Lincoln FlowMaster A Series User manual

PageSection - C8 - 298
Form 422734
February2003
FlowMaster™ Rotary Driven Electric Pump, 24 VDC
Models: 85567, 85568 and 85599
Series “A”
ForeignPatentPending
U.S.Patent No.6,102,676

Page Number - 2 Form 422734
FlowMaster™ Rotary Driven Electric Pump
Description
85567 - Pump for 60 pound drum, 360 RPM maximum,
maximum pressure rating 5,000 psi
85568 - Pump for 90 and 120 lbs. drum, 360 RPM
maximum, maximum pressure rating 5,000psi
85569 - Pump for 5 gallon pail, 100 RPM maximum
maximum pressure rating 2,500 psi.
General Description
The Lincoln Industrial rotary DC electric pump uses a
24VDC motor and either a single a double stage planetary
gear drive. Grease output is proportional to the pump RPM.
The pump is primarily designed for centralized lubrication
systems such as the Single Line parallel, Single Line
Progressive and Two Line systems.
The pump is driven by the rotary motion of the electric 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 unit is
a positive displacement double acting pump as grease
output occurs during both the up and down stroke. The
pump motor employs an integral speed control capable of
reducing pump speed to 10% of its maximum value.
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 3.
Appropriate Use
•All pump models are exclusively designed to pump and
dispense lubricants using 24 VDC electric
power, depending on how the motor is wired.
•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

Page Number - 3
Form 422734
FlowMaster™ Rotary Driven Electric Pump
Do not exceed maximum rated outlet pressure for these
pumps. Exceeding rated pressure may result in damage to
system components and personal injury.
Pump Performance and Specification
Operating Temperature, ºF (ºC)- -40 to +150 (-40 to 65)
Operating Voltage, VDC - 24 (18 MIN., 37 MAX)*
Pump Outlets, In - 1/4 NPTF
Weight, Lbs (Kg) - 30 (13.3)
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.
1. Mount the pump securely on the drum cover so that it
cannot move or vibrate during operation.
2. Connect material supply line to the pump outlet. Install a
safety unloader (such as 272722) to outlet on opposite
side of the pump.
3. Install high pressure shut-off valve in the material supply
line. (Required)
4. Connect 24VDC power supply to the
solenoid valve (35). (See Illustration #1.)
5. Connect power to motor leads. Be sure to connect red
motor lead to the positive side of the circuit. The motor is
polarity sensitive and will nto run if improperly wired.
Fuse the motor as recommended in Tables 2 & 3.
Illustration 1
ELECTRIC PUMP PERFORMANCE SPECIFICATIONS
CUBIC IN/MIN Testconducted with Alvania NLGI#2 Grade Grease at1000 psi Backpressure
TEMPERATUREDEGF(DEGC) 50 RPM 100 RPM 150RPM 200 RPM 250 RPM 300 RPM 350 RPM
80 (27) 3.5 7 10.5 14 17.5 21 24.5
40 (4) 3.5 7 10.5 14 17.5 21 24.5
20 (-7) 3 6 9 12 15 18 21
0 (-18) 3 6 9 12 15 18 21
-10 2.5 5 7.5 10 12.5 15 17.5
Mount the pump securely on the drum cover. Failure to
do so could result in personal injury and equipment
damage.
Always install a relief valve in the pump outlet to insure
pump pressure is below 5,000 PSI. Use high pressure
components to reduce risk of serious injury including
fluid injection and splashing in the eyes or on the skin.
Table 1
* Motor controller will shut motor off outside voltage limits.
** Motor will not run unless the red wire is connected to the
positive terminal. It is polarity sensitive.

