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