SERVICE & MAINTENANCE MANUAL
Contents
1. 4 5 Low Level Sensors These highly reliable capacitive sensors are fully sealed and encapsulated to operate in the most arduous conditions with NLGI 2 grease Fig 6 shows pictorial view and Fig the version for a 3 litre pump Extensions are used for larger capacity reservoirs Low Level Kit Part No Description HDI SP9 3P 3 Ltr Moulded Kit HDI SP9 6 6 KG Standard Kit 9 KG Standard Kit 15 KG Standard Kit HDI SP9 9 HDI SP9 15 Kit comprises of pump connector low level and plug 4 6 Proximity sensor Conversion kit Proximity alarm plug A plus pump plug with internal loom to PCB Part No Description HDI SP9 Low level External Alarm Facility B C HDI SP4 HDI SP8 Power push button plug with 10m cable A Proximity alarm plug B C Control Card 12 24V HDI SP15 Low level connection Proxy connection Power connection Motor Connection HDI SP15 9 HDI PROGRAMME SETTING Programming the HDI Gontroller Programming is carried out using the select and enter buttons as shown in the picture The setting details are shown on the digital display at each stage Pump Run Time Options With Time ON Mode t from 1 min to 99 mins Pump Delay Time Variable from 1 min to 99 hours 59 mins Time ON Time OFF mode Press select and enter buttons together for 5 seconds to enter programme mode 1 Display will snow ST Run time Press enter button then select button to set r2. e Tubing to the lubrication points e Fittings at the lubrication points These pumping units either fixed or adjustable output fixed pumping elements are fitted as standard feed lubricant to Fig 1 r Low Level the primary divider valve which in turn feeds where applica ble further secondary divider valves The bearings on the Ordering Method u F E daj machine plant are connected to the secondary divider valves by hose or tube bearings can also Mains supply HDILILILILIL_ be fed direct from the pump oss Earning uns 3 End of line Low Level A All pumps have dual fill options quick fill and grease nipple woe Primary Divider Valve size Kr tT oa W 3 COMPONENT OPERATION 3 1 HDI Pump Outputs All HDI Pumps are supplied with one pump element as standard Up to three pump elements can be fitted into one HDI pump Fig 3 Pumping Unit Spares Pump Elements Standard Pump Spring Return Element PU 300 350 PU 400 350 Els k Bis nin ee eee 1 m m E E m E U i 1 PT Er s ug e EE Bu m J 1 k A mot eee r a g L mo i f u Pump Elements USA Pumps Push Pull Element PU 300 350 A PU 400 350 A m LE FT Ness B FAA SO aan Operation The pump element piston sucks the grease from the The electric motor drives an eccentric cam during the
3. Delivery sequence The commencement of the delivery sequence depends on the position of the delivery pistons In each case the lubricant divider valves operate until all the lubricant which has been supplied is completely delivered If the lubricant Supply is interrupted by a pause in the lubrication then after supply is resumed the delivery sequence will be continued where it was Stopped Outlet combinations When an outlet is closed with one of the closure plugs the lubricant is automatically redirected internally to the next adjacent outlet in descending numerical order Note Outlets 1 and 2 must never be closed 13 1 DIVIDER VALVES Standard Progressive Divider Valves PartNo Number of outlets Monitoring SPL 06 6 SPL 06K 6 Indicator Pin SPL 08 8 SPL 08K 8 Indicator Pin SPL 10 10 SPL 10K 10 Indicator Pin SPL 12 12 SPL 12K 12 Indicator Pin SPL 14 14 SPL 14K 14 Indicator Pin Divider valves with _ Standard Divider Valve visual indicator pin Divider Valves Monobloc design with number of outlets from 6 to 14 Each outlet delivers 0 20ccs cycle Crossporting and single outlets possible Available with cyclic indicator pins Max operating pressure 350bar Operating temperature 30 C to 100 C Outlets Tapped M10 x 1 Inlet Tapped 1 8 BSP Proximity sensor an option 13 2 DIVIDER VALVE ACCESSORIES Proximity Switch SPL 512 4482 Proximity Adapters SPL36713 1 IMPORTANT All SPL DIVIDER VALVE OUTLETS MUST
