SKF LINCOLN FlowMaster II A Series User manual

FlowMaster II rotary driven
220/380–420 V AC, 50/60 Hz, 3
phase electric pump, series “A”
85745, 120 lbs.
85746, 400 lbs.
Operation, assembly, disassembly and
troubleshooting guide
Date of issue December 2012
Form number 404455
Section C8
Page 367A
Read manual prior to installation or use
of this product. Keep manual nearby for
future reference. Failure to follow
instructions and safety precautions may
result in death or serious injury.
DANGER

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

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

Use of this manual
Any other use not in accordance with
instructions will result in loss of claims for
warranty and liability.
General description
and information
The Lincoln industrial rotary AC electric
pump uses a AC motor and a two stage
planetary gear drive. Grease output is pro-
portional to the pump revolutions per min-
ute. The pump is primarily designed for cen-
tralized 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 con-
verted to reciprocating motion through an
eccentric crank mechanism. The reciprocat-
ing action causes the pump cylinder to move
up and down. The unit is a positive displace-
ment double-acting pump as grease output
occurs during both the up and down stroke.
During the down stroke, the pump cylin-
der 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 previ-
ous stroke is transferred through the outlet
check and discharged to the outlet port.
Typical output of the pump is shown in
table 2.
Fig. 1 is the electrical wiring schematic
for the pump with a controller and fig. 2 is
the electrical wiring schematic for the pump
motor.
Inspection
If over pressurizing of the equipment is
believed to have occurred, contact the
factory authorized warranty and service
center nearest you for inspection of the
pump.
Specialized equipment and knowledge is
required for repair of this pump.
Annual inspection by the factory author-
ized warranty and service center nearest
you is recommended.
Damaged Pumps
Do not use any pump that appears to be
damaged, badly worn or operates abnor-
mally. Remove the pump from service and
contact the factory authorized warranty and
service center nearest you for repairs.
A listing of authorized warranty and
service centers is available upon request.
Overview
This manual details the procedure that must
be followed while installing, operating, trou-
bleshooting and repairing the FlowMaster II
rotary driven AC electric pump.
All required parts, tools, and equipment
needed to complete the operation of the
FlowMaster II rotary driven AC electric pump
are defined and listed within this manual.
Review of the parts list and nomenclature
is recommended before starting
disassembly or operation.
Appropriate use
All pump models are exclusively designed to
pump and dispense lubricants using electric
power. The specifications are shown in
table 1 for the pump. The maximum
specification ratings should not be exceeded.
Table 2
Electric pump performance specifications
Temperature
°F (°C)
75 r/min. 92 r/min.
in3/min. (cm3)/min.)
80 (27) 5.4 (88) 6.7 (110)
40 (4) 5.2 (85) 6.4 (105)
20 (–7) 5.0 (82) 6.1 (100)
Table 1
Pump specifications
Operating temperature –40 to 150 °F (–40 to 65 °C)
Operating voltage 220/380–420 V AC, 50 Hz, 3 phase
220/460 V AC, 60 Hz, 3 phase
Motor speed 1,425 r/min.@ 50 Hz, 1,725 r/min. @ 60 Hz
Pump speed 75 r/min. @ 50 Hz, 92 r/min. @ 60 Hz
Motor, power 1/2 HP (0,37 kW)
Current draw, † table 2
Output/pump cycle 0.07 in.3 (1,15 cm3)
Pump performance † table 2
Pump outlets 1/4 NPTF internal
Maximum outlet pressure 5,000 psi (345 bar) Test conducted with Alvania NLGI #2 grade grease at 1,000 psi (68 bar) back pressure
!Notice
Pumps are not recommended for
airless spray systems. They should be
converted from 19:1 to 34:1 gear ratio.
Please contact technical services for
component requirement.
4

