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Graco Trabon Modu-Flo System User's Manual

1. 1 1 1 2 GENERAL SYSTEM OPERATION 1 1 131 GENERAL 1 1 1 Standard Components A wide choice of modular components may be assembled to meet a given applica tion 1 1 1 1 All Modu Flo systems consist of the following components a Areservoir or tank for holding the lubricant Reservoirs are cylindrical units for grease or oil and are equipped with a spring loaded follower for grease applications Tanks are rectangular and are used for applications using oil Further information on reservoirs may be found in Section 2 P A pump for dispensing a specific volume of lubricant Pumps may be pneumatically or hydraulically operated A selection of power ratios and displacement ranges are available Further information on pumps may be found in Section 3 A manifold attached to the base of the reservoir to provide a mounting base for any pump The manifold has all the necessary porting to allow lubricant to flow from the reservoir to the pump and from the pump to the lubricant lines Ports are also provided for pneumatic or hydraulic inputs to operate the pump Accessories such as gauges and blowout assemblies are available and may be connected to the manifold If the pump is to be located some distance from the reservoir a wall mounted manifold is available Further information on manifolds is contained in Section 4 1 1 1 1 2 Modu Flo Options 1 1 2 1 Op
2. 2 9 5 3 Grease Reservoir Low Level Assembly 5 6 2 3 Oil Tank Exploded View 2 13 6 1 High Pressure Switch ooooococononccincccccconccconannnonos 6 2 3 1 Typical Pump 3 2 6 2 High Pressure Switch Rear View 6 4 3 2 Pneumatic Pump Exploded View 3 7 6 3 Reservoir Blowout Switch Assembly Front 3 3 Hydraulic Pump Options H1 and H3 MIU Mc 6 5 Exploded View 3 11 6 4 Tank Blowout Switch Assembly 6 7 3 4 Hydraulic Pump Option H2 Exploded View 3 15 7 1 Pneumatic Solenoid 7 1 4 1 Typical Manifold 4 3 8 1 DC Timer Wiring Schematic 8 2 5 1 Oil Tank and Reservoir 15 Amp Low Level 8 2 AC Timer Wiring Schematic 8 2 Assembly 5 3 8 3 TC1000 Timer Counter Wiring Schematic 8 3 8 4 WMP Maxi Monitor Wiring Schematic 8 3 i LUBRIQUIP Lubrication amp Dispensing Solutions Modu Flo System LIST OF TABLES Number Title Page 2 1 Reservoirs and 2 2 2 2 Grease Reservoir Parts List 2 4 2 3 Oil Reservoir Parts Lists 2 8 2 4 Oil Tank Parts 5 44002202222 22 2 12 gell Pumps Hs er
3. 6 4 6 6 TANK BLOWOUT SWITCH MAINTENANCE OPTION PA oia alada 6 6 AMC 6 6 6 6 2 Tank Blowout Switch Maintenance Tips 6 6 6 6 3 Assembly Disassembly of Blowout Switch 6 6 6 6 4 Tank Blowout Switch Parts List 6 6 tank The indicator will retain the plunger in the extended position even if lubricant pressure is reduced The plunger must be manually depressed to release the switch and return the indicator to its normal position 6 1 3 Blowout Disc The standard blowout disc rated at 1450 psig 100 bar may be used on any unit This assem bly does not provide any electrical signal when the blowout pressure has been reached The blowout disc will rupture at the high pressure and the lubricant escaping from the blown disc will provide a visual indication of failure Discs rated at higher pressures than 1450 psig 100 bar are available separately in kits of six For identification pur poses discs are color coded Table 6 1 lists the discs available and the kit number for each Table 6 1 Blowout Discs and Kits Kit No Rating contains Disc Part No Color psi bar 6 discs 509 292 000 Yellow 1450 100 560 900 270 509 293 000 Red 1750 121 560 900 280 509 294 000 Orange 2050 141 560 900 290 509 295 000 Aluminum 2350 162 560 900 300 509 297 000 Blue 2950 203 560 900 320 509 298 000 Purple 3250 224 560 900 330 LUBRIQUIP Lubrication Dispensing Solutions Modu Flo System
4. p o Remove enclosure screw 14 Remove and discard gasket 15 Remove check valve spring 16 ball 32 and check seat 29 Remove and discard o ring 30 from seat 29 Remove adjustment screw body 19 and o ring 12 from pump body 10 Discard o ring 12 Removal of adjustment screw 13 from adjustment screw body 19 will change output setting when pump is reassembled If adjustment screw 13 requires removal perform the following IP 1 Remove adjustment screw cap 22 from adjust ment screw 13 Butt the adjustment screw cap 22 against jam nut 21 and use the stamped numbers on the cap to measure how far the adjustment screw 13 extends from the jam nut Record this dimension 2 Remove jam nut 21 and two gaskets 20 Discard gaskets 3 Remove adjustment screw 13 by screwing it towards the hex portion of the adjustment screw body 19 until it is free a Remove retainer ring 4 LUBRIQUIP Lubrication amp Dispensing Solutions Modu Flo System e Insert wooden dowel or soft rod into pump body 10 and push lube piston 5 until cylinder cap 3 is out of air cylinder 7 Remove and discard o ring 2 from cylinder cap 3 Continue to push lube piston 5 through pump body 10 until air piston 1 is exposed and can be removed from air cylinder 7 Remove air piston 1 lube piston 5 and piston return spring 24 from air cylinder 7 g Remove ret
