Contact Address:
URL : www.lincolnindia.com
SECTION 1.0
1. INTRODUCTION
SECTION 2.0
2. REFERENCE DRAWINGS & CATALOGUES
SECTION 3.0
3. INSTALLATION & COMMISSIONING OF CENTRALISED LUBRICATION SYSTEM
SECTION 4.0
4. GENERAL INSTRUCTIONS
SECTION 5.0
5. TROUBLE SHOOTING
SECTION 6.0
6. SCHEDULE FOR CHECKS
SECTION 7.0
7. LIST OF RECOMMENDED SPARES
SECTION 1.0
INTRODUCTION
The system is connected inline with the enclosed schematic drawing no. 22337BH-100. The
system comprises of a pump suitable to be mounted on 200 liters standard barrel, Injectors,
timer, tubing and fittings.
The Lincoln Rotary Hydraulic Pump is fully hydraulically operated grease pump. Grease
Output is proportional to the Hydraulic Input Flow. An integrated Pump Control Manifold is
incorporated with motor to control input flow & pressure. A 24 V DC Solenoid Valve is also
incorporated to turn the pump on or off. This is controlled in the system by means of a Timer
provided in the Control Panel circuit.
The pump operates as long as the solenoid valve is in open position allowing the hydraulic
motor to run. Once the solenoid valve is cut off the oil flow to the hydraulic motor is also cut.
This causes the pump to stop and the grease in the line to relieve back to the reservoir through
vent valve assembly. Once the grease line pressure relieves, the injectors will dispense the
lubricant to the points and get ready for charging for the next cycle.
The system is monitored by means of the Pressure Switch provided in the line and this signal
is used for solenoid switching action to control the pump run and off times.
Additionally we have offered Hose Reel with Grease Gun, for manual Lubrication for points
covered in the Manual Lubrication as in Swing Circle points.
SECTION 2.0
CENTRALISED LUBRICATION
1 21642-000394 CONNECTOR TUBE ASSLY FOR LH-IMINJECTOR 2 EA
2 22337-000223 LIFTING TACKLE FOR 200 LTR. STANDARD BAR 1 EA
3 22337-000043 TIE ROD FOR 200 LITRES BARREL 2 EA
4 22337-000083 4 WAY MANIFOLD WITH MOUNTING H 1 EA
5 22337-000153 PUMPSTATION ASSY 1 EA
CHKD
PRPD
APRD
26 H20-154134-9 EVGE 10S,3/8"BSP,STRAIGHT STUD STANDPIPE 1 EA
27 H20-155312-9 ADAPTER #3/8"BSP(M)X1/2"BSP(F)GALV.BLUE 2 EA
28 H20-155712-9 ADAPTER #3/8"NPT(M)X1/2"BSP(F)GALV.BLUE 2 EA
29 H20-155811-9 ADAPTER #3/8"BSP(M)X3/8"NPT(F)GALV.BLUE 6 EA
30 H20-155816-9 ADAPTER #3/8"NPT(F)X1/2"BSP(M)GALV.BLUE 2 EA
31 H20-155916-9 ADAPTER #1/2"NPT(M) X 3/8"NPT(F)GALV.BLU 2 EA
32 H20-156011-9 ADAPTER 3/8"NPT(M)X3/8"NPT(M)GALV.BLUE 6 EA
33 H20-156916-9 ADAPTER #1/2"NPT(M) X 3/8"BSP(M)GAL.BLUE 2 EA
34 H22-241704-1 PR GAUGE, DIAL:100MM, RANGE :O-600KG/CM2 1 EA
35 H60-190903-7 BALL VALVE 3/8" 2 EA
36 H63-1000306-9AP SEAMLESS CS TUBE #6X1.0 AFTER PLATING 40 M
37 H63-1000516-9AP SEAMLESS CS TUBE #16X2.0 AFTER PLATING 11 M Alteration
38 H63-1000410-9AP SEAMLESS CS TUBE#10X1.5 AFTER PLATING 8 M
39 H84-150834-9 STRAIGHT FTG#XGE 10S,3/8"BSP GALV.BLUE 1 EA
40 H99-999019-9 HEX LOCK NUT, M20, GAL YELLOW 4 EA
41 M06-103019-7 MTG. BRACKET FOR SSV 12. 1 EA
42 M07-103093-2 TUBE CLAMP TC-1-6-WEL-MS 10 EA
43 M99-105032-1 SEAT A FOR INJECTOR 12 EA
44 M99-105032-2 SEAT B FOR CLAMP. 6 EA
Index
Table of Contents service center nearest you for repair or adjustments other
than maintenance specified in this manual.
Page
Safety
.
