ALL-1 Heavy User Manual
Contents
1. CENTRAL LUBRICATION SYSTEMS amp EOUIPMENT ALL 1 Heavy Industry Type ELECTRICAL GREASE PUMPS INTRODUCTION AND USER MANUAL VERSION 2 00 THE PHYSICAL LIFE DETERMINED BY MINISTRY OF INDUSTRY AND TRADE OF TURKEY IS 10 YEARS ALLFETT CENTRAL LUBRICATION SYSTEMS amp EQUIPMENT www allfett net O _ INTRODUCTION All industrial machinery equipments and vehicles are working under abrasive operating conditions The wear between frictional parts become the most highest level at these conditions Machinery expose bad weather dust dirt rain snow and heavy weight in most cases Consequently unwanted breakdowns occur and by that way productivity loss is inevitable Using automatic lubrication system only increase your profitability ALLFETT completely take over the work load spend on lubrication with a system which is bringing togather a pump control unit distributors tubes and couplings Lubrication work is done by ALLFETT centralized lubrication systems in efficient time of machinery or vehicle which is while operating Lubrication is important for all frictional parts but using correct lubrication system and method only protect parts from wearing for a long time Feeding lubrication points with correct dosage of lubricant at certain intervals while machinery is operating provides lubricant film in place longer between parts By ALLFETT lubrication systems life time of parts on your machinery and vehicles will be increased2. _ FUNCTIONAL DESCRIPTION Appropriate electrical energy 12 or 24 V DC is connected to system Electrical motor start to operate and agitator inside reservoir rotates clockwise Spring returned pump element piston vacuums the lubricant inside reservoir Rotational movement of the eccentric pushes pump element piston so that the lubricant vacoomed before is sended to pump element outlet with high pressure Working pressure can be adjusted on security valve The lubricant coming out from pump elements Displacement volume of the pump element s can be connected to single lubrication point However displacement volume can also be divided by progressive distributor to feed multiple lubrication points Optional system control units Lubrication system and its components can be controlled and monitored with integrated electronic control cards Digital sensores and also pressure switches where placed on system components send information to control card Pump elements distributors and control cards are offered optionally While ordering a pump other components have to be ordered separately according to their properties A Any maintenance on ALL 1 pumps under electrical voltage could lead to personal injury Disconnect all electrical power before any maintenance A Any maintenance on ALL 1 pumps under high pressure could lead to personal injury Discharge the system pressure before any maintenance 2 Unouthorized modifications to
3. ALLFETT PAZARLAMA VE DIS TICARET LTD STI Yeni Ey p Bulvar Top ular Caddesi Set st No 1 Demirkap Rami Istanbul Telefon 0 212 501 32 01 PBX Fax 0 212 501 33 37 Vvvvvv allfett net info allfett net www allfett net WARRANTY ALLFETT CENTRAL LUBRICATION SYSTEMS amp EQUIPMENT Utilisation of this warranty certificate has been permitted by The Republic of Turkey The Ministry of Industrial and Commerce The general Administration of Protection of Consumer Right and Competition in accordance with the law numbered 4077 PRODUCER COMPANY NAME CENTRAL ADRESS TELEPHONE FAX AUTHORISED PERSON SIGNATURE STAMP PRODUCT TYPE BRAND MODEL SERIAL NUMBER DELIVERY DATE PLACE WARRANTY REPAIR TIME SALER COMPANY NAME CENTRAL ADRESS TELEPHONE FAX BILL DATE NUMBER ALLFETT Mekanik ve Elektronik Sistemler San ve Tic Ltd ti Yeni Eyup Bulvari Topcular Cad Set Ustu No 1 Demirkap Rami Istanbul 0212 501 32 01 PBX 0212 501 33 37 Electrical grease pump ALLFETT ALL 1 Heavy industry type PAGE 16 ALLFET T CENTRAL LUBRICATION SYSTEMS amp EQUIPMENT www allfett net O 2 N PAGE 17 WARRANTY CONDITIONS The warranty period is two years from the date of delivery The product including all its components is under the warranty of our company In case of defects within the warranty period the period spent in repairing is added to the warranty pe
