Lincoln Electric FlowMaster 85480 User manual

PageSection - C8 - 269H 7.5A-18100-G01 Form 403139 November 2001
FlowMaster Rotary Driven Hydraulic Pump
Models 85480, 85481, 85482, 85483,
Series B
Models 85247, 85610, 85586
Series A
This pump conforms to the European Directive for Product Safety
Foreign Patent Pending
U.S. Patent No. 6,1 2,676

FlowMaster Rotary Driven Hydraulic Pump
Page Number - 2 7.5A-18100-G01 Form 403139
Description
85480 - Pump for 120 pound drum (16 gallon)
85481 - Pump for 60 pound drum
85482 - Pump for 400 pound drum (55 gallon)
85483 - Pump for 5 gallon pail
85247 - Similar to 85480, but wit a manual override
85610 - Low Temperature Pump for 400 lb. drum (55 gallon)
85586 - Heavy Duty pump for 400 lb. drum
General Description
T e Lincoln Industrial rotary Hydraulic Pump is a fully ydraulical-
ly operated grease pump. Grease output is proportional to t e
ydraulic input flow. T e pump is primarily designed for central-
ized lubrication systems suc as t e Single Line parallel, Single
Line Progressive and Two Line systems. An integrated pump
control manifold is incorporated wit t e motor to control input
flow and pressure. A 24 volt DC solenoid valve is also incorporat-
ed as a met od to turn t e pump on and off. A 24 volt DC sole-
noid valve wit a manual override is standard on model 85247
and is an option on ot er models. ©
T e pump is driven by t e rotary motion of t e ydraulic motor.
Rotary motion is converted to reciprocating motion t roug an
eccentric crank mec anism. T e reciprocating action causes t e
pump cylinder to move up and down. T e unit is a positive
displacement double acting pump as grease output occurs
during bot t e up and down stroke.
During t e down stroke, t e pump cylinder is extended into t e
grease. T roug t e combination of s ovel action and vacuum
generated in t e pump cylinder c amber, t e grease is forced
into t e pump cylinder. Simultaneously, grease is disc arged
t roug t e outlet of t e pump. T e volume of grease during
intake is twice t e amount of grease output during one cycle.
During t e upstroke, t e inlet c eck closes, and one alf of t e
grease taken in during t e previous stroke is transferred t roug
t e outlet c eck and disc arged to t e outlet port. Typical output
of t e pump is s own on page 4.
Appropriate Use
All pump models are exclusively designed to pump and
dispense lubricants using ydraulic power.
T e maximum specification ratings s ould not be
exceeded.
Any ot er use not in accordance wit instructions will
result in loss of claims for warranty and liability.
t an maintenance specified in t is manual.
Annual inspection by t e factory aut orized warranty and
service center nearest you is recommended.
A list of factory aut orized warranty and service centers is
available upon request.
Damaged Pumps
Any pump t at appears to be damaged in any way, is badly
worn or operates abnormally, s all be removed from use
until repairs are made. Contact t e factory aut orized
warranty and service center nearest to you for repairs.
Table of Contents
Page
Safety .................................................................2
Description....................................................................................2
Appropriate Use................................................................2
Pump Performance and Specifications..............................3
Installing t e Pump.....................................................................4
Operation.....................................................................................5
Maintenance and Repair...........................................................5
Pump Dimensions.............................................................7
Repair Parts List................................................................................9
Trouble S ooting.........................................................................10
Safety
Read and carefully observe t ese operating instructions
before unpacking and operating t e pump! T e pump must
be operated, maintained and repaired exclusively by per-
sons familiar wit t e operating instructions. Local safety
regulations regarding installation, operation and
maintenance must be followed.
Operate t is pump only after safety instructions and t is
service manual are fully understood.
Indicates a potentially azardous situation w ic , if not
avoided, could result in deat or serious injury.
Indicates a potentially azardous situation w ic , if not
avoided, may result in minor or moderate injury.
Safety Instructions
T is equipment generates very ig grease pressure.
Extreme caution s ould be used w en operating t is
equipment as material leaks from loose or ruptured
components can inject fluid t roug t e skin and into t e
body causing serious bodily injury. Adequate protection is
recommended to prevent splas ing of material onto t e
skin or into t e eyes.
If any fluid appears to penetrate t e skin, get emergency
medical care immediately. Do not treat as a simple cut.
Tell attending p ysical exactly w at fluid was injected.
Inspection
If overpressurizing of t e equipment is believed to ave
occurred, contact t e factory aut orized warranty and service
center nearest you for inspection of t e pump.
Specialized equipment and knowledge is required for repair
of t is pump. Contact t e factory aut orized warranty and
service center nearest you for repair or adjustments ot er
©
© indicates c ange
©
©

