Lincoln industrial A Series User manual

Page
Section - C8 -282
Form 402977
July2000
Single Shot Hydraulic Pump with Hydraulic Return
Model 85416
Series A

Page Number - 2
Single Shot Hydraulic Pump
Form 402977
Table of Contents
Page
Safety......................................................................................................2
GeneralDescription.........................................................................2
Appropriate Use...............................................................2
PumpSpecifications...................................................................2
PumpOperation.......................................................................................3
Installing the Pump.................................................................3
Maintenance andRepair..................................................................4
PumpDimension..........................................................................5
RepairPartsList..................................................................................7
TroubleShooting.................................................................................8
Safety
Read and carefully observe these operating instructions
before unpacking and operating the pump! The pump must
be operated, maintained and repaired exclusively by
persons familiar with the operating instructions. Local
safety regulations regarding installation, operation and
maintenance must be followed.
Operate this pump only after safety instructions and this
service manual are fully understood.
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
Safety Instructions
This equipment generates very high grease pressure.
Extreme caution should be used when operating this
equipment as material leaks from loose or ruptured
components can inject fluid through the skin and into the
body causing serious bodily injury. Adequate protection
is recommended to prevent splashing of material onto the
skin or into the eyes.
If any fluid appears to
penetrate the skin, get
emergency medical
help immediately. Do
not treat as a simple
cut. Tell attending
physician exactly what
fluid was injected.
Description
General Description
This unit is a hydraulically operated, single acting, hydraulic
return, positive displacement pump designed to deliver
grease under pressure. The pump is primarily designed for
Airless Spray Lube and Single Line Progressive Centralized
Lubrication Systems. A 12-volt DC four-way solenoid valve to
control hydraulic input is integrated into the pump.
The pump uses grease from standard 14.5 oz. grease
cartridges, eliminating the need for bulk filling equipment.
The pump may be filled from a bulk lubricant container if
desired.
Appropriate Use
This pump is exclusively designed to dispense grease in
centralized and Airless Spray lubrication systems.
It should be operated only with hydraulic power.
The maximum ratings given should not be exceeded.
Any other use not in accordance with the instructions will
result in loss of claims for warranty and liability.
Product Specification
Pump Ratio 25:1
Output per Stroke 0.11 in3
Hydraulic Inlet
Pressure (max.) 300 psig (21 bar)
Output Pressure (max.) 7500 PSIG (520 bar)
Operating Temperature -10°F to +160°F
(-23°C to +65°C)
Operating Voltage 12 VDC
Initial Current Draw 1.22 amps
Hydraulic Ports SAE -6 J1926 (3/8)(9/16-18 UNF)
Pump Outlet SAE -6 J1926 (3/8)(9/16-18 UNF)
Weight (empty) 13 lbs. (6.0 kg)

