WOERNER GMF-E User manual

Original instructions GMF-E Page 1 of 32 B0343
Reciprocating pump
GMF-E
Translation of the
Original instructions
Version EN 06/2016

Original instructions GMF-E Page 2 of 32 B0834
Translation
With delivery into member countries of the European Community,
this operating manual has to be translated into the user’s language.
If details of the translated operating manual do no coincide with the
original ones, then the original operating manual (German) is to be
referred to for clarification or the manufacturer to be contacted.
Copyright
This document shall neither be transferred to third parties nor
copied. Its content must neither be commercialized nor
communicated, if not explicitly allowed. Violating the before
mentioned will cause claim for indemnification.
All rights reserved.

Original instructions GMF-E Page 3 of 32 B0834
Table of content
1. Important information on this operating manual...........................................................5
1.1 User..........................................................................................................................5
1.2 Obligation to read.....................................................................................................5
1.3 Questions: What to do?............................................................................................5
1.4 Operating manual.....................................................................................................5
1.4.1 Validity......................................................................................................................5
1.4.2 Content and purpose................................................................................................5
1.4.3 Site of operation .......................................................................................................6
1.4.4 Meaning of the safety instructions and safety signs..................................................6
2. Identification....................................................................................................................7
2.1 Product mark and type designation...........................................................................7
2.2 Product version.........................................................................................................7
2.3 Product denomination...............................................................................................7
2.4 Manufacturer and address........................................................................................7
2.5 Conformity................................................................................................................7
3. Product description.........................................................................................................8
3.1 Use...........................................................................................................................8
3.2 Limits of application..................................................................................................8
3.3 Environmental conditions..........................................................................................8
3.4 Use according to design...........................................................................................9
4. Technical data................................................................................................................10
4.1 General technical data............................................................................................10
4.2 Drive specification ..................................................................................................10
4.3 Dimensions.............................................................................................................11
5. Description of function..................................................................................................12
5.1 Components...........................................................................................................12
5.2 Function..................................................................................................................12
5.3 Pump elements.......................................................................................................13
6. Safety instructions ........................................................................................................14
6.1 Fundamental ..........................................................................................................14
6.2 Required users’ skills..............................................................................................14
6.3 Safety devices........................................................................................................14
6.3.1 Reservoir Lid ..........................................................................................................15
6.4 Accident prevention................................................................................................18
6.5 Residual dangers....................................................................................................18
6.6 Improper use..........................................................................................................18
6.7 General safety regulations and duties.....................................................................19
6.8 Exclusion of liability ................................................................................................19
7. Transport, installation, start-up and putting out of operation....................................20
7.1 Transport................................................................................................................20
7.2 Unpacking ..............................................................................................................20
7.3 Installation..............................................................................................................20
7.4 Power supply and powering-up...............................................................................21
7.4.1 Motor......................................................................................................................21
7.5 Start-up...................................................................................................................21
7.6 Putting out of operation...........................................................................................23
8. Operating manual..........................................................................................................24
8.1 Trouble shooting and remedy.................................................................................24
8.2 Refilling the container.............................................................................................24
8.3 Powering down.......................................................................................................25

Original instructions GMF-E Page 4 of 32 B0834
9. Cleaning, servicing, fault remedy and repair...............................................................26
9.1 Cleaning.................................................................................................................26
9.2 Maintenance...........................................................................................................26
9.3 Inspection chart......................................................................................................27
9.4 Repair.....................................................................................................................27
10. Accessories.................................................................................................................28
11. Return to manufacturer...............................................................................................29
12. Disposal.......................................................................................................................31
13. Appendix......................................................................................................................31
13.1 Content of the declaration of conformity..................................................................31
13.2 Declaration of Conformity .......................................................................................32

Original instructions GMF-E Page 5 of 32 B0834
Important information on this operating manual
This operating manual forms part of the machine and has to be made
available to the operating and maintenance staff at any time.
The safety instructions specified herein have to be obeyed.
If the machine is traded, the operating manual is to be included in the
shipment.
In addition to this operating manual, the current laws and regulations of
the user’s country have to be considered as well, in any case.
1.1 User
This operating manual has been written for technically qualified users, who have been
instructed or trained for the operation of this pump unit.
1.2 Obligation to read
As owner and user of this pump unit, you are obliged reading and understanding this
operating manual, in particular the chapter “Safety instructions”. It is your safety that is dealt
with. In case of question and doubt, please get in contact with WOERNER.
1.3 Questions: What to do?
If questions arise, which you cannot solve with this operating manual, do not hesitate asking
WOERNER for support. In such case, describe the problem as precisely as possible.
1.4 Operating manual
1.4.1 Validity
This operating manual fits to the design of the reciprocating pump GMF-E.
1.4.2 Content and purpose
This operating manual delivers all the relevant information for start-up, operation and
maintenance of the pump unit to assist you using the unit efficiently as well safely according
to its design and intended purpose of use.

