LUBMANN LFS1 User manual

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Lubmann GmbH
Automatic Lubrication Systems
Lubmann Pressurized Single Line
Lubrication System
Instruction Manual
LFS1/LFS2/LFS3
Lubmann Centralized
Lubrication System

Navigation
System Overview
System Structure and Working Principle
Technical Parameter
Overall Dimensions
Installation Instructions
Lubmann GmbH
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Introduction
Operation of Filling Equipment
System Design/Cautions in Installation/Debugging
Operation of Refilling Equipment
System Maintenance (For Commercial Vehicle)
Fault Analysis and Elimination
Transport and Storage

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Lubmann GmbH
Automatic Lubrication Systems
System Overview
Lubmann Pressurized Single Line series centralized lubrication systems have been widely used in industries like
commercial vehicles, machine tools, construction machinery, Agriculture Machinery, etc.
Grease pump delivers grease alternatively into each lube points through pressurized single line distributors.
Layout of Pressurized Single Line System
Product Function Principle Grease
Thickness till
Metering
Quantity per
Pump Element
ml/Min
Reservoir
Liter
Operating
Max.
Pressure
in bar
Operating
Max.
Pressure
in psi
Power Supply
Max.
Pump
Elements
LFS-1 Gear Pump/Paddle Mode Up to 0 90 1 40 bar 751 12/24 V DC 220V AC 1
LFS-2 Gear Pump/Paddle Mode Up to 0 55 2 63 bar 923 12/24 V DC 220V AC 1
LFS-3 Gear Pump/Spring Mode Up to 0 120 2.8 40 bar 751 12/24 V DC 220V AC 1

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Lubmann GmbH
Automatic Lubrication Systems
LFS Series centralized lubrication system consists of a monitoring unit and a grease supply unit. The monitoring unit
consists of a monitor and sensors, which controls the system through electric circuits. The grease supply unit
composed of a pump module and distributors integrates the lube points of the vehicle into an enclosed system through
tubing accessories.
The system can distribute lubricant to friction pairs automatically at preset times and in a definite quantity so as to
ensure that they can get good lubrication.
System Composition
System Structure and Working Principle
The system is composed of lubrication pump, external/integrated monitor, pressurized single line distributor, sensor
(optional), grease hose and accessories.
Working Principle
Take LFS1 for example. When the pause interval ends, the pump module gets a signal from the monitor, and then the
motor-driven gear pump is activated. The grease is pressurized by the gear pump into the exit. Meanwhile, the pressure
unloading valve is opened, and the pump module pressurizes the mainline. Grease pressurizes mainlines and causes
distributers to dispense preset volumes of grease to lube points. Thereafter, when the exit of pump module has enough
pressure to open overflow valve, redundant grease reflows to the reservoir through the orifice in overflow valve. The
pump module receives the signal from monitor and the gear pump stops. Finally, the pressure unloading valve opens,
grease in mainlines reflows to the reservoir. Then the pressure in mainlines is about 0.05-0.1Mpa.

Lubrication Pump–LFS-1 Serie
Lubmann GmbH
Amtsgericht Duesseldorf HRB 76903 Steuernummer：DE316746274 Bankverbindung: Deutsche Bank IBAN：DE77 3007 0010 0058 6958 00 BIC/Swift: DEUTDEDDXXX
Automatic Lubrication Systems
Product description
The LFS-1 Serie lubrication pump can be used as a
centralized lubrication pump in small-sized pressurized
single line systems. It can drive 1 element. The pump’s
drive and eccentric shaft design, high-efficiency worm
gear, minimal number of parts and multi-range motor
provide several advantages. LFS-1 pumps are available
with a three-phase flange mount and multi-range
motor or with a free shaft end for use with other motors
Various gear ratios and reservoir sizes with or without
level control are offered.
Features and benefits
Durable, versatile and reliable pump series
Designed for continual lubrication of machines
systems operating in harsh environments
Broad range of output options
Modular design and easy maintenance
Applications
Commercial Vehicle
Food Line, Beverage Line
Machine Tool
Technical data
Function principle: electrically operated piston pump
Metering quantity Grease: 90 ml/Min
Outlets: 1
Lubricant: Grease up to NLGI 0
Operating Pressure: 40 bar/751 psi
Operating Temperature: –40 to +70 °C
Protection Class: IP 65
Line Connection: G1/4
Electrical Connection: 12 or 24V DC/220V AC
Dimensions :
Height 248mm
Width 171mm
Depth 171mm
Mounting Position: Vertical
Options: Pressure Sensor
Grease Level Sensor
Main Switch
Refill Coupling
System Structure and Working Principle