Page Number - 3
Single Shot Hydraulic Pump
Form 402977
Pump Operation
When the lube system timer/controller requires lubricant,
the four-way solenoid valve is energized. This allows
pressurized hydraulic fluid to enter the hydraulic cylinder,
which moves the piston and plunger forward. The plunger
forces pressurized lubricant past the outlet check and into
the system. Hydraulic fluid on the back side of the hydraulic
piston is vented through the four-way solenoid valve and the
tank port back to the hydraulic reservoir.
When the system timer controller turns off the pump, the
solenoid valve is de-energized, allowing pressurized
hydraulic fluid to enter the back side of the hydraulic piston.
This moves the piston and plunger back to their starting
positions. Hydraulic fluid on the front side of the hydraulic
piston is vented through the four-way solenoid valve,
through the tank port back to the hydraulic reservoir.
As the plunger returns, it opens the lubricant inlet port,
lubricant flows into the cavity due to vacuum in the cavity and
the pressure exerted on the grease cartridge by the follower
spring.
With Airless Spray Lube Systems, this process may be
repeated until the Airless Spray Lube System requirements
are fulffilled.
Installing the Pump
The pump preferrably should be mounted with the grease
cartridge housing in the vertical position, but it may be
mounted in the horizontal position. Be sure to allow
sufficient space for filling and servicing. Mount in an area
where the pump can be observed for monitoring lubricant
level and pump operation.
1. Mount securely to an even, stable and solid surface with
5/16 [8mm] dia. screws.
2. Connect material supply line to the pump outlet.
3. Connect hydraulic supply line to the INLET port and
connect the hydraulic return line to the TANK port.
4. Connect 12 VDC power line from timer/controller to the
solenoid valve (2). Use Connector Plug (1) supplied with
the pump.
5. Fill the pump with grease. See Filling Pump with Grease
instructions.
6. System may be primed by cycling the pump or by filling
manually with lever gun or other grease pump.
Filling Pump with Grease
Removing Empty Cartridge
1. Pull back on follower handle until the follower rod is fully
extended and latch the follower rod groove into the slot
on the tube cap.
2. Unscrew grease Cartridge Housing (22) from Pump
Head (15).
3. Carefully release follower handle to eject empty cartridge
from container tube.
Installing Grease Cartridge
1. Visually check follower seal lip direction before loading a
new cartridge. The follower seal lip must be directed
toward the follower handle for cartridge loading. See
Illustration #1. To change direction of the follower seal,
unscrew tube cap from container tube and pull on handle
to remove follower seal from tube. Flip follower seal over
and re-assemble.
2. Pull back on follower handle and latch the follower rod
groove into the slot on the tube cap.
3. Remove the plastic cap from the grease cartridge and
insert cartridge into container tube, with the open end
against the follower seal.
4. Remove the pull tab from grease cartridge and screw
Grease Cartridge Housing (22) into Pump Head (15).
5. Release follower rod from slot. Purge air from pump. See
air purging instructions.
Manual Filling
1. Unscrew Grease Cartridge Housing (22) from Pump
Head (15).
2. The follower seal lip must be directed toward the pump
head when cartridges are not used. To change direction of
follower, unscrew tube cap from container tube and pull
on handle to remove follower from tube. Flip follower seal
over and re-assemble.
3. Pack container tube follower end with grease to eliminate
air pocket.
4. Dip packed end of the container tube about one inch into
bulk container.
5. Slowly pull follower handle back while gradually pushing
container tube deeper into grease.
6. When follower rod is fully extended pull sideways to latch
it into slot in tube cap.
7. Wipe excess grease from outside of container tube.
8. Screw Grease Cartridge Housing (22) into Pump Head
(15).
9. Release follower rod from slot. Purge air from pump. See
air purging instructions.
Air Purging
1. Engage the Follower Rod with the follower by lightly
pulling up and rotating the Follower Handle.
2. Loosen the Container Tube from the Pump Head about 1
turn, or until it is loose.
3. Push in the Follower Handle to force any air pockets out of
Pump Head around Container Tube Threads.
Illustration 1
Follower
Handle
Tube Cap Container
Tube
Follower Rod
Follower Seal Lip
(Carriage Position)

