Tri-Lube Grease Pump Package User Manual
Contents
1. e cere e 1 1 1 2 SAPETY INSTRUCTIONS icio tator ttt eterne aee 1 1 1 3 DESCRIPTION ict i Eta erbe rete e rue d oe eet hee uates 1 1 1 4 OPERATION dte eo asd dao 1 2 1 1 GENERAL 1 2 SAFETY INSTRUCTIONS 1 1 1 This User Manual is intended to familiarize the user with a Read all of the applicable instructions before the Tri Lube grease pump and its various features operating your lubrication system It contains important information for safe correct oe i b Keep all operating instructions near system for and economical operation of the grease pump Following future reference the instructions will help avoid hazards reduce downtime and repair costs increase the reliability and c Incorrect use or unauthorized system changes may prolong the service life of the entire system result in bearing damage caused by under or over lubrication 1 1 2 This User Manual must be read and used by those who will work with the complete lubrication system d existing safety equipment must be modified when attaching the lubrication pump and system to 1 1 3 Other useful Graco Trabon Bulletins the machine a Bulletin 40000 Series Progressive System e lf any safety equipment is removed to allow Installation Guide mounting of the lubrication pump or system it must be re assembled prior to machine and or b Bulletin 30103 How to Remove Air from a Series lubrication system ope2. 2000 2 3 LIST OF ILLUSTRATIONS NUMBER TITLE PAGE NUMBER TITLE PAGE 1 1 PUMP a 1 2 3 5 EGGENTRIE a oett tabe vus 3 2 2 1 PUMP 10 2 1 3 6 DC MOTOR GOVEB tee 3 3 2 2 ELECTRICAL a 2 1 3 7 DG MOTOR LEADS oett 3 3 2 3 TYPICAL PUMP PACKAGE 2 2 3 0 MOTOR ATTACH SCREWS 3 3 2 4 ADD PUMP a 2 2 3 9 PUMP DISASSEMBLED 3 3 2 5 RELIEF VALVE ADJUS TM EN 9 3 3 10 AC MOTOR amp REDUCER 3 4 9 6 OUTPUT a 9 3 3 11 AG MOTO Rinse 3 4 3 1 RESERVOIR COVER nnns 3 1 4 1 DC PUMP PARTO 4 1 3 2 RESERVOIR amp a 3 1 4 2 AC PUMP PARIS 4 2 3 3 RESERVOIR amp PADDLE e 3 2 4 3 11 LB RESERVOIR PARTS een 4 3 3 4 RESERVOIR amp BEARING 3 2 LIST OF TABLES NUMBER DESCRIPTION PAGE NUMBER DESCRIPTION PAGE 2 1 OUTPUT 22 221 2 3 4 2 AC PUMP PARTS LIST 4 2 4 1 DG PUMP PARIS 4 1 4 3 WAGE RES PARIS EIS T 4 3 Tri Lube Grease Pump Package User Manual L42255 OPERATION AND SERVICE INSTRUCTIONS SECTION 1 INTRODUCTION ti GENERAL 5
3. a Number 2 and 3 Phillips Screwdrivers 3 must have a long blade b 4mm Allen Wrench c 8mm Open End Wrench d 27 Open End wrench e 3 8 Ratchet Wrench and Extensions f 3 8indrive 17 mm Socket 3 2 REPLACING LOW LEVEL SWITCH RESERVOIR COVER AND FOLLOWER ASSEMBLY SEE FIG 3 1 amp 3 2 NOTE Replacement Low Level Switches are available as part of a Low Level Switch Cover Follower Assembly only 3 2 1 Remove four cover screws 3 2 2 With slight rocking motion of cover withdraw follower low level switch assembly from reservoir 3 2 3 If suction below follower cannot be broken by rocking motion remove one or more pump position plug 3 2 4 Reassemble in reverse order 3 7 REPLACING AC MOTOR e Cover Attaching Screws Figure 3 2 L42255 Pump Position Plug Pump Position Plug Removed Tri Lube Grease Pump Package User Manual 3 3 3 3 1 3 3 2 3 3 3 3 3 4 3 3 0 3 3 6 3 4 3 4 1 3 9 3 5 1 3 5 2 3 5 3 REPLACING RESERVOIR SEE FIG 3 3 amp 3 4 Following removal of reservoir cover and follower assembly as outlined in 3 2 above remove any grease using a clean scoop and clean rags Remove paddle retaining nut Note nut and shaft have left hand threads Remove paddle drive adapter adapter and shaft have left hand threads Remove five reservoir to pump body attaching screws from inside reservoir Remove reservoir from pump body N