Page Number - 4 Form 422734
FlowMaster™ Rotary Driven Electric Pump
* A field installed fuse of 5 amps is recommended.
Illustration 2
A - Safety Unloader 272722
B -24 VDC from Controller
C- Outlet Shut-off Valve
D - Material Supply Line
E - Follower Plate (85492 for 120 lb. drum only)
F - Drum Cover (83115 for 400 lbs., 84616 for 120 lbs.)
G - Field Installed Fuse
BACK PRESSURE (PSI) RPM CURRENT DRAW (AMPS)
*
0375 2
1000 350 4.5
2000 325 7.3
3000 300 9.6
4000 280 12
5000 250 15.3
ELECTRIC FLOWMASTER PUMP
24 VDC,5:1 gear ratio,85567 & 85568
Operation
* A field installed fuse of 20 amps is recommended.
Table 2
BACK PRESSURE (PSI) RPM CURRENT DRAW (AMPS)
*
1000 105 2
2000 103 2.75
2500 100 3.2
ELECTRIC FLOWMASTER PUMP
24 VDC,17.8:1,gear ratio,2-stage 85569
Table 3
All pumps are set to run at fill speed. Do not change the
settings for the pump until after the start up procedure.
1. Remove the pump outlet line.
2. With the pump in a full container of lubricant, energize
the pump. Make sure all air has been expelled from the
pump and event lubricant flow is achieved.
3. Reattach the pump outlet line. Never allow the pump to
run dry of lubricant. Monitor the supply lubricant level
and refill when necessary.
Settingthe PumpSpeed
The motor used in the 24 VDC FlowMaster Pump is equipped
with a built-in speed control. THe pump speed is factory set to
the maximum setting. Changing the speed is easily adjusted
in the field as follows:
1. Locate the speed asjustment screw on the pump motor.
It is located under a cover screw 120° away from the
power wires) on the motor body.
2. Using a small flat blade screwdriver turn the screw
counter-clockwise to reduce (clockwise to increase) the
motor speed. The screw has no stops and has a total
travel of 15 turns. The minimum motor speed is 170
RPM. (Divide this speed by the gear ratio to get the pump
speed.
3. The adjustment can be done with the pump stopped or
running. It may be helpful to run the pump with the outlet
line detached to monitor pump outlet as the pump speed
is adjusted. Be sure to bleed the pressure from the
outlet line slowly before removing it.

Page Number - 5
Form 422734
FlowMaster™ Rotary Driven Electric Pump
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.
14.Remove the check seat housing (27) from the
reciprocating tube (20). There is a 3/8 Allen head socket
in the throat of the check seat housing (27) to facilitate
removal.
15.Unscrew the wrist pin anchor (13) from the reciprocating
tube (20) and pull the plunger assembly (8 through 19)
from the tube.
16.Using a 1/2” wooden or plastic rod, push the cup seal
(21) and the pump cylinder (23) from the reciprocating
tube (20).
17.Remove the pump plunger (19) from the plunger link
rod (16). A spanner wrench, which uses the holes in the
pump plunger, is required.
18.Unscrew the plunger link rod (16) from the plunger tube
(10) and slide off the cup seal (15), the backup washer
(14) and the wrist pin anchor (13).
19.Unscrew the plunger tube (10) from the outlet pin (8).
20.To dismantle the crankrod assembly (1 through 7),
remove flat head screws (1) and the counter weights (2).
21.Remove the retaining rings (5) and press the crank
eccentric (6) out of the ball bearing (7). Be sure to
support the ball bearing (7) on the inner race.
Always use Lincoln Industrial parts for service and repair.
Crank Case Oil
Open Housing Cover (30) to check the oil after every 100
hours of operation. The crankcase should be filled to the
center of the pumpshaft. Change the oil after every 500
hours of operation. Use SAE 10W30 motor oil in all units.
Disassembly Procedure (See illustration #6)
Tools Required:
- Hex Bit Socket Wrenches (3/8” square drive) with 3/8” hex,
5/16” 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 electric motor (50) by removing the three jam
nuts (42) and unscrewing the mounting screws (51).
2.Remove the gear box assembly (43, 44 and 47) by
removing the four mounting screws (46).
3.Remove four screws (48 or 67) and remove gearset(s)
and spacer, if applicable.
4.Remove the shaft adapter (41). This part is removed by
pulling it straight out of the pump shaft (37).
5.Remove the pump housing cover (30) and gasket (31).
Drain the crankcase oil from the open housing.
6.Remove the bearing cover (64).
7.Remove the pump shaft snap ring (62).
8.While supporting against the pump shaft seal (40), press
the pump shaft out of the assembly. Be sure to place a
support shim under the crank assembly (1through 7) to
prevent binding while the shaft is pushed out.
9.Remove the two outlet pin nuts (32) from the housing (73).
10.Remove the pump subassembly (1 through 27) from the
pump housing (73). Pushing the subassembly up with a
wooden or plastic rod 3/4 O.D. against the check seat
housing (27) is helpful.
11.Remove the housing tube (56) from the pump housing
(73) by inserting a 3/4” rod through the inlet holes at the
bottom of the housing tube (56) and unscrewing it.
12.Remove the bronze bearing (52), the O-Ring (53) and the
backup washer (54) from the housing tube (56).
13.Remove the crankrod assembly (1 through 7) from the
pump by unscrewing the button head screws (11) and
then pulling out the wrist pin bushings (12).