FlowMaster Rotary Driven Hydraulic Pump
Page Number - 3
7.5A-18100-G01
Form 403139
Do not exceed 3,500 PSIG (241 bar) maximum supply inlet
ydraulic pressure. Exceeding t e rated pressure may result
in damage to system components and personal injury.
Pump Performance and Specification
Supply inlet ydraulic pressure,
maximum, PSIG (bar) - 3,500 (241)
Operating working ydraulic
pressure , PSIG (bar) - 300 to 450 (20 to 32).
Hydraulic Inlet Flow,
GPM (l/min) - Up to 7 (28)
Pump Ratio wit manifold - 9:1 at low inlet pressure
(300 to 350 psi [20 to 25
ar]) and low inlet flow
( elow 2 gpm [7 lpm])
Pump ratio approaches
11.0:1 ratio at higher
inlet pressure and flow.
Hydraulic Manifold
Operating Temperature, ºF (ºC)- -20 to +150 (-29© to 65)**©
Operating Voltage, VDC - 24
Hydraulic Inlet Port, In - SAE 4
Tank Return Port, In - SAE 6
Pump Outlets, In - 1/4 NPTF
Maximum Hydraulic
Fluid Temperature, ºF, (ºC) - 250 (121)
Weig t, Lbs (Kg) - 36 (16)
HYDRAULIC PUMP PERFORMANCE SPECIFICATIONS
Test conducted with Alvania NLGI # 2 Grade Grease
Grease Output 1,000 psi Backpressure
Cubic inches/min. (cm³/min.) (70 bar)
Hydraulic Flow Input
Temperature F 1 gpm 2 gpm 3 gpm 4 gpm 5 gpm 6 gpm 7gpm
(Temperature C) (4 l/min) (8 l/min) (11 l/min) (15 l/min) (19 l/min) (23 l/min) (26 l/min)
80 7 142128344045
(27) (115) (229) (344) (459) (557) (656) (737)
40 7 142128333841
(4) (115) (229) (344) (459) (541) (623) (642)
20 6 131722283236
(-7) (98) (213) (279) (361) (459) (594) (590)
0 6 11 15 19 23 27 30
(-18) (98) (180) (245) (310) (376) (442) (491)
-10 5 7 8 9 10 12 13
(-23) (82) (115) (131) (148) (164) (197) (213)
-20 4 6 8 10 12 14 15
(-29) (66) (98) (131) (164) (197) (229) (245)
Hydraulic
Fluid Inlet
Hydraulic
Fluid Return
to Tank
Solenoid Valve
(Items 34*© & 35)
Pressure Reducing
Valve (Item 38) Vent
Valve
Pressure Gauge
(Item 32)
Flow Control
Valve (Item 39)
Hydraulic Motor
(Item 42)
Material
Outlet
llustration 1
© indicates c ange
*Solenoid valve wit manual override standard on Model 85247,
optional on ot er models.©
** 85610 Operating Temperature, ° F(°C) is -70 to 150 (-57 to 65)©

FlowMaster Rotary Driven Hydraulic Pump
Page Number - 4 7.5A-18100-G01 Form 403139
A
F
G
H
J
B
D
E
C
KL
Grease Output vs Hydraulic Input
0
5
10
15
20
25
30
35
40
45
50
1234567
Hydraulic Flow Input (g/m)
Grease Output (inches³/min.)
A - Pump Outlet Plug
B - Hydraulic Supply Line
C - Hydraulic Return to Tank
line (3/4 ID min.)
D - Supply Line S ut-off Valve
E - 24 VDC from Controller
F - Return Line S ut-off Valve
(3/4 ID min.)
G - Vent Valve Port wit Restrictor
H- Outlet S ut-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.)
Grease Output vs. Hydraulic Input
0
100
200
300
400
500
600
700
800
4 8 12 16 20 24 28
Hydraulic Flow Input (l/m)
Grease Output (cm³ /min.)
Illustration 2
Installing the Pump
Typical installation is s own 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.
T e pump was tested in lig t weig t oil w ic was left in to
protect t e pump from corrosion. Flus t e pump before
connecting it to t e system to prevent contamination of t e
grease wit residual oil.
T e pump as flow and pressure controls integrated into
t e manifold (37). A normally closed ON/OFF Solenoid Valve
(35) is also integrated into t e manifold and will start or
stop t e pump operation.
1. Mount t e pump securely on t e drum cover so t at it
cannot move or vibrate during operation.
2. Attac ydraulic supply line to t e Inlet and return line to
t e Tank ports.
3. Connect material supply line to t e pump outlet. Plug
t e unused outlet on opposite side of t e pump.
4. Install ig pressure s ut-off valve in t e material supply
line. (Required)
5. Connect 24 VDC power supply to t e solenoid valve (35).
See Illustration #1. Use connector plug (36) supplied
wit t e pump.
NOTE: To install t e pump Model 85481 as a replacement
pump for 84961 used on Model 84944, use adapter/spacer
kit p/n 272013 wit bolts p/n 50014, included in t e pump
package (see illustration #4).
30º C
0º C
-10º C
-30º C
80º F
0º F
-20º F
20º F
Illustration 3
24VDC Connections
No Connection to
Center Lug
Solenoid Valve

