Roughneck 27893 User manual

Thank you very much for choosing a Roughneck™ Product! For future reference, please
complete the owner’s record below:
Model: _______________ Purchase Date: _______________
Save the receipt, warranty and these instructions. It is important that you read the entire manual
to become familiar with this product before you begin using it.
This machine is designed for certain applications only. The distributor cannot be responsible for
issues arising from modification. We strongly recommend this machine is not modified and/or
used for any application other than that for which it was designed. If you have any questions
relative to a particular application, DO NOT use the machine until you have first contacted
distributor to determine if it can or should be performed on the product.
For technical questions, please call 1-800-222-5381.
WARNING
Read carefully and understand all INSTRUCTIONS before operating. Failure to follow the
safety rules and other basic safety precautions may result in serious personal injury.
Save these instructions in a safe place and on hand so that they can be read when required.
Keep these instructions to assist in future servicing.
INTENDED USE
This digital control valve is designed pump greases only.
TECHNICAL SPECIFICATIONS
GENERAL SAFETY REGULATIONS
WARNING: Read and understand all instructions.
WARNING: The warnings, cautions, and instructions discussed in this instruction
manual cannot cover all possible conditions or situations that could occur. It must be under-
stood by the operator that common sense and caution are factors that cannot be built into this
product, but must be supplied by the operator.
1. Keep the work area clean and dry. Damp or wet work areas can result in injury.
2. Keep children away from work area. Do not allow children to handle this product.
3. Store idle equipment. When not in use, tools and equipment should be stored in a dry location
to inhibit rust. Always lock up tools and equipment, and keep out of reach of children.
4.
Use the right tool for the job. Do not attempt to force small equipment to do the work of larger
industrial equipment. There are certain applications for which this pump was designed. It will
do the job better and more safely at the capacity for which it was intended. Do not modify this
pump, and do not use this pump for a purpose for which it was not intended.
5. Check for damaged parts. Before using this product, carefully check that it will operate
properly and perform its intended function. Check for damaged parts and any other conditions
that may affect the operation of this product. Replace damaged or worn parts immediately.
6. Do not overreach. Keep proper footing and balance at all times to prevent tripping, falling,back
injury, etc.
DIGITAL GREASE CONTROL VALVE
OWNER’S MANUAL
DIGITAL GREASE CONTROL VALVE OWNER’S MANUAL
WARNING: Read carefully and understand all
INSTRUCTIONS before operating. Failure to
follow the safety rules and other basic safety
precautions may result in serious personal injury.
Item# 27893
1 of 9
Model
Inlet connection
Max. working pressure
Precision
Power source
27893
1/4in.
8700 PSI
±2%
2*AA (1.5V) batteries

4. FIRE AND EXPLOSION HAZARD: Improper grounding, poor ventilation, open flames or sparks
can cause a hazardous condition and result in a fire or explosion and serious injury.
• Ground the equipment and the object being dispensed to
• If there is any static sparking or you feel an electric shock while using this equipment, stop
dispensing immediately. Do not use the equipment until the grounding or any other problem
is identified and solved.
• Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the
fluid being dispensed.
• Keep the dispensing area free of debris, including solvent, rags, and gasoline.
• Do not smoke in the dispensing area.
5. TOXIC FLUID HAZARD: Hazardous fluid or toxic fumes can cause serious injury or death if
splashed in the eyes or on the skin, inhaled, or swallowed.
• Know the specific hazards of the fluid you are using.
• Store hazardous fluid in an approved container. Dispose of the hazardous fluid according
to all local, state and national guidelines.
• Always wear protective eyewear, gloves, clothing and respirator as recommended by the
fluid and solvent manufacturer.
INSTALLATION
Typical installation refers to Fig.1.
1. Check valve
2. Filter
3. Pressure regulator
4. Lubricator
5. Control valve
6. Drum cover
7. Plate
8. Grease pump
NOTE: The above typical installation is only for reference. It may
be different from your actual system design.
Fig 1 Typical installation
1. PRE-INSTALLATION PROCESS
WARNING: To reduce the risk of serious injury, the pressure release should be concerned.