................................................................2
Annual inspection by the factory authorized warranty and
Description....................................................................................2
service center nearest you is recommended.
Appropriate Use................................................................2
Pump Performance and Specifications..............................3
A list of factory authorized warranty and service centers is
Installing the Pump.....................................................................4
available upon request.
Operation.....................................................................................5
Maintenance and Repair...........................................................5
Pump Dimensions.............................................................7 Damaged Pumps
Repair Parts List................................................................................9 Any pump that appears to be damaged in any way, is badly
Trouble Shooting.........................................................................10 worn or operates abnormally, shall be removed from use
until repairs are made. Contact the factory authorized
Safety warranty and service center nearest to you for repairs.
Read and carefully observe these operating instructions
before unpacking and operating the pump! The pump must
Description
be operated, maintained and repaired exclusively by per- 85480 - Pump for 120 pound drum (16 gallon)
sons familiar with the operating instructions. Local safety 85481 - Pump for 60 pound drum
regulations regarding installation, operation and 85482 - Pump for 400 pound drum (55 gallon)
maintenance must be followed. 85483 - Pump for 5 gallon pail
Operate this pump only after safety instructions and this General Description
service manual are fully understood. The Lincoln Industrial rotary Hydraulic Pump is a fully
hydraulically operated grease pump. Grease output is
proportional to the hydraulic input flow. The pump is
primarily designed for centralized lubrication systems such
as the Single Line Parallel, Single Line Progressive and
Indicates a potentially hazardous situation which, if not Two Line systems. An integrated pump control manifold is
avoided, could result in death or serious injury. incorporated with the motor to control input flow and
pressure. A 24 volt DC solenoid valve is also incorporated
as a method to turn the pump on and off.
Hydraulic Motor
Hydraulic Manifold
(Item 42)
Hydraulic Material
Fluid Return Outlet
to Tank
Hydraulic
Fluid Inlet
Flow Control
Valve (Item 39)
Solenoid Valve
(Items 34 & 35)
Pressure Gauge
Pressure Reducing
Vent (Item 32)
Valve (Item 38)
Valve
Illustration 1
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+\GUDXOLF)ORZ,QSXW
*UHDVH2XWSXWYV+\GUDXOLF,QSXW *UHDVH2XWSXWYV+\GUDXOLF,QSXW
80º F
30º C
*UHDVH2XWSXWFPñPLQ
Q
L
0º C P
20º F
ñ
H
V
-10º C K 0º F
F
Q
L
W
X
-30º C S
W
X -20º F
2
V
H
D
H
U
*
+\GUDXOLF)ORZ,QSXWJP
+\GUDXOLF)ORZ,QSXWOP
© Indicates change
11.46 9.08
(291) (231)
4.61
9.54
(117)
(242) 8
1.5
3.125 (38)
(79)
5.025
2 (128)
ø 1.25
(32)
4
02'(/ ',0$LQPP ',0%LQPP
2.25
(57)
7
2
3 1
4
29 5
6
7
32 30
8
6
31
34 33 4
3
2 9
58
35
1 10
36 60 11
37 12
59
45 13
38 14
39 46
61 15
40 41 47
48 16
42 49
17
43
50
44 51
52
53
54 18
19
20
55
21
56
57
22
23
24
25
26
27
28
Illustration #6
Troubleshooting
Condition Possible Cause Corrective Action
Pump speeds up or runs erratically. Low level of grease or reservoir Refill reservoir.
is empty.
Follower plate is stuck and separated Check follower plate and container
from grease. for damage.
Pump piston or checks are worn. Disassemble the pump and repair.
Copyright 1999
Pump runs, but output is low. Insufficient hydraulic fluid supply. Check hydraulic supply and adjust
flow using valve 39.
Weepage from housing cover 30. Cup seal (16) or O-Ring (48) wore out. Check the seals and replace if
necessary.
Pump becomes noisy. No crank case oil. Add crank case oil. Remove Pipe
Plug (45) from Pump Housing (46).
Oil level should be at the bottom of
the Pipe Plug opening. Add 10W30
Printed in the U.S.A.
Worn wrist pin bushing 13. Check the bushings and replace if
necessary.
84980
242631
(PART OF
HYDRAULIC
PUMP)
ASSEMBLY INSTRUCTIONS
3 ) Bring drum cover onto pump tube and align vent valve
to bracket. Secure with 66246 Lockwashers and
50034 (1/2" long) Screws, and bolt drum cover to
pump.
6 ) Remove 10724 Union Nut, 11907 Union Nipple & 34049 Washer intact
trom 81753 Elbow Union Assembly and install into coupling. Reassemble
elbow union.
7 ) Screw the straight end of the 241963 Hose into the 242631 Orifice
Assembly which is assembled into the bottom side of the Valve Assembly.
