Lincoln industrial A Series User manual

Models94822
CHASSISLUBE ELECTRICGREASE PUMP
Series"A"
Section Page
- Q3
MAY-00 FORM 402951 - 14
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Page 2 Form 402951
.35"
(9 mm)
Mounting
Holes
6.37"
(162 mm)
Mounting Holes
17.72"
(450 mm)
9.84"
(250 mm)
13.00"
(330 mm)
4.72"
(120 mm)
8"
(202 mm)
SPECIFICATIONS
Electrical Requirements
Input ..................................... 24 VDC @ 2 amps
EnclosureRating ................ IP 6K9K - Protected from water
sprayed in all directions.
Alarm Time ......................... 30 minutes
Interval between lube
cycles .................................. 4 minutes minimum
60 minutes maximum
Pump Output ....................... 0.171 in³/min (2.8 cm³/min)
with instaled 6 mm element
OutletConnection .............. 1/8" NPT (female)
Maximum Recommended
Operating Pressure ........ 3600 psi (248 bar)
Reservoir Capacity ............ 488 cu. in. (8000 cc)
Lubricant ............................. Greases up to NLGI grade 2
(depending on the operating
temperature and type of
lubricant)
Temperature Range ........... - 13°F(-25°C) to
+158°F(+70°C)
Pressure Relief Valve ........ 4000 psi +/- 250 psi
(276 bar) +/- (17 bar)
DESCRIPTION
The chassis lube pump is electrically operated and is used in
a progressive type centralized lubrication system. The pump
incorporates a low-level sensor which will cause a LED light
on the circuit board to blink if a low-level condition occurs. This
signal may also be sent to an optional dash mounted light if
desired.
The frequency of the pump's lubrication cycles is controlled by
the internal microprocessor. A proximity switch, installed on
one of the systems secondary divider valves, must be utilized
to signal completion of a lubrication cycle. If a signal is not
recieved within 30 minutes a fault signal, as described above,
will also occur. This feature is used to monitor the pump's
operation and to detect any blocked or broken supply lines.
The pump consists of a pump housing, electric gear motor,
the microprocessor and a plastic reservoir with stirring paddle.
The high operating pressure capability allows the pump to
supply lubricant up to NLGI #2 grease.
MOUNTING THE PUMP
Select an easily accessible place of installation which allows
access to the timer and lubricant reservoir filler fitting. The
pump must be mounted vertically on an even surface by
means of three bolts. (See Fig. 1 on page 3.)
TO FILL RESERVOIR
Fill the reservoir through the grease fitting located at the base
of the reservoir. Reservoir can be filled using a hand operated
grease pump, a pneumatic pump or electronic transfer pump.
Caution must be used when
filling reservoir with pneumatic
or electric transfer pump so as
not to burst reservoir.
Refill reservoir when grease reaches MIN mark located on
the reservoir. Fill the reservoir up to the MAX mark located
on the reservoir.
TO PRIME SYSTEM
Pump & Supply Line: After reservoir has been filled with
recommended lubricant, loosen the supply line fitting. Operate
the pump until lubricant flows from outlet, then tighten fitting.
Feed Lines: Pre-fill each feed line with lubricant before
connecting to outlet of divider valve and bearing.
Figure 1
Do not use pump without
pressure relief valve.
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Form 402951 Page 3
MOUNTING HOLE LOCATIONS
Figure 3
Figure 2
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Page 4 Form 402951
ProximitySwitches
The following proximity switches
for black colored blocks only:
234-13178-2 3-meter (9.8 ft) cable
length
234-13178-5 7-meter (23.0 ft) cable
length
PARTS LIST
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Figure 4 - Proximity Switch
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Form 402951 Page 5
SERVICE PARTS/KITS
Part No. Qty. Description Item No.
5050 1 Greasefitting 25
242125 1 Greasecap 39
246421 1 Housingcover 30
246422 1 Closureplug 17
246423 1 Sealingplug 22
246424 2 O-ring 7
246425 1 Intermediateplate 8
246426 1 Pumphousing 16
246427 1 Eccentriccam 12
270816 1 Socket withcord 18
Proximity connector
270817 1 Flat packing 19
4 Screw 20
1 Socket 32
Bearing&SealKit contains:
2 Bearingring 5
246434 1 Bearing 6
1Shim 9
2 Snapring 10
1 Inner ring 11
24VDCMotorKitcontains:
3Screw 13
3 Washer 14
3O-ring 15
246436 1 Woodruff key 27
1 Radialseal 28
124VDCmotor 29
1 Plugformotor 38
HousingSealKit contains:
246437 3 O-ring 15
1 Radialseal 28
PowerPlugKit contains:
270818 1 Flat packing 19
4Screws 20
1Plug 21
247671 1 Lid 42
247672 1 Fixedpaddle 43
247674 1 Reservoir 1
247676 1 Hose 2
247677 1 O-ring 44
247678 1 Adapter 45
249565 1 Adapter for relief assembly 41
270864 1 Pressurerelief assembly 37
249903 1 ControlCam 4
249904 1 Magnetic Switch 48
249905 1 Microprocessor 26
249906 1 Stirringpaddle 3
206-13796-7 10 Screw 24
219-14138-2 1 O-ring 46
226-14105-5 1 Nipple 23
PumpElement Assemblycontains:
600-26876-2 1 Checkvalve 34
1 Pumpelement 35
1Gasket 36
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Page 6 Form 402951
REMOTELIGHT
& PUSHBUTTON
IGNITION
SWITCH FUSE
NOT USED
CONNECTOR
& CABLE CONNECTOR
& CABLE
PROXIMITY
SWITCH
PUMP HOUSING
PRINTED
CIRCUIT
BOARD
24 VDC BATTERY
IMPORTANT
POLARITY ON REMOTE LIGHT MUST BE OBSERVED.