Original instructions GMF-E Page 6 of 32 B0834
1.4.3 Site of operation
Make the operating manual available to the users at their workplace at any time.
1.4.4 Meaning of the safety instructions and safety signs
Safety instructions
The pictograms and warning words used in safety instructions, safety rules and references of
this operating manual do mean:
Danger! Immediately threatening danger that may lead to heavy body
injuries.
Warning! Possibly dangerous situation that may lead to heavy body
injuries.
Caution! Possibly dangerous situation that may lead to slight body
injuries.
Caution! Warning of material damage.
Note! Possibly dangerous situation that may lead to possible damage
to the product or objects in its environment.
Important! Instructions for use and other useful information that facilitate
usage of the product according to its design.
Danger! Immediately threatening danger by electric current that may
lead to heavy body injuries.

Original instructions GMF-E Page 7 of 32 B0834
2. Identification
2.1 Product mark and type designation
Piston pump unit of the manufacturer Eugen Woerner GmbH & Co. KG
Product type: GMF
2.2 Product version
Version from the year of production 2015
2.3 Product denomination
The identification plate has been attached to the side of the pump case and informs on:
Manufacturer
Type (GMF-E)
No. <order number>.<order pos.>.<consecutive number>
Gear ratio
Year of production <mm/jjjj>
Example:
GMF-E
123456.10.001
97:1
12/2013
2.4 Manufacturer and address
Eugen Woerner GmbH & Co. KG
Hafenstrasse 2
DE-97877 Wertheim
Phone [phone]
Facsimile [phone]
Net www.woerner.de
E-Mail [e-mail]
2.5 Conformity
The pump unit meets the provisions as specified in the EC-directive for machines
(2006/42/EC)
Declaration of conformity, see annex (chapter 13).

Original instructions GMF-E Page 8 of 32 B0834
3. Product description
The reciprocating pump is capable of accommodating up to 6 pump elements. Delivery
volume per element each is 0,08 or 0,15 cm³/stroke at maximum and can be regulated (see
description at page 3). Maximum operating pressure amounts to 350 bar. The reservoir is
made of stainless steel providing a capacity of 8 litres.
3.1 Use
The pump unit has been exclusively designed for the supply of
lubricating oils and greases up to the NLGI-class 3.
3.2 Limits of application
The range of application of the pump unit has been limited as follows:
Admissible supply pressure: max. 350 bar
Medium: Oil and grease up to consistency class 3
In addition, the range of application of the pump unit is determined by the medium to be
supplied. Therefore, to finally define the range of application, consult also the technical data
sheets of the medium to be used.
3.3 Environmental conditions
Operating this pump unit in aggressive atmosphere (vapour of solvents,
acids, bases, salt water mist, etc.) may cause damage, respectively
corrosion of components and consequently, failure of the equipment and
hazards due to emerging lubricant!
Ambient temperature range
Lower limit temperature: -20 °C
Upper limit temperature with motor: +55 °C
Relative air humidity: max. 90%
Noise level : <70 dB(A)
Physical environment
If the equipment is planned to be operated at a level higher than 1,000 m above sea level,
consult the manufacturer, in every case.

Original instructions GMF-E Page 9 of 32 B0834
3.4 Use according to design
The pump unit must be exclusively used for the supply of lubricating oils or greases in central
lubricating installations, which the following conditions have to be considered for:
Observance of the safety instructions and safety rules in this operating manual
Compliance with the maintenance and service instructions in this operating manual
Any other usage or any usage beyond the designed one may lead to
heavy personal and material damages.
Forbidden: Supply of gases, liquefied gases, gases solved under pressure,
vapours and other liquids, whose saturation pressure exceeds 0,5 bar above
the normal atmospheric pressure (1013 mbar) at the admissible maximum
temperature, also highly flammable or explosive media as well as foodstuff!
Important! Please consider the safety specification sheets of the applied
substances as well!