Please follow the Pressure Relief Procedure in OPERATION INSTRUCTIONS section for the
release process.
(1) Turn off the air check valve 1 as shown in Fig. 1.
(2)
Effective grounding to grease supply system. Do not use an insulation material to the ground.
The grounding is a very important part to maintain the security system. Follow the instructions
below for effective grounding.
WARNING: To reduce the risk of static sparking, effectively ground all of this equipment.
• Control valve: Use proper grounding wire to connect it to the pump. Always keep the metal
part of the control valve connected with the grounding equipment.
•
Air and fluid hoses: Make sure they are effectively grounded.
•
Air compressor: Follow the manufacturer's instruction to ground it.
•
Grease barrel: Use a barrel that meets the local standard and ground it properly. A metal
barrel can be put directly on a surface of an electrical conductor which is well grounded.
•
Staying grounded during the working and grease release process: Make sure that the metal
units are effectively grounded before operating the control valve.
DIGITAL GREASE CONTROL VALVE OWNER’S MANUAL DIGITAL GREASE CONTROL VALVE OWNER’S MANUAL
7. DO NOT use the equipment when tired or under the influence of drugs, alcohol, or medication.
A moment of inattention while operating this equipment may result in serious personal injury.
8. Industrial applications must follow OSHA requirements.
SPECIFIC OPERATION WARNINGS
WARNING:
To prevent personal injury, perform Pressure Relief Procedure before and
after operating the control valve and before performing any disassembly or assembly.
WARNING: No complying with below requests will result in severely harm to your
body even death.
1. EQUIPMENT MISUSE HAZARD: Equipment misuse can cause the equipment to rupture or
malfunction and result in serious injury.
• Only trained or authorized people should operate this equipment.
• Read all instruction manuals, tags, and labels before you operate this equipment.
• Use the equipment only for its intended purpose. If you are not sure, call the distributor.
• Do not modify this equipment. If you need to replace the parts, use the standard parts or
components.
• Check equipment daily. Repair or replace worn or damaged parts immediately.
• Do not exceed the maximum working pressure of the lowest rated system component. This
equipment has an 8700 PSI maximum working pressure.
• Check equipment daily. Repair or replace worn or damaged parts immediately.
• Make sure all application comply with local, state, and national fire, electrical, and safety
regulations.
• Do not use a low pressure flexible extension on a high pressure dispensing valve.
• Wear heat-resistant gloves when using the control valve.
• Do not move or lift the equipment when the control valve is in use.
• Do not attempt to force lubricant into a fitting.
•
The operation environment must be fireproof, safety electric use and other security a sured.
2. SKIN INJECTION HAZARD: Fluid from the dispensing valve, leaks, or ruptured components
can splash into your body, eyes or skin, which may cause extremely serious injury. If this
happens, ask for medical help immediately.
• Do not point the dispensing valve at anyone or at any part of the body.
• Do not stop or deflect leaks with your hand, body, glove or rag.
• Do not use grease that has been polluted.
• Use only extensions and no-drip tips that are designed for use with your dispensing valve.
• Follow the Pressure Relief Procedure in the OPERATION INSTRUCTIONS section if the
grease fitting coupler clogs and before you clean or service this equipment.
• Before each use, make sure that all connections are properly installed.
• Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
Do not repair high-pressure couplings; you must replace the entire hose.
3.
MOVING PARTS HAZARD: Moving parts, such as the air motor piston, can pinch or amputate
your fingers.
• Keep clear of all moving parts when you start or operate the control valve.
• Before you service this equipment, follow the Pressure Relief Procedure in OPERATION
INSTRUCTIONS section to prevent the equipment from starting unexpectedly.
• Before operating the control valve, make sure no moving parts of your system is exposed outside.
• Never operate the control valve with the identification plate removed. This plate protects
your fingers from pinching or amputation by moving parts.
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DIGITAL GREASE CONTROL VALVE OWNER’S MANUAL DIGITAL GREASE CONTROL VALVE OWNER’S MANUAL
2. INSTALLATION PROCESS
WARNING: To reduce the risk of serious injury, the pressure relief should be done very
carefully. Follow the PRESSURE RELIEF PROCEDURE in OPERATION INSTRUCTIONS
section.
