Lincoln industrial 84960 User manual

INDUSTRIAL
MODELS 84960,84961 84962
HYDRAULICALLY OPEhATED
GREASE PUMP- SERIES “B”
OWNERS MANUAL
SPECIFICATIONS
POWER REQUIREMENTS: SV1 &SV2 =.6 Amps @24 VDC each
RATlO (See Note in Fig. 2) 16:1
INPUT PRESSURE 300-3000 P.s.l.
INPUT FLOW @30 CYCLES PER MINUTE 1.OG.P.M.
MAXIMUM HYDRAULIC TEMP. 210° F
OUTPUT PRESSURE 7500 P.S.I. MAX.
OUTPUT FLOW 11 CU. lN./MlN.
AMBlENT TEMP. -40° TO +1 35° F
SEALS BUNA-N
FILTRATION REQUIRED 10 MICRON
DESCRIPTION
Models 84960, 84961 and 84962 are
hydraulically operated grease pumps
designed for centralized lubrication
systems on off-road equipment which
utilize 24VDC power sources.
OWNEIWOPERATOR
RESPONSIBILITY
Itis the owner/operator responsibility to
properly use and maintain this equip-
ment.
The instructions and warnings con-
tained in this manual shall be read and
understood by the owner/operator prior
to operating this equipment.
If an owner/operator does not under-
stand English, the contents of this
manual shall be explained in the
ownerloperator native language to
assure the owner/operator compre-
hends.
It is the owner/operator responsibility to
maintain the legibility of all warning and
instruction labels.
The owner/operator shall retain this
manual for future reference to
Important warnings, operating and
maintenance Instructions.
FAILUREIK) HEEDTHE FOLLOWING
WARNINGS INCLUDING MISUSE,
DVER PRESSURIZING, MODIFYING
PARTS, USING INCOMPATIBLE
2HEMfCALSAND FLUIDS, OR USING
tVORN OR DAMAGED PARTS, MAY
3ESULT IN EQUIPMENT DAMAGE
NND/OR SERfOUS PERSONAL
NJURY.
●Do not exceed the stated maxi-
●
9
●
●
mum working pressure of the
pump or of the lowest rated
component in your system.
Do not alter or modify any part of
this equipment.
Do not attempt to repair or
disassemble the equipment while
the system is pressurized.
Make sure all fluid connections
are securely tightened before
using this equipment.
Alwavs read and follow the fluid
man~facturer’s recommendations
regarding fluid compatibility, and
the use of protective clothing and
equipment.
●Check all equipment regularly
and repair or replace worn or
damaged pans immediately.
One Lincoln Way Copynghf 1996 Section -C8 ‘
St Louis Missouri 63120-1578 F’rmted mUS A Page -240B
lNDUSTR/AL [phone]
Sep-96 Form 402667

p
01
11-3/16” 4
r
15-1/4”
i
~~u
+ + 1“ DIA. PU
ION
90
SAFETY INSTRUCTIONS Contact the factory authorized warranty
This equipment generates very high and service center nearest you for
grease pressure. Extreme caution repair or adjustments other than
DO NOT alter or modify any part of
should be used when operating this maintenance specified in this manual.
the equipment as this may cause a
equipment as material leaks from
loose or ruptured components can malfunction and result in serious Annual inspection by the factory
bodily injury.
inject fluid through the skin and into authorized warranty and service center
the body causing serious bodily injury nearest you is recommended.
including possible need for amputa-
tion. Adequate protection is recom-
mended to prevent splashing of INSPECTION
material onto the skin or into the eyes.
Alist of factory authorized warranty
and service centers is available upon
request.
IMPORTANT
If any fluid appears to penetrate the
skin, get emergency medical care
immediately Do not treat as a
simple cut. Tell attending physician
exactly what fluid was injected.
