WOERNER GMF-S01 User manual

GMF-S01 Operation manual Page 1 of 31 B0836
Multi-line pump unit
Type GMF-S01
Translation of the
original operation manual
Version EN 07/2017

GMF-S01 Operation manual Page 2 of 31 B0836
Translation
When delivery is made into EEC countries, this operation manual
needs to be translated into the user’s country language accordingly.
In case that any inconsistency in the translated text occurs, the
original (German) operation manual should be referred to for
clarification or the manufacturer contacted.
Copyright
Unless permitted explicitly, the dissemination, reproduction, and
utilisation of this document as well as the communication of its
contents are prohibited. Any violation of this stipulation shall involve
the obligation to compensate damage.
All rights reserved.

GMF-S01 Operation manual Page 3 of 31 B0836
Table of contents
1. Important notes on this operation manual.....................................................................5
1.1 Users........................................................................................................................5
1.2 Obligation to read.....................................................................................................5
1.3 What to do in case of questions................................................................................5
1.4 Operation manual.....................................................................................................5
1.4.1 Applicability ..............................................................................................................5
1.4.2 Content and purpose................................................................................................5
1.4.3 Location....................................................................................................................6
1.4.4 Meanings of safety notes and safety symbols...........................................................6
2. Identification....................................................................................................................7
2.1 Product brand and type designation .........................................................................7
2.2 Product version.........................................................................................................7
2.3 Product marking .......................................................................................................7
2.4 Manufacturer and contact address............................................................................7
2.5 Conformity................................................................................................................7
3. Product description.........................................................................................................8
3.1 Purpose of use .........................................................................................................8
3.2 Limits of use.............................................................................................................8
3.3 Ambient conditions...................................................................................................8
3.4 Conventional usage..................................................................................................9
3.5 Technical data..........................................................................................................9
3.5.1 Assemblies...............................................................................................................9
3.5.2 Dimensions.............................................................................................................10
3.5.3 Multi-line pump unit technical data..........................................................................11
3.5.4 Technical data hydraulic motor...............................................................................11
4. Functional description ..................................................................................................12
4.1 Components...........................................................................................................12
4.2 Drive.......................................................................................................................13
4.2.1 Hydraulic motor ......................................................................................................13
4.2.2 Electric motor (option).............................................................................................13
4.3 Functioning.............................................................................................................13
4.4 Pump elements.......................................................................................................13
5. Safety notes...................................................................................................................14
5.1 Basic principle ........................................................................................................14
5.2 Requirements on user training................................................................................14
5.3 Safety facilities........................................................................................................15
5.3.1 Reservoir lid ...........................................................................................................15
5.4 Accident prevention................................................................................................17
5.5 Residual risks.........................................................................................................18
5.6 Incorrect applications..............................................................................................18
5.7 General safety regulations and duties.....................................................................18
5.8 Disclaimer...............................................................................................................19
5.9 Particularities for versions according to directive 2014/34/EU (ATEX)....................19
6. Transportation, installation, commissioning and shutdown......................................20
6.1 Transportation ........................................................................................................20
6.2 Unpacking ..............................................................................................................20
6.3 Installation..............................................................................................................20
6.4 Power supply and switch-on...................................................................................21
6.4.1 Hydraulic motor ......................................................................................................21
6.4.2 Electric motor (option).............................................................................................21
6.5 Commissioning.......................................................................................................21

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6.6 Shutdown ...............................................................................................................23
7. Operation .......................................................................................................................24
7.1 Troubleshooting, fault remedy ................................................................................24
7.2 Refilling the reservoir..............................................................................................24
7.3 Switch-off................................................................................................................25
8. Cleaning, servicing, fault remedy, and repair..............................................................25
8.1 Cleaning.................................................................................................................25
8.2Servicing.................................................................................................................25
8.3 Inspection schedule................................................................................................26
8.4 Repair.....................................................................................................................26
8.5 Accessories............................................................................................................27
9. Return shipment to factory...........................................................................................28
10. Disposal...................................................................................................................30
11. Appendix..................................................................................................................30
11.1 Content of the declaration of conformity..................................................................30
11.2 Declaration of conformity........................................................................................31

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1. Important notes on this operation manual
This operation manual forms part of the machine and must be available
to the operation and maintenance personnel at any time.
The safety notes contained herein need to be observed. When reselling
the machine, this operation manual must be handed over in any case as
well.
In addition to this operation manual, always be careful to observe the
laws and regulations being applicable in the country of use.
1.1 Users
This operation manual is intended for technically qualified users, who have been instructed
or trained in the operation of the pump unit.
1.2 Obligation to read
As an operator and user of the pump unit, you are obliged to read and understand this
operation manual and, in particular, its section "Safety regulations". It is your safety that is at
stake! Should you have any question or uncertainty, contact WOERNER, please.
1.3 What to do in case of questions
In case of questions that you cannot solve by means of this operation manual, WOERNER
will help you. In such situations it is indispensable that you provide us with a precise
description of the problem at stake.
1.4 Operation manual
1.4.1 Applicability
This operation manual is applicable to the series versions of the GMF-S01 multi-line pump
unit. Should any part thereof be related to particular versions only, special reference will be
made.
1.4.2 Content and purpose
This operation manual contains the relevant information for the commissioning, operation
and maintenance of the multi-line pump. It is designed to help you in using the pump unit
properly, efficiently and safely.