Screw the other end of the hose assembly into the top of the vent valve.
244652
244653
14722
239330
14723
31047
3/4"
NPTF
3/4"
NPTF
239336
SERVICE PARTS
Part Qty. Description Part Qty. Description
LINCOLN provides a Distributor Network that stocks equipment and replacement parts.
PDD-OM-C-014 Nov 04
INJECTOR
LH-IR-100
OWNER’S MANUAL
page1 of 8
Lincoln Helios (India) Ltd, Devanahalli Road, Off Old Madras Road, Bangalore – 560 049 Tel: 080-8472727, 8472424
E-Mail: mktg@lincolnindia.com www.lincolnindia.com
PDD-OM-C-014 Nov 04
Table of contents
Sl. No. Contents Page No.
1 Introduction 2
2 Specifications 2
3 Operation 3-4
4 Manifold Assembly 5
5 Service Parts List 6-7
6 Trouble Shooting 8
1. INTRODUCTION
Centromatic Injector LH-IR incorporated in the lubrication system measures out and
provides required quantity of grease to each bearing under high pressure.
2. SPECIFICATION
Injectors can be mounted in any position and can be used in circuits with SL-32 and / or
SL-33 injectors for dispensing grease up to N.L.G.I. # 2
page2 of 8
Lincoln Helios (India) Ltd, Devanahalli Road, Off Old Madras Road, Bangalore – 560 049 Tel: 080-8472727, 8472424
E-Mail: mktg@lincolnindia.com www.lincolnindia.com
PDD-OM-C-014 Nov 04
3. OPERATION:
MEASURING
CHAMBER
INJECTOR
PISTON
DISCHARGE
CHAMBER
PASSAGE
SLIDE
VALVE
LUBRICANT
SUPPLY
STAGE 1 STAGE 2
Subject to improvements without notice
The injector piston is in its normal or rest When the slide valve uncovers the passage,
position. The discharge chamber is filled lubricant is admitted to the measuring
with lubricant from the previous cycle. chamber above the piston which forces
Under the pressure of incoming lubricant lubricant from the discharge chamber
the slide valve is about to open the passage through the outlet port to bearing.
leading to the measuring chamber above
the injector piston.
page3 of 8
Lincoln Helios (India) Ltd, Devanahalli Road, Off Old Madras Road, Bangalore – 560 049 Tel: 080-8472727, 8472424
E-Mail: mktg@lincolnindia.com www.lincolnindia.com
PDD-OM-C-014 Nov 04
Subject to improvements without notice
STAGE 3 STAGE 4
As the injector piston completes its stroke, it After venting, the injector spring expands,
pushes the slide valve past the passage, cutting causing the slide valve to move, so that the
off further admission of lubricant to the passage passage and discharge chamber are
and measuring chamber. The injector piston connected by a valve port. Further
and slide valve remain in this position until expansion of the spring causes the piston to
pressure in the supply line is vented (relieved at move upward, forcing the lubricant in the
the pump). measuring chamber through the passage and
valve port to refill the discharge chamber.
page4 of 8
Lincoln Helios (India) Ltd, Devanahalli Road, Off Old Madras Road, Bangalore – 560 049 Tel: 080-8472727, 8472424
E-Mail: mktg@lincolnindia.com www.lincolnindia.com
PDD-OM-C-014 Nov 04
40NM±10%
1/8"NPTF
OUTLET
REPLACEMENT
INJECTOR
LH-IR-100
41
NXØ10
MANIFOLD
41
3/8"NPTF 3/8"NPTF
INLET INLET
TIGHTEN TO TORQUE
38 31.70
80NM±10%
22.25 31.75 31.75
Subject to improvements without notice
page5 of 8
Lincoln Helios (India) Ltd, Devanahalli Road, Off Old Madras Road, Bangalore – 560 049 Tel: 080-8472727, 8472424
E-Mail: mktg@lincolnindia.com www.lincolnindia.com
PDD-OM-C-014 Nov 04
19
3
22 4
17 2
10 1
14
15
18
20
7 5
16 13
6 8
9 12
11
21
Subject to improvements without notice
page6 of 8
Lincoln Helios (India) Ltd, Devanahalli Road, Off Old Madras Road, Bangalore – 560 049 Tel: 080-8472727, 8472424
E-Mail: mktg@lincolnindia.com www.lincolnindia.com
PDD-OM-C-014 Nov 04
ASSLY
SL.NO. TITLE QTY/SET
PART/DRG.NO.