If overpressurizing of the equipment is
believed to have occurred, contact the DAMAGED PUMPS
factory authorized warranty and service
center nearest you for inspection of the Any pump that appears to be damaged
pump. in any way, is badly worn or operates
abnormally shall be removed from use
Specialized equipment and knowledge until repairs are made. Contact the
is required for repair of this pump. factory authorized warranty and service
center nearest you for repairs.
Page 2FORM 402667

649S0 PUMP AND VALVE ASSEMBL Y
r.—. —-—-— -—-— -—. —. —-—-—-. 1
1
[
PUMP
ONLY 241814 CYLINDER ONLY
GREASE
RESERVOIR
i
I
I649s0
VENT VALVE III
1
I
I
!-—--~ !
1A1
w
“L: —-i I
L-- —._ -1-.--—--- —-—-—-
COM~&ON ~;~~~:j.
VALVE IElbow
CYLINDER i
PRESSURE I
220 P.S.I. MAX. ,
iSvl i
I
S0S42
RELIEF VALVE I
r- —-l I
ATMOSPHERE
a6SS30 I
1
—. -1 I
—
Ull
‘P I
L- .——.—.J
I
H
L---------- —- -—. —-—-—-— J
PRESSURE II I
SWITCH TANK* PFRESSURE(300T03000P.S.I.)
N.C. N.O. 11
LUBE PRESSURE OUT
4000 P.S.I. MAX. FIGURE (2) TYPICAL LUBRICATION SYSTEM INSTALLATION SCHEMATIC
NOTE
THE THEORETICAL RATIO OF THIS PUMP IS 16:1
MAXiMUM DEPENDING ON THE APPLICATION AND
VARIABLE INTERNAL FRICTION. THE ACTUAL RATIO
MAY BE LESS, BUT SHOULD BE AT LEAST 10:1.
●Important note maximum allowable return line pressure not to
@Indicatea Change exceed 30 psi for proper venting of SL-1 injectore. (15 PSI for SL-11)
INSTALLATION Flush the supply lines and hoses with Figure (3), Controller Schematic for
compatible solvent and blow dry with this description.
See Figures (1) and (2). Atypical air before connecting them to the
installation is shown only as aguide for system. This is to purge any contami- The system operates as follows:
selecting and installing system nation such as dirt, moisture, or metal
components. Contact your Lincoln shavings that could damage the pump A. With the pump and controller
representative for assistance in or system components. systems in arest state apreset
time interval occurs as determined
designing asystem to suit your specific
need.
Maximum allowable output pres-
sure of this pump is 7500 p.s.i. Be
sure that all system equipment and
accessories are rated to withstand
the maximum working pressure of
this pump. DO NOT exceed the maxi-
mum working pressure of the low-
est rated component in the system.
The pump was tested in lightweight oil
which was left in it to protect the pump
from corrosion. Flushing of the pump
before connecting it to the system
might be desired to prevent contamina-
tion of the grease you are pumping.
SYSTEM OPERATION
This section describes the operation of
the hydraulic pump, the controller and
how they function with other Lincoln
components in the system. See Figure
(2), System Installation Schematic and
by the bearings lubrication require-
ments.
B. When the controller times out a
24 VDC signal will energize SVI,
forcing it to open.
C. As SV1 opens the resulting
hydraulic fluid pressure closes the
vent valve and flows through the
pressure reducing valve.
D. The pressure reducing valve lowers ,
hydraulic fluid pressure to the
operating range of the hydraulic
pump.
FORM 402667 Page 3

MODEL S4530
IMUST CUT PIN FOR
I24 VDC OPERATION ~l. .
M
-o
24 BAT -
22 BAT. +24 VDC
22
21
20
l\
I\/EHm ‘O’’’sss”
wII
—
,dhMNAL AI
211S]141]5][61]711Sl191]1~ I111112111311141
\\ \ /II o
--
‘AT+L?-IIla
Ilw
~):1 %NO CONNECTION I?. . . ... . .
... .,... .. .. ..
=k=E- I I -:.’:_ ‘2U2,,
~~ T. CENTER LUG +>— ❑ROWN vaRE .