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1.4.3 Location
This operation manual must always be available to the users at their places of work.
1.4.4 Meanings of safety notes and safety symbols
Safety notes
In this operation manual, the pictograms and key words for safety instructions, precautions,
and notes have the following meanings:
Danger! Any danger threatening immediately and capable of causing
serious personal injuries.
Warning! Any possibly dangerous situation capable of causing serious
personal injuries.
Caution! Any possibly dangerous situation that might cause minor
personal injuries.
Caution! Warning about property damage.
Note! Any possibly harmful situation in which the product itself or an
object in its close vicinity might be damaged.
Important! Notes on application and other useful information facilitating the
proper usage of the product.
Danger! Any danger threatening immediately due to the presence of
electric current that may cause serious personal injuries.

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2. Identification
2.1 Product brand and type designation
Piston pump unit manufactured by Eugen Woerner GmbH & Co. KG
Product type: GMF-S01
2.2 Product version
Version as of model year 2015
2.3 Product marking
The type label is located at the side of the pump body and contains information as follows:
Manufacturer:
Type (GMF-S01)
No. <order-number> (e.g. 612345/1)
Model year
2.4 Manufacturer and contact 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 is in conformity with the EC directive on machinery (2006/42/EC).
For the declaration of conformity see the appendix (section 11)

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3. Product description
3.1 Purpose of use
The pump unit is designed for the delivery of lube oils as of 140 cP and
lube greases up to NLGI class 3 exclusively.
3.2 Limits of use
The application area of the pump unit’s components is restricted as follows:
Temperature range: -20 …+80 °C
Adm. delivery pressure: max. 350 bar
Medium: Oil and grease up to consistency class 3
Depending on the version, these limits of use may be restricted further. Such further
restrictions are dealth with in this operation manual later on.
Besides, the pump unit’s area of application is determined by the medium to be delivered.
Hence, when determining the area of application, you also need to refer to the technical data
sheets for the medium to be used.
3.3 Ambient conditions
Pump unit operation in an aggressive atmosphere (solvent vapours,
acids, lyes, salt water mist, etc.) may cause damage to or corrosion of
components and, thus, failure of the system and endangerment due to
leaking lubricant!
Ambient temperature range
lower temperature limit: -20 °C
upper temperature limit: +80 °C
Relative humidity: max. 70%
Noise level: <70 dB(A)
Physical environment
In heights as of 1.000 metres above sea level, the system should be operated after
consultation with the manufacturer only.

GMF-S01 Operation manual Page 9 of 31 B0836
3.4 Conventional usage
The pump unit is exclusively designed for the delivery of lubricating oils or lubricating
greases in central lubrication systems. Conventional usage also includes:
the observance of the safety notes and adherence to the safety regulations contained
in this operation manual
the adherence to the maintenance and servicing instructions given in this operation
manual
Any usage contrary hereto or going beyond the conventional one may
cause serious personal and property damage.
The delivery of gases, liquefied gases, gases dissolved under pressure,
vapours, and liquids the vapour pressure of which exceeds, at the permissible
maximum temperature, the normal atmospheric pressure (1013 mbar) by
more than 0,5 bar, as well as that of highly inflammable or explosive media
and foodstuff is prohibited!
Important! Please also note the safety data sheets pertaining to the
materials used!
3.5 Technical data
3.5.1 Assemblies
The GMF-S01 pump unit consists of three assemblies:
Pump body with pump elements
Reservoir
Hydraulic motor
Pump body with pump elements
Reservoir
Hydraulic motor

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3.5.2 Dimensions
The dimensions of the GMF-S01 multi-line pump are as follows:
Reservoir
capacity
Width B
mm
Depth T
mm
Height H
mm
with hydraulic
motor
max. weight
(without lubricant)
for electric
motor
max. weight
(without lubricant,
without electric
motor)
2 l
419
330
231
31,3 kg
22,8 kg
4 l
419
330
291
31,5 kg
23,0 kg
7 l
419
330
390
32,3 kg
23,8 kg
25 l
419
330
506
34,9 kg
26,4 kg
Numbering of the pump elements