@ 1 PISTON STOP PLUG - 1
2 PISTON ROD - 1
* 3 ADJSUTING SCREW - 1
@
@ 4 LOCK NUT - 1
5 SPRING SEAT - 1
* 6 INJECTOR BODY 7363-03009-3 1
7 PLUNGER - 1
*
8 INLET DISC - 1
*
9 ADAPTER BOLT 7013-03010-4 1
@ 10 GASKET - 1
* 11 ADAPTER GASKET 7315-22008-4 1
12 PACKING - 1
* 13 PACKING - 1
* 14 PACKING - 1
@*
15 O-RING - 1
* 16 WASHER - 1
* 17 WASHER - 1
@
* 18 COMPRESSION SPRING 7713-07008-3 1
@ 19 INJECTOR CAP - 1
20 FITTING ASSEMBLY 6641-01100-4 1
21 WASHER 7315-04002-4 1
@ 22 SEAL FOR CAP - 2
NOTE:
Accessories:
1. Connecting Tubes
2. Fittings
3. Fittings Assembly
page7 of 8
Lincoln Helios (India) Ltd, Devanahalli Road, Off Old Madras Road, Bangalore – 560 049 Tel: 080-8472727, 8472424
E-Mail: mktg@lincolnindia.com www.lincolnindia.com
PDD-OM-C-014 Nov 04
6. TROUBLE SHOOTING
5. Erratic output & inconsistent -Internal leakage at slide -Check packing &replace
movement of indicator pin. valve packing & piston if required.
packing.
page8 of 8
Lincoln Helios (India) Ltd, Devanahalli Road, Off Old Madras Road, Bangalore – 560 049 Tel: 080-8472727, 8472424
E-Mail: mktg@lincolnindia.com www.lincolnindia.com
TIMER GN50A
TECHNICAL DATA
TIME SETTINGS
1. Power ON : red
2. Pump ON : green
3. Short circuit / overload trip : amber
4. Supervisory fault 1 : amber
5. Supervisory fault 2 : amber
6. Continuos lubrication : green
7. Start (ignition) : Red
SWITCH DETAILS
• For selecting operating timings : PCB mounted dip switches
• For auto / continuos lubrication : Green Push button on the enclosure
• For fault reset : Red Push button on the enclosure
SWITCH ARRANGEMENT FOR OPERATING TIME SELECTION
INSTALLATION
PRE-ASSEMBLY
• Mount the Pump Assembly and make the hydraulic oil -line connections with the hoses
as per the layout.
• Weld the seats for Injectors and clips to the chassis / deck / cabin of the equipment as
desirable.
• Mount the above functional components and secure them with bolts, nuts and washers
tightly.
• Connect the main line Hoses / Steel Tube to the Pump outlet and to the Injector inlets /
outlets as per the standard layout.
• Connect the Hose Assemblies to the outlets of the Injectors and to the inlets of the
bearing points as per the standard layout.
• During the above assemblies, ensure proper crimping of the ferrules and secure the
coupling nuts of the fittings tightly.
ELECTRICAL CONNECTIONS
• Clamp the Tube and Hoses to the seats welded on the body of the equipment and
secure them tightly.
COMMISSIONING
• Place the pump in a Grease Barrel with sufficient amount of grease for topping up of all
point.
• Set the hydraulic pressure and the flow as per site conditions
• Tighten the connections at all the outlets and inlets after grease is observed at all the
points.
• All components of the Centralized Lubrication Systems should be secured tightly to the
mounting brackets and proper clamping of all tubing’s / a hose has to be ensured.
• Sufficient loop of Hoses Assemblies should be allowed for the moving points.
• All fittings and connectors should be tightly connected such that no leakage is observed.
• The Pump reservoir / Barrel should be filled with grease before starting the system.
• Maintain the grease level in the reservoir and do not run the Pump when grease level is
low.
• Always bleed the Pump through the Vent hole before commissioning, re-commissioning.
• Always bleed the system during commissioning and also when old components / tubing
and hoses are replaced, to avoid air-lock in the system.
• Ensure that all fittings and connectors are secured properly and there is no leakage
from any joint / tubing / hoses / outlets / inlets of components.
• Always, strictly follow the procedures and precautions for commissioning the system
(refer preceding section).
NOTE:
• The manufacturer will not accept any liability for damage caused due to:
1. SYMPTOM: Pump does not run / does not run at pre-set run time.
2. SYMPTOM: Pump does not deliver the lubricant / does not prime
Air pockets in the supply line Remove plug from Injector at the end of the
shortest supply line, bleed and re-assemble.
Repeat for each supply line.
Leakage in the supply line Inspect all connections and tighten / replace, as
necessary
Improper adjustment of Injector output Check and adjust the output with the Injector
adjusting stem.
Restriction at the lube point entry Clean / re-work the entry point and re-assemble
Operation Daily
Leakage Weekly
Fittings
Fitment Weekly