WARNING: Make sure the whole system is clean before installing/ replacing a new
control valve. No impurities or contaminant are allowed to enter the control valve.
(1) Installing the new grease control valves
Follow the following steps to clean the grease supplying system before a new control valve is
installed. (The system also needs cleaning when the grease in the system is polluted).
①. Turn off the check valve before each dispensing point in the system.
②. Turn off the check valve close to the grease pump outlet.
③. Turn off the check valve in the air line. Lower the air inlet pressure, and then open the air line
check valve again, so that the grease pump is ready to work.
④. Slowly open the check valves close to the grease pump
outlet and then the check valve to the dispensing point
to drain the grease to a waste tank.
⑤.
If there are several dispensing points, you need to drain the
grease at each point, one by one
, starting with the furthest
one from the pump, and ending with the nearest one to the
pump.
⑥. When installing a new control valve, first apply appropriate
sealing glue around the male thread of grease supplying
system, then connect the male thread into the female thread
of grease inlet of the control valve, and fix them together.
⑦. Turn on all check valves of grease system.
⑧. Press the trigger to drain enough grease to make sure the grease system is completely
cleaned. See “OPERATION INSTRUCTIONS” section for the control valve operation.
⑨. Repeat steps ⑥to ⑧for other grease control valves to be installed at each dispensing point
in the system.
(2) Replacing grease control valve
①. Disconnect and take the grease control valve off the system.
②. Follow the steps ⑥to ⑨in “(1) Installing the new grease control valve" section above.
OPERATION INSTRUCTIONS
1. PRESSURE RELIEF PROCEDURE
WARNING: Skin injection hazard: The equipment stays pressurized until pressure is
manually relieved. To reduce the risk of serious injury from pressurized fluid, fluid from the valve
or splashing fluid, follow this procedure whenever you:
• Are instructed to relieve pressure
• Stop dispensing
• Check, clean or service any system equipment
• Install or clean dispensing devices
(1) Pressure relief procedure
①. Close the pump air regulator and the bleed-type master air valve.
②. Hold a metal part of the dispensing valve firmly to a grounded metal waste container and
trigger the valve to relieve the fluid pressure.
③. Open the air line valve and grease line valve.
④. Close the control valve after the pressure is relieved.
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(2) Clean the obstruction in the grease system, when any of the following cases occurs:
①. Problem on control valve, flexible hose, rigid tube or manual/auto tip.
②. Pressure can not be relieved enough after above procedures are done.
③. It takes more than 5 seconds to relieve the pressure thoroughly.
2. LCD DISPLAY
INDICATIONS: See the following displaying illustration
of the LCD panel.
①. Partial register (4 figures with moving comma from
0.1 to 999.9): Measurement exceeds the maximum
value will become zero and re-measure.
②. Battery condition (Low-power alarm device is built in.)
③. Model identification
④. Indication of resettable total or total register
⑤. Resettable total or total register (Total register can
not reset; 7 figures with moving comma from 1 to 99999.9)
⑥. Indication of flow rate mode
⑦. Indication of unit of measurement of partial (oz, g)
⑧. Indication of unit of measurement of total (Ib, kg)
3. OPERATIONAL FUNCTIONS
The control valve features two keys (MENU and RESET).
(1) Setting measurement unit
①. Press “MENU” and “RESET” simultaneously and hold for about 5 seconds to enter the unit set mode.
②. Press "RESET" to select the unit.
③. When desired measurement unit is displayed, press “MENU” and hold about 1 second or the
digit stops blink to quit the setting mode.
(2) Resetting the present total
Press "RESET", full-screen shows. After about 1 second, the display shows “0.0”.
(3) Displaying current correction factor and general total
Press “MENU” and “RESET” simultaneously and hold for 2 seconds. The display shows the
correction factor and total value.
4. CALIBRATION PROCEDURE
(1) Procedure for entering the correction factor directly
①. Wait for the control valve to go to standby.
②. Press the “MENU” key. Keep it pressed until the digit flashes in Zone ①. Press the “RESET”
key to choose the right digit from 0 to 9. Press the “MENU” key to go the next digit so that the
Actual Value can be input.