4. PUMP MAINTENANCE 1 IF PUMP NOT STARTS a Electrical connections of the pump may be loosen or broken Check the electrical cables and connections of the system according to schemas on page 9 and page 10 b Connected electricity to pump may different then DC voltage Connect the electricity 12 or 24 V DC which is marked on pump sticker c Connected electericity may be converted to DC voltage from AC voltage by a transformer Transformer must be minimum 5A current d If pump has low level indicator Control unit PLC or integrated control card may give failure and stops the pump because of the grease inside pump decreased under minimum level Fill the reservoir according to items 10 11 12 13 14 15 and 16 in RULES TO COMPLY WHILE USING AND WARRANTY CONDITIONS e If ALLFETT control card is connected the system Electronic control card may be in waiting period Wait until working time starts If necessary control card pass to working period by pressing ADDITIONAL CYCLE button 2 IF PUMP NOT SENDING GREASE a Grease inside pump decreased under minimum level Fill the reservoir according to items 10 11 12 13 14 15 and 16 in RULES TO COMPLY WHILE USING AND WARRANTY CONDITIONS b Pump elements may take air due to work without grease Read and apply PUMP ELEMENT MAINTENANCE information on page 14 Unouthorized modifications to the units and the use of unouthorized spare parts and aids prohobited and disq
5. ABOUT MANUFACTURER With over 25 years experience of manufacturing Centralized Lubrication Systems ALLFETT is able to provide a wide professional approach to select the correct Centralized Lubrication System for industry and heavy machinery A highly accurate manufacturing process is involved in producing Centralized Lubrication Systems in order that systems meet the very tight quality procedures and state of the art processes are employed ALLFETT is among the few companies whose products meet the exact technical and quality standards for a correct central lubrication We present our high quality and advanced product design concept to our worldwide costumers through our strong brand ALLFETT creates new opportunities and innovative solutions As a result of the satisfaction of our customers with our good quality lubrication systems we are continuing in growing in the local and international market and became one of the successful companies in the field Symbols and words shown below are meant to warn a particular risk to persons material assets or the environment Please carefuly read this manual before installing Failure to follow the instructions and safety precautions in this manual could result in serious injury or property damage A Caution N Notice AN Electricity Prohobition PAGE 1 ALLFETT www allfett net CENTRAL LUBRICATION SYSTEMS amp EQUIPMENT Hu _ CONTENTS INTRODUCT10N 80 12 27 1 CONTENTS PAGE 2 PR
6. element displacement volume created by single or multiple pump elements Result values are defined in bar Single 06 mm pump element piece 06 mm pump element 6 piece 06 mm pump element Tube Lubricant 2 5 minute 7 5 minute 15 cm minute diameter 48 2 6 0 78 0 48 7 8 4 2 2 4 1 44 0 84 8 144 24 13 08 13 7 4 2A 1 4 12 8 7 38 2 1 28 20 8 11 2 6 4 3 84 2 24 2 7 1 32 0 72 1 0 42 0 24 3 9 2 1 1 14 0 66 0 42 4 5 2 2 12 07 0 4 6 5 3 5 19 1 1 0 7 72 3 52 1 92 1 121 0 64 10 41 5 6 3 1 76 1 12 1 44 0 72 0 36 0 21 0 12 2 16 11 0 6 0 3 0 18 010 1 2 4 1 2 0 6 0 35 0 2 3 6 18 1 0 5 0 3 98mm 3 84 1 92 0 96 0 56 0 32 5 76 2 88 1 6 0 8 0 48 0 6 0 96 0 45 0 22 0 12 0 06 1 32 0 66 0 36 0 18 0 1 012 1 1 6 0 75 0 38 0 2 0 1 2 2 11 0 6 0 3 0 18 10mm 2 561 1 2 0 61 0 16 3 52 1 76 0 96 0 48 0 29 0 451 0 2 0 09 0 6 0 27 0 12 0 07 7 0 75 0 34 0 16 1 1 0 451 0 2 0 12 12 0 26 1 6 0 72 0 32 0 19 0 33 0 15 0 06 0 55 0 25 0 1 0 0 4 0 16 PAGE 9 ALLFETT www allfett net CENTRAL LUBRICATION SYSTEMS amp EQUIPMENT OO 2 ELECTRICAL CONNECTIONS Pumps have an electric driven motor Electrical lines must be connected properly as described in schema below Electrical socket is placed under moto