CYCLE
TIMER
/II ASV1
SOLENOID VALVE I~M
FIGURE (3) CONTROLLER SCHEMATIC
ADJUSTMENT SCREW (15 TURNS)
TURN COUNTER-CLOCXWISE TO DECREASE
TIME. TURN CLOCXWISE TO INCREASE TIME.
PRED LIGHT
0INDICATES TIMER
HAS TURNED ON
FIGURE (4) CYCLE TIMER ADJUSTMENT
Controller with pmesure switch and
safety valve must be used in the lube
system if cylinder pressure exceeds
220 p.s.i.! Failure to use these
monitoring and safety devices may
reeuft in damage to system compck
nente and personal injury!
E.
F.
After the system pressure has
been reduced it passes on to SV2
which controls the direction of the
hydraulic cylinder which operates
the grease pump.
The 24 VDC signal is also sent to
the cycle timer located at SV2. The
cycle timer will send apulsing
signal, 1second on and 1 second
off, to SV2. Solenoid Valve SV2
directs the hydraulic fluid to the
pump at 30 cycleslminute.
G. With the vent valve closed the pump
continues to cycle until maximum
pressure is achieved and the
injectors have metered grease to the
bearings. In most grease systems
this is 2500 p.s.i.
H. When the maximum system
1.
J.
pressure is reached the pressure
switch closes.
The closed pressure switch signals
the controller to stop the pumping
cycle.
At this time the controller terminates
the signals to SVI and SV2.
K. As SV2 is deenergized the pump
stops cycling.
L. As SV1 is deenergized the hydraulic
fluid stops flowing to the pressure
reducing valve and the vent valve.
M. As the vent valve is deenergized it
opens and allows the grease
pressure to drop to zero so the
injectors can recharge for their next
output cycle.
N. The system is now at rest, ready
for another lube cycle and the
sequence repeats itself.
WIRING INSTRUCTIONS
To use with Model 84965 Controller,
refer to instructions in Owner’s Manual
Section C8, Page 240.
Refer to following instructions when
wiring Model 84530, Cycle Timer -
P/N 244270 and Solenoid Valves -
SW and SV2. See Figure 3.
Model 84530:
Cut 24 VDC pin on power supply
board.
Connect battery positive voltage at
terminal 1 on Terminal Strip A(terminal
7 on terminal strip Ais internally
connected to terminal 1)and at
terminal 23 on Terminal Strip B.
Connect battery negative voltage at
terminal 2 on Terminal Strip A(terminal
9 and 12 are internally connected to
terminal 2) and at terminal 24 on
Terminal Strip B.
Cycle Timer, SV1 and SV2:
Connect cycle timer to SV2. Be sure to
install gasket.
Connect awire from Model 84530
Terminal Strip Aterminal number 8to
the brown wire from the cycle timer
and one of the wires coming from
Svl
Note: Greenwire from cycle timer
not used.
Connect awire from Model 84530
Terminal Strip Aterminal number 9to
the white wire from the cycle timer and
the other wire coming from SV1.
CYCLE TIMER
ADJUSTMENT
Cycle timer is factory set at 1second
Ion and 1 second off-for 30 cyclesl
minute. If adjustment is necessary refer
to Figure 4 and the following procedure.
The one adjustment screw adjusts
both the ON time and OFF time
equally. The adjustment range is from
.5 seconds (60 cycles/minute) to
I5seconds (6 cycles/minute)
Page 4FORM 402667

The adjustment screw allows 15 turns
of adjustment over the timing range.
The adjustment screw should be
turned 20 turns counter-clockwise to
insure you are starting at minimum.
Note: You can not adjust below
minimum -additional turns counter-
clockwise have no effect.
Each clockwise turn will equal approx-
imately.3 seconds. Add the number of
turns clockwise to reach the approx-
imate desired timing. Some additional
adjustment may be necessay depend-
ing on the accuracy needed.
Use the light on the cycle timer to help
in setting the time. The light will turn on
when there is power going to SV2.