③. Make sure the correction factor is right and then press the “MENU” key. Keep it pressed until
calibration is finished and the factor is saved. The control valve will then return to standby.
(2) Modify the correction factor in field
①. Press the “RESET” for 1 second, Zone ①displays “0.00”.
②. Start dispensing into a container whose weight is known.
③. Stop dispensing when over two-thirds of volume is reached, weigh the container for gross
weight and minus the tare weight of the container to get the net weight. The weight that is
displayed on the LCD is the Display Value, not the Actual Value. The net weight of the grease
is the Actual Value.
④. Press the “MENU” key. Keep it pressed until the digit flashes in Zone ①. Then press the
RESET key to choose the right digit from 0 to 9. Press the “MENU” key to go the next digit so
that the Actual Value can be input.
⑤. Make sure the Actual Value is input right and then press the “MENU” key. Keep it pressed until
calibration is finished and the factor is saved. The meter will then return to standby.
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1 Grease inlet
2 Trigger
3 Adjustable bolts
4 Grease outlet
Fig. 2 Grease Control Valve
Fig. 3 LCD panel displays region

DIGITAL GREASE CONTROL VALVE OWNER’S MANUAL
5 OPERATION
WARNING: Follow the instructions in PRESSURE RELIEF PROCEDURE before each
operation.
WARNING: To reduce the chance of serious bodily injury, NEVER work with pressure
more than the maximum working pressure 8700 PSI.
①. Grab the trigger (refer to part# 2 shown in Fig. 2) gently, then the control valve starts to work.
②. Release the trigger, the control valve stops working.
Adjustment of flow rate
①. Loosen the Adjustable nut (part #3 shown in Fig. 2), the free flow will be increased.
②. Tighten the Adjustable nut (part #3 shown in Fig. 2), the free flow will be decreased until there
is no output.
6. BATTERY REPLACEMENT
If Voltage is below 2.6V, low-power alarm device will be activated and twinkle shows in Zone ②.
When the LCD panel displays nothing or twinkle shows in Zone ②, the battery should be replaced.
Follow the steps below to replace new batteries.
①. Open the battery cover with a flat screwdriver.
②.
Remove the old two batteries. Discard the batteries in accordance with local laws and ordinances.
③. Insert two AA batteries into the battery compartment. Install the batteries according to the
direction of polarity “+” & “-” indicated and insert the end of anode “+” first.
④. Place back the battery cover.
7. DISASSEMBLING/ ASSEMBLING
(1) Disassembling
•
Disassembling of grease outlet
①. Remove the grease coupler (part# 3) from the control valve.
②. Remove the Rigid tube (part# 4).
③. Discharge the Outlet valve body (part# 5).
• Disassembling of trigger
①. Remove the Adjust knob (part# 19).
②. Remove the hex nut (part# 20).
③. Remove the two hex bolts (part# 27).
④. Remove the trigger (part# 17) and tapered spring (part# 18).
• Disassembling of circuit board
①. Remove the 4 pieces of hex bolt (part# 27).
②. Remove the Top cover 2 and Lens (part# 8).
③. Remove the three screws (part# 12) from the board
WARNING: Take care and do not break the wires on the circuit board.
(2) Assembling
Do the opposite steps of the disassembling to re-assemble the control valve. Test the flow rate
before using it.
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PROBLEM
Grease leakage from trigger
Grease leakage from bottom
Grease leakage from the upper
Trigger fails
No displaying
Precision doesn’t reach up
to +/-2%
Flow rate reduced or no flow
Normal flow rate but no
measurement
Grease keep dispensing
after releasing the trigger
Damage of shaft (part# 22) or
steel ball (part# 30)
Loose connection of bottom
Sealing ring (part# 25) is worn
Trigger is loose
Battery is out of charge
Precision is not properly
adjusted
Air mixed into the grease
Grease clotted
Improper installation of oval
gears (part# 6)
Circuit board fails
Trigger is out of place
Steel ball is out of place
Replace shaft or steel ball
Re-tighten it
Replace the sealing ring
Tighten adjust knob (part# 19) to
squeeze the trigger
Replace a new trigger
Replace the battery
Refer to CALIBRATION PROCEDURE
above to re-set the correction factor
Adjust the working position of pump
Refer to Cleaning the chamber of
control valve below to clean the gear
and chamber
Re-install
Replace the circuit board
Adjust the trigger
Re-install it
POSSIBLE CAUSE CORRECTIVE ACTION
DIGITAL GREASE CONTROL VALVE OWNER’S MANUAL
TROUBLE SHOOTING
WARNING: Relieve pressure before you check or service any system equipment.