7. equipments Damages or faults occur from this reason DISQUALIFIES THE WARANTY 15 Pump must be filled from the grease nipple If grease level is lower than the minimum level as you can not see grease level grease nipple must be used to prevent air entrance inside the pomp body Lockable filling cover option can only be used after filling pump from grease nipple up to minimum level PAGE 11 ALLFETT www allfett net CENTRAL LUBRICATION SYSTEMS amp EQUIPMENT RULES TO COMPLY WHILE USING AND WARRANTY CONDITIONS 16 If lockable filling cover will be used to fill pump environment must be clean to avoid any foreign materials entering to reservoir Any foreign materials dirt or small particules while filling lead to system units failing and possibly property damage Damages or faults occur from this reason DISQUALIFIES THE WARANTY 17 If the pump works without lubricant pump elements will send air to the points instead of grease Because of that any points connected to pump will not get any lubricant Damages on pump and on the system coming from that reason DISQUALIFIES THE WARANTY 18 Using ALL 1 pumps with integrated control card models high frequency wireless cominication devices 1 meter distance from the pump may couse malfunction Damages or faults occur from this reason DISQUALIFIES THE WARANTY 19 Integrated control card works between 10 to 30 Voltage Although there is a protection against high voltage
8. ODUCT DESCRIPTION AND GENERAL SPECIFICATIONS PAGE 3 PRODUCT DIMENSIONS PAGE 4 PRODUCT COMPONENTS PAGE 5 FUNCTION PAGE 6 PUMP ELEMENT DESCRIPTION PAGE 7 LUBRICANT INFORMATION PAGE 8 9 ELECTRICAL CONNECTION PAGE 10 RULES TO COMPLY WHILE USING AND WARRANTY 11 12 PUMP MAINTENANCE PAGE 13 PUMP ELEMENT MAINTENANCE PAGE 14 ORDER INFORMATION PAGE 15 WARRANTY PAGE 16 WARRANTY CONDITIONS 001 17 TRANSPORT AND STORAGE PAGE 18 PAGE 2 ALLFETT CENTRAL LUBRICATION SYSTEMS amp EQUIPMENT PRODUCT DESCRIPTION www allfett net ALL 1 electrical grease pumps are manufactured only for lubrication purpose Pump displacement is varius to provide required lubrication needs Optionally obtained pump element s creates pressurized grease out with different displacement volumes 1 and up to 6 pump elements can be added on pump body The pump reservoir is manufactured from transparent polycarbonate to allow user easily check the level of grease In case the pump is installed so that operator cannot see the level of grease the ALLFETT low level sensor can be used to follow the level of grease Top filling application is possible with different filling covers with or without lock ALL 1 pumps can be controlled and monitored with integrated electronic control cards Optional control card feature also displays warnings as broken fuse fault and alarms GENERAL SPECIFICATIONS Motor type Working pressure Motor pr
9. control card may be broken if connected to high voltage power source Damages or faults occur from this reason DISQUALIFIES THE WARANTY 20 Disassembling or loosing any part while pump working is prohibited Any damage coming from this reason DISQUALIFIES THE WARANTY Also any personal injury occur from this reason ALLFETT does not accept responsibility 21 Another goal of Centralized Lubrication Systems is to protect environment So it is adviced to fill grease to the systems by mobile or hand pumps 22 Unouthorized modifications to the units and the use of unouthorized spare parts and aids prohobited and DISQUALIFIES THE WARANTY Only maintenance may apply descibed in PAGE 14 15 ALLFETT Technical Service must be informed to any other possible troubles and necessary procedures must be performed 23 ALLFETT Mekanik ve Elektronik Sistemler SAN TIC LTD STI and ALLFETT Pazarlama ve Dis Ticaret LTD STI does not accept responsibility for damages described in items above on equipments which ALLFETT systems are installed QUALITY SYSTEM This product is produced by ALLFETT Mekanik ve Elektronik Sistemler San Tic Ltd Sti company which is certificated by Bureau Veritas with certificate to compatible for ISO 9001 2008 standard and owner of the quality management system ISO 9001 x BUREAU VERITAS Certification 12 ALLFETT CENTRAL LUBRICATION SYSTEMS amp EQUIPMENT www allfett net kT _
