Oilsafe Lubrication work center User manual

Lubrication Work Center

Owners Manual

IMPORTANT

• Please read this Owners Manual carefully and thoroughly before installing and

operating your Lubrication Work Center.

• Please retain this owners manual for future reference after reading it thoroughly.

Lubrication Work Center

TABLE OF CONTENTS

Explanation of Symbols Used 2

Warnings and Cautions 3

OilSafe Limited Warranty 4

1. Introduction 5

2. Parts and Pre-Installation Checklist 7

3. Static Discharge Grounding Reel 9

4. Installation and Setup 10

5. Installation 11

6. Electrical Installation 20

7. Initial Operation 22

8. Maintenance 29

9. Moving Your System 32

10. Troubleshooting 33

11. Repair and Replacement Procedures 36

12. Replacement Parts 37

13. Tank or Motor Replacement 42

14. Data Tables 43

Customer Service and Warranty Issues 44

FOR YOUR RECORDS

Write the model and serial numbers here:

(You can find them on the Serial/Model No. Plate mounted at

the rear of your system on a lower tank frame rail.)

Serial / Model #:

Supplier Name:

Date Purchased:

READ THIS MANUAL

Inside you will find important information on how

to use and maintain your OilSafe®Lubrication

Work Station.

INTELLECTUAL PROPERTY

OilSafe®is a Registered Trademark of Whitmore.

All Trademarks are the property of their respective owners.

Patents Pending.

Lubrication Work Center

Owners Manual

EXPLANATION OF SYMBOLS USED

This manual contains some common symbols and indications to alert you to specific areas of importance.

WARNING!

A situation that, if not avoided, could result in severe property damage, equipment damage, severe injury,

or even death. FAILURE TO FOLLOW this warning will void your product warranty.

CAUTION!

A situation that, if not avoided, could result in property damage, equipment damage, or injury. FAILURE TO

FOLLOW this caution will void your product warranty.

IMPORTANT:

This text will be used before text that has been designated as important to the proper installation, operation, or

maintenance of your system. FAILURE TO READ and understand this text may result in improper installation, operation,

or maintenance procedures and may void your warranty.

TIP:

This text will be used to highlight text that is helpful in the installation, operation, and maintenance of your system.

NOTE:

This text will be used to highlight text that is important to read in order to fully understand the terms and procedures used

in this manual.

Lubrication Work Center

WARNINGS AND CAUTIONS

The OILSAFE®Lubrication Work Center is designed for the storage of machinery lubricating oils and other NON-VOLATILE fluids. STORAGE OF FLUIDS

WITH A FLASHPOINT BELOW 150°F (65.5°C) IS STRICTLY PROHIBITED.

Components within this system consist of materials that may not be compatible with your fluid. ALWAYS consult your supplier and refer to the fluid

manufacturer’s Material Safety Data Sheet (“MSDS”) before introducing a fluid to this system.

WARNING!

When replacing tanks, a Whitmore employee must be present to participate in, or supervise the removal of tanks on

frames.

ALWAYS ensure the main power supply is first locked out and the system depressurized before any service is

performed on this system. NEVER connect or disconnect lines or change filter elements or undertake any service

work when this system is running or energized. SEVERE INJURY OR DEATH MAY OCCUR.

IMPORTANT:

ALWAYS REFER TO THIS MANUAL OR CONSULT YOUR SUPPLIER FOR MORE INFORMATION.

•ALWAYS ensure that you wear appropriate Personal Protective Equipment (“PPE”) when operating this system.

• ALWAYS ensure that all system hoses, filters and fittings are securely fastened and in good working condition.

• THE TANK ISOLATION VALVES (LOCATED ON THE UNDERSIDE OF EACH TANK) MUST BE IN THE OPEN POSITION WHEN OPERATING THE SYSTEM

AND IN THE CLOSED POSITION WHEN SERVICING THE SYSTEM.

• ALWAYS ensure that the System Pressure Return Hoses (discharging to the upper port on the rear face of each tank) are never restricted or damaged.

• THE BULK TANKS MUST ALWAYS BE VENTED TO ATMOSPHERE (preferably utilizing a Desiccant Air Breather).

