Lincoln 85751 User manual

Hose reel pump assembly
85751
85753
Assembly, disassembly and
repair guide
Date of issue December 2012
Form number 404483
Section A21
Page 9A
Read manual prior to installation or use
of this product. Keep manual nearby for
future reference. Failure to follow
instructions and safety precautions may
result in death or serious injury.
DANGER

Contents
Safety ................................................................................ 3
Explanation of signal words for safety ................................. 3
Use of this manual .............................................................. 4
Overview............................................................................ 4
Appropriate use .................................................................. 4
General description and information ................................... 4
Operation ........................................................................... 8
Disassembly ....................................................................... 9
Assembly ......................................................................... 12
Parts and tools ................................................................. 16
Lincoln industrial standard warranty ................................. 21
2

Indicates a hazardous situation which,
if not avoided, could result in minor or
moderate injury.
CAUTION
Explanation of signal
words for safety
Safety
Read and carefully observe these installation
instructions before installing, operating or
troubleshooting the assembly. The assembly
must be installed, maintained and repaired
exclusively by persons familiar with the
instructions.
Assemble this equipment only after safety
instructions and this guide have been read
and are completely understood.
Adequate personal protection must be
used to prevent splashing of material on the
skin or in the eyes.
Always disconnect power source (elec-
tricity, air or hydraulic) from the pump when
it is not being used.
This equipment generates very high
grease pressure. Extreme caution should be
used when operating this equipment as
material leaks from loose or ruptured com-
ponents can inject fluid through the skin and
into the body. If any fluid appears to pene-
trate the skin, seek attention from a doctor
immediately.
Do not treat injury as a simple cut. Tell
attending doctor exactly what type of fluid
was injected.
Any other use not in accordance with
instructions will result in loss of claim for
warranty or liability.
• Do not misuse, over-pressurize, modify
parts, use incompatible chemicals, fluids,
or use worn and/or damaged parts.
• Do not exceed the stated maximum
working pressure of the pump or of the
lowest rated component in your system.
• Always read and follow the fluid manufac-
turer’s recommendations regarding fluid
compatibility, and the use of protective
clothing and equipment.
• Failure to comply may result in personal
injury and/or damage to equipment.
Indicates a hazardous situation which,
if not avoided will result in death or
serious injury.
WARNING
Safety instruction signs indicate specific
safety-related instructions or
procedures.
SAFETY INSTRUCTIONS
This is the safety alert symbol. It is used
to alert you to potential physical injury
hazards. Obey all safety messages that
follow this symbol to avoid possible in-
jury or death.
Indicates a hazardous situation which
if not avoided will result in death or
serious injury.
DANGER
3