10. d parts DISQUALIFY THE WARANTY 5 Pumps have an electric driven motor Electrical lines must be connected properly as described in PAGE 10 11 and applied only by qualified and instructed personel 6 All electrical connections and lines must be checked regularly for damage and to ensure that they firmly in place 7 Damages coming from voltage fluctuation wrong electricity installation connecting wrong voltage to product DISQUALIFIES THE WARANTY 8 Keeping an uncovered cable s during system assembly may cause fatal damages where high voltage is transformed to low voltage Lines must be connected properly to prevent personal injury and damage to property 9 Transformer is necessary if there is 24 V electrical source Use minimum 5A current transformer 10 Only proper NLGI class lubricants must be used with in system NLGI class must be changed according to weather conditions Use NLGI 0 for cold weather increase the NLGI class up to 3 towards hot weathers 11 Only LITHIUM based and EP additive lubricants must be used with in system 12 Rubber based lubricant types must not be used in the system Damages or faults occur from this reason DISQUALIFIES THE WARANTY 13 Lubricant will be used in the system must certainly be clean and any foreign materials must not enter while filling 14 Any foreign materials dirt or small particules while filling lead to system units failing and possibly property damage to
11. e harmfull to environment Their transport and storage require that special safety measures be taken 1 Only LITHIUM based and additive liguid greases must be used with in system It is important that the grease will be used must resistant to high pressure Make sure the liguid grease you are using is EP additive Do not use rubber based grease in system Do not use grease types with graphite in system PAGE 8 ALLFETT CENTRAL LUBRICATION SYSTEMS amp EQUIPMENT www allfett net OO LUBRICATION INFORMATION Grease penetration properties is variable at different environment temperatures The environmental temperature around lubrication lines must be concidered for choosing the correct grease Grease properties should be appropriate that environmental temperatures Changing NLGI classes at different temperatures is important to correct lubrication If necessary high temperature resistant lubricants should be used in some cases N It should not be forgotten that the grease penetration properties is variable at different environment temperatures PRESSURE LOSE CHART Loosing pressure in lubrication lines depends on differend variables The most important variables are pump displacement environmental temperatures tube diameter and NLGI class Each variable must be considered for correct lubrication The chart below represents the approximate pressure loose in tube which 1 meter long Results are varies according to pump
12. otection class Grease type Working temperature 12 24 V DC 400 bar IP 54 NLGI 00 30 C 10 NLGI 0 10 0 C NLGI 1 0 C 10 NLGI 2 10 C 30 C NLGI 30 25 C 80 C Reservoir capacities 14 Liters OPTIONAL SPECIFICATIONS Pump elements Pump element displacement 1 6 05 1 5cm3 minute 96 2 5cm3 minute 07 3 5cm3 minute pumps more than 2 hours continuously pums are manufactured only lubrication purpose It is not convenient to run these PAGE 3 ALLFETT www allfett net CENTRAL LUBRICATION SYSTEMS amp EQUIPMENT PRODUCT DIMENSIONS Technical drawings below represents the ALL 1 pump general dimensions VERTICAL ASSEMBLY GROUND ASSEMBLY PAGE 4 ALLFETT CENTRAL LUBRICATION SYSTEMS amp EQUIPMENT www allfett net 2 PRODUCT COMPONENTS Technical drawings below represents the ALL 1 pump components Optional specifications described seperately Reservoir cover Plastic filling standard cover Optional Assembly bracket Height assembly holes Reservoir monobloc type Filling type Level indicator reservoir cover socket Optional Optional Agitator Level indicator Optional Filling filter Optional Pump element positions Motor cover Ground assembly holes Electrical socket PAGE 5 ALLFETT www allfett net CENTRAL LUBRICATION SYSTEMS amp EQUIPMENT HMM
13. ove the pump element and clean with diesel based liquid Assemble it to the pump body after drying with pressurized air Sealing ring inside the pump elements check valve may weared or damaged Change the sealing ring d Grease may seen coming out from the security valve discharge This means there is a blockage in lubrication point or distributor connected this pump element Blockage may cause the system to reach very high pressures and couse explode the lubrication lines Blockage must be identified and fixed Pump body Pump element outlet Security valve body Pump element body Grease suction hole Piston spring Piston Security valve discharge A ALL 1 pump body is suitable for 1 and up to 6 pump elements PAGE 14 ALLFE 11 CENTRAL LUBRICATION SYSTEMS amp EQUIPMENT PAGE 15 ORDER INFORMATION Product name Description www allfett net Ordering number ALL 1 12 V DC 14 Lt standard type 10 12 14 1 ALL 1 12 V DC 14 Lt filling type 111214A1 ALL 1 24 V DC 14 Lt standard type 10 2414A1 ALL 1 24 V DC 14 Lt filling type 11 24 14 A1 COMPONENTS Product Description Ordering number ALL 1 Pump element 95 10 00 05 02 ALL 1 Pump element 26 10 00 06 02 ALL 1 Pump element 97 10 00 07 02 Filling filter Type Small 10 0260 Filling filter Type Big 10 0261 Motor 12 V DC 1012 MT 01 Motor 24 V DC 10 24 01 SALES
14. r cover N Transformer is necessary if there is 24 power source Use minimum current transformer 12 24 V DC Electrical socket POWER SUPPLY 00 Electrical socket Any maintenance on ALL 1 DC pumps under electrical voltage could lead to personal injury Disconnect all electrical power before any maintenance If ALL 1 DC pump will be used with ALLFETT EK 9 external control card electrical lines must be connected properly as described in schema below EK 9 external control card ALL 1 Pump Electrical socket EK 9 Control card socket S NER S PPL 9181716151413 211 00 4 ozi 10 ALLFETT CENTRAL LUBRICATION SYSTEMS amp EQUIPMENT www allfett net RULES TO COMPLY WHILE USING AND WARRANTY 5 1 Damages occur while additional transports after delivering the goods from ALLFETT to the customer DISQUALIFIES THE WARANTY 2 Pumps are produced to lubrication purpose only and are not convenient to work more than 2 hours continuously Working under maximum pressure more than 2 hours will harm the system Damages occur from this reason DISQUALIFIES THE WARANTY 3 Washing of the pump with pressured water causes damage Any damage occur from this reason DISQUALIFIES THE WARANTY 4 Pump reservoir is made of transparent material to see grease level Painting any part of the pump is not recomended Any painte
15. riod The repairing period is maximum 30 days This period starts from the date of delivery of the product to the services centers or to the seller the agency the representative the importer or the manufacturer of the product respectively in case there are service centers In case the product has material workmanship or manufacturing defects the product will be repaired free of charge and expenses of any sort including labor the value of the parts replaced or any our charges The product will be replaced free of charge If the product permanently disfunctions due to repeating the same defect more than four times within the warranty period If the maximum period for repairing is exceeded If it is determined that the defect cannot be repaired by report written by the service or in the absence of service centers by the seller agency representative importer or manufacturer of the product respectively The present warranty does not cover damages resulting from importer handling by deviating from the instructions in the manual General administration of protection of consumer rights and competition in the ministry of industry and commorce may be applied for problems concerning the warranty certificate ALLFETT www allfett net CENTRAL LUBRICATION SYSTEMS amp EQUIPMENT DANGEROUS OR HARMFUL CONDITIONS TO ENVIRONMENTAL AND HUMAN HEALTH DURING USE All ALLFETT systems are producing according to relevant provisions of
16. security regulations There is no risk for environmental and human health during use TRANSPORT AND STORAGE There are no restrictions on transportation by land air and sea In general products should be stored in a dry and dust free environment The storage temperatures are between 10 C and 40 All products are packed with paper based support matarial to reduce damage Upon receiving the package please check the items for possible damage PAGE 18 ALLFETT EE m SYSTEMS amp EQUIPMENT ALLFETT MEKANIK VE ELEKTRONIK SISTEMLER SAN VE TIC LTD STI Top ular Mahallesi Top ular Caddesi No 1 1 Ey p Istanbul Telefon 0 212 501 32 01 PBX www allfett net Fax 0 212 501 33 37 info allfett net