4. 7500 PSI 1 to 20 points from a single valve assembly up to 400 points from a Master Secondaries circuit or systems that handle an entire plant PUMPS fixed and variable displacement manual and air hydraulic electric motor or mechanically driven TIMER AUTOMATIC CONTROLS from simple on off to complete flow and pressure monitoring either timer or machine actuated ACCESSORY VALVES balancing check and flow INDICATORS performance and broken line ACCESSORIES fittings brackets clamps filters and strainers All written and visual data contained in this document are based on the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice Contact us today To receive product information or talk with a Graco representative Call 800 533 9655 or visit us online at www graco com 2006 2009 Graco Inc Form No L42255 Rev B 3 09 Printed in U S A All other brand names or marks are used for identification purposes and are trademarks of their respective owners All written and GRACO visual data contained in this document are based on the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice
5. Make sure that power of correct voltage is being supplied to motor and that motor is operating d If power is not present check fuses and wiring and correct any problems found refer to section 2 2 If power is present and motor does not operate remove pump element Refer to section 2 5 and check for motor operation If motor still does not operate replace motor refer to section 3 4 and 3 5 If motor operates check for bent or binding components pump piston and cylinder cam and retract ring or gear reducer Replace any damaged components refer to sections 3 3 3 4 and 3 5 9 2 0 2 2 LOW LEVEL SWITCH DOES NOT SIGNAL LOW LEVEL Make sure that level switch is properly wired see figure 3 1 and correct any problems found Make sure that the follower tracks the drop in grease level to the bottom of the reservoir d If follower appears stuck in reservoir at mid travel there is most likely a pocket of air between the bottom of the follower and the top of the grease column Purge air pocket by filling reservoir until follower is just above vent hole in reservoir side wall and grease free of air is seen at vent refer to section 2 3 If follower tracks fall of grease level and switch does not signal replace Level Switch Cover Follower assembly refer to section 3 1 Look to GRACO Inc for all of your Centralized Lubrication System needs Products include DIVIDER VALVES for oil and grease to
6. SIESS S N hy D SGS 55 N Wh UIT 7 Ci lt RE eC D Ng JSO SSS L Figure 4 2 4 2 Tri Lube Grease Pump Package User Manual L42255 11 LB 5 KG RESERVOIR Switch Low Level 6 Cover Reservoir 09 Seal V Follower 529 905 076 Gasket 529 905 080 Follower 529 905 075 Seal Follower Rod 529 905 074 Tr Ca n ap ia ANAS 1 p KENN Figure 4 3 4 3 4 4 Tri Lube Grease Pump Package User Manual L42255 4 4 Blank Tri Lube Grease Pump Package User Manual OPERATION AND SERVICE INSTRUCTIONS L42255 SECTION 5 TROUBLESHOOTING 51 PUMP DOES NOT PRODUCE 5 1 5 2 LL SWITCH DOES SIGNAL LL iussit cope 5 1 5 1 PUMP DOES NOT PRODUCE FLOW 9 1 1 5 1 2 5 1 3 Make sure that reservoir contains an adequate supply of air free grease that is pumpable at the operating temperature being encountered d If reservoir is empty refill following the instructions in section 2 3 and purge pump free of air If grease is too heavy for the temperature conditions empty reservoir and refill with grease of the correct NLGI grade number refer to section 2 3 If grease contains air pockets and pump is air bound empty reservoir and refill with grease that is free of air refer to section 2 3 On adjustable pumps make sure the output adjustment is not set to minimum refer to section 2 6 2