Low voltage High voltage
220-230 380-420
10
4
4
11
11
5
5
12
6
10
10
10
4
11
5
12
12
12
61
4
35
2
6
6
7
7
1
1
8
8
2
2
9
3
7
1
8
2
9
9
3
3
Line Line
WHT/BLU or
WHT/ORG or
WHT/YEL or 11-ORG
-PRP
-GRY
-PNK
-YEL
-BLU
-WHT
-BLK
-RED
THERMAL
Control wiring diagram
using Model 85530
lubrication system controller
Must be in 230 position
Power
Switch
Vent
Valve
N.O.
Pressure
Switch
Motor
Starter
Pump
Motor
Alarm
M
Terminal B
Terminal A
2 31 5 64 8 97 11 12 13 1410
2
1
3
4
5
6
7
8
9
11
12
10
230 VAC
MS
MS
MS
MS
L2
L3
L1
OL
OL
OL
OL
Fig. 2
Motor wiring diagram
Fig. 1
Pump with controller
Interchange any two line leads to reverse rotation.
Actual number of internal parallel circuits may vary.
Lead colors are optional. Leads must always be numbered as shown.
Vent valve, motor starter coil and alarm signaling device are 230 components. These components are purchased separately.
5

1.25
(32)
A
B
3.78
(96)
8.78
(223)
2.25
(57)
2.25
(57)
3.90
(99)
2.75
(70)
6.75
(171)
4.25
(108)
(4X)
0.28 ( ) 7 holes
(4X) 1/4-20 threads
2.72
(69)
2.27
(58)
(13.91
(353)
16.07
(408)
Fig. 3
Pump dimensions
Dimensions
Model Dimension “A” in. (mm) Dimension “B” in. (mm)
85745 27.56 (700) 35.50 (902)
85746 34.06 (865) 42.00 (1,067)
6

Installing the Pump
1 Refer to figure 4 and connect the
material supply line (80) to the pump
outlet (55).
Fig. 4
2 Install a safety un–loader (77) in the
open outlet port.
3 Install the high pressure shut-off valve
(79) in the material supply line (80).
!Notice
If it is necessary to drill mounting
holes into reservoir cover, refer to fig. 3
for hole pattern and dimensions.
!Notice
Typical installation as shown in
figure 4 is only for selecting and install-
ing system components. Contact your
Lincoln Industrial representative for as-
sistance in designing a system to suit
your specific needs.
!Notice
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.
Prior to connecting electrical wiring,
perform lock out/tag out of system.
Failure to comply may result in personal
injury and/or damage to equipment.
DANGER
A high pressure shut-off valve (79) must
be installed to maintain a pressure
below 5,000 psi (344 bar).
Failure to comply may result in
serious personal injury.
DANGER
37 Motor
55 Outlet
77 Safety un-loader 272722
78 120 VAC or 230 VAC
79 Outlet shut-off
80 Material supply line
81 Follower plate (85492 for 120 lb. (54 kg) drum only)
82 Drum cover 85474 120 lb. (54 kg)
Drum cover 85475 400 lb. (181 kg)
83 Auxiliary motor mount
84 Field installed fuse
Table 3
Electric FlowMaster II pump
380–420 V AC , 50 Hz 19:1 gear ratio, 2 stage
Back pressure current
psi (bar) r/min. A1)
0 (0) 78 1.0
1,000 (68) 75 1.0
2,000 (137) 75 1.0
3,000 (206) 75 1.1
4,000 (275) 75 1.2
5,000 (344) 75 1.3
77 37
79
55 80
83
84
81
82
78
4 Connect 220 V AC power supply to the
solenoid valve. Refer to table 3 to fuse
the motor.
5 Connect power to the motor leads
6 Mount the motor (37) to the drum cover
(82) using the auxiliary mount (83).
7