Page Number - 6 Form 422734
FlowMaster™ Rotary Driven Electric Pump
PumpAssembly Procedure
1. When the pump is dissembled, it is recommended to
replace all seals and gaskets, which are included in the
270663 repair kit. In addition, replace o-rings (44), (36)
and (63).
2. In the process of disassembly, examine the following
components and replace if excessive wear is indicated:
ball bearing (7), crank eccentric (6), crankrod (4), wrist
pin bushings (12), plunger tube (10), pump plunger and
upper check parts (19, 18 and 17), pump cylinder (23),
check seat housing and lower check ball (27 and 25),
upper bronze bushing (52), housing tube (27), shovel
plug (59), and reciprocating tube (20). Also check shaft
seal (40).
3. Assembly Procedure is the reverse of the Disassembly
Procedure except for the following:
4. Install parts (21) through (27) into the reciprocating tube
(20) after the plunger assembly (8 through 19) is
installed.
5. Install the pump subassembly (1 through 27) into the
pump housing (73) before tightening the housing tube
(56) to the pump housing (73). Be sure the reciprocating
tube (20) is inserted through both bushings before
tightening the housing tube (56).
6. When pressing the pump shaft in (item 37), support the
inner race of the rear ball bearing (item 60) and the crank
assembly (items 1 through 7) to insure proper assembly.
7. If replacing the pump shaft ball bearings (items 38 & 60),
support the housing (item 73) inner wall behind the snap
rings (39 & 61) when re-installing the bearing.
8. 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.
9. Torque Specifications:
A. Plunger tube (11) to outlet pin (9) - 100 to 110 In.-Lbs.
B. Button head screws (11) to wrist pin anchor (13) 100
to 110 In.-Lbs.
C. Plunger tube (10) to plunger link rod (16) - 100 to 110
In.-Lbs.
D. Plunger link rod (16) to pump plunger (19) - 100 to
110 In.-Lbs.
E. Flat head screws (1) to counter weight (2) - 100 - 110
In.-Lbs.
F. Wrist pin anchor (13) to reciprocating tube (20) - 20 to
25 Ft.-Lbs.
G. Check seat housing (27) to reciprocating tube (20) -
20 to 25 Ft.-Lbs.
H. Outlet pin nut (32) to pump housing (73) - 30 to 35 Ft.-
Lbs.
I. Housing tube (56) to pump housing (73) - 20 to 25
Ft.-Lbs.
J. Gearbox mounting screws (46) - 20-25 Ft.-Lbs.
K. Gearset mounting screws (48) - 60-70 In.-Lbs.
L. Motor mounting screws and jam nuts (51 & 42) -
100-110 In.-Lbs.
M. Bearing Cover Screws (66) - 32-38 In. Lbs.
10.Fill crankcase with SAE 10W30 motor oil up to the center
of the pump shaft (37) before fastening housing cover
(30) and housing gasket (31). If pump will be used in
very cold environments, use Mobil Arrow HFA Low Tem-
perature Oil. This oil stay fluid even at -70°.

Page Number - 7
Form 422734
FlowMaster™ Rotary Driven Electric Pump
Illustration #3
MODEL DIM "A" in (mm) DIM "B" in (mm
)
85567 27.50 (699) 35.00 (889)
85568 19.00 (483) 26.60 (676)
85569 13.69 (348) 21.25 (540)

Page Number - 8 Form 422734
FlowMaster™ Rotary Driven Electric Pump
Illustration #4