5. 1 i rr j H IND PORT pup trt 3 LUBE OUTLET Figure 6 2 High Pressure ELBOW Switch Rear View Description HIGH PRESSURE SWITCH ASSEMBLY Option P1 SWITCH Pressure TEE Male 1 4 inch pipe BLOWOUT ASSEMBLY 1450 psi FITTING Adapter DISC Blowout NUT Pressure relief W ae Ti H Quantity ek zb ck ek de KS TANKOR RESERVOIR LUBE OUTLET 6 5 RESERVOIR BLOWOUT SWITCH MAINTENANCE OPTIONS P2 and P3 6 5 1 General Maintenance tips disassembly and assembly instructions for reservoir blowout switches are discussed in Paragraphs 6 5 2 and 6 5 3 A typical reservoir with blowout switch is shown in Figure 6 3 and should be referred to during the discussion 6 5 2 Reservoir Blowout Switch Maintenance Tips No maintenance is required on the blowout switch If the switch assembly is suspected to be defective check all wiring to the switch before removing any components Disconnect and lock out all power from the assembly before attempting disassembly Serious injury may result from electrical shock LUBRIQUIP Lubrication amp Dispensing Solutions NOTE Relieve system pressure before removing any components 6 5 3 Assembly Disassembly of Blowout Switch Figure 6 3 shows a typical blowout switch mounted on a reservoir All components are connected by pipe threads and tubing and are easily assembled or disassembled
6. Items 21 through 26 Support are not serviceable NUT Jam 3 4 16 by the user replace 1 O RING entire reservoir 1 RING Retaining 1 PLUG Low Level 3 Ib 1 GASKET 3 Ib 1 FOR OPTION GP5 ONLY Do not attempt to remove retain ing ring 2 or cable assembly 5 Figure 2 1 or retaining ring 26 or guide rod 5 for Option GP5 Injury could result from sudden expansion of spring 4 DIMENSIONS OPTION A B GP1 GM1 7 25 inches 15 inches GP2 GM2 184 mm 381 mm GP3 GM3 7 25 inches 22 inches 184 mm 559 mm GP4 GM4 7 25 inches 10 5 inches 184 mm 267 mm GP5 7 25 inches 6 87 inches 184 mm 174 mm Mating fill coupler 506 322 000 order separately Reservoir Tube Kit includes gasket item 9 Figure 2 1 Grease Reservoir Exploded View LUBRIQUIP Lubrication amp Dispensing Solutions Modu Flo System 2 5 RESERVOIR MAINTENANCE OPTIONS OP1 THROUGH OP4 2 5 1 General Maintenance tips disassembly and as sembly procedures for oil reservoirs are discussed in Para graphs 2 5 2 2 5 3 and 2 5 4 An exploded view of a typical oil reservoir is shown in Figure 2 2 and should be referred to during the discussion 2 5 2 Oil Reservoir Maintenance 2 5 2 1 Maintenance on the oil reservoir consists of the following a Visually check for oil leakage between reservoir tube 6 Figure 2 2 and base 8 Leakage may indicate that the gasket 7 is defective or that nuts
7. Modu Flo System EYLUBRIQUIP Operation and Service Instructions Bulletin 42000 Modular LUBRIQUIP Pumping Lubrication amp Dispensing Solutions Packages O LUBRIQUIP INC 1988 All Rights Reserved Revised November 2005 Modu Flo System 42000 TABLE OF CONTENTS Section Para Page Section Para Page 1 INTRODUCTION ener 1 1 5 3 AND RESERVOIR 15 AMP 1 1 GENERAL 5 15 elationis 1 1 LOW LEVELASSEMBLY MAINTENANCE 1 2 GENERAL SYSTEM 1 2 OPTIONS Li L2 and 13 sms 5 2 5 4 RESERVOIR 10 WATT LOW LEVEL 2 2 1 ASSEMBLY MAINTENANCE OPTIONS L5 L6 21 DESCRIPTION S ANDE ARE ae uen a dares 5 4 D ESCHIPTION 55 GREASE RESERVOIRLOW LEVEL ASSEMBLY 22 MOUNTING INSTRUCTIONS 2 1 MAINTENANCE OPTION L4 ES 23 2 2 24 GREASE RESERVOIR MAINTENANCE HIGH PRE RE AND BLOWOUT OPTIONS GP1 THROUGH GP5 AND GM1 5 gt SWITCHES iii 6 1 THROUGH GM4 12000 2 3 T DESCRIPTION d em O MAINTE Ge 6 2 HIGH PRESSURE SWITCH ADJUSTMENT 6 2 OPTIONS OP1 THROUGH 2 7 26 OILTANK MAINTENANCE 6 3 MOUNTING INSTRUCTIONS 6 3 OPTIONS T1 T2 and T3 2 11 6 4 HIGH PRESSURE SWITCH MAINTENANCE E OPTION Pi 6 3 6 5 RES
8. 5 4 5 4 5 Tank and Reservoir 10 Watt Low Level Assemblies Parts List 5 4 5 5 GREASE RESERVOIR LOW LEVEL ASSEMBLY MAINTENANCE OPTION 4 5 5 AC 5 5 5 5 2 Grease Reservoir Low Level Assembly Maintenance 5 5 5 5 3 Disassembly of Grease Reservoir Low Level Assembly 5 5 5 5 4 Assembly of Grease Reservoir Low Level Assembly 5 6 5 5 5 Grease Reservoir Low Level Assembly Parts Eist 5 ei herren 5 6 The option used is designated by the entry in the ordering code as shown below MPP XXX XXX XX XX XX XX XX XXX XX Low Level Option 5 2 MOUNTING INSTRUCTIONS 5 2 1 Oil Reservoirs and Tanks To install any low level Switch in a reservoir or tank requires the removal of the tank cover or reservoir cap All covers or caps are equipped with a 1 4 inch NPT tapped hole The low level switch has an adapter which threads into the hole For complete instruc tions on mounting these units refer to Paragraphs 5 3 4 and 5 4 4 5 2 2 Grease Cylinders The low level switch for grease cylinders consists of the switch itself mounted to a bracket which is in turn attached to the top of the grease cylinder For complete instructions on mounting these units refer to Paragraph 5 5 4 LUBRIQUIP Lubrication amp Dispensing Solutions Modu Flo System
