903 348
Screw
4
F 1219-2
Pin
903 383
Screw
1, 4
F 1220-2
Base (not for type FLM)
903 665
Nut
F 1230
Hand crank
903 753
Washer
F 1899-2
Counter ratchet housing
904 732
Screw
F 1901
Space washer
904 738
O-ring
Note 1 All articles with Note 1 are supplied only Note 3 This article is supplied only together with pin
together as one unit, Art. No. LF 338-2 F 1107A as one unit, Art. No. F 1106-R.
Note 2 This part is supplied only together with Note 4 All parts with Note 4 are also included in the
pin F 40 as one unit, F 49-R. complete top section
Top section 2 litres, Art. No. LF 347-1
Top section 4 litres, Art No. 100 739
Top section 8 litres, Art No. 100 740
Top section 16 litres, Art No. 100 741
Gear ratio
Direction of rotation
Gear A
FLP FLR
Drive shaft B
FLR
Drive shaft C
FLP
Drive side right
Drive side left
2,5:1
Counter-clockwise
Clockwise
F 1226-R
F 1223
F 1229
2,5:1
Clockwise
Counter-clockwise
F 1226/I-R
F 1223/I
F 1229/I
8,2:1
Counter-clockwise
Clockwise
F 1270-R
F 1271
F 1269
8,2:1
Clockwise
Counter-clockwise
F 1270/I-R
F 1271/I
F 1269/I
22,5:1
Counter-clockwise
Clockwise
F 1225-R
F 1222
22,5:1
Clockwise
Counter-clockwise
F 1225/I-R
F 1222/I
45:1
Counter-clockwise
Clockwise
F 1224-R
F 1221
45:1
Clockwise
Counter-clockwise
F 1224/I-R
F 1221/I

Drive unit type FLM
Complete gear
without motor
Gear ratio
Drive
shaft D
Gear E
Gear F
Drive
shaft G
100 837
506.25:1
F 2245-3
F 1266-2
F 1225-R
F 2267-3
100 838
1012.25:1
F 2246-3
F 1267-1
F 1225-R
F 2267-3
100 839
2025.00:1
F 2246-3
F 1267-1
F 1224-R
F 2267-2
Art.no.
Designation
B 2551
Packing
B2552-1
Cover
F 1910
Disc
F 2215
Gasket
F 2233
Lock ring
F 2234
Spacer sleeve
F 2244-1
Gear housing
F 2266-1
Base
F 2269
Spacer
F 2270
Sleeve
F 2271
Washer
J 1459
Gasket
SKF KM1
Lock nut
SKF MB1
Lock washer
SKF 6200
Ball bearing
SKF 6203
Ball bearing
SV 25
Oil level gauge
900 153
Plug
900 246
O-ring
900 639
Gasket
900 742
Gasket
901 251
Motor 220 / 380 V 1400 rpm 50 Hz
901 252
Motor 220 / 380 V 2800 rpm 50 Hz
901 2XX
Motor, special execution. Please give type
designation, voltage, frequency and rpm as per
motor plate.
903 072
Screw
903 082
Screw
903 308
Screw
903 391
Screw
903 753
Washer
903 824
Seal ring
903 828
Circlip
903 845
Circlip
903 960
Needle bearing
904 732
Screw
904 802
Key

Cover with level indicator for closed refilling
FE / FL 5 litres & FL 2 litres
Art. No.
Designation
E1219115
Nut
F 1121-2
Grease vane
TB 2429
Spring
100 660
Cover
100 667
Switch
100 744
Cover
100 745
Sight glass
101 178
Float, complete
120 687
Plunger disc
120 692
Rod
120 755
Rod
120 757
Pin
120 758
Valve bracket
120 759
Valve disc
120 760
Cover
120 761
Bushing
120 762
Bushing
900 202
O-ring
900 825
Cable fitting
900 933
Washer
903 062
Screw
903 290
Screw
903 353
Screw
903 750
Washer
903 754
Washer
903 827
Spring clip
903 850
Spring clip
904 716
Nut
904 721
Washer
904 739
Screw
904 740
Cable fitting
904 741
Screw
904 742
Nut

7.7

Cover for closed refilling with high-, low- and alarm level control
FL / FE 5 and 13 litres & FE 40 litres
Art.no.
Designation
101 047
Float, complete
120 633
Cover for level transducer (5, 13 litres)
120 634
Cover for level transducer (40 litres)
120 758
Valve bracket
120 759
Valve disc
900 194
Filter
900 248
O-ring
901 143
Level transducer (5 litres)
901 144
Level transducer (13 litres)
901 145
Level transducer (40 litres)
903 359
Screw
903 664
Nut
903 753
Washer
903 784
Washer
904 741
Screw
F 2054-1
Gasket (5,13 litres)
F 2055-1
Pipe
F 2075
Gasket (40 litres)
Oe 408
Nut
Tb 2429
Spring