Original instructions GMF-E Page 10 of 32 B0834
4. Technical data
4.1 General technical data
Admissible delivery pressure max. 350 bar
Number of elements 1 ... 6
Delivery volume per stroke and element
pump element 6 max. 0,08 cm³
pump element 8 max. 0,15 cm³
special pump element 0,22 cm³
(on request)
Stroke numbers of elements 14 min-1
Delivery volume/ element 17 ... 67 cm³/hour
Reservoir content 8 l
Temperature range
with electric motor -20 ... +55 °C
at high humidity 90%
Medium Oil and grease up to NLGI-class 3
Lubricant The intended lubricant must be suitable for use with
centralized lubrication equipment.
Reciprocating pump installation position vertical
Material Casing: Metal alloy
Pump element: Steel, galvanised
Reservoir 8 l: stainless Steel,
Gaskets: NBR
Weight 17 kg
4.2 Drive specification
Drive type "M" with gear and motor: size 71
Overall transmission 97:1
Max. Operating pressure
with pump element 6: 330 bar
Motor electrical data
Mains voltage 220/380 V
Frequency 50 Hz
Synchronous speed 1350 min-1
Power 0,4 kW
Protection system DIN EN 60529 IP55
Thermal category F

Original instructions GMF-E Page 11 of 32 B0834
4.3 Dimensions

Original instructions GMF-E Page 12 of 32 B0834
4
6
5
8
2
9
7
1
3
Pressure
control valve
5. Description of function
5.1 Components
1 Container
2 Pump case
3 Agitator
4 Agitator blade
5 Pump shaft
6 Pressure ring
7 Worm wheel
8 Worm
9 Pump element
5.2 Function
The drive puts the pump shaft into rotation through a worm gearing. Together with this pump
shaft, a pressure ring rotates eccentrically, which the pump elements are hung in. Due to the
eccentricity of the pressure ring related to the pump shaft, each displacing piston passes,
mechanically operated, through equally long pressure and suction strokes with every
revolution of the pump shaft. The function of the pump elements will be explained later. An
agitator is linked with the pump shaft forcing the lubricant to the suction borehole of the pump
elements to comminute air bubbles.

Original instructions GMF-E Page 13 of 32 B0834
5.3 Pump elements
4
3
R
7
Fördervolumen
1
2
6
The displacing piston 1 and control piston 2 generate the suction stroke. For that purpose,
the eccentric shaft moves the displacing piston 1, whilst a spring actuates the control piston
2. The control piston closes the pressure borehole 3 and stops at a defined position
according to the adjusted volumetric displacement. The displacing piston continues
traversing and produces a vacuum in the measuring-out chamber and the lubricant is taken
in from the container by the displacing piston after opening the suction borehole 4.
For the pressure stroke, the displacing piston 1 travels to the left to shut the suction borehole
4 and the control piston 2 is displaced by the lubricant enclosed between displacing piston
and control one until the control piston opens the pressure borehole 3 to enable the
displacing piston to feed the lubricant to the outlet.
The pump element 8 = 0.15 cm³/stroke is marked with a red ring ‘R’.
Adjustment of the volumetric displacement:
The volumetric displacement can be reduced to a minimum of about 25% of the rated one.
For that purpose, take the following actions:
Turn out the plug screw 7.
Set the required volumetric displacement at the adjusting nipple 7 with the wrench
included in the delivery.
Clockwise turn: Reducing the volumetric displacement.
Anticlockwise turn: Increasing the volumetric displacement.
The adjusting nipple features a hexagon, against which a spring-loaded piston exerts
pressure in radial direction. In this way, the volumetric displacement is prevented
from automatically changing. At the same time, this type of locking serves as a
measure for the adjustment of the volumetric displacement. Six notches correspond
to one turn of the adjusting nipple and reduction by approximately 33% of the rated
volumetric displacement. As for precise adjustment to a defined volumetric
displacement per stroke, a volumetric prove-measurement has to be taken. The
pump elements are delivered adjusted to maximum volumetric displacement.
Turn in the plug screw 7.
Volumetric displacement

Original instructions GMF-E Page 14 of 32 B0834
6. Safety instructions
6.1 Fundamental
The pump unit is shipped from the works in faultless condition and guarantees high technical
safety.
The pump unit complies with the rules of technology as well as current labour safety and
health protection regulations. There is, however, danger in case of maloperation and abuse
for the:
Body and life of both users and third parties,
Pump unit or other material values of the users, and
Efficient usage of the pump unit.
6.2 Required users’ skills
Persons, who work with and on the pump unit, have to be authorised and instructed
accordingly by the user. They must be able detecting and eliminating possible danger. For
that purpose, knowledge on accident prevention rules, first-aid measures and local rescue
equipment is imperative.
Technically skilled staff properly instructed on the product is allowed to carry-
out inspection, service and maintenance only.
Skilled electricians are the only ones permitted to intervene in electrical
installations according to DIN VDE 1000-10.
For planning and inspection of the work, specialists with product-specific training are
responsible.
6.3 Safety devices
From mechanical aspect, the pump unit is inherently safe due to its design.
The pump unit must be operated only with the cover of the container closed.