4. Grease Nipple with Adaptor with Adaptor EDR KBM Quick Fill Adaptor MALE A HDI SP28 Blanking Plug pa HDI SP10 C Standard Reservoir Seal BA HDI SP11 3 Paddle Blade Assy for 3Ltr Reservoir 1 Nut Included HDI SP11 6 Paddle Blade Assy for 6Ltr Reservoir 1 HDI SP11 9 Paddle Blade Assy for 9Ltr Reservoir 1 HDI SP11 15 Paddle Blade Assy for 15Ltr Reservoir 1 HDI SP5 3 Spare Low Level Sensor 3LTR HDI SP5 6 Spare Low Level Sensor 6LTR Lead Nut amp Washers Incl HDI SP5 9 Spare Low Level Sensor 9LTR HDI SP5 15 Spare Low Level Sensor 15LTR HDI SP29 Reed Switch Supplied with no Control Version HDI 17 13 HDI PROGRESSIVE SYSTEM EXAMPLES USING INTERLUBE SPL VALVES 16 Lubrication points from one central application point Feed from HDI Pump 2 Primary Valve 26 Lubrication points from one central application point Feed from HDI Pump Secondary Valves closed outlet X open outlet in cm3 stroke gt lubricant output in cm3 stroke 18 Specification and outlet combinations for the lubricant divider valves Since the divider valves are positive progressive piston displacement devices it means that whatever quantity of lubricant is continuously supplied to the inlet port it is positively divided in relation to the outlet port combinations and equals the sum total of the output quantities
5. Programme complete re Notes To view current programmed settings a press the select button for 10 seconds this will activate the programme view mode displaying the setting of each Step for 3 seconds After showing PC for 3 seconds the pump will return to run mode Low level warning b If a low level alarm is triggered the pump will continue operating and any alarm warnings will continue until the reservoir is re filled OFF TIME PROGRAMMED CYCLE To prime the system c set the delay time to 00 hours and 00 minutes Please note this time setting is not intended as an operating mode Note The manual override button on the pump can be operated at any time without the need for the ignition circuit to be on a positive safety benefit Operating the manual override will Start one cycle of the pre set run time 6 PUMP DIMENSIONS Diagram shows a standard HDI pump C Front elevation cumpi Dimensions Side elevation 7 TECHNICAL DATA 3 Ltr Moulded 340mm Ma sirenai 7 1 Pump with integral controls 6 Ltr Standard Available with 3 6 9 or 15 litre reservoirs Supplied in either 12 or 24v DC Output speed 19 23 9 Ltr Standard 490mm 191 2 15 Ltr Standard 700mm 271 2 i j RPM f m 12v DC max running current 5A Mounting Positions of the HDI Pump 24v DC max running current 5A Standard HDI 3 6 9 15 Ltr Start up current 10A 180mm 7 PCB dual voltage am
6. 18 KG cover 265mm to 310mm IL 108502 USA Pump 35Ib cover 285mm to 330mm HDI 57549 1 IL 417001 Grease follower plate 260mm to 298mm IL 417003 Grease follower plate 300mm to 340mm 11 9 TROUBLESHOOTING PROBLEM A All lubrication points appear dry One or more lubrication point appears dry while others receive sufficient lubrication All lubrication points are over lubricated One or more lubrication points are over lubricated Inoperative pump F Inoperative Pumping Unit G Grease flowing from Pumping Unit Relief Valve POSSIBLE CAUSE REMEDY Empty reservoir Inoperative pump Time between lube cycle is too long Reservoir has been filled with an unsuitable lubricant Inoperative Pumping Unit Pumping unit not sitting in cam ring USA Version Main Pressure Line damaged broken Reservoir vent blocked from over filling Broken or severed secondary grease lines Incorrect specification of divider valves Incorrect setting of on time or Delay Time Incorrect specification of divider valves No input power Fuse is blown Loose wire connection inside the pump Defective PCB Defective Motor Pumping Unit not sitting in cam ring USA Version Inoperative Pump No Grease flow One or more lubrication points are blocked and will not accept grease Fault in Divider valve assembly 12 Refill t
7. BE FITTED WITH SPL CHECK VALVES OR s BLANKED OFF WITH SPL CLOSURE Check Valve Outlet Fittings PLUGS NEVER BLANK PORTS 1 amp 2 ONA SPL VALVE pd SPL 30364 4 M10x1 Check Valve SPL 12374 9 6mm Nut SPL 12295 2 6mm Olive Closure Plug SPL 17499 3 19 Plymouth Factory UK For all Accessories refer to our Catalogue request from Interlube Systems Ltd or look on our website www interlubesystems com p anss j 27Oj 1 Sal1ossao0y Interlube Group Interlube Systems Ltd St Modwen Road Parkway Industrial Estate Plymouth Devon England PL6 8LH Tel 44 0 1752 676000 Fax 44 0 1752 676001 e mail info interlubesystems com Web Site www interlubesystems com USA Headquarters Interlube Systems Malaysia Sdn Interlube Systems Inc 30 Jalan Appollo U5 189 Bandar Pinggiran Subang Sesyen 4696 Wadsworth Road Dayton Ohio 45414 USA 40150 Shah Alam Selangor Malaysia Tel 1 937 276 4507 Fax 1 937 276 4518 Tel 603 7845 5377 Fax 603 7845 5977 e mail nmackay interlubeusa com Email acllube streamyx com ISSUE 02 2011
8. page 6 and wiring diagram on page 6 4 End of line or primary flow proximity sensor alarm connection not supplied as standard on base models 4 4 Remote Alarm Functions The HDI Pump can be supplied with or without an internal controller PCB The pump without control facility is fitted with an internal reed switch this can be used to monitor the pumps internal cam rotation Flow Alarm The pump with control facility has an in built alarm function which can be connected to an external alarm relay as an option In general the HDI is connected to progressive divider valves as illustrated The progressive divider valves are designed to feed a positive set amount of grease to each connected point in turn without missing a point out The primary divider valve is fitted with a proximity flow indicator switch which will signal positive flow back to the HDI PCB Should the pump operate and the PCB not receive a flow signal the pump would alarm This alarm signal could be connected to an external remote audio or visual alarm on the machine or alternatively connected to the machines PLC The PLC could be programmed to stop the machine from operating should the lubrication system fail to operate correctly Wiring for Alarm Switch Primary divider valve fitted with p proximity flow indicator switch RELAY OPTIONAL zm 1 Secondary divider valve PROXIMITY BLACK SWITCH OPTIONAL BLUE
9. seat the piston 3 into the cam ring 4 Tighten the pumping unit body 1 using the 27mm AF spanner 3 3 Relief Valve Settings PU 300 350 The relief valve is a fixture of the pump elements both spring return and push pull type The relief valves are factory set to 350 Bar to protect the pump from damage should a blockage occur in the system The relief valve can be adjusted manually to vent at lower pressure this can be adjusted on site using a standard spanner 4 WIRING 4 1 WIRING DETAILS Wiring Diagram for HDI Pump With Gontrols Fuse SAMP Red BATTERY VE Yellow Green BATTERY VE Fuse SAMP Blue IGNITION epee nr ee I I CAB MOUNTED LAMP OPTION Black CAB MOUNTED MANUAL OVERRIDE OPTION SWITCH Pump supplied with power push button plug with 10m of 7 4 2 Wiring Diagram for HDI core cable Without Controls MOTOR ve REED SW Note Red Terminal 5 is connected to the ignition of the vehicle or mobile plant If terminal 1 is connected to the Battery then the pump will operate without the ignition on MOTOR ve REED SW Brown Grey Push Button Push Button Wiring diagram White 12V HDI 36070 5 24V HDI 36070 6 4 3 ALARM FUNCTIONS 1 Pump elements see page 4 amp 5 2 Low level connection not supplied as standard on base models 3 Power cable 30ft and 7 pin connector supplied as standard with all models see details on
10. 1 Using a 27mm AF spanner loosen pumping unit body Remove spring loaded pumping unit Ensure there is no loose dirt around the pumping unit aperture then screw in the new pumping unit tightening with a 27mm AF spanner 11 Pump Exploded View 3Ltr Moulded 11 1 Parts List pe Omni ww 1 HDISP7 3P 3 LT Reservoir 0 Ring SP10 P and Screws Incl 2 HDISP13 P Restrictor Plate a 3 HDI SP4 HDI SP4 A Cam Assy amp Seals i 1 1 4 HDI SP26 Blanking Plug HDI SP8 Proximity Alarm Plug Conversion Kit with 1 Internal Loom HDI 2P12 12 24 7 Way Connector Assy amp PCB 1 Gasket 7 Way Connector Screws and 7 Internal Loom 12 24V Pin Hirschmann CNCTR Incl 1 Gaskets Connector Base Screws amp Din Connector Incl 1 1 1 1 1 HDI SP9 3P Low Level Conversion Kit with Internal Loom Low Level sensor HDI SP24 Bottom Cover Assy a Screws Seal amp Vent Incl Cam for spring return pump element Cam for push pull pump element Gaskets Connector Base Screws amp Din Connector Incl HDI SP2 Spare HDI 24V Motor HDI SP18 Housing W O Controls HDI SP19 Housing with Controls ARAE EUREN HDI SP27 Grease Nipple with Adaptor 1 HDISP3 Quick Fil Adaptor VALE KMN ww Aach i Spring Return Pump Element PU300 350 A Pump Element with PRV UNIT 350BAR ush Pull Pump Element 1 HDI SP11 3P Paddle Blade Assy Nut Included HDI SP10P Reservoir Seal 3LTR Moulded KR sh HDI SP5 3P Spare Low Level Sensor 3LTR Lead Nut amp Wa
11. LL0Z7Z0 INSSI BE ATIMKEN Brand SAFETY As with all equipment all due care must be used when servicing the HDI lubrication system Throughout this manual there will be information provided which requires special attention This information will be displayed under the headings of WARNING CAUTION or NOTE UK Headquarters Interlube Systems Ltd St Modwen Road Parkway Industrial Estate Plymouth Devon England PL6 8LH Tel 44 0 1752 676000 Fax 44 0 1752 676001 e mail info interlubesystems com Web Site www interlubesystems com USA Headquarters Interlube Systems Inc 4696 Wadsworth Road Dayton Ohio 45414 USA Tel 1937 276 4507 Fax 1 937 276 4518 e mail nmackay interlubeusa com Interlube Systems Malaysia Sdn 30 Jalan Appollo U5 189 Bandar Pinggiran Subang Sesyen 40150 Shah Alam Selangor Malaysia Tel 603 7845 5377 Fax 603 7845 5977 Email acllube streamyx com TABLE OF CONTENTS 1 INTRODUCTION 2 GENERAL DESCRIPTION 3 COMPONENT OPERATION 3 1 Pumping Units 3 1 Pump Operation 3 3 Relief Valves WIRING 4 1 Wiring with Controls 4 2 Wiring without Controls 4 3 Alarm Functions 4 4 Remote Alarm 4 5 Low Level 4 6 Pump Connectors Go CO NI NN amp G amp G CO ao A R CJ CJ PROGRAMMING PUMP DIMENSIONS TECHNICAL DATA 8 PUMP FILLING mak 9 TROUBLESHOOTING N 10 SERVICE PROCEDURES 10 1 Lid Replacement all Mod
12. els 10 2 Reservoir Replacement all Models 13 10 3 Paddle Blade Replacement all Models 13 10 4 PCB Replacement all Models 13 10 5 Pump Element Replacement 13 11 PUMP EXPLODED VIEW Moulded 14 11 1 Parts List Moulded 15 h O W 12 PUMP EXPLODED VIEW Standard 3 6 9 amp 15Kg 16 12 1 Parts List 17 13 HDI PROGRESSIVE SYSTEM EXAMPLES 18 13 1 Divider Valves 19 13 2 Divider Valve Accessories 19 __INTERLUBE ATIMKEN Brand 1 INTRODUCTION This manual gives instructions for operating maintaining Pumps are available with 3 6 9 and 15 litre reservoirs and servicing the Interlube HDI Pump amp Distribution Fig 2 shows 6 litre version There is a specific version for systems Because of the importance of providing the the USA with push pull style pumping units correct lubricant amount to the moving parts of the equipment read this manual to become familiar with your Fig 2 HDI pump and system Review and follow the procedures given before attempting maintenance or service Illustrations are provided to aid in disassembly and reassembly lf there are any questions not answered by this manual contact Interlube Systems 2 GENERAL DESCRIPTION A typical HDI lubrication system includes the following components see fig 1 e Pump with integral controls and reservoir Pumping Units The HDI pumps are electrically operated 12 24v DC piston Divider Valves pumps able to accept up to 3 pumping units