Page Number - 9
Form 422734
FlowMaster™ Rotary Driven Electric Pump
Item No. Qty Description All Models Item No. Qty Description All Models
1 2 FlatHead Screw 36 1 O-Ring 272567
(1/4 x1-3/4) 270635 37 1 Pump Shaft 272548
2 2 Counter Weight 272197 38 1 Ball Bearing 272556
3 2 Retaining Ring 270609 39 1 Retaining Ring 272561
4 1 Crankrod 270665 40 1 ShaftSeal 272554
5 2 Retaining Ring 270608 41 1 AdaptorShaft 272546
6 1 Crank Eccentric 270666 42 3 Nut - 1/4-20 51304
7 1 Ball Bearing 270607 43 2 GearboxHousing 272541
8 1 OutletPin 270670 44 1 O-Ring 272544
9 1 O-Ring (Nitrile) * 45 4 Lock Washer 272566
10 1 Plunger Tube 270667 46 4 Screw 272564
11 2 Button Head Screw 47 1 Gear Set See ChartBelow
(1/4 x1/2) 270634 48 4 Screw 272574
12 2 WristPin Bushing 270668 49 1 Motor Coupler 272709
13 1 WristPin Anchor 270669 50 1 Motor 272545
14 1 Backup Washer * 51 3 Screw 272568
15 1 Cup Seal 52 1 Bronze Bearing 270674
(Polyurethane) * 53 1 O-Ring (Polyrethane) *
16 1 Plunger Link Rod See ChartBelow 54 1 Backup Washer *
17 1 Spring 270616 55 1 O-Ring (Nitrile) *
18 1 Ball 66010 56 1 Housing Tube See ChartBelow
19 1 Pump Plunger 270671 57 1 Bronze Bushing 270637
20 1 Reciprocating Tube See ChartBelow 58 1 Shovel Plug 270707
21 1 Cup Seal 59 1 Retaining Ring 270705
(Polyurethane) * 60 1 Ball Bearing 272555
22 1 O-Ring 61 1 Retaining Ring 272562
(Polyurethane) * 62 1 Retaining Ring 272563
23 1 Pump Cylinder 270672 63 1 O-Ring 272559
24 1 Ball Cage 270675 64 1 Bearing Cover 272549
25 1 Ball 66001 65 4 LockWasher 66051
26 1 O-Ring (Nitrile) * 66 4 Screws 272557
27 1 CheckSeat 270664 67 4 Screws 272552 (for 2
28 6 Self-Threading stage Gear Boxes)
Screw (8 x1/2) 270633 68 1 Gearset See Chart Below
29 6 Gaskets (Screw) 252986 69 1 Gearset Spacer 272541 (Used on 2
30 1 Housing Cover 270629 stage gearboxes only
)
31 1 Cover Gasket 70 4 Lockwasher 272553
(Nitrile) * 71 1 Woodruff Key 272560
32 1 Outlet, Pin-Nut 270619 72 3 Lock Washers 272569
33 4 O-Ring * 73 1 Pump Housing 272540
34 2 Backup Washer * Softparts Kit 270663
35 2 O-Ring *
RepairParts List
(Common to all Models)
RepairParts List
(Non-common items)
* Included in 270663 Soft Parts Kit.
1. Includes Gasket (Item 41) and O-Rings (Item 40).
2. Includes Seal Kit (Item 58).
Item Qty. Description Model Model Mode
l
No. 85569 85567 85568
16 1 Plunger Link Rod 270641 270614 27064
8
20 1 Reciprocating Tube 270642 270617 27064
9
56 1 Housing Tube 270643 270628 27065
0
47 1 Gear Set (Final Stage) 272542 272663 27266
3
68 1 Gear Set (First Stage) 272543 --- ---
3. Includes Seal Kit (Item 59).
4. Includes Seal Kit (Item 60).

Page Number - 10 Form 422734
FlowMaster™ Rotary Driven Electric Pump
Lincoln Industrial
25 International Business Park
#01-68 German Centre
Singapore 609916
([phone]
Lincoln Industrial
One Lincoln Way
St. Louis, MO 63120-1578
([phone]
Lincoln GmbH
69190 Walldorf
Heinrich-Hertz Strasse 2-8
([phone]
© Copyright 2003
Printed in USA
Web site:
www.lincolnindustrial.com
Condition Possible Cause Corrective Action
Pump does notrun. Pump is seized or damaged. Dismantle the pump and repair
defective or seized component. See
disassemblyand assembly
procedure.
IncorrectPolarity Check to ensure red motor lead is
connected to the positive batterytermina
l.
Pump speeds up or runs erratically. Low level of grease or reservoir Refill reservoir.
is empty
Followerplate 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,butoutputis low. Pump speed settoo low. Increase motor speed setting.
Faultyinlet (25,26, 27)or discharge Replace faultycomponents.
check valve (18,19,20).
Weepage from housing cover 30. Cup seal (16) orO-Ring (48) wore out. Checkthe seals and replace if
necessary.
Pump becomes noisy. No crank case oil. Add crank case oil.Remove crankcase
cover (30) from Pump Housing (73).
Oil level should be atthe middle of
the crankshaft (37). Add 10W30 motor
oil until the crankcase is full.
Ifunitis used in cold climates, use
Mobil Arrow HFAHydraulic Oil in
crankcase.
Worn wristpin bushing (13). Check the bushings and replace if
necessary.
Pump dies notbuild pressure. Foreign material holding lower Dismantle & clear check.Consider
checkopen. installing inletscreen 272180
before returning pump to service.
Motor runs, but no pump outlet. Gearset or adapter shaft stripped or Dismantle and replace damaged
broken. part.
Troubleshooting