Operation
Verify a relief valve is installed in the
pump outlet to insure pump pressure
remains below 5,000 psi (345 bar). Use
only high pressure components. Failure
to comply may result in serious personal
injury.
WARNING
Crankcase oil service interval
• Check the oil level after every 750 hours
of machine operation, or monthly.
• Change the oil after every 2,000 hours of
machine operation or every year.
• Use SAE 10W30 motor oil in all units
used in an ambient temperature of –40 to
150 °F (–40 to 65°C). For ambient tem-
peratures of –70 to 50 °F (–56 to 10 °C) ,
use Mobil Aero HFA low temperature oil.
• Oil level should be at indicating dot on
dipstick (middle of crankshaft).
• Use 10W30 motor oil 15 oz. (0,44 l).
Priming the pump
1 Remove the pump outlet line from the
outlet port (55).
2 With the pump in a full container of
lubricant, energize the pump.
3 Purge air from the pump.
4 Verify lubricant is flowing evenly from
the pump.
5 Stop the pump.
6 Attach the pump outlet line to the outlet
port (55).
End of procedure
!Notice
Never allow the pump to run dry
of lubricant. A dry pump quickly speeds
up, creating friction heat, which can
damage the seals. Monitor supply
lubricant level and refill when necessary.
Failure to comply may result in damage
to equipment.
Pumps are not equipped with a high
pressure shut off valve. Do not exceed
maximum rated outlet pressure. Failure
to comply may result in personal injury
and/or damage to equipment.
DANGER
8

Disassembly
Pump
1 Place pump into a vise.
2 Remove the dipstick (31).
3 Drain crankcase oil from the crankcase.
4 Remove the housing cover screws (33)
(† fig. 5).
5 Remove the housing cover (35) and
gasket (36).
6
Remove the electric motor (64) mounting
screws (75) with lock washers (74).
7 Remove the electric motor (66).
8 Using a pick, remove the motor
o-ring.
9 Refer to fig. 6 and using a hex head
wrench, remove the gear box mounting
screws (74) and washers (75) and
remove the gear box (72).
10 Loosen and remove the screws (65)
holding the first stage gear set (66),
spacer (67) and final stage gear set (68)
in place.
11 Remove the first stage gear set (66),
spacer (67) and final stage gear set (68)
from the gear box.
12 Remove the shaft adapter (73).
13 Using a pick, remove the gear box
o-ring (38).
14 Loosen the screws (44) holding the shaft
cover (46) on the pump housing (37)
(† fig. 7).
15 Remove the retaining ring (48) from the
pump shaft (40).
16 Remove the pump shaft (40) by pushing
the pump shaft on the retaining ring (48)
side.
17 Remove the retaining ring (63) from the
housing tube (60). Refer to fig. 9.
18 Remove the shovel plug (62) from the
housing tube (60).
19 Remove the spiral retaining ring (61).
Fig. 6
Fig. 5
33
35
31
36
74,75
64
34
37
7 44
45
46
48
40
52
53
54
Fig. 7
55
56
57
58
Fig. 8
59
60
61
62
63
20 Loosen and remove the tube housing
(60) († fig. 8).
21 Remove the bronze bearing (56) from
the tube housing (60).
22 Using a flat, blunt tool, remove the
o-ring (57) from the tube housing (60).
23 Remove the back up washer (58) from
the tube housing (60).
24 Using a flat, blunt tool, remove the
o-ring (59) from the tube housing (60).
25 Using a rubber mallet and piece of brass
or other suitable piece of soft metal, tap
on the crank rod (7) inside the
housing (37).
26 Pull the eccentric (5) and crank rod (7)
out of the top of the pump housing (37).
End of procedure
37
73
71 6970
65
38
72
68
67
66
Notice
Slight force may be necessary to
remove the eccentric (5) and crank rod
(7) from the housing (37).
!
9