Page Number - 4
Single Shot Hydraulic Pump
Form 402977
4. Tighen container tube into Pump Head Container Tube
Threads.
5. Open Purge Valve by rotating Purge Valve counter
clockwise 1 turn.
6. Cycle Pump until lubricant, free of air, is present at Purge
Port.
7. Close Purge Valve by turning clockwise, finger tight.
5. Remove Packing (21) from Pump Head (15).
6. Remove Solenoid Coil (2) from Solenoid Valve Cartridge
(3).
7. Remove Solenoid Valve Cartridge (3) from Valve Body (14).
8. Loosen four Hex Head Screws (4) from Pump Body and
remove Cylinder from Pump Body, pulling Plunger free of
Pump Body.
9. Remove four Hex Head Screws (4) and four Spacers (27)
from cylinder assembly.
10. Remove four Socket Head Cap Screws (13) and Valve
Body.
11. Remove two O-Rings (26) from Cylinder Ends (5 & 25).
12. Remove Cylinder End (25) from Cylinder (7).
13. Remove Cylinder (7) from Cylinder End (25).
14. Remove Plunger and Piston Assembly from Cylinder End
(25).
15. Disassemble piston (9) from Plunger (11) by removing
nut (10) and sliding piston (9) off Plunger (11).
16. Remove U-Cup Seals (8) from Piston (9).
17. Remove O-Ring (12) from Plunger (11).
18. Remove O-Ring (6) from Cylinder Ends (5 & 25).
19. Disassemble Cylinder End (25) by removing U-Cup (24)
and Wiper (28).
20. Disassemble Pump Body by removing Purge Valve
Screw (16) and ball (29).
21. Remove Check Valve Assembly by removing Check Plug
(20), Spring (18) and Check Ball (17) from Pump Body
(15).
22. Remove O-Ring (19) from Check Plug (20).
23. Remove Wiper (28) from Pump Body (15).
24. It is recommended that all seals which are included in the
seal kit, be replaced when re-assembling the pump.
25. Reassembly is the reverse of the disassembly
procedure.
26. When installing wiper (28) into Pump Body (15) the single
lip on the Wiper (28) must face out of the Pump Body (15)
towards the Cylinder End (25). Do not cut seal.
27. When installing Wiper (28) into Cylinder End (25) the
single lip on the Wiper (28) must face out of the cylinder
end (25) facing towards the pump body (15). Do not cut
seal.
28. When installing U-Cup into Cylinder End (25) the seal
lips must face towards Cylinder (7). U-Cup snaps into
groove. Do not cut seal.
29. When installing U-Cup Seals (8) on Piston (9), the seal
lips must face away from each other.
30. Pre-Assemlbe the Hydraulic Cylinder prior to assembling
to the Pump Body, in reverse order of assembly. Leave
the Socket Head Cap Screws (13) loose until final
assembly is made.
31. When assembling the Hydraulic Cylinder to the Pump
Body, carefully work the chamfered end of the plunger (11)
into the Wiper Lips (28) so the wiper is not damaged.
32. Slide the four Hex Head Screws (4) through both Cylinder
Ends (5 & 25) through four spacers (27) and into pump
body (15).
33. Tighen four Hex Head Screws (4) for a snug fit. Fully
tighten four Socket Head Cap Screws (13). Then tighten
fully four Hex Head Screws (4).
Maintenance and Repair
Relieve pressure from the pump and supply lines and
remove power from the solenoid before servicing or
repairing the pump, to reduce the risk of an injury from
injection, splashing fluid or moving parts.
Always use Lincoln
Industrial parts for
service and repair.
Disassembly Procedure (See Illustration #4)
Tools Required:
- 3/16 Allen wrench
- 1 wrench
- 1/2 wrench
- 9/16 wrench
- 3/4 wrench
- 7/8 wrench
1. Disconnect Solenoid Coil (2) at Connector (1).
2. Remove tension on follower spring in Grease Cartridge
Housing (22) by pulling up on follower handle and
latching notch on follower rod into slot on tube cap.
3. Remove Grease Cartridge Housing (22).
4. Remove Grease Cartridge.
Purge Outlet
Purge Valve
Illustration 2

Page Number - 5
Single Shot Hydraulic Pump
Form 402977
3/8 (-6) SAE J1926
O-Ring Port
(9/16 -18 UNF)
5.62
(143)
Illustration 3
14.80
(376)
Hydraulic Return
Hydraulic Inlet
2.75
(70)
.62
(16) 1.00
(25)
1.56
(40)
1.12
(28)
10.99
(279)
4.60
(117)
3/8 (-6) SAE J1926
O-Ring Port
(9/16-18 UNF)
Material Outlet
.73
(19)
1.38
(35)
Deutsch D.T.
Series Female
Connector (2 way)
3/8 (-6) SAE J 1926
O-Ring Port
(9/16-18 UNF)