GMF-S01 Operation manual Page 11 of 31 B0836
3.5.3 Multi-line pump unit technical data
The GMF-S01 comprises the pump body with the pump elements, a mounted reservoir, and
a hydraulic motor. The unit’s technical data is as follows:
Number of pump elements 1 …24
Delivery volume per stroke
per pump element 6 0,08 cm³
per pump element 8 0,15 cm³
(adjustable)
Number of strokes of the elements 1 …25 min-1
Admissible delivery pressure 350 bar
Drive volume flow depending
on pump shaft speed Q = 0,541 x nGMF Q in l/min
n in min-1
Ratio 66:1
Temperature range -20 … +80 °C
Material Casing: Spheroidal graphite iron lacquered
Pump element: Steel, galvanised
Reservoir: stainless steel
Gaskets: NBR
3.5.4 Technical data hydraulic motor
3.5.4.1 Hydraulic motor
Technical data:
Minimum hydraulic pressure ≥40 bar
Speed min. 50 min-1
Speed max. 1,950 min-1
Speed at 1 l/min drive volume flow approx. 100 min-1
Pressure gradient max. 100 bar
Oil flow max. 16 l/min

GMF-S01 Operation manual Page 12 of 31 B0836
3.5.4.2 Electric motor (option)
The technical specifications of the electric motor, please refer to the type plate, which is
mounted on the electric motor.
4. Functional description
4.1 Components
10
1 Hopper reservoir
2 Pump casing
3 Stirring unit
4 Stirring wing
5 Pump shaft
6 Pressure ring
7 Worm wheel
8 Worm
9 Pump element
10 Hydraulic motor

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4.2 Drive
4.2.1 Hydraulic motor
The hydraulic motor of the pump unit is operated by means of a pressurised hydraulic fluid.
This fluid is supplied via a fixed piping. Such piping may be laid by qualified professionals
only.
The hydraulic fluid is fed and discharged through two G 3/8 connection holes. The direction
of flow can be selected freely.
4.2.2 Electric motor (option)
By using the attaching parts (752.528-70) a three-phase current motor, with flange-FT85
DIN EN 50347 (C105 DIN 42948) can be mounted on the side of the pump case. Connec-
ting of the electric motor may be laid by qualified professionals only.
4.3 Functioning
The hydraulic motor is used to drive the pump shaft through a worm gear. Together with
this pump shaft, a pressure ring, which the pump elements are hooked into, is rotating
eccentrically. Due to the eccentricity of the pressure ring in relation to the pump shaft, every
delivery piston is forced with every rotation of the pump shaft to perform one steady delivery
and suction stroke each. The functioning of the pump elements will be described later on.
The pump shaft is connected with a stirring unit that pushes the lubricant to the suction holes
of the pump elements and crushes the air bubbles.
4.4 Pump elements
4
3
R
7
Delivery volumen
1
2
6
The suction stroke is performed by delivery piston 1and control piston 2. In this action,
delivery piston 1is actuated by the eccentric shaft, and control piston 2is actuated by the
spring. The control piston closes delivery hole 3and is retained in a certain position de-
pending on the delivery volume set. The delivery piston continues to move. As a result, a
vacuum is built up in the metering chamber. After opening of suction hole 4by the delivery
piston, lubricant will be drawn from the reservoir.
In delivery stroke, delivery piston 1moves to the left. In this motion, suction hole 4will be
closed and control piston 2displaced by the lubricant being available in between the delivery
piston and the control piston until it releases delivery hole 3and the lubricant is delivered by
the delivery piston to the outlet.
Pump element 8is marked by a red ring R.

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Adjustment of the delivery volume:
The delivery volume 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 delivery volume at the adjusting nipple 7with the wrench included in
the delivery.
Clockwise turn: Reducing the delivery volume.
Anticlockwise turn: Increasing the delivery volume.
The adjusting nipple features a hexagon, against which a spring-loaded piston exerts
pressure in radial direction. In this way, the delivery volume is prevented from auto-
matically changing. At the same time, this type of locking serves as a measure for the
adjustment of the delivery volume. Six notches correspond to one turn of the adjust-
ing nipple and reduction by approximately 33% of the rated volumetric displacement.
As for precise adjustment to a defined delivery volume 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.
5. Safety notes
5.1 Basic principle
The pump unit leaves the factory in flawless condition and ensures high technical safety.
The pump unit is in conformity with the rules of technology and the applicable safety and
health regulations. Nevertheless, in case of incorrect operation or misuse, risks are threat-
ening to the:
Lives and bodies of the users or third parties
Pump unit or other operator assets
efficient use of the pump unit
5.2 Requirements on user training
Any person getting to work on the pump unit must be authorised and trained for that purpose
by the operator. They must be able to recognise and avoid potential risks. This also includes
knowledge in the accident prevention regulations, first-aid measures, and local rescue
facilities.
The unit may be inspected, maintained and repaired by technically skilled
personnel with product-specific training only.
Work on electric facilities may be performed by skilled electricians in conform-
ity with DIN VDE 1000-10 only.
For the planning and inspection of the work, professionals with product-specific training are
responsible.

