Lincoln industrial FlowMaster A Series User manual

PageSection - C8 - 269A 7.5A-18100-A98 Form 402864 February1999
FlowMaster™ Rotary Driven Hydraulic Pump
Models: 85480, 85481, 85482 and 85483
Series “A”
ThispumpconformstotheEuropeanDirectiveforProductSafety
ForeignandU.S.PatentPending
To order call 1-800-548-1191 or visit www.partdeal.com - [email protected]

FlowMaster™ Rotary Driven Hydraulic Pump
Series “A”
Page Number - 2 7.5A-18100-A98 Form 402864
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
General Description
The Lincoln Industrial rotary Hydraulic Pump is a fully
hydraulically operated grease pump. Grease output is
proportional to the hydraulic input flow. The pump is
primarily designed for centralized lubrication systems such
as the Single Line Parallel, Single Line Progressive and
Two Line systems. An integrated pump control manifold is
incorporated with the motor to control input flow and
pressure. A 24 volt DC solenoid valve is also incorporated
as a method to turn the pump on and off.
The pump is driven by the rotary motion of the hydraulic
motor. Rotary motion is converted to reciprocating motion
through an eccentric crank mechanism. The reciprocating
action causes the pump cylinder to move up and down. The
pump is a positive displacement double acting pump as
grease output occurs during both the up and down stroke of
the pump.
During the down stroke, the pump cylinder is extended into
the grease. Through the combination of shovel action and
vacuum generated in the pump cylinder chamber, the
grease is forced into the pump cylinder. Simultaneously,
grease is discharged through the outlet of the pump. The
volume of grease during intake is twice the amount of
grease output during one cycle. During the upstroke, the
inlet check closes, and one half of the grease taken in
during the previous stroke is transferred through the outlet
check and discharged to the outlet port. Typical output of the
pump is shown on page 4.
Appropriate Use
All pump models are exclusively designed to pump and
dispense lubricants using hydraulic power.
The maximum specification ratings should not be
exceeded.
Any other use not in accordance with instructions will
result in loss of claims for warranty and liability.
service center nearest you for repair or adjustments other
than maintenance specified in this manual.
Annual inspection by the factory authorized warranty and
service center nearest you is recommended.
A list of factory authorized warranty and service centers is
available upon request.
Damaged Pumps
Any pump that appears to be damaged in any way, is badly
worn or operates abnormally, shall be removed from use
until repairs are made. Contact the factory authorized
warranty and service center nearest to you for repairs.
Tableof Contents Page
Safety….……………………................................................................2
Description....................................................................................2
Appropriate Use................................................................2
Pump Performance and Specifications..............................3
Installing the Pump.....................................................................4
Operation.....................................................................................5
Maintenance and Repair...........................................................5
Pump Dimensions.............................................................7
RepairPartsList................................................................................9
TroubleShooting.........................................................................10
Safety
Read and carefully observe these operating instructions
before unpacking and operating the pump! The pump must
be operated, maintained and repaired exclusively by per-
sons 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 care immediately. Do not treat as a simple cut.
Tell attending physical exactly what fluid was injected.
Inspection
If overpressurizing of the equipment is believed to have
occurred, contact the factory authorized warranty and service
center nearest you for inspection of the pump.
Specialized equipment and knowledge is required for repair
of this pump. Contact the factory authorized warranty and
To order call 1-800-548-1191 or visit www.partdeal.com - [email protected]

FlowMaster™ Rotary Driven Hydraulic Pump
Series “A”
Page Number - 3
7.5A-18100-A99
Form 402864
Do not exceed 3,000 PSIG (200 bar) maximum supply inlet
hydraulic pressure. Exceeding the rated pressure may result
in damage to system components and personal injury.
Pump Performance and Specification
Supply inlet hydraulic pressure,
maximum, PSIG (bar) - 3,000 (200)
Operating working hydraulic
pressure , PSIG (bar) - 300 to 450 (20 to 32).