9. Install three new o rings 15 and one o ring 16 into body 7 Securely attach pump assembly to manifold with four socket head screws 8 3 4 4 2 When the assembly steps listed above have been completed adjust the pump output as described in Para h Install new o ring 23 on check seat 22 and install graph 3 2 2 seat assembly into pump body 3 4 5 Hydraulic Pump Options H1 and H3 Parts List i Install steel ball 24 and check valve spring 13 into Table 3 3 identifies the parts indexed in Figure 3 3 Table 3 3 Hydraulic Pump Options H1 and H3 Parts List Item Number Part Number Description 521 000 011 PUMP ASSEMBLY HLJ 5 Option H1 521 005 900 PUMP ASSEMBLY HLJ 5X Option 560 001 051 REPAIR KIT consists of Items 3 4 5 8 9 12 thru 16 18 and 21 thru 23 Quantity PISTON Lube HLJ 5 1 2 521 000 190 PISTON Hydraulic HLJ 5 1 3 411 101 630 PIN Groove part of kit 560 001 051 HLJ 5 1 4 422 021 110 O RING Part of kit 560 001 051 HLJ 5 1 5 422 011 160 O RING Part of kit 560 001 051 HLJ 5 1 422 021 160 O RING Part of kit 560 001 940 HLJ 5X 1 6 521 000 180 CAP Cylinder 1 7 BODY Pump HLJ 5 1 8 419 130 070 SCREW Socket head 1 4 20 x 1 1 4 inch part of repair kit 560 001 051 4 9 422 011 140 O RING Part of kit 560 001 051 HLJ 5 1 422 021 140 O RING Part of kit 560 001 940 HLJ 5X 1 10 521 003 000 SCREW Adjustment 1 11 521 008 460 SCREW Enclosure 1 12 500 132 000 GAS
10. 2 3 the pump mounting pad 12 and the level sight glass 11 Leakage in either of these areas indicates the components are loose or that gasket 10 or o ring 13 is defective The cover 1 will need to be removed to either tighten the components or replace defective seals b Visually check fill screen 4 to make sure it is not clogged If necessary remove the screen for cleaning c Check that the tank is securely fastened to the wall or supporting structures Securely tighten any loose attaching hardware Disconnect and lock out power before opening electrical enclosures or conduit connections Serious injury may result from electrical shock 2 6 3 Disassembly of Oil Tanks Figure 2 3 shows a typical oil tank but does not include other Modu Flo compo nents which may be mounted to the tank These compo nents include the manifold pump level switches and blow out switches Disassembly of tank may require that some of these components be removed The manifold and pump do not normally require removal but may be removed if desired The level and blowout switches may or may not require removal depending on the level of disassembly required The electrical connections to the switches should be discon nected in order to remove various parts without restriction of movement by the electrical cord The removal of these com ponents is explained in other sections of the manual Refer to the table of contents to find where these compo
11. 13 holding jam nut 21 if necessary b Butt adjustment cap 22 against jam nut 21 and use the stamped numbers on the cap to determine how much adjustment is needed Loosen jam nut 21 and use a flat screwdriver to turn adjustment screw 13 Turn adjustment screw in for less output turn out for more output p d Tighten jam nut 21 and install adjustment cap 22 over the adjustment screw 13 3 2 2 2 When adjusting pump output one complete turn of the adjusting screw will change the output by the following amounts a 0 0018 cubic inch for pump options A1 and A2 b 0 006 cubic inch for pump options A3 and A4 0 009 cubic inch for pump options A5 and d 0 0018 cubic inch for pump option H1 e 0 006 cubic inch for pump option H2 and H3 3 3 PNEUMATIC PUMP MAINTENANCE OPTIONS A1 THROUGH A6 3 3 1 General Maintenance tips disassembly and assembly procedures for pneumatic pumps are discussed in Paragraphs 3 3 2 through 3 3 4 An exploded view of a typical pneumatic pump is shown in Figure 3 2 and should be referred to during the discussion 3 3 2 Pneumatic Pump Maintenance Tips 3 3 2 1 The only maintenance required on the pneumatic pump is to check for the following a Check four socket head screws 11 Figure 3 2 to make sure they are tight Loose screws could allow air and or lubricant to leak between the pump and the manifold This condition could result in erratic pump output 3 3 4200
12. 2 Pneumatic Pump Parts List Continued Description RING Retainer part of kit 560 001 021 AL5 RING Retainer part of kit 560 001 031 AL25 RING Retainer part of kit 560 001 041 AL50 O RING Part of kit 560 001 021 AL5 O RING Part of kit 560 001 031 AL25 O RING Part of kit 560 001 041 AL50 SEAT Check valve part of kits 560 001 021 560 001 031 and 560 001 041 O RING Part of kits 560 001 021 560 001 031 and 560 001 041 SCREW Enclosure BALL Steel 1 8 Dia SCREW Set 10 32 x1 4 ROLL PIN REPAIR KIT consists of Items 2 4 6 8 9 11 12 15 thru 18 20 21 24 25 27 thru 30 and 34 thru 36 AL5 REPAIR KIT consists of Items 2 4 6 8 9 11 12 15 thru 18 20 21 24 25 27 thru 30 and 34 thru 36 AL25 REPAIR KIT consists of Items 2 4 6 8 9 11 12 15 thru 18 20 21 24 25 27 thru 30 and 34 thru 36 AL50 PUMP ADJUSTMENT ASSEMBLY consists of Items 13 and 19 thru 22 AL5 PUMP ADJUSTMENT ASSEMBLY consists of Items 13 and 19 thru 22 125 PUMP ADJUSTMENT ASSEMBLY consists of Items 13 and 19 thru 22 AL50 Included in Repair Kit Refer to Repair Kits above LUBRIQUIP Lubrication amp Dispensing Solutions 42000 Quantity dl dl lll ll 3 6 Modu Flo System 42000 4 bad TEST AIR 9 PURGEPORT 34 35 N Y 29 2 b i Hh 13 CHECK VALVE COMPONENTS PREVIOUS TO L93 Not Available as Replacement Parts December 19
13. 4 418 050 3104 RING Retainer part of kit 560 001 021 AL5 418 050 450 RING Retainer part of kit 560 001 031 AL25 418 050 520 RING Retainer part of kit 560 001 041 AL50 PISTON Lube 6 527 000 790 O RING Part of kit 560 001 021 AL5 423 700 111 O RING Part of kit 560 001 031 AL25 423 700 112 O RING Part of kit 560 001 041 AL50 7 521 000 080 CYLINDER Air AL5 521 000 200 CYLINDER Air AL25 521 000 450 CYLINDER Air AL50 8 422 010 200 O RING Part of kits 560 001 021 560 001 031 and 560 001 041 9 423 700 113 O RING Part of kits 560 001 021 560 001 031 and 560 001 041 10 BODY Pump 11 419 130 070 SCREW Socket head 1 4 20 x 1 1 4 inch 12 422 011 140 O RING Part of kits 560 001 021 560 001 031 and 560 001 041 13 521 003 000 SCREW Adjustment AL5 521 003 010 SCREW Adjustment AL25 521 003 020 SCREW Adjustment AL50 A EI sch sch sch sch sch sch sch sch sch sch sch sch sch sch sch sch sch sch sch sch 14 521 008 460 SCREW Enclosure 15 500 132 000 GASKET Part of kits 560 001 021 560 001 031 and 560 001 041 16 511 893 000 SPRING Check valve part of kits 560 001 021 560 001 031 and 560 001 041 17 401 030 030 BALL Steel 3 16 inch diameter part of kits 1 560 001 021 560 001 031 and 560 001 041 18 423 700 114 O RING Part of kit 560 001 021 560 001 031 560 001 041 19 521 003 030 BODY Adjustment screw AL5 521 003 040 BODY Adjustment screw AL25 521 003 050 BODY Adjustment
14. 419 170 010 439 050 060 439 060 110 438 028 283 521 000 921 423 700 096 410 701 986 421 010 010 421 010 010 412 150 040 Table 2 4 Oil Tank Parts List Description RESERVOIR ASSEMBLY RESERVOIR ASSEMBLY RESERVOIR ASSEMBLY 12 pint 5 68 liters 1 24 pint 11 4 liters 2 40 pint 18 9 liters 3 COVER 12 pint COVER 24 pint COVER 40 pint SCREW Self threading 1 4 28 x 5 16 inch 12 pint SCREW Self threading 1 4 28 x 5 16 inch 24 40 pint PLUG Pipe 1 4 inch NPT SCREEN 40 Mesh CUP Fill GASKET Cover 12 pint GASKET Cover 24 pint GASKET Cover 40 pint SCREW Socket head 3 8 16 x 1 2 inch GASKET 3 8 stat o seal WELDMENT Reservoir Not available as a item replacement GASKET SIGHT GLASS PAD Pump mounting O RING NUT Self threading Lockwasher 1 4 inch 12 pint Lockwasher 1 4 inch 24 40 pint Plug 3 8 NPT Reservoirs with separate aluminum pump mounting pads only Steel pump mounting pads are welded in place and are not replaceable Used on reservoirs with front pressure fill port only LUBRIQUIP Lubrication amp Dispensing Solutions Quantity DR Aa 42000 Modu Flo System 42000 Reservoirs with separate aluminum pump mounting pads only Steel pump mounting pads are welded in place and are not replaceable Used on reservoirs with front pressure fill port only
15. 5 Oil Tank and Reservoir 10 Watt Low Level Assemblies Parts List Table 5 3 identifies the parts indexed in Figure 5 2 Modu Flo System 42000 Table 5 3 Oil Tank and Reservoir 10 Watt Low Level Assemblies Parts List Item Number Part Number Description Quantity 456 010 172 LOW LEVEL ASSEMBLY 5 pint 12 pint 456 010 173 LOW LEVELASSEMBLY 20 pint 456 010 171 LOW LEVELASSEMBLY 6 pint 1 541 603 001 SWITCH 10 watts 115 VAC NC SPST 1 541 603 002 OPTIONAL SWITCH 10 watts 115 VAC NO SPST 2 COUPLING 1 3 NIPPLE 1 4 ADAPTER 1 Figure 5 2 Oil Tank and Reservoir 10 Watt Low Level Assembly RESERVOIR COVER REF N 4 pc f 2 3 Not available as replacement parts 2 OPTION L4 replace a defective switch Before attempting disassembly check all electrical connections to make sure they are secure and check for any physical obstruction which might be EN Mai i i 5 5 General Maintenance tips disassembly and preventing the switch from operating assembly procedures for low level assembly option L4 are discussed in Paragraphs 5 5 2 5 5 3 and 5 5 4 A sectional 5 5 3 Disassembly of Grease Reservoir Low Level view of a typical assembly is shown in Figure 5 3 and should Assembly be referred to during the discussion 5 5 2 Grease Reservoir Low Level Assembly Mainte Dom ou nance Tips No maintenance is required on the low level assemblies used on grease reservoirs If the grease level runs
16. 6 1 3 1 When any pressure or blowout switch is actuated personnel must determine the cause for the rise in pres sure After the cause has been corrected any blowout discs which have been ruptured will need to be replaced with an approved disc 6 1 4 High Pressure and Blowout Switch Options Table 6 2 lists the pressure and blowout switch options available for use Listings in the option column are used to identify the assembly selected when a Modu Flo system is ordered The option used is designated by the entry in the ordering code as shown below MPP XXX XXX XX XX XX XX XX XXX XX Pressure Indicator Option 42000 6 2 HIGH PRESSURE SWITCH ADJUSTMENT 6 2 1 General The high pressure switch assembly has an adjustable range from 400 to 4700 psi 28 to 324 bar If the pressure setting is to be changed from the standard factory setting of 1150 psi 79 bar the blowout disc must also be changed To prevent system damage the pressure switch setting should not exceed 80 percent of the blowout disc rating Table 6 3 lists the blowout discs available and the maximum pressure switch setting to be used Table 6 2 High Pressure and Blowout Switch Assemblies Part Number Description Electrical Ratings Used On Option 521 001 220 Pressure Switch Kit 5 amp at 115 230 VAC Any reservoir 1 521 001 190 Blowout Assembly 15 amp at 115 230 or 480 VAC 5 pint or 5 pound P2 0 5 amp at 115 VDC cylindrical reservoir 0 25 amp at 230
17. 9 are not tight Torque nuts 9 to 5 ft Ibs If leakage continues replace gasket 7 Check for cracks and nicks on tube 6 Replace the tube as required b Visually check screen 2 in fill cup 3 to make sure it is not clogged If necessary remove the screen for clean ing c Check reservoir bottom for debris Clean as required Disconnect and lock out power before opening electrical enclosures or conduit connections Serious injury may result from electrical shock 2 5 3 Disassembly of Oil Reservoir Figure 2 2 shows a typical oil reservoir but does not include other Modu Flo components which may be mounted to the reservoir These components include the manifold pump level switches and high pressure blowout switches Disassembly of the reser voir may require that some of these components be re moved The manifold and pump do not normally require removal but may be removed if desired The level and blow out switches may or may not require removal depending on the level of disassembly required The electrical connections to the switches should be disconnected in order to remove various parts without restriction of movement by the electrical cord The removal of these components is explained in other sections of the manual Refer to the table of contents to find where the components are discussed 2 5 3 1 The disassembly procedure may be performed with the reservoir mounted to the mounting surface However some mounting lo
18. ACCESSORY VALVES balancing check and flow INDICATORS performance and broken line LUBRIQUIP ee fittings brackets clamps filters Lubrication amp Dispensing Solutions ISO 9001 REGISTERED FIRM ISO 14001 Registered trademark of LUBRIQUIP INC REGISTERED FIRM Printed in U S A LUBRIQUP INC 18901 Cranwood Pkwy L Clevdand 44128 1 Phone 216 581 2000 or 800USALUBE L FAX 2165818945
19. ASSEMBLY consists of Items 10 17 thru 20 HLJ 5 Not Available as Replacement Parts Included in Repair Kit LUBRIQUIP Lubrication amp Dispensing Solutions k 3 10 Modu Flo System 42000 FOR H1 OPTION HLJ 5 ek TEST AI e PURGE PORT CHECK VALVE COMPONENTS PREVIOUS TO L93 December 1993 Not Available as Replacement Parts Included in Repair Kit Refer to Page 3 10 for Repair Kits SEE NOTE ON PAGE 4 2 Figure 3 3 Hydraulic Pump Options H1 and Exploded View wnocBaw BRP Lubrication amp Dispensing Solutions Modu Flo System 35 HYDRAULIC PUMP MAINTENANCE OPTION H2 3 5 1 General Maintenance tips disassembly and assembly procedures for hydraulic pump Option H2 are discussed in Paragraphs 3 5 2 through 3 5 4 An exploded view of the pump is shown Figure 3 4 and should be referred to during the discussion 3 5 2 Hydraulic Pump Option H2 Maintenance Tips 3 5 2 4 The only maintenance required on the hydraulic pump Option H2 is to check for the following a Check four socket head screws 11 Figure 3 4 to make sure they are tight Loose screws could allow air and or lubricant to leak between the pump and the manifold This condition could result in erratic pump output b Check for leakage past gasket 15 Replace gasket if required Check jam nut 21 to make sure it is tight against adjustment screw body 19 If the jam nut is l
20. H3 Maintenance 3 9 3 1 DESCRIPTION 3 1 1 General There are six models available for use Three models are pneumatically operated and three are hydraulically operated The pneumatic models may be single or double acting An internal spring will return the piston to the reload position in single acting pumps All hydraulic models are double acting 3 1 1 1 All models are designed to mount directly to either the pump to reservoir manifold or the pump to wall mani fold When the pump is properly mounted on a manifold the manifold will have all the porting for air and lubricant connections to and from the pump 3 1 1 2 Operating sequences for single acting and double acting pumps are listed below Figure 3 1 shows a sec tional view of a typical pump and will help in understanding pump operation a With single acting models air under pressure is supplied through the inlet port SA to chamber C This moves the air and lube pistons to the right This closes the lube inlet port and forces the lubricant already in chamber B past the check valve and into the system Air in chamber A must vent out port DA A plastic pipe plug with a vent hole is installed in port DA After a preset time interval the solenoid valve shuts off the air supply and vents chamber C through port SA The spring returns the air and lube pistons opening chamber B to the lube reservoir This completes
21. RING Part of kit 560 001 061 BODY Adjustment screw GASKET Stat O Seal part of kit 521 001 061 NUT Jam 7 16 20 CAP Adjustment screw RETAINER RING Backup part of kit 560 001 061 SEAT Check valve part of kit 560 001 061 O RING Part of kit 560 001 061 O RING Part of kit 560 001 061 SCREW Enclosure BALL Steel 1 8 Dia SCREW Set 10 32 x1 4 ROLL PIN REPAIR KIT consists of Items 3 4 5 8 9 11 12 15 thru 18 20 21 24 thru 27 and 31 thru 33 PUMP ADJUSTMENT ASSEMBLY consists of Items 13 and 19 thru 22 Quantity m och ok oc aa Jeck K Aa ck scht lk 4 c ch cA l l ck 3 14 Modu Flo System 42000 Gei 23 10 TEST AIR PURGE PORT 31 32 No N 13 11 3 Not Available as Replacement Parts TE EE Included in Repair Kit Refer to Page 3 14 for Repair Kits PREVIOUS TO L93 December 1993 Xxx SEE NOTE ON PAGE 4 2 Figure 3 4 Hydraulic Pump Option H2 Exploded View LUBRIQUIP Lubrication amp Dispensing Solutions Modu Flo System OPERATION AND SERVICE INSTRUCTIONS 42000 Modu Flo System SECTION 4 MANIFOLDS 41 DESCRIPTION conociera 4 1 essen 4 1 4 2 PREPARATION FOR USE 4 1 42 1 Mounting 5 cer ie eene ene 4 1 4 2 2 Connection to Othe
22. SUPPLIED MAX TIGHTENING TORQUE 5 IN LBS SET TIMER ON AND OFF TIMERS CLOSE AND FASTEN COVER WITH 2 10 X 3 4 SCREWS SUPPLIED MAX TIGHTENING TORQUE 7 IN LBS AND APPLY POWER MANUAL RUN BUTTON TOTAL CYCLE TIME CB caution Selle DISCONNECT A LOCK OUT POWER PRIOR INPUT LOAD MAN EES A TO SERVICING TO AVOID 445 230 3AMP RUN T POSSIBLE ELECTRICAL 50 60 HZ SHOCK MAX il LOAD ENERGIZED 24 5 7 8 16 Li n 2 Y 5 24 E m 2000 f 0 2 113 2 1 e E 5 30 V 32 LUBRIQUIP 16 e ON TIME MINUTES TOTAL CYCLE TIME P MINUTES INPUT LOAD HOURS ASSY NO 572 142 590 Figure 8 2 AC Timer Wiring Schematic LUBRIQUIP Lubrication amp Dispensing Solutions 8 2 Modu Flo System 42000 CAUTION INPUT VOLTAGE WILL BE PRESENT ON TERMINAL 5 FOR DC MODELS ONLY 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 gt N or AC HO pump IO O m O sw VO lo a 7 9 gs 2 2 e 4 ENABLE AE z DO NOT USE oO D L ADD JUMPER L 2 MANUAL IF ENABLE OUTPUT MACHINE COUNT FEATURE IS SEE BELOW NOPUSED 010 11 So zu 13 E DRY CONTACT SWITCH L SOURCE SWITCH 2 OR 3 WIRE TYPE 1 10 11 Caution Voltage will be present at low level switch and may be present at lamp when power 13 to TC 1000 is on S
23. System 9 1 9 2 4 System 9 1 9 1 GENERAL 9 1 1 This section describes operating procedures for a Modu Flo System Detailed descriptions of the system components are covered in Sections 1 through 8 9 2 SYSTEM INFORMATION 9 2 1 System Setup 9 2 1 1 Before attempting to operate any system check the following a Check that the reservoir or tank is securely fastened to a vertical surface Make sure that the fill cup or grease fill fitting may be easily reached o Check that the manifold is securely connected to the base of the reservoir or tank If a remote manifold is used make sure it is securely fastened to a vertical surface and tubing or hose is connected from the reservoir to the manifold inlet Ie Check that the pump is securely fastened to the manifold e Check all electrical connections to any solenoids controllers level switches or pressure switches used on the system o Check that all accessories plumbed into the manifold are secure Make sure all hose or tubing connections are tight 9 2 2 System Filling The reservoirs or tanks should be filled as described in Section 2 of this manual To fill the remainder of the system attach a hand pump to the system fill check valve on the manifold and cycle the hand pump until the system is filled 9 2 3 System Bleeding Proper fillin