"P" LOCATED ON BACK OF LIGHT GOES TO RED WIRE.
"N" LOCATED ON BACK OF LIGHT GOES TO YELLOW WIRE.
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Figure 5
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Form 402951 Page 7
Fig. 6 - Printed circuit board 236-13870-1
 The printed circuit board automatically controls the
sequence of the pause and operating times of the 203
central lubrication pump as a function of the vehicle or
machine working hours tB (Fig. 7).
 The sequence of the pause and operating times is
activated when the machine contact or ignition switch is
switched on.
 A lubrication cycle consists of one pause time and one
operating time. Once the pause time has elapsed, the
operating time starts to run. This lubrication cycle is
repeated permanently after the machine or vehicle has
been put into operation. Refer to Fig. 7.
 During the operating time the pump element dispenses
the lubricant to the lubrication points via progressive me-
tering devices.
Fig. 7 - Time sequence diagram
tB - Working hours T - Lubrication cycle
tP - Various pause times T1 - Stored pause times
T2 - Operating times
Pause time
 The pause time
- determines the frequency of the lubrication cycles within a
working cycle;
- is started and stopped via the machine contact or
ignition switch;
- is adjustable.
 When the machine contact or the ignition switch is
switched off, the pause times which have already
elapsed as well as the momentary operating conditions
(faults) are stored and added up by an electronic memory
(EEPROM) until the time which has been set on the blue
rotary switch is reached.
 After the machine contact or ignition switch is switched
on again, the printed circuit board operates from the
point where it had been interrupted.
 If the setting is modified within the pause time, the printed
circuit board takes over the new value only at the end of the
operating time.
 The pause time setting may be different for each applica-
tion. It must be adjusted in accordance with the respective
lubrication cycles. Also refer to To set the pause time.
Fig. 8 - Proximity Switch
Operating time
Aproximity switch (initiator) which has been installed on
a metering device instead of a piston closure plug moni-
tors and brings the pump operating time to a close after
all the pistons of this metering device have dispensed
their
lubricant quantity.
 The operating time depends on the systems lubricant
requirement and on the location of the proximity switch
(either on the main metering device or on the secondary
metering device).
 During the operating time, the signal lamp is
permanently lit.
Monitoring time
 A fixed monitoring time of maximum 30 minutes.
Note: Normally, the monitoring time ends at the same time
as the operating time.
 If there is no switching off signal from the proximity switch
to the printed circuit board within 30 minutes, a fault
signal will occur.
The signal lamp flashes with the corresponding flashing
frequency. See Fault indication.
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Page 8 Form 402951
Figure 11 - To acknowledge a fault
 When the pushbutton is pressed briefly (< 1 second) the
fault is acknowledged, i.e. the lamp stops flashing and is
permanently lit.
Note: Any acknowledged fault remains stored even after the
driving switch or machine contact has been switched off.
Upon switching on again, the signal lamp flashes again in
accordance with the fault.
To Remedy to a Fault
* In the case of a malfunctioning, check the central
lubrication pump and the connected system for faults.
* Eliminate the cause of the fault.
* Switch on the pump again by triggering an additional
lubrication cycle. For this, press the pushbutton >2
seconds.
·When the fault is eliminated, the signal lamp will
extinguish at the end of the lubrication cycle.
Important: If there has been any fault, the pump will not
start automatically after the elimination of that fault. It must
be switched on, i.e. an additional lubrication cycle must be
triggered. See To trigger an additional lubrication cycle.
Note: It is also possible to acknowledge/reset a fault or
trigger an additional lubrication cycle by means of the
pushbutton on the printed circuit board (Fig. 14). For this,
press it < 1 second and > 2 seconds. Condition: The
machine contact or driving switch must be switched on.
To acknowledge a Fault
Functional check
 Each time the machine contact (external contact) or the
driving switch is switched on, a functional check of the
drive motor and signal lamp takes place automatically.
 During the functional check the motor is switched on for
0.1 second (the stirring paddle slightly rotates) and the
signal lamp lights up for 2 seconds.
 If there is a fault, the signal lamp flashes. See Fault
Indication.
Note: LED display Figure 9 indicates the same operating
state as the signal lamp.
Figure 9 - LED for the monitoring time or fault indication
Pushbutton (Fig. 11)
 The following functions can be performed with the
pushbutton:
- triggering an additional lubrication cycle - Press
pushbutton for over 2 seconds (> 2 s)
- fault acknowledgement < 1 s
- in the case of a fault, switching on pump again by
pressing pushbutton (> 2 seconds)
Figure 10 - Indicated operating states
A - Fault indication
B - Indication of operation or acknowledged fault
Functions of the Pushbutton and Signal Lamp
Note: It is also possible to acknowledge any fault or to
trigger an additional lubrication cycle via pushbutton 4 of
the printed circuit board (Fig. 14).
Signal lamp
 The signal lamp or the LED Figure 9 indicates the opera-
ting state of the centralized lubrication system.
 The faults are indicated by different flashing frequencies
of the signal lamp or the LED Figure 9. See Fault
Indication.
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Form 402951 Page 9
*To set the pause time, remove the cover on the pump
housing.
Important: After having set the pause time, screw the cover
on the pump housing again.
Fig. 12 - The cover to the printed circuit board has been
removed
Time Setting
Fig. 13 - Rotary switch - Pause time
To set the pause time
The pause time can be adjusted to 15 settings by means of
the blue rotary switch.
Note: The 0 position corresponds to the shortest time, see
pos. 1.
 To check the function of the pump it is possible to perform
an operational test.
* If necessary, switch on the battery voltage
* Switch on the driving switch
 To check whether power is applied to the printed circuit
board, observe whether the left-hand LED 1, Fig. 14, is lit.
* Press the pushbutton (> 2 seconds) for triggering an
additional lubrication (illuminated pushbutton, Fig. 11, or
pushbutton on the switch cabinet) until the right-hand LED
3 lights up.
 The right-hand LED indicates the following functions:
- operating time
- monitoring time (in normal cases it is as long as the
operating time, in the case of a fault: 30 minutes)
- faults
 When an additional lubrication cycle has been triggered,
a shorter pause time occurs, followed by a normal
lubrication cycle.
 Additional lubrication cycles can be triggered at any time.
Fig. 14 - LED of the printed circuit board
1 - LED, left-hand 3 - LED, right-hand,
Power supply Indication of operation
2 - Rotary switch 4 - Pushbutton for
pause time additional lubrication
cycle
Operational Test /To Trigger an Additional
Lubrication Cycle
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Page 10 Form 402951
Drive motor defective
If the motor does not run when the driving switch is
switched on or if the feed line to the motor is damaged, the
signal lamp flashes after 2 seconds as follows:
A1 second - ON - 1 second - OFF
Malfunctions
such as
- blocked lubrication point (s)
- blocked metering devices (s)
- interruption in the main line leading to the metering
device equipped with a proximity switch
- air in system
- reservoir empty
are indicated as described under B.
The above mentioned faults cause the pistons in the
monitored metering device to stop. The signal lamp
indicates the respective fault signal with the following
flashing frequencies:
Lubrication circuit 1 malfunctioning
B0.5 second - ON - 1 second - OFF
Low-level control
The signal lamp is flashing with the following frequency:
Reservoir empty
E0.5 second - ON - 0.5 second - OFF
Fault Indication
Fig. 15 - Flashing frequencies in the case of malfunctions
A- Drive motor defective
B - Lubrication circuit 1 malfunctioning
E - In the case of low-level control: reservoir empty
F - Fault acknowledged (maintained lightening)
Note: The low-level signal is converted into a flashing
signal with the a.m. frequency only after 6 motor
revolutions.
 In the case of a malfunction the proximity switch (initiator)
can no longer record the piston movements and
therefore, it cannot switch off the pump.
 Due to the monitoring time which runs in parallel to the
operating time, the printed circuit board switches off the
pump at the end of the monitoring time.
 A fault signal occurs.
 The signal lamp is flashing.
 The pump no longer starts automatically. See To
Remedy to a Fault
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Form 402951 Page 11
printed circuit board are lit or the signal lamp of the illumina-
ted pushbutton/switch cabinet is lit.
Note: The pump operation can be checked from the outside
by observing whether the stirring paddle is rotating (e.g. by
triggering an additional lubrication), whether the LED on the
Troubleshooting
Fault: The pump motor does not run
Remedy:
 Check the voltage supply to the pump. If necessary,
eliminate the cause of the fault.
 Check the line leading from the pump plug to the printed
circuit board.
 If the voltage is applied, the left-hand LED is lit.
 Replace the printed circuit board.
Cause:
 Voltage supply interrupted
 Voltage supply to the printed-circuit board is interrupted
 Printed circuit board defective
Remedy:
Disconnect the main line leading to the monitored
metering device.
Unscrew the proximity switch and check it. For this, insert a
metallic pin into the borehole of the detector. Let it there
over 2 seconds and then remove it. If the pump is not
switched off afterwards, check the cable connections to the
pump. If necessary, replace the proximity switch along with
the connector.
Check the cable connections to the pump. If necessary,
replace the proximity switch with the connector.
Replace the printed circuit board.
Fault: The pump motor runs permanently (30 minutes)- Duration of the monitoring time
 Cause:
Proximity switch (initiator) defective.
Cable connection of the proximity switch to the pump
interrupted.
Printed circuit board defective
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Page 12 Form 402951
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