Hydraulic Inlet Flow,
GPM (l/min) - Up to 7 (28)
Pump Ratio with manifold - 9:1 at low inlet pressure
(300 to 350 psi [20 to 25
bar]) and low inlet flow
(below 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 (-10 to 65)
Operating Voltage, VDC - 24
Hydraulic Inlet Port, In - 3/8 NPTF
Tank Return Port, In - 3/8 NPTF
Pump Outlets, In - 1/4 NPTF
Maximum Hydraulic
Fluid Temperature, ºF, (ºC) - 200 (93)©
Weight, Lbs (Kg) - 36 (16)
HYDRAULIC PUMP PERFORMANCE SPECIFICATIONS
Test conducted with AlvaniaNLGI # 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 101213
(-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
Illustration 1
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FlowMaster™ Rotary Driven Hydraulic Pump
Series “A”
Page Number - 4 7.5A-18100-A98 Form 402864
FG
HJ
B
D
E
CK
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 - Follower Plate
B - Pump Outlet Plug
C - Hydraulic Supply line
D - Supply Line Shut-off Valve
E - Supply Line Shut-off Vavle
F - 24 VDC from Controller
G - Return Line Shut-off Valve
(3/4” ID min).
H- Vent Valve PortPlug
J - Outlet Shut-off Valve
K - Material Supply L:ine
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
InstallingthePump
Typical installation is shown 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.
The pump was tested in light weight oil which was left in to
protect the pump from corrosion. Flush the pump before
connecting it to the system to prevent contamination of the
grease with residual oil.
The pump has flow and pressure controls integrated into
the manifold (37). A normally closed ON/OFF Solenoid Valve
(35) is also integrated into the manifold and will start or
stop the pump operation.
1. Mount the pump securely on the drum cover so that it
cannot move or vibrate during operation.
2. Attach hydraulic supply line to the Inlet and return line to
the Tank ports.
3. Connect material supply line to the pump outlet. Plug
the unused outlet on opposite side of the pump.
4. Install high pressure shut-off valve in the material supply
line. (Required)
5. Connect 24 VDC power supply to the solenoid valve (35).
See Illustration #1. Use connector plug (36) supplied
with the pump.
NOTE: To install the pump Model 85481 as a replacement
pump for Model 84944, use adapter/spacer p/n 249616 with
bolts p/n 50014, included in the 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
A
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FlowMaster™ Rotary Driven Hydraulic Pump
Series “A”
Page Number - 5
7.5A-18100-A99
Form 402864
Mount the pump securely on the drum cover. Failure to do
so could result in personal injury and equipment damage.
Do not exceed 450 PSIG (32 bar) working hydraulic
pressure. Use high pressure components to reduce risk of
serious injury including fluid injection and splashing in the
eyes or on the skin. All accessories connected to the pump
outlet must have at least 5,000 PSIG (350 bar) minimum
hydraulic pressure. All accessories connected to the pump
inlet must have at least 3,000 PSIG (200 bar) minimum
working pressure.
Operation
All pumps are factory set at 350 PSIG (24 bar) working inlet
hydraulic pressure with 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. Shut off the material supply line valve.
2. Turn on the hydraulic pressure.
3. Energize the solenoid On/Off valve.
4. Prime the pump by slowly opening the shut-off lubricant
supply line valve. Make sure that all air has been
expelled from the pump and even lubricant flow is
achieved.
5. Adjust the pump pressure and flow to the desired
application requirements. Do not exceed pump
operating pressure of 450 PSIG (32 bar).
6. Always use the lowest pump output pressure and
hydraulic fluid flow to obtain the desired results. This
will reduce the pump wear.
Do not exceed maximum operating temperature of the
hydraulic fluid (200º F/93º C) ©. Never allow the pump to run
dry of lubricant. Adry pump quickly speeds up, creating friction
heat, which can damage the seals. Monitor the supply
lubricant level and refill when necessary.
MaintenanceandRepair
Relieve pressure from the pump and supply lines 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 #6)
ToolsRequired:
- Hex Bit Socket Wrenches (3/8” square drive) with 3/8” hex,
5/32” hex, 1/4” hex.
- 3/8” O.D. Steel Rod
- 12” Crescent Wrench
- Spanner Wrench (for 3/8” diameter tube, 1/8” pin)
- 1/2” to 3/8” square drive adapter
- Torque wrench (1/2” square drive, 0 - 50 ft-lb capacity)
- Torque wrench (3/8” square drive, 0 - 120 in-lb capacity)
- 1/4” nut driver
- Screwdriver (flat blade, 1/8” blade width)
1.Remove the four Socket Head Screws (33) and separate
Manifold from the Hydraulic Motor (42).