17. the units and the use of unouthorized spare parts and aids prohobited also disgualify the warranty PAGE 6 RLUF TT valet nt CENTRAL LUBRICATION SYSTEMS amp EQUIPMENT PUMP ELEMENT DESCRIPTION ALL 1 grease pumps are available in several displacement volumes These volumes can be created with pump elements which are optionally offered 1 to 6 Pump elements can be applied onto ALL 1 pump body to take grease out Even though single pump element can be used as outlet multiple pump elements can be bridged as single outlet to get more displacement Pump element is equiped with security relief valve to protect any damage may occure from high pressure Lubrication system pressure is increasing when a lubrication point is blocked Up to 450 bar pressure lubrication system s working pressure can be adjusted by security relief valve Lubricant with over pressure will be out from exhoust hole Pump elements are manufactured in 3 types according to diplacement amounts These types can be described as its piston diameter with 5 mm piston pump elements outlet displacement is 1 5cm3 minute with 6 mm piston pump elements outlet displacement is 2 5cm3 minute with 7 mm piston pump elements outlet displacement is 3 5cm3 minute Exhaust hole 2 r Security relief valve adiust screvv Suction hole Piston Spring Outlet coupling AN ere elements are offered optionally When ordering a pump pump elemen
18. ts have to be ordered separately according to displacement properties PAGE 7 ALLFETT www allfett net CENTRAL LUBRICATION SYSTEMS amp EQUIPMENT LUBRICANT INFORMATION Lubricant specifications can be used with ALL 1 pumps are described below Before filling reservoir please read carefuly these informations Lubricant will be used in the system must certainly be clean and any foreign materials must not enter while filling ALL 1 pumps are designed to use with in centralized lubrication systems only It is not suitable to use ALL 1 pump for lubricant tranfering or circulation purpose important that the county specific regulations and laws on the use and disposal of To remind that lubricants has content which may hazardous to environment It is lubricants must be observed Lubricant type GREASE NLGI classes can be used with ALL 1 pumps are described below Because of the flow characteristics of grease the NLGI class range should be changed at different weather conditions and also temperature differencies for NLGI 00 grease recomended working temperature is between 30 C and 109C for NLGI 0 grease recomended working temperature is between 10 C and 0 C for NLGI 1 grease recomended working temperature is between 0 C and 10 C for NLGI 2 grease recomended working temperature is between 10 C and 30 C for NLGI 3 grease recomended working temperature is 30 C and over A Keep in mind that the substances of any lubricant ar
19. ualify the warranty TECHNICAL SERVICE ALLFETT MEKAN K VE ELEKTRONIK S STEMLER SAN VE T C LTD T Yeni Ey p Bulvar Top ular Caddesi Set st No 1 Demirkap Rami Istanbul Telefon 0 212 501 32 01 PBX www allfett net Fax 0 212 501 33 37 info allfett net PAGE 13 ALLFETT www allfett net CENTRAL LUBRICATION SYSTEMS amp EQUIPMENT PUMP ELEMENT First use of the pump after filling reservoir air mut be send out from pump element s To do this operation please read description below A Filling the pump must be done by grease nipple on pump body Remove connected tube from pump element s outlet coupling Loose pump element from pump body for 2 3 turns Start to operate pump When grease coming from around pump element body tighten again pump element body to pump Pump should run contiuously untill grease without air is seen from pump element outlet When the grease without air seen from pump element outlet coupling must be tightened to outlet again With this process pump element is now ready to send grease to lubrication point Grease coming out from end point of lubrication line may take long time according to line length If problems may appear while operate a Pump element piston spring may broken Remove the pump element and spring carefully Pay attention spring does not fall into body Change the spring if necessary b Pump element s piston may blocked Rem
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