Page Number - 6
Single Shot Hydraulic Pump
Form 402977
1
2
3
23 13
14
26
7
624
25 28
27
21
17
29
16
18
19
20
34
4
31
26
5
630
10
8
9
812
11
22
32 33
15
Illustration 4

Page Number - 7
Single Shot Hydraulic Pump
Form 402977
Item Qty Description Part No.
1 1 Connector 270926
2 1 Solenoid Coil (includes Item 1) 270852
3 1 Solenoid Valve Cart (includes Item 23) 270849
4 4 Hex Screw 1/4-28 x 5" 270847
5 1 Cylinder End 270837
6 2 O-Ring (Nitrile) Note 1
7 1 Cylinder 270833
8 2 U-Cup (Polyurethane) Note 1
9 1 Piston 270841
10 1 Nut (5/16-18 UNF) 51026
11 1 Plunger 270844
12 1 O-Ring (Nitrile) Note 1
13 4 Socket Head Cap Screw (1/4-28 x 1 1/2) 270848
14 1 Valve Body 270839
15 1 Pump Body 270831
16 1 Knob & Stud (3/8 - 16 x 1") 270856
17 1 Check Ball 270863
18 1 Check Spring 270846
19 1 O-Ring (Nitrile) Note 1
20 1 Check Plug 270845
21 1 Packing (Nitrile) 34793
22 1 Grease Cartridge Housing (Includes Item 32 & 33) 249786
23 1 Seal kit (Nitrile) 270859
24 1 U-Cup (Polyurethane) Note 1
25 1 Cylinder End 270835
26 2 O-Ring (Nitrile) Note 1
27 4 Spacer 16073
28 2 Double Lip Wiper (Nitrile) Note 1
29 1 Ball 66003
30 1 Lockwasher (5/16") 66246
31 4 Lockwasher (1/4") 66186
32 1 Follower Assembly 93485
33 1 Handle 261514
34 1 Pipe Plug 68645
NOTE 1: Seal kit 270858 contains all seals required for rebuilding the
pump assembly. This kit does not contain items 23, 21 or 32.
Repair Parts List

Page Number - 8
Single Shot Hydraulic Pump
Form 402977
Americas:
One Lincoln Way
St. Louis, MO 63120-1578
USA
Phone [phone]
Fax [phone]
Europe/Africa:
Heinrich-Hertz-Str 2-8
D-69183 Walldorf
Germany
Phone [phone]
Fax [phone]
Asia/Pacific:
25 Intl Business Park
#01-65 German Centre
Singapore 609916
Phone [phone]
Fax [phone]
© Copyright 1999
Printed in USA
Web site: www.lincolnindustrial.com
Troubleshooting
Condition Possible Cause Corrective Action
Pump does notoperate. No hydraulic pressure to pump. Turn on orconnecthydraulic supply.
No electricpower to solenoid. Turn on orconnect timer/controller
to solenoid.
Solenoid valve failure. Replace Solenoid Valve.
Piston or plunger is stuck. Disassemble pump,inspectfor
damaged or worn parts.Replace if
necessary.
Pump does notdispense grease. Grease cartridge empty. Replace emptygrease cartridge.
Follower is stuck. Check cartridge housing for damage.
Pump is air bound. Purge pump - see Air purge procedure
Pump fails to build pressure. Check valve is not working. Disassemble Check Valve & inspect
for worn or damaged parts.
Plunger leaks. Disassemble pump & inspect for
worn or damaged parts.
Pump fails to build pressure. Solenoid Valve Failure. Replace Solenoid Valve.
Excessive leakage between Seal Failure Disassemble Pump inspect for torn
Pump Body & Hydraulic or damaged seals.
Cylinder