2.Remove Pipe Plug (45) and drain the crankcase oil from
the Pump Housing (46).
3.Remove six self-threading Screws (29) and remove the
Housing Cover (30) and the Cover Gasket (31).
4.Remove Retaining Ring (57) and pull the Shovel Plug
(56) from the Housing Tube (55).
5.Remove two Socket Head Screws (44) and separate the
Hydraulic Motor (42) from the Pump Housing (46).
6.Remove two Outlet Pin Nuts (50) from the Pump Housing
(46).
7.Remove the Pump Subassembly (1 through 28) from
the Pump Housing (46). Pushing the subassembly up
with a wooden or plastic rod 3/4 O.D. against the Check
Seat Housing (28) is helpful.
8.Remove the Housing Tube (55) from the Pump Housing
(46) by inserting a 3/4 rod through the inlet holes at the
bottom of the Housing Tube (55) and unscrewing it.
9.Remove the Bronze Bearing (51), the O-Ring (52), and
the Backup Washer (53) from the Housing Tube (55).
10. Remove the Crankrod Assembly (1 through 8) from the
pump by unscrewing the Button Head Screws (12) and
then pulling out the Wrist Pin Bushings (13).
11. Remove the Check Seat Housing (28) from the
Reciprocating Tube (21). There is a 3/8 Allen Head
socket in the throat of the Check Seat Housing (28) to
facilitate removal.
12. Unscrew the Wrist Pin Anchor (14) from the
Reciprocating Tube (21) and pull the Plunger Assembly
(9 through 20) from the tube.
13. Using a 1/2” wooden or plastic rod, push the Cup Seal
(22) and the Pump Cylinder (24) from the Reciprocating
Tube (21).
14. Remove the Pump Plunger (20) from the Plunger Link
Rod (17). A spanner wrench, which uses the holes in
Illustration 4
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FlowMaster™ Rotary Driven Hydraulic Pump
Series “A”
Page Number - 6 7.5A-18100-A98 Form 402864
the Pump Plunger, is required.
15. Unscrew the Plunger Link Rod (17) from the Plunger
Tube (11) and slide off the Cup Seal (16), the Backup
Washer (15) and the Wrist Pin Anchor (14).
16. Unscrew the Plunger Tube (11) from the Outlet Pin (9).
17. To dismantle the Crankrod Assembly (1 through 8),
remove Flat Head Screws (1) and the Inner and Outer
Weights (2 & 3).
18. Remove the large Retaining Rings (6) and press the
Crank Eccentric (7) out of the Ball Bearing (8). Be sure
to support the Ball Bearing (8) on the inner race.
19. Remove the small Retaining Rings (6) and press the
Crank Eccentric (7) out of the Ball Bearing (8). Be sure
to support the Ball Bearing (8) on the inner race.
Pump Assembly Procedure
1.When the pump is dissembled, it is recommended to
replace all seals and gaskets, which are included in the
270663 repair kit.
2.In the process of disassembly, examine the following
components and replace if excessive wear is indicated:
Ball Bearing (8), Crank Eccentric (7), Crankrod (5), Wrist
Pin Bushings (13), Plunger Tube (11), Pump Plunger and
Upper Check Parts (20, 19 and 18), Pump Cylinder (24),
Check Seat Housing and Lower Check Ball (28 and 26),
upper Bronze Bushing (51), Housing Tube (55), Shovel
Plug (56), and Reciprocating Tube (21).
3.Assembly Procedure is the reverse of the Disassembly
Procedure except for the following:
4.Install parts (22) through (28) into the Reciprocating Tube
(21) after the plunger assembly (9 through 20) is
installed.
5.Install the Pump Subassembly (1 through 28) into the
pump Housing (46) before tightening the Housing Tube
(55) to the Pump Housing (46). Be sure the
Reciprocating Tube (21) is inserted through both
bushings before tightening the Housing Tube (55).
6.Use loctite 242 (or similar product) medium strength
thread lock on all torqued threaded connections. Extreme
care must be exercised to prevent excess compound from
flowing into critical areas such as clearance fits and ball
check. Allow a minimum of 30 minutes cure time before
operating the pump.
7.Torque Specifications:
A. Plunger Tube (11) to Outlet Pin (9) - 100 to 110 In.-Lbs.
B. Button Head Screws (12) to Wrist Pin Anchor (14) 100
to 110 In.-Lbs.