Original instructions GMF-E Page 15 of 32 B0834
6.3.1 Reservoir lid
Description
The container lid is locked by two fasteners as shown in
this picture.
In normal use both fasteners must be closed.
If it´s necessary to open the lid it is mandatory to follow
the instructions below.
Locking hook
Locking lug
Safety latch (Locked)
Safety cover
Locking lever

Original instructions GMF-E Page 16 of 32 B0834
Opening
Step 1:
Push the safety latch with a suitable tool from top
(e.g. screwdriver).
Step 2:
After safety latch is unlocked, lift the locking lever and
release the locking lug from the locking hook to fully
unlock the fastener.
Safety latch unlocked
Step 3:
Repeat step 1 and 2 for the second fastener.

Original instructions GMF-E Page 17 of 32 B0834
Closing
Before locking the fasteners, make sure that the locking lugs are hung in the
locking hook.
Warning! Try if safety latch is snapped in by pulling the locking
lever.
Lifting the locking lever is not possible if the safety latch
is in the locked position
Step 1
Push the locking lever until the safety latch snaps in
(audible “klick”).
Step 2
Repeat step 1 for the second fastener

Original instructions GMF-E Page 18 of 32 B0834
6.4 Accident prevention
Stick to these measures to prevent accidents:
Hinder unauthorised persons from access to the pump unit.
Keep foreign persons away from dangerous areas and dangerous sites.
Inform repeatedly present foreign persons on residual dangers. As for residual dangers, see
section "Residual dangers".
6.5 Residual dangers
As regards the pump unit itself, there are no residual dangers for persons and equipment if
that pump unit is used according to its design as well as intended purpose, and the specified
cycles as well as measures for maintenance and service are kept.
If the pump unit is delivered with the media pre-filled, then consider the product and safety
sheets of the filled-in medium in addition to this instruction manual.
6.6 Improper use
If the pump unit is used for purposes other than specified and agreed upon,
there is danger for heavy damage to both persons and equipment.
Referring to experience, improper use may include, for example:
Supply of highly flammable or explosive media
Supply of media, which are able reacting with materials the pump unit has been made
of.
Supply of foodstuff

Original instructions GMF-E Page 19 of 32 B0834
6.7 General safety regulations and duties
In general, using the pump unit the following safety regulations and duties are
to be complied with:
Consider the generally accepted rules for labour safety. This is also true, in
addition, for the current basic rules on labour safety and accident prevention
on the site of operation.

When used in vehicles, obey to the generally accepted rules and
regulations of the Road Code.
As user comply with the regulations for the usage of working equipment.
Operate the pump unit in clean and faultless state only.
Never remove, modify, bridge or neglect any protection, safety and
monitoring equipment, in no case.
Do not reconstruct or modify the pump unit.
Report faults or damage to the user.
For repair, incorporate original spare parts only.
The user has to inspect and maintain in good condition all the protection,
safety and monitoring equipment on a regular basis.
After each repair, make sure that the pump unit is in faultless state and
take a test run.
6.8 Exclusion of liability
If damage to persons, equipment, environment and assets occurs due to ignoring this
operating manual regardless if intentionally or unintentionally, WOERNER shall not be held
responsible. No claim for warranty will be accepted. This is also true for any consequential
damage.

Original instructions GMF-E Page 20 of 32 B0834
7. Transport, installation, start-up and putting out of operation
7.1 Transport
Transport the pump unit cautiously to its destination. For that purpose, make use of proper
equipment (for example, handcart, or the like).
7.2 Unpacking
Lift the pump unit carefully from the packaging and place that unit on a stable as well as
plane support.
Note! Consider that inside the pump unit and components attached
according to the bill of delivery, there might be residues of blue-
coloured test oil.
7.3 Installation
The pump unit is prepared for being mounted on floor by means of four screws M8. The
mounting area has to be that stable to be able absorbing the weight of the pump unit
including the filled container. In addition, make sure that the mounting surface is plane.
As for the installation the pump unit take necessary prevent measures to protect the unit from
unintentional shocks.
Drilling pattern: