INSTALLATION MANUAL
Contents
1. INTERLUBE Multi Line Svstems INSTALLATION MANUAL index INTRODUCTION DO S AND DON TS Health amp Safety at Work Act 1974 General System Description Planning The System Preparing The Pump Siting Mounting The Pump Making the Looms Fitting The Looms Connecting The Looms A e rs Eletrical Connections 9 Testing The Svstem 10 Timer Adjustment 11 Accessories 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 interlubesvstems com USA Headquarters Interlube Systems Inc 4696 Wadsworth Road Dayton Ohio 45414 USA Tel 1 937 276 4507 Fax 1 937 276 4518 e mail Nmackay earthlink net This Publication covers the fitting and connecting of Interlube s range of Multi Line Automatic Chassis Lubrication Systems AC SERIES FOR MORE INFORMATION ON PUMP OPERATION AND SPARES PLEASE REFER TO MULTI LINE OPERATION AND MAINTENANCE GUIDE DO S AND DON TS Do s Do read all instructions before commencing installation Do observe safety regulations regarding operating the vehicle in confined spaces Do take precautions to keep all components in the system clean Do use existing holes in chassis for mounting where possible Don ts Don t drill any holes in chassis flanges Don t drill holes through any part of the vehicle un2. a mark indicates a suggested starting point Starting with the bottom row of outlets and pumping unit 1 the loom should then run right around the pump then on to connect with the next row of pumping units so that the loom takes the form of a spiral and so on until all pumping units are connected Alternatively the pump units in all rows can be connected by working around the pump ring but the loom should still be formed as per fig 8 Alternatively the loom can be run in the opposite direction Approximate distance of the loom from pump should be approx 60mm Tubes should be clipped together every 6 pump units The loom looms can then be routed on to the chassis as required FIG 8 Loom Direction a Protective sleeving Half Lapped Tape Pinch a tab of tape across the end of the tube to secure the I D No Loom stand 8 ELECTRICAL CONNECTIONS Connect the twin core cable via an in line fuse 2Amin 5A max to an ignition controlled circuit See figures 9 amp 10 9 TESTING THE SYSTEM With the ignition ON check that the indicator light is illuminated see figures 11 amp 12 Operate the manual override button and check for paddle rotation The indictor light should flash slowly NB Should the motor fail it will be indicated by a fast flash 10 TIMER ADJUSTMENT AC1 AC The pump cycle time can be changed from the factory set option if required There are four settings as listed below and show the cycle
3. al Binding 1 2 lines 1837 001 ELBOW CONNECTORS Spiral Binding 8mm I D 3 4 lines 1837 002 T Mns Spiral Binding 10mm I D 5 7 lines 1837 003 Spiral Binding 14mm I D 8 12 lines 1837 004 Elbows Conduit 7mm diameter 27315 707 Pull Thread Size i m bilan a za onduit 12mm diameter NN Conduit 17mm diameter 27315 717 PM90484 a 28UNF Split Conduit 7mm diameter 27315 907 PM90485 5 16 24UNF Split Conduit 10mm diameter 27315 910 PM90487 lis BSPT Split Conduit 12mm diameter 27315 912 PM90489 M6X1P Split Conduit 17mm diameter 2 315 917 PM90490 M8X1P GREASE PM90491 M8X1 25P PM90492 M10X1P Premium Grade NGLI 000 FG3 0 RA cd 25717 284 12 x 1 Litre Bottles 25717 284 12 5K 12 5 KG Pail 25717 284 25K 25 KG Pail SAGN CUNEO Tr 25717 284 50K 50 KG Pail 25717 284 180K 180 KG Pail Straight Connectors Part Number Thread Size NLGI Grade 2 PM80412 1 8 PTF SAE ci a e 25717 270 12 5K 12 5 KG Pail 25717 270 25K 25 KG Pail PM80485 5 16 24UNF PM80487 lig BSPT PM80489 M6X1P GREASE SPECIFICATIONS PM80490 M8X1P NGLI 000 FG3 0 PM80491 M8X1 25P PM80492 M10X1P MN Amber PM80493 M10X1 5P V RR ere ean terrae et Fluid Tacky 25478 056 4mm to 4mm NLGI RRRRRRRRRRARRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRGRGGRGGE 000 100 L Calcium Penetration 25 C 445 475 Base Visc
4. coded for easy identification during instalation and with push in type tubing cartridge E Red 0 010 CC 78033 IM Green OD 78034 LJ Yellow 0 025 cC 18035 IN Blue GOE TE m 78036 Grey ae EE 78037 IM Black 0 100 GG tt 18038 Blanking PIU 34237 402 Manual Over Ride FIG 2 Button Filling Point for Oil Soft Grease Filling Adaptor for Heavy Grease FIG 3 A SITING MOUNTING THE PUMP Select a suitable mounting point for the pump on main AG3 3 litre Reservoir chassis in a position where it is protected from debris Maximum 60 Lubrication Points thrown up by the wheels Ensure adequate clearance for For more than 60 points please contact Interlube reservoir top up to be achieved Do not mount the pump Operates for up to 2000 hours on each reservoir filling onto ancillary equipment i e battery covers etc Using the adhesive template supplied position and drill the bracket mounting holes as shown in figs 5 amp 6 see 11 Do s and Don ts page 1 Using the spring washers and screw nuts secure the pump in position 273 Min 1 ROW FIG 4 313 Max 5 ROWS Add 10mm per row PP AC2 2 litre Reservoir il Maximum 36 Lubrication Points Fixing Holes Operates for up to 1500 hours on each reservoir filling 3x M8 1 25P Pa 75 ur Filler Access 250 Allowance for looming lt CALIBRATION CHART ssis Layout Typical Bearing Chart Pumping Unit Eu Power Steering Cylinde
5. osity 40 C 35 to 45 CST ACCESSORIES Drop Point N A 192023 29 iori 4mm OD soft grease filled tube x 25M 152823 50 4mm OD soft grease filled tube x 50M NLGI Grade 2 e wd CE sali Colour eee Pale Amber E Ae RR A eaeeceess slightly Fibrous 0A50397 1 2 off Numbered Sleeves 1 _ 12 NLGI RISE O ja a ate 2 0A50397 2 2 off Numbered sleeves 1 24 Soap Type Lithium 0A50397 3 2 off Numbered sleeves 1 36 Penetration 25 C ssse 265 295 0A50397 4 2 off Numbered sleeves 1 48 Base Viscosity 40 C 125cSt 0A50397 5 2 off Numbered sleeves 1 60 Drop POM gaar 185 C MULTI LINE INSTALLATION REGORD _ INTERLUBE Leaders in Lubrication Solutions Vehicle Type eene nnns MO 2 EEE EEE NE GS EE NE TIMerSeiGs ria SYSTEM TYPE
6. r Front 0 025 Power Steering Cylinder Intermediate 0 025 Power Steering Cylinder Rear 0 025 Track Rod End 0 040 Shackle Pins Front 0 040 Clutch operating Shaft Split Feed see note 0 015 TYPICAL Spring Pins 0 025 MULTI LINE Shackle Pins Rear 0 040 CHASSIS Brake Cam Shaft Front 0 015 LAYOUT King Pins 0 040 Brake Cam Shaft Rear 0 015 Split Feeds are only permitted on oil lubrication systems Grease Systems 1 2 3 4 5 6 7 8 9 10 11 Other Bearings usually connected to the lubrication system Balance Beam Bearings 2 feeds 2 x 0 040 Drag Link Ball Joint 0 040 Gear Lever Linkage 0 015 Pump Accelerator Cross Shaft 0 015 fani Pedal Linkages 0 015 gumon Brake Slack Adjusters 0 025 Controlled Tipping Body Hinges 0 025 Electrical Supply Fifth Wheel Coupling Pivot Point 0 025 Fifth Wheel Coupling Jaws 0 025 5 MAKING THE LOOMS The loom should be formed using Interlube 4mm semi rigid nylon tubing It is recommended that grease filled tube is used so that the system does not have to be primed prior to operation From the pump position ascertain the most convenient favourable route for the looms The number of looms required will depend on pump location and quantity and positioning of grease points Using looming stands if available form individual tubes into a loom allowing sufficient length for connection to pump and bearings and allowing for chassis movements e g springs steering lifts etc In conj
7. til you have checked the area is free of electric cables and pipe work Don t drill a series of holes that may cause a weakening of the chassis Don t attach Interlube pipe work to the existing pipes that are subject to heat e g the outlet pipe from the vehicle air compressor etc Don t work underneath raised body without full body props in place SAFETY PRECAUTIONS Health and Safety at work Act 1974 Never direct High Pressure Air Grease or Oil Delivery Nozzles at any part of the body Always switch off and remove the fuse from the electrical supplies uncouple pressure supplies before commencing any maintenance work Make sure that any guards or covers removed for maintenance work are replaced before operating the equipment ISF098 ISSUE 4 PE INTE Leaders in Lubrication Solutions 1 ENERAL SVSTEM DESGRIPTION The Interlube AC range has been designed to provide reliable and virtually maintenance free service in the most demanding applications The system comprises an electrically operated 12 24 V pump with integral controller and a loom of tubing which connects each chassis bearing directly to its own respective pumping unit Each bearing is fed independently meaning that points can be individually calibrated and also damage to one line does not affect the rest of the system The pumps come in two variations the AC1 and AC2 fig 2 which have 1 amp 2 litre top fill reservoirs and have the motor and controller ho
8. time including 2 5min run time and delay period The rotary timer is on the PCB which is inside the motor housing This is accessed by removing the lid and opening the motor housing The switch positions are 0 Continuous 2 5 min cycle time 1 9 minutes cycle time 2 12 minutes cycle time 3 15 minutes cycle time AC3 The pump is available with 10 settings with the delay timing control via a rotary switch located behind a screw Cap at the front of the motor housing The motor runs for 1 minute and 8 seconds Switch positions 0 continuous double speed 1 8 RPM 1 continuous at normal speed 0 9RPM normal trailer applications 2 3 minute delay 4 minute total cycle time 3 7 minute delay 8 minute total cycle time 4 11 minute delay 12 minute total cycle time 5 15 minute delay 16 minute total cycle time 6 19 minute delay 20 minute total cycle time 7 24 minute delay 25 minute total cycle time 8 30 minute delay 31 minute total cycle time 9 36 minute delay 37 minute total cycle time _7YFy_ o FIG 11 Manual Override button Indication Light FIG 9 INSTALLATION DIAGRAM AC1 amp AC2 INSTALLATION DIAGRAM AG3 Ery vann ETE FIG 12 Indication Manual Light Override button 11 ACCESSORIES LOOMING ACCESSORIES Plastic tape 1 Black 1755 830 ee Spir
9. unction with the installation record sheet fit number identification sleeves to tubing at pump and bearing ends The loom should be protected along its length with the conduit spiral binding sleeving and or tape for part numbers see section 11 Accessories The loom can consist of tubes of varying lengths which can leave the loom at the required point fig 7 6 FITTING THE LOOMS Working from the furthest point from the pump feed the loom through the chassis following existing vehicle services where possible see do s and don ts page 1 Ensure tubes are positioned to fit bearing connectors Where bearing is on a moving part ensure tube length is sufficient to allow for full movement To avoid rubbing or friction with chassis grommets or protective sleeving should be used FIG 7 Loom stand Sufficient length of tube to reach bearing points Typical Loom Stand 7 GONNEGTING THE LOOMS Cut each tube to length ensuring a clean square cut is achieved and connect to bearing using push fit connectors ENSURE TUBING IS PUSHED FIRMLY INTO CONNECTOR TEST ASSEMBLY BY PULLING FIRMLY ON THE TUBE Using System Specification Sheet connect the loom to corresponding numbered pumping units When running the tubing into the pumping units to give the loom strength and rigidity the tubes should be clipped together to form an arrangement as shown in fig 8 below The starting point for the loom can be as required On the underside of the AC2
10. used in the lid and the AC3 fig 1 which has a 3 litre reservoir and has the motor and controller housed in the pump base The motor drives the impellor which draws grease into the pumping chamber and also gives a visual indication of cam rotation It also drives the cam which operates the individual pumping units and feeds grease into the tubing The pumps can operate with a wide range of lubricants from SAE 80 oil up to and including NLGI grade 2 grease 2 PLANNING THE SYSTEM 1 Tilt cab where applicable 2 Flush out all bearings to be connected to the system and clean all bearing surfaces 3 Remove grease nipples and insert connectors to establish number of bearings to be lubricated 4 Prepare specification sheet by listing bearings to be connected and referring to the calibration chart to determine pumping unit output recommendation FIG 1 Quick Fill Connector Manual Over ride Button Timing Adjustment 3 PREPARING THE PUMP Fit the pumping units into the carcass ring of the pump taking care not to over tighten Where spare positions occur use blank plugs It is recommended that where possible pumping units are spaced symmetrically around the pump and not grouped together in one area PUMPING UNITS Each chassis bearing requires a measured volume of lubricant determined by size and function To meet this requirement INTERLUBE provides a range of six pumping units with the outputs shown below colour
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