Reservoir for closed refilling FE & FL
Art.No.
Designation
F 1106-R
Bottom plate
F 1108
Strainer
F 1109A
Angled-pin plate
F 1110/I
Disc
F 1111
Angled pin
F 1153
Retaining pin
F 19-4
Grease vane
F 47
Scraper
F 49-R
Pre-feed roller
F 66
Pin
F 1700-R
Bottom plate
F 1701
Strainer
SKÖ 2356
Instruction plate
0073451
T-nipple
101 305
Safety valve
101 553
Reservoir, complete FL
101 554
Reservoir, complete FE
120 988
Follower piston
120 989
Cover
120 992
Magnet retainer
900 153
Plug
900 165
Gasket
900 742
Gasket
901 129
Air filter ½” steel
901 162
Compression spring
901 215
Level transducer
902 488
Magnet
902 881
Seal ring
902 907
O-ring
903 348
Screw
903 020
Air filter ¼” plastic
903 349
Screw
903 359
Screw
903 383
Screw
903 391
Screw
903 753
Washer
904 103
Adapter
905 208
Seal ring
905 209
Anti-friction ring

Lubricator type FEM
Art.No.
Designation
See
note
Art.No.
Designation
See
note
C 27
Spring
F 2231-1
Base
B 2551
Gasket
F 2232
Drive shaft, ratio 45:1
B 2552-1
Cover
F 2232-1
Drive shaft, ratio 22.5:1
F 19-2
Grease vane
F 2233
Washer
F 40
Pin
F 2234
Spacer
F 41/I
Guide roller
F 2244-1
Housing
F 47
Scraper
F 2245-3
Screw shaft, ratio 22.5:1
F 49
Pre-feed roller
1
F 2246-3
Screw shaft, ratio 45:1
F 49-R
Pre-feed roller with pin
F 2270
Sleeve
F 66
Pin
F 2271
Washer
F 271
Key
LF 305-1
Adjusting wrench
F 1107A
Pin
LF 318-3
Reservoir, 46 litres
F 1109A
Angled-pin plate
LF 321
Cover, complete, 46 litres
F 1110/I
Washer
LF 336
Pump unit
F 1111
Angled pin
J 1459
Gasket
F 1120A
Driver
OE 408
Nut
F 1266-2
Gear, ratio 22.5:1
SKF KM1
Lock nut
F 1267-1
Gear, ratio 45:1
SKF MB1
Lock washer
F 1533
Pin
SKF 6200
Ball bearing
F 1700
Bottom plate
2
SKF 6203
Ball bearing
F 1700-R
Bottom plate with pin
SV 25
Oil level gauge
F 1701
Strainer
100 737
Cover, compl., 8 & 16 litres
F 1722-1
Gasket
101 206
Reservoir, 8 litres
F 1785A
Housing
3
101 207
Reservoir, 16 litres
F 1785A-R
Housing with pins
120 815
Plug
F 1786
Pump disc
5
900 153
Plug
F 1788D
Pump unit
4
900 194
Filter
F 1790A
Pump plunger
4
900 246
O-ring
F 1791A
Setting screw
900 639
Gasket
F 1793
O-ring
900 742
Gasket
F 1794
Pressure stud
5
901 251
Motor 220/380 V
1400 rpm 50 Hz
F 1795
Guide plate
901 252
Motor 220/380 V
2800 rpm 50 Hz
F 1797
Central shaft
901 2XX
Motor, special execution
Please give type, V, Hz and
rpm as per motor plate
F 1798
Ring nut
903 072
Screw
F 1799A
Plug
903 082
Screw
F 1803C
Gear, ratio 22.5:1
903 308
Screw
F 1803E
Gear, ratio 45:1
903 313
Screw
F 1857
Pin
903 321
Screw
F 1858
Spring
903 348
Screw
F 1870A
O-ring
903 383
Screw
F 1910
Washer
903 391
Screw
F 2054-1
Gasket
903 824
Seal ring
F 2055-1
Pipe
903 828
Circlip
F 2075
Gasket
903 845
Circlip
F 2151
Cover, 8 & 16 litres
903 961
Needle bearing
F 2152
Cover, 46 litres
904 780
Screw
F 2215
Gasket
904 802
Key
Note 1 This article is supplied only together Note 4 This article is supplied only as
with pin F40 as one unit, Art. No. F49-R complete pump unit , Art. No. LF336
Note 2 This part is supplied only together with Note5 This article is supplied only as
‘pin F1107A as one unit, Art. No. F1700-R complete pump disc, Art. No. 100886
Note 3 This article is supplied only together with pin
F 1533 as one unit, Art. No. F 1785A-R.