• When filling Bulk Tanks from drums or barrels always ensure the grounding cable is connected to the drum or barrel before starting the pump.

• ALWAYS ensure the system is appropriately grounded to earth utilizing the grounding jacks provided at the rear base of the system, together with

relevant grounding equipment as specified and installed by your authorized electrical personnel in accordance with your local and federal regula-

tions and safety procedures.

• Ambient room temperature where the system is installed should be in the range of 60°F (15°C) TO 80°F (26°C) with optimum room temperature being

70°F (21°C). For ambient temperatures below 60°F (15°C) consult the manufacturer or your supplier for the supply of electric blanket heaters for

oil barrels, pails and bulk tanks to ensure stability of lubricant viscosity, condition and system performance. Temperatures less than (<60°F / 15°C)

can result in lubricant viscosity increasing above the rated ISO Code you specified at the time of order. Such adverse viscosity changes can cause

higher system operating pressures than those set at the factory. System operating pressure should never exceed 300 PSI as this can cause a gasket

failure on the spin-on filter resulting in a high pressure oil leak. Normal system operating pressure should be less than 240 PSI. Operating pressures

above 240 PSI will necessitate adjustment of the pump pressure relief bypass valve located on the pump head. Contact the manufacturer for more

information prior to commissioning the system if the ambient room temperature will ever fall below 60°F (15°C).

WARNING!

FAILURE TO FOLLOW System installation, safety and operating instructions may result in SEVERE INJURY OR DEATH, damage to

plant and equipment and void warranties.

CAUTION!

System Operating Pressure should NEVER exceed 300 PSI. Operating pressures can be regulated by

adjusting pump bypass relief valves located on pump heads to suit specific lubricant viscosities and

temperatures.

OILSAFE LIMITED WARRANTY

OilSafe (“OS”) warrants to the original product purchaser (hereinafter the “Customer”) that the OS product for which the

Customer received this warranty was designed, developed and manufactured using all due reasonable commercial care and good manufacturing practices.

OS’ products shall be free from defects in material and workmanship for 365 days from the original date of purchase by Customer. OS’ sole obligation

under this warranty is to repair or replace the product, at OS’ option. OS must be notified by Customer in writing of any claim under this warranty within

30-days of any claimed lack of conformity of the product. THIS WARRANTY IS INTENDED TO BE IN LIEU OF ALL OTHER WARRANTIES, WHETHER EXPRESS

OR IMPLIED. OS SPECIFICALLY DISCLAIMS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

Warranty Limitations:

In no event shall OS be liable for any loss, inconvenience or damage, whether direct, incidental, consequential or otherwise, resulting from breach of any

express or implied warranty or condition, of merchantability, fitness for a particular purpose or otherwise with respect to this product, except as set forth

herein. Some states or countries do not allow limitation on how long an implied warranty lasts so the above limitations or exclusions may not apply to

you. This warranty gives you specific legal rights, and you may also have other rights, which may vary, from location to location. This warranty will be

interpreted pursuant to the laws of the United States and the State of Illinois. The original English language version (meaning) of this warranty controls over

all translations; OS is not responsible for any errors in translation of this warranty and/or any product instructions. This warranty is not intended to confer

any additional legal, jurisdictional or warranty rights to you other than those set forth herein or required by law. If any portion of this warranty is held to

be invalid or unenforceable for any reason, such finding will not invalidate any other provision. For products purchased in countries other than the United

States, please contact OS’ authorized representative (i.e., the ‘company’ or ‘person’ who represented OS or brokered the ‘sale’) in the country where the

product was purchased.

Warranty Service Options:

For service under this warranty you must notify OS in writing. Such notification must specify in writing the product in question by model and serial number,

applicable purchase order number and/or the original of date of your written notification.

You may contact OS as follows:

Telephone: (972) 771-1000

930 Whitmore Drive Fax: (972) 722-3252

Rockwall, TX 75087 USA Email: [email protected]

www.oilsafe.com

Any insurance and/or shipping costs incurred in returning your OS product for service pursuant hereto are your responsibility. OS will not be responsible

for any products lost or damaged in shipment.