TROUBLESHOOTING
Itthe following procedures do not
correct the problem, contact afactory
authorized service center. When
submitting equipment to be repaired,
be sure to state the nature of the
problem and indicate if arepair cost
estimate is required.
PROBLEMS
CYLINDER PRESSURE GAUGE
DOES NOT REGISTER PRESSURE.
A. No system pressure to the pump.
B. No 24 VDC signal at solenoids SV1
and SV2.
C. Pressure reducing valve set too low.
Increase setting by 1/2 turn to check
operation.
D. Primary solenoid valve SV1 may be
inoperative.
PUMP PRESSURE BUILDS VERY
SLOWLY OR NOT AT ALL.
A. No pulsing signal at SV2.
B. Pressure reducing valve maybe set
too low.
C. Grease viscosity maybe too high for
temperature at which pump is
operating.
D. If pressure is not building at all,
secondary solenoid valve SV2 may
be inoperative.
E. Pump piston ball checks and inlet
checks may have foreign matter
trapped causing leakage. Remove,
inst)ect and clean if necessarv.
F. Inspect sealing surfaces between
upper and lower inlet checks.
Replace if rough or pitted.
G. Replace shovel rod if rough or
pitted. Replace shovel rod packing.
H. Inspect lubricant supply line for
leaks or breaks.
1. If hydraulic vent valve is used, check for
clogged orifice. (Refer tow 3&w6)
DISASSEMBLY
Refer to SERVICE PARTS for part
numbers and location. Bleed all
pressure from hydraulic and grease
lines before disassembling pumps.
A.
B.
c.
D.
E.
F.
G.
Disconnect hose assemblies
(241 806 and 241 963) from upper
portion of the pump.
Remove cylinder adapters and
gaskets (241 961 and 24181 O).
Remove bolts and washers securing
cover to pump (50058 and 48083).
Remove cover and valve assembly
(241 799 and 84970).
Using two wrenches, unscrew
coupling nut (241 805) from pump
shaft end (11329).
Remove four upper bolts (50771 )
and lock washers (681 86) securing
mounting plate (241 803) to the tie
rods (241 804).
Remove hydraulic cylinder (241 814)
and moun{ng plate (241803).
H. The hydraulic cylinder can be
1.
J.
K.
disassembled f;om mounting plate
by removing four bolts (242048) and
lock washers (681 86).
Tie rods (241 804) can now be
removed from pump outlet body
(40537) by removing four lower bolts
and lock washers (50771 and
681 86).
Unscrew pump tube from outlet
body (40537).
Extend txImtI lIiston rod (11340) out
of the bottom of outlet body (40637).
Place wrenches on piston end
(11329) and flats of piston rod
(11340) and unscrew piston rod.
Thread the piston rod through the
gland packing to allow removal of
the pump tube.
L. Unscrew gland packing nut (12333)
from outlet body and remove all
gland parts.
M. Remove the priming tube (61275)
from the bushing extension (61273).
N. Extend plunger rod (11723) out of
bushing extension and unscrew
priming plunger (11724) to allow
removal of priming check parts and
plunger rod (11723).
O. Remove bushing extension (61273) ~,
and unscrew plunger and bushing
assembly (90554) from pump tube.
Unscrew coupling nut (11345) from
plunger adapter (11344) to allow
removal of plunger and bushing
assembly intact, reducing the
chance of loosing ball stop (57027)
and check ball (6601 O).
ASSEMBLY
To reassemble, perform DISASSEM-
BLY procedures in reverse.
IMPORTANT
To prevent damage to pump gland
packing and to help increase
packing life, lube pump piston rod
before assembly. Thread piston rod
through gland packing when
assembling pump.
REPAIR
RelIalr is limited to t13PlaC&?N?f)t of
listed service parts. S“pecial procedures
and tools are required. Contact Lincoln
Technical Sewice, One Lincoln Way,
St. Louis, MO 63120-1578, (314)
679-4200 Ext. 782 for your nearest
authorized service center.