FlowMaster Rotary Driven Hydraulic Pump
Page Number - 5
7.5A-18100-G01
Form 403139
Mount t e pump securely on t e drum cover. Failure to do
so could result in personal injury and equipment damage.
Do not exceed 450 PSIG (32 bar) working ydraulic
pressure. Use ig pressure components to reduce risk of
serious injury including fluid injection and splas ing in t e
eyes or on t e skin. All accessories connected to t e pump
outlet must ave at least 5,000 PSIG (350 bar) minimum
ydraulic pressure. All accessories connected to t e pump
inlet must ave at least 3,500 PSIG (241 bar) minimum
working pressure.
Operation
All pumps are factory set at 350 PSIG (24 bar) working inlet
ydraulic pressure wit a flow rate of 2.5 GPM (9.5 l/min).
Do not change the settings for the pump until after the
start up procedure.
1. S ut off t e material supply line valve.
2. Turn on t e ydraulic pressure.
3. Energize t e solenoid On/Off valve.
4. Prime t e pump by slowly opening t e s ut-off lubricant
supply line valve. Make sure t at all air as been
expelled from t e pump and even lubricant flow is
ac ieved.
5. Adjust t e pump pressure and flow to t e desired
application requirements. See Pressure and Flow
Control Valve Adjustment for instructions to adjust
pressure and flow, Do not exceed pump operating
pressure of 450 PSIG (32 bar).
6. Always use t e lowest pump output pressure and
ydraulic fluid flow to obtain t e desired results. T is
will reduce t e pump wear.
Do not exceed maximum operating temperature of t e
ydraulic fluid (250º F/121º C) . Never allow t e pump to run
dry of lubricant. A dry pump quickly speeds up, creating fric-
tion eat, w ic can damage t e seals. Monitor t e supply
lubricant level and refill w en necessary.
Setting the Pump Manifold Pressure and
Flow Controls
T e pressure must first be adjusted to insure t e desired flow
setting is ac ieved.
Pressure Control Valve Adjustment
- Loosen t e lock nut on t e Pressure control by turning t e
nut COUNTERCLOCKWISE.
- Turn t e valve stem COUNTERCLOCKWISE until it no
longer turns. T e valve stem will unscrew until it reac es
t e stop. It will not come off. T is is t e minimum pressure
setting, w ic is about 170 psi (12 bar).
- Wit t e pump stalled against pressure, turn t e Pressure
Control Valve stem CLOCKWISE until t e desired pressure
is attained on t e manifold Pressure Gage. (Do not exceed
450 PSI.
- Tig ten t e lock nut by turning CLOCKWISE.
Flow Control Val e Adjustment
- Loosen t e lock nut on t e Flow Control Valve by turning t e
nut COUNTERCLOCKWISE.
- Adjust t e flow by turning t e valve stem CLOCKWISE to
reduce t e flow and COUNTERCLOCKWISE to increase it.
T e Flow Control Valve can be turned in until t e valve is
completely closed, and out a maximum of 2 1/2 turns. T e
valve stem will not come out w en fully open (unscrewed)
as t ere is a stop at t is position.
- After adjusting t e flow to t e desired setting, tig ten t e
lock nut by turning it CLOCKWISE.
Maintenance and Repair
Relieve pressure from t e pump and supply lines before
servicing or repairing t e pump, to reduce t e risk of an
injury from injection, splas ing fluid or moving parts.
Always use Lincoln Industrial parts for service and repair.
Crank Case Oil
C eck t e oil after every 100 ours of operation. T e crank-
case s ould be filled to t e center of t e drain plug located on
t e back of t e crankcase. C ange t e oil after every 500
ours of operation. Use SAE 10W30 motor oil in all units
except 85610. In 85610, use Mobil Arrow HFA Low Temp oil for
use at -70°F ambient temperatures.
*
*
* Included in Spacer Kit 272013
*
*
Illustration 4