Lubmann GmbH
Amtsgericht Duesseldorf HRB 76903 Steuernummer：DE316746274 Bankverbindung: Deutsche Bank IBAN：DE77 3007 0010 0058 6958 00 BIC/Swift: DEUTDEDDXXX
Automatic Lubrication Systems
Product description
The LFS-2 Serie lubrication pump can be used as a
centralized lubrication pump in small-sized pressurized
single line systems. It can drive 1 element. The pump’s
drive and eccentric shaft design, high-efficiency worm
gear, minimal number of parts and multi-range motor
provide several advantages. LFS-2 pumps are available
with a three-phase flange mount and multi-range
motor or with a free shaft end for use with other motors
Various gear ratios and reservoir sizes with or without
level control are offered.
Features and benefits
Durable, versatile and reliable pump series
Designed for continual lubrication of machines
systems operating in harsh environments
Broad range of output options
Modular design and easy maintenance
Applications
Commercial Vehicle
Food Line, Beverage Line
Machine Tool
Technical data
Function principle: electrically operated piston pump
Metering quantity Grease: 55 ml/Min
Outlets: 1
Lubricant: Grease up to NLGI 0
Operating Pressure: 63 bar/923 psi
Operating Temperature: –40 to +70 °C
Protection Class: IP 65
Line Connection: G1/4
Electrical Connection: 12 or 24V DC/220V AC
Dimensions :
Height 290mm
Width 226mm
Depth 198mm
Mounting Position: Vertical
Options: Pressure Sensor
Grease Level Sensor
Main Switch
Refill Coupling
Lubrication Pump–LFS-2 Serie
System Structure and Working Principle

Lubmann GmbH
Amtsgericht Duesseldorf HRB 76903 Steuernummer：DE316746274 Bankverbindung: Deutsche Bank IBAN：DE77 3007 0010 0058 6958 00 BIC/Swift: DEUTDEDDXXX
Automatic Lubrication Systems
Product description
The LFS-3 Serie lubrication pump can be used as a
centralized lubrication pump in small-sized pressurized
single line systems. It can drive 1 element. The pump’s
drive and eccentric shaft design, high-efficiency worm
gear, minimal number of parts and multi-range motor
provide several advantages. LFS-3 pumps are available
with a three-phase flange mount and multi-range
motor or with a free shaft end for use with other motors
Various gear ratios and reservoir sizes with or without
level control are offered.
Features and benefits
Durable, versatile and reliable pump series
Designed for continual lubrication of machines
systems operating in harsh environments
Broad range of output options
Modular design and easy maintenance
Applications
Commercial Vehicle
Food Line, Beverage Line
Machine Tool
Technical data
Function principle: electrically operated piston pump
Metering quantity Grease: 120 ml/Min
Outlets: 1
Lubricant: Grease up to NLGI 0
Operating Pressure: 40 bar/751 psi
Operating Temperature: –40 to +70 °C
Protection Class: IP 65
Line Connection: G1/4
Electrical Connection: 12 or 24V DC/220V AC
Dimensions :
Height 319mm
Width 287mm
Depth 177mm
Mounting Position: Vertical
Options: Pressure Sensor
Grease Level Sensor
Main Switch
Refill Coupling
Lubrication Pump–LFS-1 Serie
System Structure and Working Principle

Lubmann GmbH
Amtsgericht Duesseldorf HRB 76903 Steuernummer：DE316746274 Bankverbindung: Deutsche Bank IBAN：DE77 3007 0010 0058 6958 00 BIC/Swift: DEUTDEDDXXX
Automatic Lubrication Systems
The pressurized single line LRK-SLA type metering device is
a rack type metering device. Its metering sections cover a
metering volume per outlet and cycle of 0,13 ml to 0,40 ml.
According to the needs of the greasing points, the volume
of the outlet fitting can be amounted very easily.
Technical data
Dimensions
Outlets
Max.
Height
(mm)
Depth
(mm)
Width W1
(mm)
Width W2
（mm）
4
87 22
83 96
6121 134
8159 172
10 197 210
12 235 248
14 273 286
16 311 324
18 349 362
20 387 400
Function principle: Rack metering device
Outlets: 4-20
Lubricant: Grease up to NLGI 0
Input Pressure: 63 bar
Displacement: 0.13/0.2/0.4 ml/cy
Working Temperature: –40 to +70 °C
Material: Steel/Copper
Surface treatment (Coating): Zn-Ni plated (free of Cr-VI)
More details for the distributor accessories like
input/output fitting, closure plug and pressure
sensor please check the following pages from x
to x in this catalogue.
Metering Unit –LRK-SLA
System Structure and Working Principle

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Lubmann GmbH
Automatic Lubrication Systems
Monitor （Integrated）
Control Mode：ECU Microcomputer Control
Operating Voltage: 12/24V DC/220V AC
Off Time: 1-30 hours
Operating Mode: Run according to the preset time
Signal Output: Grease Level/Fault(due to pressure)
Monitor （External）
Control Mode：ECU Microcomputer Control
Operating Voltage: 12/24V DC/220V AC
Off Time: 1-30 hours
Operating Mode: Run according to the preset time
Signal Output: Grease Level/Fault(due to pressure)
External/Integrated Monitor
System Structure and Working Principle
AK04/06 monitor displays the real-time data from the system dynamically, such as grease pressure, countdown in the pause
interval, running time, accumulative running cycles and fault code. Moreover, it has the features of overload protection and
fault warning. It is suitable to DC12V and DC24V power supply and installed at drivers' compartment for watching conveniently.
Monitors are also equipped with remote controls in order to repair the system. Pause interface: It tells countdown in the pause
interval and running cycles, which can be stored perpetually. The system’s pause interval has 15 adjustable steps from 6 hours
to 20 hours, and the default setting is 12 hours. Running interface: It tells grease press OFF or ON and running time.
Operation: Take pause interval set at 12 hours for example, after ignition being turned on, the LCD screen counts down
remaining time in the pause interval. If the time reaches 00:00, the monitor initiates the pump to pressurize the mainline, the
screen starts to count the lube time. When the pressure at the end of the mainline is up to 2.6MPa, the pressure sensor
transmits the signal to the monitor immediately, the ON pressure reverts to the OFF one, and the pump operates 60 more
seconds (AK04) until de-energized. Then the monitor counts down to the next lube cycle, and 1 is added to the cycle count.
Fault display: If the monitor doesn’t detect the preset pressure from the mainline, the pump module operates total 120
seconds until de-energized. At this moment, the OFF pressure and the fault code EE-1 occurs on the screen, accompanied by
an alarming signal (buzzer sound). The signal will disappear automatically in 20 seconds. Then please check the system
immediately.

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Lubmann GmbH
Automatic Lubrication Systems
Determination of Lube Points
Determination of the required volumes of grease of lube points
Lube points are the friction fairs lubricated by grease fitting in the machine. Those can rotate 360 degrees or have a
high temperature are excluded.
Generally, the interval time for lubricating is from 4-8 hours. The volume each point required is from 0.1 to 0.4 ml/cy.
Determination of the supply volumes
Q= q1+q2+q3=(1+20%)q1(ml)+c (ml/m)×L(m）
Q- The supply volumes of the system
q1- The sum of the volumes that lube points required
q2- Safe added-value（20%q1）
q3- The loss of the mainline
c- Increasing volume of the mainline per meter from 0.05Mpa to regular working data
L- The length of the mainline
Cautions in Installation
Installing notice of the pump module
Pump module should be installed vertically and firmly in a place where the device is polluted less , convenient
maintenance and easy to observe and operate If conditions permit, a separate door can be set near the pump module.
Installing notice of distributers
Distributors also should be installed in a place where the device is polluted less and convenient to fix, maintain and
observe. A few distributers can be caught together in groups and finally connect to the mainline.
Installing notice of system tubes
1. The mainline usually useΦ10×1.5 nylon tubing whose pressure-proof should above 10MPa and orifice should have
rigid bushing. Moreover, Φ10× 1steel tubing is also available.
2. The distribution lines should be short as much as possible, especially the distribution lines to firmly hermetical lube
points whose length should not be longer than 3 meters. In addition, the distribution lines from exits of distributers to
lube points should not be longer than 3.5 meters. The distribution line use nylon tubing and their both ends must have
rigid bushing.
3. Tubes should be incised vertically in axial direction and avoid squashing, cracking and scratching.
System Design/Cautions in Installation/Debugging

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Lubmann GmbH
Automatic Lubrication Systems
System Design/Cautions in Installation/Debugging
Cautions in Installation
4. The mainline and distribution line should be short as much as possible in order to avoid more bends (when they are
bended, the minimum bending radius of Φ10×1.5 and Φ4×0.75 nylon tubing is R90 and R40). Less bends can decrease
the loss of the pressure and ensure free discharge.
5. The distribution line must be full of grease before installation. The Mainline also must be full of grease in installation
below centigrade 5℃.
6. Tubes must keep clean and have not contaminator.
7. Flexible tubes should be 1% longer than straight length when they are installed on in-line installation.
8. The installation of mainlines and distribution lines should avoid engine, warm air blower and the bends of and steel
spring plates.
9. If the mainline and distribution line use nylon tubing, they should be enclosed by corrugated tubes.
10. Some tubes, which are removable or across holes in the beam, must be protected by tube shroud.
Debugging
When the system are being debugged, terminals of mainlines must keep open (i.e. don’t screw on choke plug and
pressure sensor). Pressing the C key in the remote control will make the pump module work 20 seconds, and then do it
again after the pause for 20 seconds. The discontinuous running can exhaust air from mainlines. Afterwards the
terminals that are bleeding should be blocked by choke plug or connected the pressure sensor.
Press C key in the remote control makes the pump module work. Then press it again after the pump stops for 120
seconds. Repeat it several times until every friction pairs is overflowing.
If some lube points are not overflowing, a manual operated reservoir-fill gun must be full of grease that is also used in
the system to clear the blockage. And then see if the working condition is in accord with requirements.
[Note]: Opening and shutting methods of the reservoir housing
1. Opening method: Pressing the semicircular bulges on both sides of the reservoir cap with both thumbs, and then
propping the earlike parts on both sides of the housing with your bent index finger. Squeezing and then pulling
upward the parts sharply can remove the housing easily. Single-hand operation is also available at your inconvenience.
2. Shutting method: Taking the housing, and making its ear-holes on the both side level at the semicircular bulges on
both sides of the reservoir cap. Then pressing the top of the housing can make the housing and the reservoir cap
locked.

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Lubmann GmbH
Automatic Lubrication Systems
Operation of Refilling Equipment
Operating procedures of grease gun
Thanks for the special transfer coupling for grease gun (manual, pneumatic, electrical), the refilling nozzle of lubrication
pump and grease gun can be easily connected with each other for pump refilling.
Before connecting the grease gun and refilling nozzle of lubrication pump, it is necessary to read the instruction for
pump reservoir refilling again to make sure no air go into the reservoir during the refilling procedure.
Operating procedures of Grease Refilling Device
By high pressure grease transfer unit including high pressure hoses, connectors and pressure relief valve, the refilling
nozzle of lubrication pump and grease refilling devices (manual, pneumatic, electrical)can be easily connected with each
other for pump refilling.
Before connecting the grease refilling devices and refilling nozzle of lubrication pump, it is necessary to read the
instruction for pump reservoir refilling again to make sure no air go into the reservoir during the refilling procedure.
Connector
for Refilling
Device
Connector
for Pump
Pressure
Release
Transfer Coupling
High Pressure Grease
Transfer Unit
Grease Refilling
Device (manual,
pneumatic, electrical)
Nozzle of Lubrication
Pump
Nozzle of Lubrication
Pump
Grease Gun （manual,
pneumatic, electrical）

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Lubmann GmbH
Automatic Lubrication Systems
System Maintenance (For Commercial Vehicle)
The first level service of the vehicle:
1. After ignition being turned on, press C key in the monitor and verify that LCD screen is working correctly.
2. Check if mainlines and distribution lines are leaking or bended and if every lube point can get grease. If there are
lube points in the engine, please check if distribution lines in the engine are ruptured and if each lube point can be
lubricated.
3. Check if pipe bundles are fastened firmly and if wiring harness are connected firmly. Then check if some movable
distribution lines are tied firmly.
4. Clear away the dirt from each part of system and grease dirt leaked from lube points.
5. Check remaining grease in the reservoir and refill the reservoir in time. Note: Some customers say that sometimes
the grease cannot be injected to the reservoir smoothly. The problem is caused by blockage in the gauze filter.
Cleaning or changing the gauze filter will solve the problem. Moreover, it should be noted that the process of filling
the reservoir and storage of grease (grease can) should be in a sanitary condition.
The second level service of the vehicle:
1. To do the all items that should be done in the first level service.
2. Check remaining grease in the reservoir and make sure that the reservoir should be filled to the upper limit in the
second level service.
Cautions:
Centralized lubrication system is controlled by the monitor automatically, so the driver should not perform any
operation but monitor the LCD screen. If adjusting discharge frequencies is necessary, this should be performed by the
maintenance and management department.
Grease recommended for the system is NLGI 0# or NLGI 00# . Storage of grease and the process of filling the reservoir
should be kept clean. Filling the reservoir should not exceed the upper limit and should not be performed on the
condition that the reservoir is empty, which can ensure smooth filling in the second level service.
If some tubes need to be moved or dismounted temporarily from the system in maintenance, the original installation
state must be remembered. After maintenance being accomplished, these tubes must be back to their original state, or
else they will be broken.