7. 905 066 1 52 90 06 1 529 905 087 1 59 90 08 O Ring Cover Seal O Ring Follower Rod Seal O Ring Follower Plate Seal Upper Gearmotor Cover Lower Gearmotor Cover SECTION 4 PARTS LIST 4 1 DC PUMP PACKAGE 4 4 LB 2 KG 5 4 1 4 2 AC PUMP PACKAGE 4 4 LB 2 KG RESERVOIR 4 2 4 3 1118 5 KG RESERVOIR 4 3 Table 4 1 L42255 4 1 Figure 4 1 Tri Lube Grease Pump Package User Manual L42255 AC PUMP PACKAGE 4 4 LB 2 KG RESERVOIR ORDERING INFORMATION Cmm 1 Switch LL Cover Follower 4 4Lb 2K o o 1 o 5990511 7 O Ring Reservoir to Body Seal o 1 52990 0833 10 EccenricAssembly A4 AO OE 1 5990 084 10 Eccentric Assembly 11 1b AO 1 52990 0855 12 j Sed22xi0x7mm o 1 _ 5299008 16 Reducer Gear 80 1 1 _ 5990 089 20 Bearing S R Ball 26x10x8 mm o 1 5990 05 24 Motor 230 460VAC 3ph 1 1 _ X 52990 0882 Element Pump Adjustable Fill Fitting 1 8 GMH 0 __ 59 90 086 Plug Pump Position 2202 59 90 068 0 Table 4 2 NS
8. Pump Housing Upper Motor 0 Cover GearMotor Figure 3 9 Tri Lube Grease Pump Package User Manual 3 7 3 7 1 3 7 2 3 7 3 3 74 3 7 5 3 7 6 REPLACING AC MOTOR SEE FlG S 3 10 amp 3 11 Turn off power to motor Remove cover from motor conduit box Tag motor leads and remove from terminals Remove four motor mounting bolts that attach motor to gear reducer Slide motor shaft with key out of hollow input shaft of gear reducer Reassemble in reverse order making sure that key is aligned with keyway in hollow input shaft of gear reducer Gear Reducer AC Motor Mounting Bolts Motor 4 Figure 3 10 Motor Figure 3 11 L42255 Tri Lube Grease Pump Package User Manual OPERATION AND SERVICE INSTRUCTIONS DC PUMP PACKAGE 4 4 LB 2 KG RESERVOIR ORDERING INFORMATION Description Quantity PartNo OldPartNo 1 SwithlL CoverFolower44lb 2Kg 1 529 905 111 Reservoir 4 4 Lb 2 Kg Plastic 529 905 053 8 O Ring Reservoir to Body Seal 1 52950509 11 Eccentric Assembly All DC Units 21 529590504 19 Seal 22xt0x7mm 1 52905058 15 Geamoori2VDC 21 529505050 18 Bearing S R Ball 26x10x8mm 1 52990505 20 Plug Pump Position 1 2 529505068 22 FillFiting V 8GMH 1 52950506 Connector Electrical with Cover 1 59 90 15 0 1 52 90 02 529
9. Tri Lube Grease Pump Package User Manual Tri Lube Grease Pump Package PROVEN QUALITY LEADING TECHNOLOGY Tri Lube Grease Pump Package User Manual L42255 TABLE OF CONTENTS SECTION PARAGRAPH PAGE SECTION PARAGRAPH PAGE 1 0 INTRODUCTION 3 0 SERVICE AND REPAIR 1 1 GENERA ase 1 1 3 1 REQUIRED TOOLS indio ades e ee tones 3 1 1 2 SAFETY INSTRUCTIONS 1 1 3 2 REPLACING COVER LL amp FOLLOWER 3 1 1 3 DESCRIPTION 5 e e tec Eum 1 1 3 3 REPLACING 3 2 1 4 OPERATION 1 2 3 4 REPLACING ECCENTRIC SHAFT BEARING 3 2 3 5 REPLACING CAM 3 2 2 0 INSTALLATION 3 6 REPLACING DC 3 3 2 1 MOUNTING ecce ducet tta utut s 2 1 3 7 REPLACING AC 3 4 2 2 2 1 2 3 FILLING 00022 2 2 2 4 0 PARTS LISTS 4 1 THRU 4 3 2 4 PURGING AIR FROM 2 2 5 0 TROUBLESHOOTING 5 1 2 5 ADDING PUMP ELEMENTS 2 3 2 6 PUMP