Warranty Exclusions:

Representatives and brokers of OS products are not authorized to modify this warranty in any way. It is the Customer’s responsibility to regularly examine

the product to determine the need for normal service or replacement. This warranty does not cover the following:

• Products that have been modified, neglected or poorly maintained, misused, abused or involved in accidents or natural disasters.

• Damage occurring during shipment of the product (such claims must be presented directly to the freight forwarder or shipping company).

• Damage to the product resulting from improper maintenance or repair, the use or installation of parts and/or accessories that are not compatible with

the original intended use of the product, or the failure to follow the product warnings and usage instructions.

• Damage or deterioration to the surface finish, aesthetics or appearance of the product.

• The labor costs required to remove and/or refit and readjust the product covered by this warranty.

• Normal wear and tear to the product.

• Filter Cartridges, Desiccant Air Breathers, Level Gauges and other consumable items.

• Service Trips to Customer’s location to teach Customer how to use the product.

• Defects that result from improper installation or damage not cause by OS.

Lubrication Work Center

1. INTRODUCTION

Thank you for purchasing an OilSafe®Lubrication Work Center. This System was designed to store and dispense bulk lubricants in the workplace.

The system was designed with quality in mind and is fully modular. The interchangeable series of tanks, frames, pumps, filters, and storage modules have

been customized for your application. The installation, operation, and maintenance instructions in this document will provide you with all the information

you will need for the lifetime of your system.

The system was specially configured per your specification. It features up to four standard tank sizes mixed and matched to your specifications, and color-

coding to prevent cross-contamination and misapplication of fluids. Your system was designed to store and dispense lubricants up to ISO 680 (if specified

at the time of order).

Throughout this document, we will be referring to each section of the system as a “Pod.” The section which includes the tanks and motors will be called

the “Tank Pod” or “Pod-1” and the section which includes the Dispensing Faucets and the electrical power enclosure will be called the “Dispensing Pod”

or “Pod-2.”

Each Tank Pod can contain many different varieties of tanks including:

• One - 240 gallon tank

• Two - 120 gallon tanks

• Four - 65 gallon tanks (configuration shown in this manual)

• Eight - 30 gallon tanks

• Any combination of these tanks can be configured for your system as

desired and any number of Pods can be purchased to accommodate the

total number of tanks required to meet your applications.

Each Dispensing Pod can contain up to six (6) Dispensing Faucets and four (4) Dispensing Reels. If a Tank Pod

includes more than six (6) tanks, two (2) Dispensing Pods will be included with your system.

See Figure 1 and Figure 2 on page 6.

Please make sure operating valves are in “Recirculation” positions before start-up and at shut-down of units. This

provides the lowest amp draw and system pressure, ensuring the safest conditions for operators during start-up

and shut down of the unit.

FIGURE 1: Tank Pod (Pod-1)

FIGURE 2: Dispensing Pod (Pod-2)

Lubrication Work Center

2. PARTS AND PRE-INSTALLATION CHECK LIST

IMPORTANT:

CHECK packaging list to ensure you have all applicable parts before continuing. CONTACT YOUR SUPPLIER if it appears that

any parts are missing or damaged. Refer to the specification sheet for your customized system for detailed system informa-

tion including electrical requirements, and total weight of system.

Each system section is referred to as a “Pod” in this manual. Check that you have received the appropriate number of Pods for your order. OilSafe has

completed the assembly for each individual Pod. The only installation and assembly required after delivery is the placing of the Pods, and connecting the

Pods together.

Each Bulk Tank has its own piping system designed to keep fluids segregated.

NOTE: For this manual, the Tank Pod/s will each be shown with four 65 gallon Bulk Tanks.