Use of this manual
General description
and information
The Hose Reel Pump Assembly is a portable
5 U.S. gallon (18,9 liter) pump intended to
operate from a 12 or 24 V DC power source,
depending on model, for dispensing grease
or other lubricant through a hose and
control valve.
Model 85751 is 24 V DC and model
85753 is for 12 V DC operation. The pumps
include a pressure switch in the wiring
harness to turn off the pump when
maximum pressure is achieved.
Model 85751 is a 24 V DC, 5 gallon,
7:1 ratio FlowMaster II pump. Model 85753
is a 12 V DC, 5 gallon, 19:1 ratio,
FlowMaster II pump.
The pump outlet pressure is controlled by
a pressure switch, (8) mounted on the rear
of the pump housing. An outlet check, item
(2), is connected to the pump outlet to
maintain pressure on the hose reel, mini-
mizing leak-back through the pump. A safety
unloader, (4), prevents pressure from ex-
ceeding 7,000 psi (482 bar). A manifold, (5),
is used for connections to the pump outlet.
The manifold includes a pipe plug, (6), that
can be removed for installing an optional
pressure gauge, 274872. These features
are included on all models.
Models 274887 and 276359 consist of a
pump, bucket cover assembly, follower, hose
reel (which includes swivel and control
valve), and a 7 ft. (2 m) connecting hose.
Refer to table 3 for appropriate models.
Models 274886 and 276358 consist of a
pump, bucket cover assembly, and follower.
Refer to table 3 for appropriate models.
Refer to figure 2 for the wiring diagram
for the pump motor.
Inspection
If over pressurizing 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.
Annual inspection by the factory
authorized warranty and service center
nearest you is recommended.
Damaged Pumps
Do not use any pump that appears to be
damaged, badly worn or operates
abnormally. Remove the pump from service
and contact the factory authorized warranty
and service center nearest you for repairs.
A listing of authorized warranty and
service centers is available upon request.
Overview
This manual details the procedure that must
be followed while installing, operating,
troubleshooting and repairing the
FlowMaster II hose reel pump.
All required parts, tools, and equipment
needed to complete the operation of the
FlowMaster II hose reel pump are defined
and listed within this manual.
Review of the parts list and nomenclature
is recommended before starting
disassembly or operation.
Appropriate use
The hose reel pump assembly is intended
for use in mobile applications where there
are grease points that require the use of a
grease fitting due to abusive environments
or an inability to reach the lube point with a
grease hose. An example of this situation is
the bucket lubrication points on an earth
mover or backhoe.
The hose reel pump assembly can also
serve well in applications where a lower cost
option to a fully automated lubrication
system is desired.
Table 1
Pump specifications
Model 85751 Model 85753
Operating
temperature
–20 to 140 °F (–29 to 60 °C) –20 to 140 °F (–29 to 60 °C)
Operating voltage 24 V DC, (18 to 32)
Gear ratio 7:1 19:1
12 V DC, (9 to 16)
Motor, power 1/3 HP (0,33 kW) 1/3 HP (0,33 kW)
Output/pump cycle 0.07 in.3 (1,15 cm3)0.07 in.3 (1,15 cm3)
Pump performance 18.0 in.3/min (295 cm3/min) at 0 psi back
pressure 14.0 in.3/min (230 cm3/min) at
5,000 psi (345 bar) back pressure
7.0 in.3/min (115 cm3/min.) at 0 psi
back pressure 3.9 in.3/min
(64 cm3/min.) at 5,000 psi (345 bar)
back pressure
Pump outlets 1/4 NPTF internal 1/4 NPTF internal
!Notice
The hose reel pump assembly is
intended to be used in kits that include
all parts necessary to mount and
dispense grease to points that are not
serviced by an automated lubrication
system.
Table 3 lists the kits and accessories
available for use with the hose
reel assembly.
4

Connector Pressure switch
Red
Black
Pump motor
To battery
Fig. 1
Motor wiring diagram
Description Model Voltage Pump
assembly
Lid Follower Connecting
hose
Reel, control valve
and swivel
Pump w/ bucket lid and follower 274886 24 V DC 85751 274878 274888 NA NA
276358 12 V DC 85753 274818 274888 NA NA
Pump as above with reel, 50 ft. (15 m)
hose, control valve, swivel and connecting
hose
274887 24 V DC 85751 274818 274888 276366 94553H
276359 12 V DC 85753 274818 274888 276366 94553H
Accessories
Description Part number
Pressure gauge 10,000 psi (690 bar) 274872
Container mount 35 lb. (16 kg) /
5 U.S. gallon (19 l)
274934
Table 3
Kits
Table 2
Torque specifications
Part Torque
Spool stop (30) 18–22 ft. lbf. (24–29 Nm)
Jam nut (27) 12–15 ft. lbf. (16–20 Nm)
Adapter (39) 12–15 ft. lbf. (16–20 Nm)
Cover screws (15) Compress gasket 0.015–0.020 in.
(0,381–0,508 mm)
Switch screws (20) Hand tight
5

13.74
(349)
8.93
(227)
5.79
(147)
8.71
(221)
6.97
(177)
10.82
(275)
A
A
Fig. 2
Pump dimensions
6