10. ble at the lowest anticipated operating temperature Do not fill the reservoir with grease heavier than NLGI 2 For temperatures below 5 F 20 C use NLGI 1 or lighter grease Filling is accomplished by connecting a suitable transfer pump to the fill fitting in the front of the pump housing See Figure 2 3 Before connecting the transfer pump make sure that both the lube fitting and the coupler are clean and that the hose and transfer pump are full of clean grease that is free of air Vent Hole Pump Position Plug Figure 2 3 For the initial filling or if the reservoir has been allowed to run dry removing one of the pump position yellow plugs from the pump body will facilitate expelling air from the body and reservoir Slowly start to fill the reservoir until grease free of air flows from the open pump position At this point stop the transfer pump and re install the yellow plug After the plug is installed fill slowly until the follower seal is slightly above the vent hole in the reservoir tube This will allow air remaining below the follower to escape When grease free of air is seen at the vent stop filling 2 4 2 4 1 2 4 2 2 4 3 L42255 For subsequent re filling unless the reservoir has been allowed to run dry or air was pumped into the reservoir it will not be necessary to remove the yellow plug or fill above the vent hole PURGING THE PUMP AND SYSTEM OF AIR Operate the pump with t
11. he main line disconnected until grease free of air is seen at the pump outlet Fill and purge system lines and divider valves following the procedures outlined in Trabon Bulletin L30103 Once all lines and dividers have been purged free of air reconnect pump to mainline Figure 2 4 Tri Lube Grease Pump Package User Manual 2 9 2 5 1 2 5 2 2 5 3 2 5 4 2 5 5 2 5 6 2 5 7 ADDING PUMP ELEMENTS CAUTION To avoid personal injury or severe internal damage to the drive train or pump element these procedures must be followed carefully Disconnect power to the pump motor Remove sealing plug 1 figure 2 4a Pull out pump piston 2 until it extends approximately 1 1 8 29 mm from end of cylinder to end of mushroom head Insert element into housing at approximately a 15 degree angle as shown in figure 2 4b NOTE If pump is full of grease it will be necessary to clear a path through the grease using a clean screwdriver Rotate element down figure 2 4c engaging mushroom head between cam 3 and retracting ring 4 Tighten element 18 22 fl lbs 25 30 N m Do not over torque as housing threads will be stripped Fill reservoir with clean grease See Section 2 3 and run pump for 1 minute to check for grease output If none is seen it could indicate that the element was not properly installed Figure 2 5 2 6 2 6 1 2 6 2 L42255 PUMP ADJUSTMENTS Adjusting the Relief Valve Fach pump
12. ing element incorporates an adjustable relief valve to protect the system against overpressure The relief setting can be adjusted by loosening the locking nut 1 See Figure 2 5 and turning the cap clockwise to increase the relief pressure and counterclockwise to decrease the relief pressure as required by the system application CAUTION Do not adjust above 2900 psi 200 bar for DC pumps or 5075 psi 350 bar for AC pumps as pump or motor damage may result Pump Output Adjustment The nominal delivery rate of the pumping element can be adjusted by loosening the locking nut 1 See Figure 2 6 and rotating the adjustment screw 2 clockwise to reduce delivery or counterclockwise to increase delivery of the lubricant The output adjustment table describes the equivalent outputs that can be obtained by varying the distance A of the adjustment screw See Table 1 Figure 2 6 Tri Lube Grease Pump Package User Manual L42255 2 4 Blank Tri Lube Grease Pump Package User Manual OPERATION AND SERVICE INSTRUCTIONS SECTION 3 SERVICE AND REPAIR 3 1 REQUIRED TOOLS 3 2 REPLACING COVER LOW LEVEL amp FOLLOWER 3 3 REPLACEMENT RESERVOIR 3 4 REPLACING ECCENTRIC SHAFT BEARING 3 5 REPLACING ECCENTRIC amp PISTON RETRACT RING 3 6 REPLACING DC GEARMOTOR 3 1 REQUIRED TOOLS 3 1 1 The following standard hand tools plus a vice with padded jaws are required for disassembly and repair of the Tri Lube Pump Package