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5.3 Safety facilities
Mechanically, the pump unit is built intrinsically safe.
The pump unit may not be operated unless the reservoir lid is closed.
5.3.1 Reservoir lid
Always ensure that the pump is switched off before opening the lid!
The reservoir 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.

GMF-S01 Operation manual Page 16 of 31 B0836
Description
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.
Locking hook
Locking lug
Safety latch (locked)
Safety cover
Locking lever

GMF-S01 Operation manual Page 17 of 31 B0836
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.
5.4 Accident prevention
For accident prevention, take these measures:
Prevent unauthorised persons from accessing the pump unit
Keep foreign persons away from the areas and places of risk
Inform present foreign persons about residual risks repeatedly. Inform yourself about
such risks in the "Residual risks" section.
Step 1
Push the locking lever until the safety latch snaps in
(audible "klick").
Step 2
Repeat step 1 for the second fastener.

GMF-S01 Operation manual Page 18 of 31 B0836
5.5 Residual risks
When using the pump unit properly and adhering to the maintenance and repair cycles and
measures prescribed, there are no residual risks to persons and objects within the pump
unit’s area.
If the pump unit is delivered in pre-filled condition, the product and safety data sheets related
to the medium filled in need to be observed in addition to this operation manual.
5.6 Incorrect applications
Any usage contrary hereto or going beyond the conventional one may cause
serious personal and property damage.
As experience shows, possible incorrect applications include, for instance, the following:
the delivery of highly inflammable or explosive media,
the delivery of media being capable of reacting with the materials used for the pump
unit,
the delivery of foodstuff.
5.7 General safety regulations and duties
Basically, the following safety regulations and duties are applicable to the use
of the pump unit:
The generally accepted rules for work safety need to be observed.
Besides, the basic regulations and rules on work safety and accident
prevention being applicable to the place of use have to be followed.
When using it inside vehicles, the generally accepted traffic law-related
rules need to be observed.
The user is obliged to observe the regulations pertaining to the use of
working appliances.
The pump unit must be operated in flawless and clean condition only.
It is prohibited to remove, modify, bridge or bypass any and all protect-
tion, safety or monitoring facilities.
It is prohibited to reconstruct or modify the pump unit.
The operator should be notified of any fault or damage immediately.
For repair, no others than original spare parts may be used.

GMF-S01 Operation manual Page 19 of 31 B0836
The operator is required to regularly check and maintain all protection,
safety, and monitoring facilities.
After every repair, the flawless condition of the pump unit must be
ensured by means of a test run.
5.8 Disclaimer
Should any damage be caused to persons, objects, the environment and/or property due to
the non-observance of this operation manual, no matter whether intentionally or uninten-
tionally, WOERNER shall be held harmless thereof. Besides, all warranty claims will be
rejected. The same also applies to any and all consequential damage.
5.9 Particularities for versions according to directive 2014/34/EU (ATEX)
The multi-line pump is designed for application in ambient temperatures ranging
between -20 …+80 °C only.
The multi-line pump should be installed such that direct neighbourhood to electrical
equipment is avoided.
(EN1127-1, items 5.3.5 … 5.3.9)
The multi-line pump as well as all metallic and electrically insulated attachment parts
have to be incorporated into the existing equipotential bonding. Pipelines and connected
components must be grounded.
Frictional electricity on plastic parts and cables needs to be avoided.
When cleaning plastic surfaces, damp fabrics should be used.
If any equipotential bonding or part fitted with equipotential bonding is disconnected from
a metallic part in the system, as for instance during repairs, then a connecting line
having an appropriate cross-section needs to be installed for bridging in case that an
electrically conducting connection had been abolished.
When performing cleaning or maintenance work, be careful to avoid the generation of
ignitable sparks by friction or impact.
Corroded components must be replaced.
The operating instructions pertaining to the auxiliary parts, especially the electric compo-
nents, have to be taken into account.
As regards drives that do not comply with the operation manual, the operator is required
to assess the ignition risks.
In case of faults and/or failures, the pump must be checked or repaired by trained
professionals or WOERNER itself only.
Both pump dismantling and handling of single components shall only be done outside
the hazardous area.

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6. Transportation, installation, commissioning and shutdown
6.1 Transportation
Transport the pump unit to its destination carefully and by using suitable aids (e.g. hand-carts
or the like).
6.2 Unpacking
Lift the pump unit out of its packaging carefully and put it on a stable and plane base.
Note! The pump unit and the components attached in accordance with
the scope of delivery may still contain residues of blue-dyed test oil.
6.3 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 in-
cluding 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.
Drill pattern: Mounting
for M8