Pump installation
Verify a relief valve is installed in the
pump outlet to insure pump pressure
remains below 5,000 psi (345 bar). Use
only high pressure components. Failure
to comply may result in serious personal
injury.
WARNING
Pressure switch adjustment
The pressure switch is factory set at
5,800 psi (400 bar). Pump life will be
increased by maintaining a lower pump shut
off pressure. It is recommended that the
pressure be set no higher than the
application requires.
The pump should be wired using 12 AWG
(3,5 mm2) wire capable of carrying 20 A at
24 V DC.
A separate fuse should be wired between
the pump and power supply on the positive
side of the circuit.
1 Mount the hose reel and pump in the
desired location.
!Notice
Never allow pump to run dry of
lubricant. A dry pump quickly speeds up,
creating friction heat and can damage
seals. Monitor supply lubricant level and
refill when necessary.
Failure to comply may result in
damage to equipment.
Pumps are not equipped with a high
pressure shut off valve. Do not exceed
maximum rated outlet pressure. Failure
to comply may result in personal injury
and/or damage to equipment.
DANGER
!Notice
Pump motor is polarity sensitive
and will not run if connected incorrectly.
!Notice
Refer to the FlowMasterII pump
service sheet for information on the
pump. Refer to parts list on page 13.
!Notice
If optional pressure gauge is used,
install in manifold by removing plug and
screwing gauge into manifold port. Use
a teflon based thread sealant on fitting
threads to ensure proper sealing.
!Notice
If the optional pressure gauge is
not used, install a temporary
gauge in the provided manifold port
until the switch is reset.
Do not exceed a shutoff pressure of
6,000 psi (414 bar). Failure to comply
may result in damage to equipment.
1 Loosen adjustment stem locknut (27)
Refer to figure IPB 1.
2 Using a 5/16 hex head wrench, turn the
adjustment spring cap (28) clockwise to
increase (or counterclockwise to
decrease) the pump shut-off pressure.
3 Turn the stem 1/8 of a turn at a time,
checking the setting by releasing the
pressure and allowing it to build again.
4 While holding the adjustment stem with
a 5/16 hex head wrench, tighten the
locknut.
5 Check the setting once more to ensure
the adjustment stem did not move when
the locknut was tightened.
2 Connect the pump outlet from the
manifold to the hose reel inlet using the
supplied hose and fittings. Use a teflon
based thread sealant on fitting threads to
ensure proper sealing.
3 With the pump in a full container of
lubricant, energize the pump.
4 Purge air from the pump.
5 Verify lubricant is flowing evenly from
the pump.
6 Stop the pump.
7 Attach the pump outlet line to the outlet
port (55).
End of procedure
7

Disassembly
While the pressure switch will provide years
of service, in time, components will wear
out. It is possible to replace the switch
element and all of the soft parts to overhaul
the pressure switch.
1 Unplug the electrical connector to free
the switch from the assembly.
2 Refer to figure 3 and remove the two
1/4–20 screws (14) holding the unit to
the support bracket (9).
3 Unscrew the adaptor fitting (39) from the
manifold (34). Refer to figure 6.
4 Remove the four cover screws (15) along
with the cover (16) and cover gasket
(17).
!Notice
Wire terminals (23) can be freed
from the connector body (25) by pushing
back locking tab inside the connector
body (25) while pulling on the individual
wire. A small screwdriver is needed to
depress this tab.
5 Pull back the boot (24) from the connec-
tor body (25) and slide it back down the
wire about 1 in. (25,4 mm).
Fig. 3
6 Pull out the locking wedge (26) using
needle nose pliers.
7 With the connector body (25) removed,
pull the boot (24) off of the wire.
8 Loosen and remove the cap and rubber
plug from cord grip connector (22).
9 Disconnect the cord grip connector body
(22) from the switch body (21).
10 Refer to figure 5 and remove the two
screws (20) and pull out the switch and
wire assembly (21).
11 Remove the ball (19).
12 Remove the adaptor fitting (39) from
the switch body (34).
13 Loosen the jam nut (27).
Fig. 5
27
28
29
30
31
32
33
34
35
36
37
38
39
17
16
15
19
18
Fig. 6
13
21
22
26
25
24
23
20
14
9
Fig. 4
22
24
25
26
14 15
16 17 39
14 Remove the spring cap (28) using a 5/16
hex head wrench. Refer to figure 6,
page 8.
15 Loosen the spool stop (30) using a 1 in.
open end wrench and remove from the
body (34).
16 Remove the spring (32).
!Notice
Jam nut (27) and thread seal (29)
can remain in place on spring cap (28).
9
12
8