13. operating sequence d Grease in the reservoir keeps the pump body full during normal operation and maintains a head pressure to accomplish two objectives e Provide constant lubrication to the moving pump components e Supply lubricant to the piston chamber in the pump cylinder A rotating cam Item 1 forces the pump piston Item 2 forward displacing lubricant from the pump cylinder past an internal discharge check valve and out of the pump outlet As the cam Item 1 continues to rotate the pull back ring Item 3 pulls the pump piston Item 2 back to the prime position allowing grease to re prime the piston chamber for the next stroke Also attached to the eccentric shaft is a paddle not shown with an angled surface that forces grease into the pump chamber as it rotates and also aids in dispersing any small air pockets that might be present in the grease Outlet Tri Lube Grease Pump Package User Manual L42255 OPERATION AND SERVICE INSTRUCTIONS SECTION 2 INSTALLATION 21 MOUNTING 2 1 VIRINO N 2 1 2 9 PILLING RESERVOIR 2 2 2 4 PURGING AIR FROM PUMP eene 2 2 2 5 ADDING PUMP ELEMENTS eene 2 3 2 6 PUMP 6 460020 0 2 3 21 MOUNTING THE PUMP 2 1 2 The pump is mounted using two 5 16 or two 8 mm 7 bolts furnished by user tha
14. ote If eccentric shaft bearing will be reused and remains in old reservoir remove it from the old reservoir bearing cavity bearing is a light push fit in cavity Reassemble in reverse order REPLACING ECCENTRIC SHAFT BEARING SEE FIG 3 4 Following removal of the reservoir as described in 3 3 above the bearing will either be on the eccentric shaft or in the bearing cavity of the reservoir bearing is a lightpush fit in both components Remove the old bearing and check both the eccentric shaft and the bearing cavity for scoring a is found the new bearing may be installed in the bearing cavity a If scoring in either location is found it may be possible to clean up the surface with fine 600 grit wet or dry paper a If severe or if the scoring cannot be cleaned up replace the damaged components along with the bearing REPLACING ECCENTRIC AND PISTON RETRACT RING SEE FIG 3 5 Following removal of the reservoir cover and the reservoir as outlined in 3 2 amp 3 3 above remove spacer from eccentric shaft Note If pump element was not previously removed remove it now following the instructions in Section 2 5 Eccentric and retract ring can now be slipped off eccentric shaft as a unit NOTE Do not attempt to disassemble eccentric from retract ring as individual repair parts are not available Reassemble in reverse order L42255 Paddle Nut Left Hand Threads Figure 3 3 Reservoir A
15. ration Progressive System f Keep lubrication system away from any high heat Bulletin 30101 How to locate Blockage in a Series source Progressive System g Disconnect and lock out electrical power source before attempting any repairs to the Tri Lube Pump Package h Use only original replacement parts Tri Lube Grease Pump Package User Manual 1 3 1 3 1 DESCRIPTION All Tri Lube Pump Packages consist of the following components d A reservoir for holding the lubricant Reservoirs are cylindrical in shape and are made from transparent plastic or metal depending on the specific model Each reservoir is