4Bulk Tank (240, 120, 65, or 30 gallon tank,

color-coded per order specifications, pre-installed)

4Motor/Pump (pre-installed)

4Dispensing Faucet (standard style comes with color-coded

ball knob, fire upgrade comes as a brass valve)

4Spin-on Filter

4Fluid Level Gauge

4Desiccant Air Breather Air Filter

4Suction Hose Assembly

4System Pressure Gauge

4Isolation Valve (located on underside of tank)

FIGURE 3: Pod Designations

POD-1:–

Tank Pod

POD-2:

Dispensing Pod

Bulk Tank System Checklist

Optional Equipment

4Fluid Level Gauge Overfill Alarm 4Spill Pan Connector Kit - Part# SP-CK-(# of pods to be connected)

FIGURE 4: Using the Cabinet Handles

Additional Features

Cabinet Handles

Your system includes additional features for the security and storage of your bulk fluids and other items. The cabinets are secured using a twist and

pull type of handle which works as shown in Figure 4. The cabinet handles may or may not include a locking mechanism depending on your specific

customization.

Pull the Handle Away Twist the Handle Pull the Cabinet Open

Lubrication Work Center

3. STATIC DISCHARGE GROUNDING REEL

Static Discharge Grounding Reels are used to ground static charges on service equipment during the transfer of combustible fuel and other flammable

liquids. The Static Discharge Grounding Reels supplied with your OilSafe®System are spring operated automatic retrieve reels containing standard steel

aircraft cable.

The reel is compact in design, for convenient mounting to your OilSafe®tank frame and provides a light, constant spring tension on the grounding cable,

keeping the cable from becoming tangled.

The reels are constructed of steel and are equipped with a 100-ampere ground clamp and rubber covered bumper. An instant-acting lock and release

provides operator convenience.

IMPORTANT:

CARE MUST BE TAKEN when reeling the cable back onto the reel. DO NOT let go of the cable – walk it back towards the

reel, keeping tension on the cable at all times.

The cable stop assembly may be adjusted to any position. The mechanical locking device works positively at all times and in any position, regard-

less of the cable retraction speed. The lock engages at the desired position by pulling the cable approximately ½". The lock release knob completely

disengages the lock to constant tension. Care should be taken to mount the reel on the front face of the OilSafe®tank frame where threaded holes have

been provided.

For instructions on use, see page 24.

FIGURE 5: Static Discharge Grounding Reel

4. INSTALLATION AND SETUP

Tools, Materials, and Personnel Requirements:

• A minimum of two people are recommended to complete this install.

• Electrical hook-ups and installation should be completed by your authorized electrical personnel in accordance with all local and federal laws and

regulations.

• A hand pallet truck is required to move each Pod into position.

• 1 - 1/2” wrench for connecting spill pallets.

• 3/4" wrench for system leveling/jacking bolts.

• 2 - 3/8" wrench to tighten Fluid Level Gauge.

• Spin-on filter wrench.

• Personal Protective Equipment (“PPE”) should be worn when installing and operating this system.

Determine Placement:

1. The system should be installed indoors on a flat, level surface with sufficient load-bearing capacity to support the total system weight. See Table 5

on page 43.

2. Each mains supply electrical enclosure and each motor requires a separate power outlet. See your specification sheet (or system supply quotation)

for electrical requirement details. Give consideration to whether more than one pump could be running at the same time, in which case it is recom-

mended that each power outlet be wired with independent circuits. CONSULT WITH AN AUTHORIZED AND TRAINED ELECTRICIAN.

3. BEFORE beginning installation, determine where your system will be installed and ensure sufficient power outlets have been installed at the rear of

the system, positioned behind where the motors will be located. Each power outlet should be equally spaced along the wall and be placed approxi-

mately 12" up from floor level.

IMPORTANT:

• It is important to note the effect of the ambient temperature in which the system is placed for operation. System room

temperature should be in the range of 60°F (15°C) TO 80°F (26°C) with optimum room temperature being 70°F (21°C).

For ambient temperatures below 60°F (15°C) consult the manufacturer or your supplier for the supply of electric

blanket heaters for oil barrels, pails and bulk tanks to ensure stability of lubricant viscosity, condition and system

performance.

• Temperatures less than (<60°F / 15°C) can result in lubricant viscosity increasing above the rated ISO Code you speci-

fied at the time of order. Such adverse viscosity changes can cause higher system operating pressures than those set

at the factory.

• System operating pressure should never exceed 300 PSI as this can cause a gasket failure on the spin-on filter result-

ing in a high pressure oil leak. Normal system operating pressure should be less than 240 PSI. Operating pressures

above 240 PSI will necessitate adjustment of the pump pressure relief bypass valve located on the pump head.

• Contact the manufacturer for more information prior to commissioning the system if the ambient room temperature will

ever fall below 60°F (15°C).

Lubrication Work Center

5. INSTALLATION

CAUTION!

Personal Protective Equipment (“PPE”) should be worn when installing and operating this system.

System Operating Pressure should NEVER exceed 300 PSI. System operating pressures can be regulated

by adjusting pump bypass relief valves located on pump heads to suit specific lubricant viscosities and

temperatures.

System SHOULD NOT be operated in a location with an ambient room temperature less than 60°F/15°C

Contact the manufacturer for more information relating to service in cold environments.

STEP 1. The system is delivered pre-assembled, packaged, and marked “Pod-1”, “Pod-2” etc. depending on the specific customized system. This will

indicate the respective Pod’s position within the system from left to right, when viewed from the front.

STEP 2. Locate Pod-1 and remove and appropriately dispose of the freight packaging.

STEP 3. Using a suitable hand pallet truck, position Pod-1 into its service position, ensuring that there is at least 36" of free clear space at the rear and

18" either end of the system. This will enable personnel to access the system for service work. See Figure 6.

FIGURE 6: Minimum Clearance Requirements

5. INSTALLATION

STEP 4. Using a level and the provided jacking bolts in the base frame, adjust the Pod until it is level from front to back, side to side, and top to bottom.

Check to ensure it is square to any adjacent rear or side walls.

STEP 5. Locate Pod-2 and remove and appropriately dispose of the freight packaging.

STEP 6. Using a suitable hand pallet truck, position Pod-2 to the right of Pod-1 so that the spill transport pallets are square and flush next to one another.

See Figure 7 and Figure 8.

STEP 7. Using a level and the provided jacking bolts in the base frame, adjust the Pod until it is level from front to back, side to side, and top to bottom,

and square with the adjacent Pod.

CAUTION!

ALWAYS keep hands and feet clear of mating and moving parts when moving the Pods into position.

FIGURE 7: Pod-2 Placement FIGURE 8: Final Pod Positioning

Lubrication Work Center

Optional Equipment - New Product! Spill Containment Connector Kit

OilSafe®Bulk Systems are now configured to allow the containment pans to be connected at the back of each frame simply by ordering an optional

Spill Containment Connector Kit. The kit can be installed in a few minutes and is easily disconnected if it becomes necessary to move frames.

See Figure 9.

5. INSTALLATION

SPILL CONTAINMENT CONNECTOR KIT PART # ’S

2 - Pod Connector Kit SP-CK-2

3 - Pod Connector Kit SP-CK-3

4 - Pod Connector Kit SP-CK-4

5 - Pod Connector Kit SP-CK-5

6 - Pod Connector Kit SP-CK-6

7 - Pod Connector Kit SP-CK-7

8 - Pod Connector Kit SP-CK-8

9 - Pod Connector Kit SP-CK-9

10 - Pod Connector Kit SP-CK-10

If connecting more than 10 pods, please affix the appropriate

number of pods at the end of the Part#.

FIGURE 9: Spill Containment Connector Kit

Hoses

STEP 8. Proceed to the rear of the Dispensing Pod and locate the hydraulic hoses that are connected to the system pressure gauges. There is one hose

for each gauge.

NOTE: Each hose will be labeled at the open end to correspond to its related Bulk Tank.

STEP 9. Carefully feed the open end of the pressure gauge hose through the lower side wall of the relevant adjoining Tank Pod. See Figure 10

STEP 10. Connect the pressure gauge hose to the filter head on the Spin-on Filter assembly for the corresponding Bulk Tank. See Figure 11.

5. INSTALLATION

FIGURE 10: Pressure Gauge Hose

(Rear View of System)

FIGURE 11: Attach Pressure Gauge Hose

(Rear View of System)

Lubrication Work Center

STEP 11. Tighten the hose connection fitting securely.

TIP: Start with the hose closest to the adjoining Tank Pod, and thread the hose through the shortest available path.

Follow this process with all pressure gauge hoses.

STEP 12. Repeat Steps 9 – 11 for each Pressure Hose.

NOTE: For systems that have electronic filter gauges rather than hydraulic, have your authorized electrician run the

relevant wiring from the rear of the Dispensing Pod to the relevant tank filter head.

STEP 13. At the rear of the Dispensing Pod, locate the dispensing hoses that are connected to the Dispensing Faucets. There is one (1) hose for

each faucet.

NOTE: Each hose will be labeled at the open end to correspond to its related Bulk Tank.

STEP 14. Carefully feed the open end of the dispensing hose through the lower open side wall of the relevant adjoining Tank Pod. See Figure 12.

STEP 15. Connect the Dispensing Hose coming from the faucet to the threaded discharge port of the corresponding 3-way diverter operating valve

at the front of the Tank Pod for the relevant Bulk Tank. See Figure 13.

STEP 16. Tighten the hose connection fitting securely.

TIP: Start with the hose closest to the adjoining Tank Pod, and thread the hose through the shortest available path.

Follow this process with all Dispensing Hoses.

STEP 17. Repeat Steps 13 – 16 for each Dispensing Hose.

5. INSTALLATION

FIGURE 12: Dispensing Hoses

FIGURE 13: Attach Dispensing Hose (Rear View of System)

FIGURE 14: Install Fluid Level Gauge

5. INSTALLATION

STEP 18. Installing the Fluid Level Gauges See Figure 14 and Figure 15 for details.

a. Unscrew and remove the red locking nut.

b. Remove the calibration.

c. Gently pull up the red indicator.

d. Carefully insert the float assembly into the tank.

e. Screw the aluminum bushing into the tank port until tight and ensure the arrow on the flat side of the hex bushing is pointing

toward the rear of the tank.

f. Gently lower red indicator to its resting position and then gently raise and lower it to ensure the float mechanism is free and

clear inside the tank.

g. Reinstall the calibration.

h. Fasten the red locking nut (as illustrated).

Lubrication Work Center

STEP 19. If this is an initial installation, and you ordered your bulk system with an overfill alarm, proceed to STEP 13.

STEP 20. To install the alarm on an existing gauge, first install the magnet (provided) on your gauge. (If you ordered the alarm with a gauge,

the magnetized indicator will already be installed, skip to STEP 13.) See Figure 15 for Alarm details.

STEP 21. Remove the red locking nut that holds the top of the gauge in place. After you remove the nut, you will be able to remove the calibration (the

plastic tube that shows your tank level) and you should have access to the red indicator. Pull the indicator off by pulling gently upward.

STEP 22. Make a mark on the indicator rod ½" from the top. Take the small metal clip (provided) and push it onto the rod down to the mark. Then push

the magnet onto the same rod until it is sitting flush on top of the small metal clip (you may have to file off any burrs on the end of the rod in

order to fit the magnet onto the rod.)

STEP 23. Once the clip is installed with the magnet on top of it, you will then reinstall your red indicator. Be sure to use the new red indicator provided

with the alarm, and discard the old indicator.

STEP 24. Install the 9-volt lithium battery into the alarm box.

STEP 25. Loosen the set screw located on the aluminum ring of your alarm. Slide the ring over the calibration down to the center line level where you

wish the alarm to activate and tighten the set screw to hold the alarm in place.

STEP 26. The switch located on the alarm can be used to silence the audible alarm (where fitted) after it goes off. It will automatically reset to re-alarm

when the magnet moves back out of the alarm area. The switch can also be used to test the battery. Toggle it once to activate it and once more

to reset it.

IMPORTANT:

• The Switch is a toggle switch. It is meant to be moved left and right. DO NOT push down on the toggle switch.

5. INSTALLATION

NOTE: For systems that have overfill alarms, follow STEPS 11 - 14 to install your overfill alarm. If you purchase an

overfill alarm at a later date, these instructions will allow you to install the overfill alarm at that time.

FIGURE 15: Overfill Alarm

5. INSTALLATION

Installing the Desiccant Air Breather (See Figure 16 for details)

STEP 27. Install the Desiccant Air Breather air filter to each tank by screwing it (clockwise) into the threaded opening on the top right of the Bulk Tank.