24. Table 5 1 Low Level Switch Assemblies Part Number Switch Type 521 001 030 Single pole double throw 521 001 040 Single pole double throw 521 001 050 Single pole double throw 456 010 171 Single pole single throw 456 010 172 Single pole single throw 456 010 173 Single pole single throw 521 001 110 Single pole double throw Switch Rating AC 15 amps at 115 230 or 480 VAC 15 amps at 115 230 or 480 VAC 15 amps at 115 230 or 480 VAC 10 watts at 115 VAC 10 watts at 115 VAC 10 watts at 115 VAC 15 amps at 115 230 or 480 VAC 0 5 amp at 115 VDC 0 25 amp at 230 VDC 42000 Used On Option 5 and 12 pint oil L1 cylindrical reservoirs 20 pint oil cylindrical L2 reservoir 6 pint oil cylindrical L3 reservoir and all tanks 6 pint oil cylindrical L7 reservoir and oil tanks 5 and 12 pint oil L5 cylindrical reservoir 20 pint oil cylindrical reservoir L6 All grease cylindrical reservoirs L4 5 3 OIL TANK AND RESERVOIR 15 AMP LOW LEVEL ASSEMBLY MAINTE NANCE OPTIONS L1 L2 and L3 5 3 1 General Maintenance tips disassembly and assembly procedures for low level options L1 L2 and L3 are discussed in Paragraphs 5 3 2 5 3 3 and 5 3 4 A typical low level assembly is shown in Figure 5 1 and should be referred to during this discussion 5 3 2 Oil Tanks and Reservoir 15 Amp Low Level Assembly Maintenance Tips No maintenance is required on the low level assemblies used on oil tanks and reser voirs If the oil level
25. VDC 521 001 200 Blowout Assembly 15 amp at 115 230 or 480 VAC 6 12 or 20 pint or pound P3 0 5 amp at 115 VDC cylindrical reservoir 0 25 amp at 230 VDC 521 001 210 Blowout Assembly 15 amp at 115 230 or 480 VAC All tanks P4 0 5 amp at 115 VDC 0 25 amp at 230 VDC 509 206 100 Blowout Disc 1450 psi None All units P5 6 2 20 High Pressure Switch Adjustment Procedures 1 2 FEMALE CONDUIT CONNECTOR FACTORY SEALED PRESSURE SWITCH LUBRIQUIP 3 WIRE CABLE d 16 AWG SELLG CAUTION LABEL 1 4 NPT ADJUSTMENT RED N O COVER BLACK N C WHITE COM Figure 6 1 High Pressure Switch LUBRIQUIP Lubrication amp Dispensing Solutions 6 2 Modu Flo System Table 6 3 Pressure Switch Settings Maximum Recommended Disc Pressure Switch Disc Rating Setting Color psi bar psi bar Yellow 1450 1160 80 100 Red 1750 1450 100 121 Orange 2050 1640 113 141 Aluminum 2350 1880 130 162 Blue 2950 2360 163 203 Purple 3250 2600 179 224 6 2 2 1 The adjustment procedure for the high pressure switch is as follows e Disconnect and lock out all power from the assembly before attempting disassembly Serious injury may result from electrical shock To avoid possible system damage change the blowout disc to match the new pressure switch setting Refer to Paragraph 6 2 1 p Turn off electrical power to the lube system P Connect control to pressure source Ie With power disconn
26. amp Dispensing Solutions Modu Flo System 1 2 GENERAL SYSTEM OPERATION 1 2 1 Figure 1 1 shows a functional schematic of a Modu Flo system 1 2 1 1 The following steps outline the operating sequence of a Modu Flo system a Lubricant stored in the reservoir or tank flows to the manifold The manifold may be mounted directly to the reservoir or tank or it may be mounted on a wall E The manifold directs lubricant into the pump to fill the pump chamber LUBRIQUIP Lubrication amp Dispensing Solutions p a o 42000 A controller energizes a solenoid valve to dispense and the solenoid sends air or hydraulic fluid to the manifold Porting in the manifold directs the air or hydraulic fluid to the pump causing the pump to dispense lube to the manifold outlet port When the controller releases the solenoid air or hydraulic fluid is redirected causing the pump to retract On single acting pneumatic pumps a spring pushes the pump to the retracted position Lubricant from the reservoir flows through the manifold and refills the empty chamber in the pump A pressure gauge blowout disc and high pressure switch are options which may be connected to the output lube on the manifold A signal from the pressure switch can be used to actuate an alarm or warning light Low level switch options are available for all tanks or reservoirs The switch provides an electrical signal when lubricant level is low Modu Fl