C. Plunger Tube (11) to Plunger Link Rod (17) - 100 to 110
In.-Lbs.
D. Plunger Link Rod (17) to Pump Plunger (20) - 100 to
110 In.-Lbs.
E. Flat Head Screws (1) to Outer Weight (2) - 100 - 110
In.-Lbs.
F. Wrist Pin Anchor (14) to Reciprocating Tube (21) - 20 to
25 Ft.-Lbs.
G. Check Seat Housing (28) to Reciprocating Tube (21) -
20 to 25 Ft.-Lbs.
H. Outlet Pin Nut (50) to Pump Housing (47) - 30 to 35 Ft.-
Lbs.
I. Housing Tube (55) to Pump housing (47) - 20 to 25 Ft.-
Lbs.
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FlowMaster™ Rotary Driven Hydraulic Pump
Series “A”
Page Number - 7
7.5A-18100-A99
Form 402864
5.025
(128)
LEDOMLEDOM LEDOM LEDOMLEDOM "A"MID"A"MID "A"MID "A"MID"A"MID
)mm(ni
"B"MID"B"MID "B"MID "B"MID"B"MID
)mm(ni
08458)996(05.72)089(65.83
18458)384(00.91)467(60.03
28458)468(00.43)5411(60.54
38458)843(96.31)926(57.42
11.46
(291)
9.54
(242)
1
2
3
B
A
6
8
4
7
5
ø 1.25
(32)
2.25
(57)
1/4-20 THD 2.25
(57)
9.08
(231)
4.61
(117)
1. 1/4 NPTF Pump Outlets
2. 3/8 NPTF Inlet Port
3. 3/8 NPTF Tank Port
4. 1/4 NPTF Vent Valve Port
5. Solenoid Valve
6. Pressure Reducing Valve
7. Flow Control Valve
8. Pressure Gauge
Illustration #5
3.125
(79)
1.5
(38)
© indicates change
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FlowMaster™ Rotary Driven Hydraulic Pump
Series “A”
Page Number - 8 7.5A-18100-A98 Form 402864
Illustration #6
34 31
32
33
35
36
37
38
39
59
40 41
42
43
44 51
52
54
53
55
56
57
29
30
50
49
48
47
46
45
1
2
34
68
76
5
4321
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
60
58
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FlowMaster™ Rotary Driven Hydraulic Pump
Series “A”
Page Number - 9
7.5A-18100-A99
Form 402864
Item Qty Description All
No. Models
1. 2 Flat Head Screw
(1/4 x 1-3/4) 270635
2. 2 Outer Weight 270606
3. 2 Inner Weight 270605
4. 2 Retaining Ring 270609
5. 1 Crankrod 270665
6. 2 Retaining Ring 270608
7. 1 Crank Eccentric 270666
8. 1 Ball Bearing 270607
9. 1 Outlet Pin 270670
10. 1 O-Ring (Nitrile) *
11. 1 Plunger Tube 270667
12. 2 Button Head Screw
(1/4 x 1/2) 270634
13. 2 Wrist Pin Bushing 270668
14. 1 Wrist Pin Anchor 270669
15. 1 Backup Washer *
16. 1 Cup Seal
(Polyurethane) *
17. 1 Plunger Link Rod See Chart Below
18 1 Spring 270616
19. 1 Ball 66010
20. 1 Pump Plunger 270671
21. 1 Reciprocating Tube See Chart Below
22. 1 Cup Seal
(Polyurethane) *
23. 1 O-Ring
(Polyurethane) *
24. 1 Pump Cylinder 270672
25. 1 Ball Cage 270675
26. 1 Ball 66001
27. 1 O-Ring (Nitrile) *
28. 1 Check Seat 270664
29. 6 Self-Threading
Screw (8 x 1/2) 270633
30. 1 Housing Cover 270629
31. 1 Cover Gasket
(Nitrile) *
Item Qty Description All
No. Models
32. 1 Pressure Gauge 270696
33. 4 Socket Head
Screw (5/16 x 1-1/4) 270680
34. 1 Solenoid Valve
Cartridge (Note #2) 270690
35. 1 Solenoid Valve
Coil (24 VDC) 270691
36. 1 Solenoid Connector 242209
37. 1 Manifold 270694
38. 1 Pressure Reducing
Valve (Note #3) 270692
39. 1 Flow Control Valve
(Note #4) 270693
40. 2 O-Ring (Nitrile) *
41. 1 Motor Gasket *
42. 1 Hydraulic Motor
(Note #1) 270676
43. 2 Washer 48548
44. 2 Socket Head
Screw (1/2 x 1-1/4) 270658
45. 1 Pipe Plug (3/8 NPTF) 67417
46. 1 Pump Housing 270673
47. 2 Backup Ring (Nitrile) *
48. 2 O-Ring (Nitrile) *
49. 2 O-Ring (Nitrile) *
50. 2 Outlet Pin Nut 270619
51. 1 Bronze Bearing 270674
52. 1 O-Ring (Nitrile) *
53. 1 Backup Washer *
54. 1 O-Ring (Nitrile) *
55. 1 Housing Tube See Chart Below
56. 1 Shovel Plug 270707
57. 1 Retaining Ring 270705
58. 1 Seal Kit (Nitrile) 270687
59. 1 Seal Kit (Nitrile) 270688
60. 1 Seal Kit (Nitrile) 270689
Soft parts Kit 270663
* Included in 270663 Soft Parts Kit.