When ordering replacement parts, list:
part number, description, model
number and series letter.
ACCESSORIES
Model 84980 Hydraulic Operated
Vent Valve
Model 84990 Hydraulic Operated
Vent Valve Assembly
Model 84616 Drum Cover and
Tiedown Assembly
245530 VitonlTeflon
Packing Kit (For
Pumping Synthetic
Lubricants)
Model 84530 Controller
Model 244270 Cycle Timer
Model 84015 24 VDC Timer
Model 69630 Pressure Switch
83001 Lower Pump Tube
Repair Kit
FORM 402667 Page 5

SERVICE PARTS
241963
2418061 \
—F-1
242209 1
fx=— —
[( 441111 —
7
241610 ~-” ‘“j
(2 REQ.) ‘:
241961
(2”REQ.) :[__.-:
242206
242704
242208
(SV2)
242207
II 11--
—
r
—
242206
242205
(Svl)
%
.................
46083
(2 REQ.)
5005 —L-d
‘241799 \241W> 242209
(2 REQ.)
USE LOCTITE 510
GASKET
ELIMINATOR ON
THREADS.
~241814
241803
~50771 (4 REQ.)
IMPORTANT
START FASTENERS BY HAND
TO AVOID STRIPPING THREADS
WHEN REASSEMBLING.
1
LA]
57027 _&
ncludes
rifice) 0
)
1/
66166 x
(4 REQ.)
242046 ~
(4 REQ.)
241805 -
RTS) 57027
66010
31047
11726
35073
$
11702 ‘
11721
11725
11724
239719
@*See torque specifications
on page 7 for all keyed notes.
PUMP DRUM DIMENSION
TUBE SIZE A
61407 120 lb. 27-3/8
61293 50 lb. 18-7/8
61285 400 lb. 33-1 5/1 6
BASIC
PUMP PISTON
ROD
13020
84960 PI
9
0
84961 11799 LL-J
Ii1!,
Diam.
84962 11761
I11,(
@INDICATES CHANGE
Page 6FORM 402667

SERVICE PARTS
PART QTY. DESCRIPTION PART QTY. DESCRIPTION
11329 1Piston bolt 50178 2Bolt
11340 1Piston rod 50771 8 Bolt
11344 1Plunger adapter 57027 2Ball stop
11345 1Coupling nut 61273 1Bushing extension
11346 1Coupling stud 66010 4Ball
11349 1Piston rod connector 66186 12 Lockwasher
11702 1Check washer 66220 2Lockwasher
11721 1Priming check 67325 1Elbow 0
11722 1Check stop 84970 1Valve assembly
11723 1Plunger rod 90554 1Plunger and bushing assembly
11724 1Priming plunger 239719 1 Priming tube
11725 1Priming check seat 241799 1Cover assembly
11726 1 Check seat 241803 1Mounting plate
12333 1Gland packing nut 241804 4‘me rod
14940 1Gland packing spacer 241805 1 Coupling nut
15184 1Adapter 241806 1 Hose
31047 1Check seat gasket 241810 2Gasket
31048 1Connector gasket 241814 1Hydraulic cylinder
31049 2Bushing gasket 241646 1Label
31050 1Gland gasket 241961 2
31054 1Adapter
Pump tube gasket 241963 1 Hose
34180 1Gland packing (nitrile) 242048 4Bolt
34572 1O-ring (polyurethane) 242205 13-way valve
35073 1Priming check packing (nitrile) 242206 2 Solenoid coil
38165 1U-cup packing (polyurethane) 242207 1 Pressure reducing valve
40537 1Outlet body 242208 14-way valve
48083 2 Washer 242209 2Solenoid connector
48213 1Gland packing washer 242211 1Gauge
48268 1Gland packing washer 242704 2Nut
50058 2Bolt 247342 1Repair Kit* 0
247384 1 Orifice @
0Indicates Change *For 241814 Hydraulic Cylinder
hf
TORQUE SPECIFICATIONS
A10-15 FT.-LBS. A80 FT.-LBS
A30 FT.-LBS. A90 FT.-LBS
A45 IN.-LBS. A100 FT.-LBS
Lincoln, APentair Company, warrants that lubrication equipment, materials dispensing equipment and other related equipment manufac-
tured by it will be free from defects in material and workmanship during the one (1) year following the date of purchase. If equipment proves
to be defective during this warranty period, it will be repaired or replaced without charge, provided that factory examination indicates the
equipment to be defective. To obtain repair or replacement, it must be shipped, transportation charges prepaid, with proof of date of purchase
to aLincoln authorized Warranty and Service Center, within the one (1) year following the date of purchase.