13. he reservoir using the correct lubricant Refer to PROBLEM E Adjust pump CYCLE TIME setting Remove the lubricant and replace with correct grade of lubricant Replace Pumping Unit Remove amp refit correctly Find breakage amp replace with new hose Clear vent and only fill to max level Determine cause and if necessary re route Re configure divider valve specification to higher output Reduce On Time or increase Delay Time or both Re configure divider valve specification to lower output Check for power to the pump and controller Check in line fuse Replace if necessary Check all wires and connections in the pump Replace PCB Replace Motor See Section 7 5 Refer to PROBLEM E Replace pumping unit Remove pipe from fitting and flush bearing through with grease gun Replace the faulty Divider valve 10 SERVICE PROCEDURES The rugged design and simple construction of the HDI lubrication system assures the operator of a long and trouble free service If service is necessary use the following procedures to ensure correct replacement of parts 10 1 Lid Replacement All models does not apply to moulded reservoir pumps 10 1 1 Remove 3 nuts 5 holding lid to tie rods 6 10 1 2 Remove lid 7 and O ring 8 10 1 3 Replace with new lid 7 and O ring 8 position on reservoi
14. p EMC compliant Built in memory recommencing either run or delay cycle on power up Transient protection to ISO 7637 Road Vehicles Dual LED digital display used for programming amp run information 9mm 11 39 Dia IP65 protected HDI 3Ltr Moulded Reservoir Model Uses lubricants from SAE 80 oil up to amp including 120mm 4 3 NLGI 2 Grease Operating temperature 40 C to 30 C using low temperature grease 2 fill options quick fill or grease nipple Can be used with divider valves Maximum of 3 pumping units per pump e Low level sensor an option 4 x holes 6 5mm 1 47 Dia 10 8 PUMP FILLING HDI FILLING METHODS HDI Dual Fill All HDI models are supplied with dual fill A standard grease nipple use air operated grease pump to fill the reservoir B quick release coupling use a hand operated volume bucket pump C Or alternatively fit the pump with a quick fill adapter and use a quick fill gun to fill the reservoirs Bucket Pump Quick Fill Gun Hand operated bulk fill pump complete with Hand operated quick fill gun 1 5m hose female quick release coupling to fit directly onto the Interlube quick connect fitting fitted to the Part No Description pump Ideal for use with NLGI 1 or 2 greases HDI 57549 1 Quick fill gun HDI 36763 1 Straight adapter for the pump HDI 36763 2 90 adapter HDI 36763 1 HDI 36763 2 Part No Description IL 108501 European Pump 12 5
15. r 3 and tie rods 6 tighten nuts 9 10 2 Reservoir replacement Clear models 10 2 1 Remove lid as in 7 1 10 2 2 Withdraw reservoir 3 and lower O ring 9 10 2 3 Clean around area where new reservoir will be fitted Position O Ring 9 and replace reservoir between tie rods 10 2 4 Replace lid as in 7 1 3 3 Litre moulded version 10 2 5 Remove the 3 screws holding the reservoir in position on the pump body 10 2 6 Remove reservoir and O Ring 10 2 7 Position new 0 ring on new reservoir 10 2 8 Re assemble reservoir to pump body ensuring the breather tube is closest to the mounting bracket 10 2 9 Insert amp tighten screws to torque 3Nm be careful not to overtighten screws 10 3 Paddle Assy Replacement All models 10 3 1 Remove lid and reservoir as in 7 1 and 7 2 10 3 2 Remove nut 10 and washer 11 then remove paddle 16 10 3 3 Replace new paddle 12 then washer 11 and nut 10 Tighten to 6 5Nm 10 3 4 Replace Reservoir and lid as in 7 1 3 and 7 2 3 13 10 4 Replace PCB All models 10 4 1 Remove 8 screws 13 securing the bottom cover 4 and O ring 15 10 4 2 Slide out PCB 18 from housing 19 and remove all the electric connectors 10 4 3 Replace all connectors on new PCB 18 and slide back into housing 19 10 4 4 Replace cover 14 and O ring 15 securing with 8 screws 13 Tighten to 0 6Nm 10 5 Pumping unit replacement spring return version Fig 9 10 5