1. Includes Gasket (Item 41) and O-Rings (Item 40).
2. Includes Seal Kit (Item 58).
3. Includes Seal Kit (Item 59).
4. Includes Seal Kit (Item 60).
RepairPartsList
(Common to all Models)
RepairPartsList
(Non-common items)
Item Qty. Description Model Model Model Model
No. 85480 85481 85482 85483
17 1 Plunger Link Rod 270648 270614 270645 270641
21 1 Reciprocating Tube 270649 270617 270646 270642
55 1 Housing Tube 270659 270660 270661 270662
To order call 1-800-548-1191 or visit www.partdeal.com - [email protected]

FlowMaster™ Rotary Driven Hydraulic Pump
Series “A”
Page Number - 10 7.5A-18100-A98 Form 402864
Lincoln Industrial
25 International Business Park
#01-68 German Centre
Singapore 609916
([phone]
Lincoln Industrial
One Lincoln Way
St. Louis, MO 63120-1578
([phone]
www.lincolnindustrial.com
Lincoln GmbH
69190 Walldorf
Heinrich-Hertz Strasse 2-8
([phone]
Printed in the U.S.A.Copyright 1999
Troubleshooting
Condition Possible Cause Corrective Action
Pump does not run. No pressure on gauge (32):
- Closed Supply line shut off valve. Open shut-off valve.
- No power to solenoid valve (34). Correct electrical fault.
- Faulty Solenoid (35). Replace solenoid (35).
- Pressure Reducing Valve (38) is Reset Pressure Reducing Valve (38).
set too low.
- Insufficient Hydraulic Fluid supply. Check hydraulic supply for proper
pressure and flow.
Pressure is shown on gauge (32):
- Closed fluid outlet line. Check outlet line and clear
obstructions.
- Flow Control Valve is fully closed. Readjust valve to 3/4 turn open.
- Pump is stalled due to grease Check vent valve in system.
backpressure.
- Pump is stalled due to grease Check vent valve in system.
backpressure.
Pump is seized or damaged. Dismantle the pump and repair
defective or seized component. See
disassembly and assembly
procedure.
Pump speeds up or runs erratically. Low level of grease or reservoir Refill reservoir.
is empty.
Follower plate is stuck and separated Check follower plate and container
from grease. for damage.
Pump piston or checks are worn. Disassemble the pump and repair.
Pump runs, but output is low. Insufficient hydraulic fluid supply. Check hydraulic supply and adjust
flow using valve 39.
Inlet pressure too low. Increase pressure using valve 38.
Faulty inlet (25, 26, 27) or discharge Replace faulty components.
check valve (18, 19, 20).
Weepage from housing cover 30. Cup seal (16) or O-Ring (48) wore out. Check the seals and replace if
necessary.
Pump becomes noisy. No crank case oil. Add crank case oil. Remove Pipe
Plug (45) from Pump Housing (46).
Oil level should be at the bottom of
the Pipe Plug opening. Add 10W30
motor oil until the crankcase is full.
Worn wrist pin bushing 13. Check the bushings and replace if
necessary.
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