equipped with a low level switch activated by the follower assembly and a rotating paddle to assist priming of the pump A pump element is available with either a fixed or adjustable output All pump elements are equipped with an adjustable relief valve that relieves to atmosphere A second or third pump element can be added in the field to supply additional output volume or additional lube points where required A gearmotor 12 or 24 VDC or a motor and gear reducer 115 or 230 VAC 1 ph or 230 460 VAC 3 ph which drives the pump A pump body which houses the pump drive eccentric and to which all other components are attached Fixed Pump Element 1 4 Figure 1 1 L42255 OPERATION Figure 1 1 shows the general relationship of the pump element and the drive eccentric The following steps outline the
16. t pass through the mounting 2 1 1 The pump should be mounted in a vertical position with feet on the pump body The mounting bolt length will the reservoir at the top and in a protected location but depend on the thickness of the mounting surface where it is accessible for filling and routine maintenance and whether the holes are to be tapped for the bolts or locked in place with nuts and washers Mounting dimensions are shown in Figure 2 1 2 2 WIRING THE PUMP 2 2 1 Electrical connections are shown in Figure 2 2 2 2 2 Wiring to the AC motors should be 16 AWG stranded wire with insulation rated for 300 V max and 105 C 2 2 3 The DC pump motors and all low level switches may be Qo wired with 18 AWG stranded wire cable DC Motor Front View Figure 2 2b AC Cantoni amp ABB Motors Figure 2 2c DC Moto Technica 1ph Motors See NOT E AC Motor Front View AC Motor Side View a DLA paid ro POSITION 1 i SEAVOR 2 hl 27 pn FIT TIRES AUF 3 Top View DC and AC LOW LEVEL SWITCH WIRING SCHEMATIC Figure 2 1 Figure 2 2 2 1 Tri Lube Grease Pump Package User Manual 2 3 FILLING THE RESERVOIR 2 3 1 2 3 2 2 3 3 The reservoir should be filled with clean air free grease of the type recommended by the machine builder and having an NLGI grade number consistent with the ambient operating temperature of the equipment grease must be pumpa
17. ttaching Screws 5 Bearing Figure 3 4 Pump Motor Attaching Screws 3 Eccentric amp Pull Back Ring Tri Lube Grease Pump Package User Manual 3 6 REPLACING DC GEARMOTOR SEE Fic 3 6 3 7 3 8 amp 3 9 3 6 1 Following removal of the reservoir cover reservoir and eccentric assembly as outlined in 3 2 3 3 and 3 5 above remove key from eccentric shaft 3 6 2 Remove spacer from shaft 3 6 3 Invert pump unit and remove eight retaining screws from lower motor housing Separate lower housing from upper housing 3 6 4 motor leads approximately in from old gearmotor 3 6 5 X Remove lower housing leaving leads in place and set aside 3 6 6 X Remove three motor attaching screws with copper washers from inside pump housing 3 0 7 Separate pump housing upper motor housing and gearmotor using care to avoid damaging the eccentric shaft seal 3 6 8 sure replacement gearmotor is correct voltage 24 VDC or 12 VDC 3 6 9 new gearmotor leads to approximately 3 in length and strip in insulation from each lead 3 6 10 Strip 1 4 in of insulation from mating power leads Use wire nuts or crimp type wire connectors to splice leads making sure that red is connected to red and blue to blue 3 6 11 Reassemble in reverse order Motor Cover Motor Cover Attaching Screws 8 Figure 3 6 L42255 Upper Cover Lower Cover Figure 3 7 Motor Attaching Screws 3 Figure 3 8
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