16. reservoir and then dispenses an accurate precise amount of pumps operating time lubricant to the connected metering device Pump Output Standard HDI pump operates at 19 23revs min Part No Max output min pressure Output min Volume Pump Element Outlet Size 6mm 0 D Relief Valve 6mm 0 D Setting 6mm 0 D 350 BAR 6mm 0 D BAR PSI cc cu in 400 5860 32 0 20 PU 300 350 PU 300 350 A 400 5880 3 2 1 4 0 20 0 08 PU 400 350 400 5880 3 2 0 20 PU 400 350 A 400 5880 3 2 1 4 0 20 0 06 5145 PSI Operation conditions 40C to 30C The grease output figures were based on NLGI 2 Grease at ambient conditions the output volume may vary depending on lubricant specification and temperature USA Version Fig 4 USA Version Pumping unit replacement Using a 27mm AF spanner loosen pumping unit body 1 and unscrew until the thread is clear of the pump body 2 Tilt the pumping unit body 1 to lift the piston 3 clear of the cam ring 4 and then remove Ensure the piston does not remain in the pump body To replace unit pull out the piston 3 from the body 1 of the new pumping unit to the end of it s stroke Ensure the copper washer 5 is in position and insert the pumping unit body 1 into the pump body 2 This should be done with the pumping unit body 1 tilted upwards When the piston 3 touches the cam ring 6 the pumping unit body 1 should be moved to a horizontal position This should now
17. shers Incl HDI SP29 Reed Switch Supplied with no Control Version HDI HDI SP25 Bottom Cover Fixing Screws BULK as Eh 9 7 10 11 12 13 14 15 16 IA 18 19 20 1 2 15 12 Pump Exploded View 3 6 9 amp 15 Litre Standard 12 1 Parts List ii HDI SP7 3 3 LI Reservoir HDI SP7 6 6 LT Reservoir Tie Rods Nuts and O Ring Incl HDI SP7 9 9 LT Reservoir HDI SP7 15 15 LT Reservoir HDI SP4 HDI SP4 A Cam Assy amp Seals Seals Incl 5 PU3007350 Pump Element with PRV UNT 350 Bar pe W Lie GEL PU300 350A Push Pull Pump Element HDI SP8 Proximity Alarm Plug Conversion Kit with Gaskets Connector Base Screws amp Din Internal Loom Connector Incl 7 HDI SP12 12 24 i Way Connector Assy amp PCB Internal Gasket 7 Way Connector Screws and 7 Loom 12 24V Pin Hirschmann CNCTR Incl HDI SP9 3 HDI SP9 6 Low Level Conversion Kit with Internal Loom Gaskets Connector Base Screws amp Din HDI SP9 9 Low Level sensor Connector Incl HDI SP9 15 EE HDI SP24 Bottom Cover Assy ee Screws Seal amp Vent Incl 10 HDI HDISP25 Bottom Gover Fixing Screws BULK KM HDI a Spare HDI 12V Motor HDI SP2 Spare HDI 24V Motor HDI SP26 Bottom Cover O Ring BULK HDI SP14 Motor to PCB Loom CE 14 HDI HDISPIS 12 24V 12 24V Standard PCB CNTRL Board PCB CNTRL Board KAT DEE Housing Controls anta HDI SP19 Housing with Controls aSKEL Include 16 HDI HDISP27 Grease
18. un time in minutes from 01 to 99 for example 05 gives a run time of 5 mins Will provide run time from 1 min to 99 mins Press enter to accept 2 Display will show S2 Delay time Press enter button for example to set a delay time of 1 hour 20 mins press select button to display OI then enter to accept then select button to display 20 Press enter to accept 3 Display will snow S3 End of line switch setting Press enter button display shows EL press select to choose between a When EL is flashing end of line sensing is OFF or b When EL is continuously lit end of line sensing is ON Press enter to accept If end of line switch is ON next display will show Ol Select between Ol to 10 for the number of cycles of the lubrication system Press enter to accept 4 Display will show S4 low level option Press enter button display shows LL press select to choose between a When LL is flashing low level sensing is OFF or b When LL is continuously lit low level sensing is ON Press enter to accept 9 Display shows PC Programming complete After 10 seconds return to run mode CHANGING PROGRAMME Press select and enter buttons together for 5 Secs to enter programming mode 1 Display will show 5 2 Press select button to choose the setting you want to change 52 53 etc then press enter 3 After making the change press enter to accept 4 Press select button until display shows PC
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