!Notice
Cup seal (36) and backup washer
(35) are held in place by a push-in
retainer (37).
Retainer (37) grips smooth bore in
switch body (34) and must be broken to
remove.
Using small flat blade screwdriver,
wedge retainer on outside diameter and
push toward center of bore. Repeat in
two or three locations outside of retainer
until it falls out.
!Notice
The rod must contact the 1/8
diameter plunger rod on the underside
of the spool assembly (33) to push the
plunger rod through the cup seal (36).
17 Using a small rod or stiff wire 0.093 in.
(0,2 cm) or smaller, push the spool
assembly (33) up from the bottom and
remove it from the body.
!Notice
If the spring and steel plunger are
serviceable, it is recommended that the
following parts be replaced:
Gasket (17), cup seal (36), retainer clip
(37), o-ring (31), o-ring (38) and thread
seal (29).
Replace the switch element (21) if the
unit fails to operate for any
unknown reason.
Inspection
While the pressure switch will provide years
of service, in time, components will wear
out. It is possible to replace the switch
element and all of the soft parts to overhaul
the pressure switch.
1 Inspect the steel plunger (33) to ensure
there are no gouges or scratches that
would prevent proper sealing.
2 Inspect the switch body (34) for signs of
mechanical damage that would prevent
proper function.
3 Insepct the spring (32) for serviceability.
4 Inspect the switch element for pitting and
or corrosion.
18 Pull out the retainer (37), cup seal (36)
and backup washer (35) using a stiff
wire with a hook bent into it. Refer to
figure 6, page 8.
End of procedure
9

!Notice
Seat all parts against the bottom
of the bore.
Failure to comply may result in
equipment damage.
!Notice
Do not over tighten switch
housing screws.
Failure to comply may result in
equipment damage.
!Notice
Prior to starting assembly perform
inspection of all parts.
Lightly coat rubbing surfaces of spool
(33) and ball (19) as well as both o-ring
seals with a good quality NLGI grease to
ease assembly.
Torque all threaded joints to torque
specified in table 3.
Failure to comply may result in
equipment damage.
1 Insert back up washer (35).
2 Insert the cup seal (36).
3 With the concave surface out, push the
retainer clip (37) into the seal bore so
that it lightly touches or not quite touches
the cup seal. Refer to figure 7.
4 Insert the spool assembly (33).
5 Install the spring (32).
6 Apply thin coat of greast to o-ring (31)
and install on spool stop (30).
Assembly
Fig. 9
Fig. 8
Fig. 7
27
22
16 17
9
10 13 11 14
26
25
24
12
39
19
18
17
16
15
28
29
30
31
20
21
22 23
24
25
26
32
33
34
35
36
37
38
39
7 Insert spool stop (30) into body (34) and
tighten to a torque of 18–22 ft. lbf.
(24–29 Nm).
8 Install the thread seal (29) onto spring
cap (28).
9 Install the spring cap (28) into the spool
stop (30).
10 Install the jam nut (27) and tighten
using a 15/16 hex head wrench.
11 Torque jam nut (27) to a torque of
12–15 ft. lbf. (16–20 Nm).
12 Install the o-ring (38) and retainer (37)
onto the adaptor fitting (39) .
13 Thread the adaptor fitting (39) into the
switch body (34).
14 Torque the adaptor fitting (39) to a
torque of 12–15 lb. lbf (16–20 Nm).
15 Insert the ball (19) into the switch
body (34).
16 Insert the switch and wire assembly
(21) into the switch body (34).
17 Insert screws (20) into switch housing.
18 Tighten screws (20) hand tight.
19 Install the grip connector body onto the
wire and switch assembly (21).
20 Install the cord grip (22) into the switch
body (34).
21 Install the cap and rubber plug on the
grip connector (22).
22 Install the boot (24) on the wire and
switch assembly (21).
23 Install connector pins (23) into
connector body (25).
24 Insert locking wedge (26) into connector
body (25). If needed, use needle
nose pliers.
25 Place the cover gasket (17) onto the
switch body (34) mating surface.
26 Install the cover (16) on the cover
gasket (17).
27 Thread four screws (15) through cover
and into switch body (34).
28 Tighten screws (15) until a
0.015–0.020 in. (0,381–0,508 mm)
gasket squeeze is observed.
29 Place the switch body (34) in position on
the suport bracket (9) .
30 Install the two 1/4-20 screws (14)
holding the unit to the support
bracket (9).
31 Plug the electrical connector into
the assembly.
End of procedure
10