This warranty is extended to the original retail purchaser only. This warranty does not apply to equipment damaged from accident, overload,
abuse, misuse, negligence, faulty installation or abrasive or corrosive materials, or to equipment repaired or altered by anyone not authorized
by Lincoln to repair or alter the equipment. This warranty applies only to equipment installed and operated according to the recommendations
of Lincoln or its authorized field personnel. No other express warranty applies to lubrication equipment, materials dispensing equipment, and
other related equipment manufactured by Lincoln.
ANY IMPLIED WARRANTIES applicable to lubrication equipment, materials dispensing equipment, and other related equipment
manufactured by Lincoln INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR APARTICULAR
PURPOSE, WILL LAST ONLY FOR ONE (1) YEAR FROM THE DATE OF PURCHASE. SOME STATES DO NOT ALLOW
LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.
In no event shall Lincoln be liable for incidental or consequential damages. The liability of Lincoln on any claim for loss or damage arising out
of the sale, resale, or use of lubrication equipment, materials dispensing equipment, and other related equipment shall in no event exceed the
purchase price. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES,
SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU.
THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO
STATE.
FORM 402667 Page 7

m64530
CONTROLLER 69630 PRESSURE SWITCH
f“
Refer to Service Manual
~%
.Section C8, Page 167 Series.
/SUPPLY LINE
\
o
TO INJECTORS
#BASI
#
24 VDC .#ELECTRICAL
K
LUBE LINE
POWER SUPPLY’ “0 CON ACTIONS:. >
K
TYPE 76A HOSE
. . . /-’..: ‘*. (Specify Length)
OPTfONAL -./ :’
S4629 LOW-LEVEL ASSEMBLY
~~~:=~:G’’”-”
=.:’”7
@?/q
.
I-N #- A
-7~ ‘:=L=WITCH
CABLE FOR SV1 &SV2
\
“\ JUNCTION BOX
SOLENOID VALVE (SV2)
AND CYCLE TIMER
64616
DRUM COVER &
TIE ROD ASSEMBLY
Refer to Service Manual
Section C8, Page 203 Series
63371 FOLLOWER ASSEMBLY @
(Order eeDaretaly whan not uain9
‘a
the 64629 Low Level Assembly)
87070 OPTIONAL
84530 70278 HIGH PRESSURE SWITCH
CONTROLLER
\CY::K d==~:=:r,=
POWER SUPPLY -
OPTfONAL
84629 LOW LEVEL ASSEMBLY L
(Includes Follower)
Rafer to Service Manual
LOW LEVEL SWITCH
TANK CABLE FOR SV1 &SV2
PRESSURE JUNCTION BOX
300- 3W0 Psl SOLENOID VALVE (SV2)
SOLENOID VALVE
(Svl )I
84630 FOLLOWER GUIDE ROD KIT
(Must be ordered when using the
64829 Low-Level Aaaembly)
Refer to Service Manual
Section M30, Psge 21 Series
AND CYCLE TIMER
84616
DRUM COVER &
TIE ROD ASSEMBLY
Rafer to Service Manual
Section C8, Page 203 Series
83371 FOLLOWER ASSEMBLY @
(Order separately whan not using
the 84629 Low Level Aaaembiy)
OIndicates Change
Page 8FORM 402667