MAINTAINANCE
All the parts should be checked as per the following steps to be disassembled. Never use products
that are worn or damaged.
See the exploded parts list chart to check every corresponding spare parts numbers.
Cleaning the chamber of control valve
When the control valve been shelved for a longer period of time or the grease output is very small,
the body chamber of control valve should be cleaned.
①. Use an inner hexagon wrench to unfasten the 8 inner
hexagon bolts (part# 23) from the valve body (part# 1),
see Fig. 4.
②. Remove the front cover (part# 7) and the seal mat
(part# 25).
③. Take out of the two oval gears (part# 6).
④. Clean the two oval gears (part# 6) with an approved
solvent, like kerosene, and ensure the gears without
being damaged.
⑤. Clean the gear chamber with an approved solvent, like kerosene, and make sure the kerosene
not splash onto the crystal display area.
⑥. Carefully place the seal mat (part# 25) back to the front cover (part# 7).
⑦. Place the two ovals gears (part# 6) back to the two cylinders. Rotate a gear to ensure the gear
is move smoothly.
⑧. Carefully place it back the control valve body, then tighten with the 8pcs of hexagon screws
(part# 23).
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Fig. 4

DIGITAL GREASE CONTROL VALVE OWNER’S MANUAL
8 of 9
Transportation
When the control valve is in transit, do not exposure the control valves with direct sunlight and
avoid rain, falling, erosive substance, etc.
Storage
①. Storage temperature: From +14˚F to +104˚F
②. Store the pump in a dry place with good ventilation. Do not expose it to excessive heat, humidity
or sunlight. Never let it touch any corrosive substances.
③. Store it out of the reach of children.
④. Always keep the pump at least 4 feet away from any heat source.
DIAGRAMS AND PARTS LIST
WEAR PARTS
For replacement parts and technical questions, please call 1-800-222-5381.
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DIGITAL GREASE CONTROL VALVE OWNER’S MANUAL
Part No.
13*
14
15
16*
17
18
19
20
21
22
23
24
Part No.
25*
26
27
28
29
30*
31
32*
33*
34*
35*
Description
Control valve body
Top cover
Coupler
Rigid tube
Outlet valve body
Gear
Front cover
Lens
PCB assembly
Label
Bolt
Screw
Description
Battery
Spring
Battery cover
O-ring
Trigger
Spring
Adjust knob
Nut
Bolt
Shaft
Bolt
Pin
Description
Seal
Magnetic stick
Bolt
Washer
Screw
Ball
Valve cover
Retainer
O-ring
O-ring
Retainer
Qty.
1
1
1
1
1
2
1
1
1
1
1
3
Qty.
2
1
1
1
1
1
1
1
1
1
8
2
Qty.
1
2
6
1
1
1
1
1
1
1
2
Part No.
1
2
3
4
5
6*
7
8
9
10
11
12
Part No.
33*
34*
35*
Description
Gear
Battery
O-ring
Description
Seal
Ball
Retainer
Description
O-ring
O-ring
Retainer
Qty.
2
2
1
Qty.
1
1
1
Part No.
6*
13*
16*
Part No.
25*
30*
32*
Qty.
1
1
2
27
11
32
31
22
35
1
13
14 15
17
3
4
5
20
19
21
18
26
6
24
25
7
23
28
29
9
12
8
10
2
34
16
27
30
33

WARRANTY
One-year limited warranty
DIGITAL GREASE CONTROL VALVE OWNER’S MANUAL
Distributed by
Northern Tool + Equipment Co., Inc.
Burnsville, MN 55306
NorthernTool.com
Made in China