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Automatic Lubrication Systems
Fault Analysis and Elimination
Faults Reasons Solution
When the system begins to lubricate, the
motor stops working. The monitor
sounds the alarm in 150 seconds because
it does not detect the preset
pressure from the mainline. At this
time, the OFF pressure and the
fault code EE-1 occurs on the screen
and the “grease Pressure” twinkles.
The monitor is connected mistakenly Connecting as wiring diagram of the
monitor shown
The monitor is damaged Replacing the monitor
Wires of the pump module are broken Connecting the wires properly
The gear pump seizes up Cleaning and repair the gear pump
When the system begins to lubricate, the
motor works. The monitor sounds the
alarm in 150 seconds because it does not
detect the preset pressure from the
mainline. Currently, the OFF pressure and
the fault code EE-1 occurs on the screen
and the Grease Pressure twinkles.
There is air in the inlet port of the gear
pump Shaking the reservoir to expel the air
Mainlines are broken and joints are
loose Overhauling and Replacing
The consistency of grease injected into
reservoir is higher
Changing the grease according to the
instructions
The overflow valve of pump module is
damaged Replacing
Pressure sensor is damage, or the wire
is disconnected Replacing and Repairing
The holes of unloading valve core are
blocked off Removing it and cleaning it with diesel,
otherwise cleaning the reservoir and
changing the grease
The inlet port of gear pump is blocking
Several sealing cups in drainage ports
of distributer are damaged or seized
up
Replacing the related distributor
The monitor is damaged Replacing
The spiracle is blocked Pressurizing air from the reservoir to
the spiracle to clear out the blockage
There is a lack of grease in the
reservoir
Filling the reservoir to prescriptive scale
mark
When the system begins to lubricate, the
motor works. But the ON pressure reverts
to the OFF one takes longer time than
normal.
Mainlines leak Overhauling and connecting the
mainlines
Several sealing cups of drainage ports
of injectors are damaged or seized up Changing corresponding joints
The consistency of grease injected into
reservoir is higher
Changing the grease according to the
instructions

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Lubmann GmbH
Automatic Lubrication Systems
Fault Analysis and Elimination
Faults Reasons Solution
The monitor detect that pressure is normal.
The OFF pressure occurs on the screen, but
there are not time counting in the pause
interval.
The monitor is damaged Replacing the monitor
Pressure unloading valve seizes up and
do not return in order to that it cannot
relieve the pressure
Dismounting the cups, and then
cleaning them with diesel fuel or
changing them
A blue line and a green line in pressure
sensor are short-circuited
Checking wiring harness, finding the
short-circuited points, then separating
the two lines and wrapping up them
respectively with black tape
Grease cannot be delivered to several
friction pairs (grease fitting)
The injectors connected to them are
damaged Cleaning or replacing
The distribution lines connected to
them are broken or blocked (main
cause)
Connecting distribution lines rapidly
with quick change coupler or changing
them
Hard lumps of grease, which is turned
from the grease that had existed in
friction pairs before the machine was
installed, block the friction pairs
Grease gun, which is injected with the
grease that is also used in the system,
is used to clear out grease tubes
LCD screen doesn’t work or works
anomalously
Electromagnetic or static interference Turning off and subsequently turning
on the power
Wires are connected mistakenly or
loose
Checking the wires and connecting it
correctly
The monitor is damaged Replacing
Transport and Storage
Transport
During loading unloading, be careful and avoid upside down.
During loading/unloading and transportation, avoid collision with other items.
Storage
The products should be stored in a ventilated and dry warehouse free from direct sunlight and without corrosive gas
in the air.
Close all open pipelines to prevent dust and impurities from entering.
The products should be packed neatly in the warehouse and ensure the ventilation, meanwhile pay attention to the
logo on the packing box and avoid upside down. The packing box should keep a distance of at least 100mm from the
ground and wall.

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Lubmann GmbH
Automatic Lubrication Systems
Lubmann GmbH
Web: www.lubmann-gmbh.de
Mail: [e-mail]