Crankrod and eccentric
1 Remove pivot screws (11) from the
crankrod (7) († fig. 9).
!Notice
Wrist pin bushings (12) often stick
in wrist pin anchor (13). It may be nec-
essary to use a 5/16–24 bolt from kit
(276275) to remove the wrist pin
bushings (12).
14 With the crank rod in a vise and using
the special tool (T1) provided in tool kit,
remove the plunger link rod (20)
(† fig. 10).
15 Place the end of the plunger link rod (20)
into the hole of the special tool (T1).
16 Align the outlet hole of the plunger link
rod (20) with the hole in the special tool
(T1) († fig. 11).
Fig. 9
7
12
11
60
2 Using a 5/16-24 bolt, press out wrist pin
bushing (12).
3 Remove crank rod (7).
4 Refer to fig. 10 and remove the wrist pin
anchor (13) from reciprocating tube (25).
5 Pull the cup seal (16) out of the wrist pin
anchor (13).
6 Remove the steel backup ring (17).
7 Place the plunger link rod (20) in a vise.
8 Using an open ended wrench, loosen the
plunger link rod (20) and remove
from outlet pin (8).
9 Remove the plunger link rod (20).
10 Remove the retainer clip (19) from the
plunger link rod (20).
11
Using a blunt tool, remove the o-ring (18)
from the plunger link rod (20).
12 Remove the back up washer (15) from
the plunger link rod (20).
13 Remove the o-ring (14) from the plunger
tube (10).
Fig. 11
T1
17 Insert the pin included in the tool kit
(275996) through the tool and into the
plunger link rod (20) outlet hole.
18 Turn the tool counter clockwise to re-
move the lower bushing and plunger
(24) from the plunger link rod (20).
19 Remove the plunger (24).
20 Remove the check rod from (22) the
lower bushing and plunger (24).
21 Remove the ball (23) from the lower
bushing and plunger (24).
22 Remove the spring (21) from the link
rod (20).
End of procedure
10
17
18
13
14
15
16
19
20
21
30
29
28
26
27
24 25
23
22
Fig. 10
8
9
10

Reciprocating tube
1 Loosen the check seat housing (30) with
3/8 in. hex head wrench († fig. 13).
2 Remove the check seat housing (30)
from the reciprocating tube (25).
3 Remove the ball cage (28), check ball
(29) and o-ring seals (27) from the check
seat housing (30).
4 Remove the lower bushing (24) from the
reciprocating tube (25).
5 Remove the lower cup seal (26) from the
reciprocating tube (25).
Crankrod
1 Using a hex head wrench, loosen and
remove the flat head screws (1) from the
eccentric (5) († fig. 12).
2 Remove the counterbalance weights (2).
3 Remove the outer (3) and inner (4)
retaining ring from both sides of the
crank rod (7).
4 Place the crank rod (7) on the supplied
2 1/2 in. (63,5 mm) diameter steel pipe.
5 Drive the crank eccentric (5) out of the
ball bearing (6).
6 Drive the ball bearing (6) out of the
crank rod (7).
End of procedure
Fig. 12
1
7
2
4
3
3
4
2
5
1
6
10
Fig. 13
13
14
15
16
17
18
21
27
26
24
22
23
25
28
30
29
20
19
10
8
9
11

Assembly
Crankrod and eccentric
assembly
1 Place the crankrod (7) on the 2 1/2 in.
(63,5 mm) diameter steel pipe from
the kit.
2 Refer to fig. 14 and install the ball
bearing assembly (6) into the crank
rod (7).
3 Place the eccentric (5) in the ball
bearing (6).
4 Place one end of the inner retaining ring
(4) on top of the eccentric (5).
5 Squeeze the other end of the retaining
ring (4) toward the center and slide the
retaining ring (4) into place.
6 Place one end of the outer retaining ring
(3) on top of the inner retaining ring (4).
7 Squeeze the other end of the retaining
ring (4) toward the center and slide the
retaining ring (4) into place.
8 Align the holes of the counter-balance
weights (2) with the threaded holes of
the eccentric (5) and place on the
eccentric (5).
Pump
1 Install the ball (23) into the lower bushing
and plunger (24) († fig. 15).
2 Insert the check rod (22) into the pump
plunger (23).
3 Place the spring (21) onto the check
rod (22).
4 Thread the plunger link rod (20) into the
pump plunger (24).
5 Insert the lower bushing pump plunger
(24) into the tool (T1).
6 Refer to fig. 16 and align the hole in the
lower bushing pump plunger (24) with
the hole in the supplied tool (T1).
7 Insert the pin into the hole of the tool
(T1) and into the lower bushing pump
plunger (24).
8 Torque the lower bushing pump plunger
(24) to a torque of 110–125 in.lbf.
(12,4–14,1 Nm).
9 Install the steel back up ring (17) onto
the threads of the upper bushing and
the plunger end (10).
10 Slide the o-ring (18) onto the upper
bushing and plunger end (10).
11 Install the retaining clip (19) on the
upper bushing and plunger end (10).
Fig. 16
15 Thread the upper bushing and plunger
end (10) into the outlet pin (8).
16 Torque to 110–125 in.lbf.
(12,4–14,1 Nm).
17 Install the back-up washer (15) in the
wrist pin anchor (13).
18 Place a new cup seal (16) inside the wrist
pin anchor (13).
19 Clean the threads of the wrist pin
anchor (13).
20 Install the o-ring (14) on the wrist pin
anchor (13). See fig 15.
Fig. 14
1
7
2
4
3
3
4
2
5
1
6
T1
10
17
18
13
14
15
16
19
20
21
30
29
28
26
27
24 25
23
22
Fig. 15
8
9
9 Insert the flat head screws (1) into the
counter-balance weight (2) and torque
the flat head screws (1) to a torque of
100–110 in.lbf. (11,3–12,4 Nm).
12 Install the o-ring (9) on the upper
bushing and plunger end (10).
13 Place the outlet pin (8) into a vise.
14 Apply Loctite 242 to the threads of the
upper bushing and plunger end (10).
12

21 Insert the upper bushing and plunger
end (10) into the wrist pin anchor (13)
and tighten.
22 Place the wrist pin anchor (13) in a vise.
23 Tighten the wrist pin anchor (13) to a
torque of 20–25 ft.lbf. (27–34 Nm).
24 With the wrist pin anchor (13) still in the
vise, align the crankrod/eccentric
assembly (7) holes with the wrist pin
anchor (13) holes († fig. 15, page 12).
25 Install the wrist pin bushings (12)
through the crank rod (7) into the wrist
pin anchor (13) († fig. 17).
26 Apply Loctite 242 to the threads of the
wrist pin bushing screws (11).
27 Insert and thread the wrist pin bushing
screws (11) into the crankrod (7).
28 Torque bushing screws (7) to a torque of
110–125 in.lbf. (12,4–14,1 Nm).
29 Install the cup seal (26) with the slotted
side toward the center of the reciprocating
tube (25) († fig. 18).
30 Place a new o-ring (27) on the lower
bushing and plunger (24).
31 Slide the lower bushing and plunger (24)
into the reciprocating tube (25) with the
o-ring (27) near the bottom of the
reciprocating tube (25) († fig. 18).
39 Place the back up washer (58) into the
housing tube (60).
40 Insert the o-ring (57) into the housing
tube (60).
41 Insert the bronze bearing (56) into the
housing tube (60).
42 Position the crankrod assembly (7) over
the top of the pump housing (37) and
lower into the pump housing (37).
!Notice
For ease of installation of the low-
er cup, use a small piece of tubing to
slide the lower up into the reciprocating
tube and over the pump plunger.
!Notice
Failure to align the key on the
shaft and the key way in the eccentric
will result in damage to equipment.
Fig. 17
7
12
11
Fig. 19
60
59
58
57
56
32 Install the steel check cage (28) into the
reciprocating tube (25).
33 Install the ball (29) into the steel check
cage (28).
34 Apply Loctite 242 or equivalent to the
threads of the check seat housing (30).
35 Thread the check seat housing (30) into
the reciprocating tube (25) and tighten
using a 3/8 in. hex key.
36 Torque to 20–25 ft.lbf. (27–33 Nm).
37 Remove the crank rod (7) from the vise.
38 Refer to fig. 19 and insert the o-ring
(59) into the housing tube (60).
Fig. 18
25
26
28
24
30
29
27
Fig. 21
5
43 Align the crank rod (7) with the shaft (40)
mounting hole. Refer to fig. 20.
44 While aligning the key (39) on the shaft
(40) with the eccentric key way (5), slide
the shaft (40) into the eccentric (5)
(† fig. 21).
45 Install the retaining ring (48) on the
shaft. (40).
Fig. 20
44
45
46
48
40
39
7
37
47
13

Fig. 23
34
31
36
33
35
37 74, 75 64
60
46 Install the shaft cover (46) on the
pump (37) († fig. 20, page 13).
47 Insert and thread screws (44) with
lock washers (45) into shaft cover (46)
and pump housing (37).
48 Install the shaft adapter (75) inside the
pump housing (37).
49 Install gear box o-ring (38) in the pump
housing (37) groove († fig. 22).
50 Position the final stage gear set (68) in
the gear box (72).
51 Place the spacer (67) on top of the final
stage gear set (68).
52 Insert the first stage gear set (66) into
the gear box (72).
53 Install the screws (65) through the gear
sets (66), (68) and spacer (67) into the
gear box (72).
54 Torque the screws (65) to 15–20 ft.lbf.
(20,3–27,1 Nm).
55 Place the gear box (72) on the pump
housing (37).
56 Install the four gear box mounting
screws (69) and washers (70) in the gear
box (72) and into the pump housing (37).
57 Torque the gear box mounting screws
(69) to a torque of 20–25 ft.lbf.
(27,1–33,9 Nm).
58 Install the electric motor o-ring (71) in
the groove of the gear box (72).
59 Place the electric motor (64) on
the pump housing (37).
60 Insert the electric motor mounting
screws (75) with lock washers (74) into
the gear box (72) and electric motor (64).
61 Torque the mounting screws (75) to a
torque of 100–110 in.lbf. (1,3–12,4 Nm).
Refer to fig. 23.
62 Refer to fig. 24 and insert the retaining
ring (61) into the second groove of
the housing tube (60).
63 Install the shovel plug (63) into the
housing tube (60).
64 Install the spiral retaining ring (62).
65 Install new cover gasket (36) on pump
housing (37) († fig. 23).
66 Install the pump cover (35).
67 Install the screws (33) with o-rings (34)
into the pump cover (35).
68 Torque the screws (33) to a torque of
10–15 in.lbf. (1,1–1,6 Nm).
69 Install the o-ring (54) in the outlet pin
mounting hole groove of the pump
housing (37) († fig. 24).
37
73
Fig. 22
71 69 70
65
38
72
68
67
66
70 Install the back up washer(52) inside the
outlet pin nut (55).
71 Install the o-ring (53) inside the outlet
pin nut (55).
Fig. 24
55
53
5452
60
61
62
63
!Notice
Refer to page 8 crankcase oil
service, for oil recommendations.
72 Line up the outlet pin and thread the
outlet pin nuts (55) into the pump
housing (37).
73 Torque to 30–35 ft.lbf. (40,7–47,5 Nm).
74 Fill the crankcase with oil up to indicator
dot on dipstick.
75 Install the crank case oil dip stick (31)and
torque to 10–15 in.lbf. (1,1–1,7 Nm)
(† fig. 23).
End of procedure
14

Troubleshooting
Condition Possible cause Corrective action
Pump does not run. Pump is seized or damaged. Disassemble pump and repair any parts that are
damaged or worn.
Incorrectly wired. Check wiring diagram.
Pump speeds up or runs erratically. Low level of grease or reservoir
is empty.
Fill reservoir.
Follower plate is stuck and separated
from grease.
Check follower plate and container for damage.
Pump piston or checks are worn. Disassemble pump and repair.
Pump runs, but output is low. Faulty inlet check (29, 30), faulty discharge
check (23, 24) or damaged o-ring (27).
Replace faulty components.
Seepage from housing cover (35). Cup seal (16) or o-ring (14) worn out. Check seals and replace if necessary.
Pump is noisy. Crankcase needs oil. Fill with oil.
Pump does not build pressure.
Worn wrist pin bushing (12). Check the bushings and replace if necessary
Foreign material holding lower check open.
Dismantle and clear check.
Consider adding grease filter to system.
Motor runs, but no pump output. Gear set or adapter shaft stripped or broken. Dismantle and replace damaged part.
15

Parts and tools
Tool and consumable list
7/16 in. open end wrench
1 1/2 in. open end wrench
3/4 in. open end wrench
12 in. adjustable wrench
1/8 in. hex head wrench
5/32 in. hex head wrench
1/4 in. hex head wrench
5/16 in. hex head wrench
3/8 in. hex head wrench
1/4 in. drive socket
1/4 in. socket
5/16 in. socket
Flat screwdriver 0.10 in. (2,54 mm) wide 0.025 in. (0,635 mm) thick
Pick to remove seals and spiral retaining rings
Small snap ring pliers
Special tool kit 276275
Phillips screwdriver
1/2 in. hex head wrench
Hammer
Torque wrench (ft. lbf. and in. lbf.)
Hex head socket adapters (required to torque hex head screws)
Loctite 242 medium strength thread lock or equivalent
16

Parts list
Item no. Description Part no. Quantity Item no. Description Part no. Quantity
1Flat head screw (1/4-28 x 1 3/4) 270635 2 39 Woodruff key 272560 1
2 Counter weight 272197 2 40 Pump shaft 277397 1
3 Retaining ring 270609 2 41 Retaining ring 272561 1
4 Retaining ring 270608 2 42 Ball bearing 272556 1
5 Crank eccentric 270666 1 43 Shaft seal 2725542) 1
6 Ball bearing 270607 1 44 Screws 272557 4
7 Crank rod 270665 1 45 Lock washer 66051 4
8 Outlet pin 270670 1 46 Bearing cover 272549 1
9 O-ring (nitrile) 342551),2) 1 47 O-ring 2725592) 1
10 Upper bushing and plunger 2750002) 1 48 Retaining ring 272563 1
11 Pivot screw 275006 2 49 Ball bearing 272555 1
12 Wrist pin bushing 275005 2 50 Retaining ring 272562 1
13 Wrist pin anchor 274992 1 51 Drain plug 244752 1
14 O-ring 2750152) 1 52 Backup washer 2498372) 2
15 Backup washer 2749981),2) 1 53 O-ring 2498382) 2
16 Cup seal (polyurethane) 2749991),2) 1 54 O-ring 2707192) 2
17 Steel back-up ring 2749971),2) 1 55 Outlet pin nut 270619 2
18 O-ring 2727911),2) 1 56 Bronze bearing 270674 1
19 Retainer clip 2749961),2) 1 57 O-ring (polyurethane) 2498392) 1
20 Plunger link rod See Chart 1 58 Backup washer 2706522) 1
21 Spring 2771682) 1 59 O-ring (nitrile) 344312) 1
22 Check rod 277167 1 60 Housing tube See Chart 1
23 Ball (3/16 in.) 660102) 1 61 Retaining ring 277398 1
24 Lower bushing and plunger 275001) 1 62 Shovel plug 270707 1
25 Reciprocating tube See chart 1 63 Retaining ring 270705 1
26 Cup Seal (polyurethane) 2706252) 1 64 Motor 274830 1
27 O-ring (nitrile) 2750112) 2 65 Screw 272552 4
28 Ball cage 272179 1 66 First stage gear set 272543 1
29 Ball (3/16 in.) 660012) 1 67 Spacer 272547 1
30 Check seat 270664 1 68 Final stage gear set 272663 1
31 Dipstick with o-ring 275369 1 69 Screw 272564 4
32 O-ring 2750152) 1 70 Lock washer 272566 4
33 Self-threading screw (#8 x 1/2) 270633 6 71 O-ring 2725442) 4
34 Gasket (screw) 2529862) 6 72 Gear box housing 272541 1
35 Housing cover 275009 1 73 Shaft, adapter 272546 1
36 Cover gasket (nitrile) 2706302) 1 74 Lock washer (1/4) 272569 4
37 Pump housing 278230 1 75 Screw (1/4-20 x 1) 272568 4
38 O-ring 2725672) 1 76 Safety un–loader 90942 1
Non–common repair parts
Part number
Model
85745
Model
85746
20 Plunger link rod 277383 277384
25 Reciprocating tube 277734 277735
60 Housing tube 277738 277739
1) Included in 275186 repair kit
2) Included in 277723 repair kit
17

Fig. IPB 1
1
10
9
8
11
12
13
14
16
17
18
19
20
21
22
23
25
26
28
29
30
27
24
15
3
5
7
3
2
4
6
4
1
2
18

Fig. IPB 2
43
42
41 40
39 38
56
57
58
59
60
61
62
63
55
54
53
52
51
50
49
48
47
46
45
44
36
35
34
33
32
31
37
19

75
64
69
74
66
67
71
72
68
73
65
70
Fig. IPB 3
20