27. are cylindrical in shape and are used for either grease or oil lubricants If a reservoir is to be used for grease it will be equipped with a spring loaded follower which will apply pressure on the grease to force it into the pump Reservoirs use cylinders made of metal or plastic If a metal cylinder is used the reservoir will be equipped with a level indicator to allow a visual check of lubricant level Plastic cylinders are clear allowing personnel to actually see the amount of lubricant present The base of all reservoirs has the necessary tapped holes for either direct mounting of a manifold or for installing hose or tubing to a remote located manifold 2 1 2 Tank Description Tanks are rectangular weldments used for holding oil All tanks are equipped with a sight glass to allow personnel to easily check the lubricant level A pad mounted to the tank base provides the neces sary tapped holes for either direct mounting of a manifold or for installing hose or tubing to a remote located manifold 2 1 3 Reservoirs and Tanks Available Table 2 1 lists the tanks and reservoirs available for use Listings in the option column are used to identify the reservoir or tank selected when a Modu Flo system is ordered The option used is 42000 Modu Flo amp System 2 4 5 Grease Reservoir Parts Lists 2 3 2 5 OIL RESERVOIR MAINTENANCE OPTIONS OP1 THROUGH 2 7 AA 2 7 2 5 2 Oil Reservoir Ma
28. blowout assembly and pressure gauge Pump to Wall Remote Manifold Assembly Includes outlet check valve system fill check valve and blowout assembly Pump to Reservoir Manifold Combination Includes outlet check valve system fill check valve tubed blowout assembly and pressure gauge Pump to Wall Remote Manifold Combination Includes outlet check valve system fill check valve and blowout assembly for high pressure alarm Outlet Check Valve System Fill Check Valve Elbow 1 4 inch pipe Pipe Plug 1 4 inch Plastic Vent Plug 1 4 inch Located in D A Port Yellow Standard Blowout Assembly 1450 psi Tubed Blowout Assembly 1450 psi Bag of 6 Discs 1450 psi Standard Pressure Gauge 0 3 000 psi Liquid filled Pressure Gauge 0 3 000 psi Manifold to Reservoir O Ring Buna N Part Number 521 001 540 521 001 180 521 001 170 521 001 790 521 001 780 509 360 030 509 365 030 509 113 000 508 975 000 521 001 160 509 206 100 509 220 101 560 900 270 543 362 000 543 711 380 422 010 210 Included with pump to reservoir manifold assemblies Refer to Section 6 for kits in other pressure ranges Above items are for manifolds with 1 4 NPSF ports Consult factory for manifolds and accessories with SAE BSPP and metric threads 4 2 Modu Flo System 42000 O RING P N 422 010 210 LUBE SINGLE ACTING SYSTEM S A PORT OUTLET PLUNGER LUBE SY
29. feature eliminates the prelube cycle when power is reapplied after short shut downs A manual run button simplifies startup testing and bleeding of lubrication lines and points When the manual run button is depressed it resets the system to the begin ning of the cycle and signals the pump to run for the duration of the lubrication cycle Refer to Paragraph 8 2 2 for installation instructions Refer to bulletin 14521 for addi tional information 8 1 3 1000 Timer Counter The TC 1000 Solid State Timer Counter is a microprocessor based multi use controller dedicated to the operation of centralized lubrica tion systems 8 1 The TC 1000 schedules lube frequency either on a time or stroke cycle basis in values ranging from 1 9999 The pump run interval is also selectable in time or counts over the same range The TC 1000 is easily programmed in the field using four mini push buttons No special training or knowledge of computer language is necessary During power down or outage data is saved in EEPROM Electrically Erasable Programmable Read Only Memory When power is restored counting and pump status is restored to values prior to loss of power Available for 115 VAC 230 VAC 12 VDC or 24 VDC opera tion Pump Output voltage is the same as supply voltage Refer to bulletin 14530 for additonal information 8 1 4 WMP Maxi Monitor The WMP Maxi Monitor is designed to control and monitor a lubrication system and its acce
30. is mounted the enclosure screw on the pump will be on top This will ensure proper bleeding and priming of the system 4 2 2 Connection to Other Components Four 1 4 20 tapped holes are provided on the manifold for pump attachment The holes are laid out in a way that prevents the pump from being mounted incorrectly The operating ports listed in Table 4 1 must be connected by hose or tubing to their appropriate locations 4 3 MAINTENANCE 4 3 1 There is little maintenance required on the mani fold assemblies All fittings and accessories used on the unit should be tightened to avoid leakage If any accessory shows evidence of failure it may be removed by simply unscrewing it from the manifold Refer to disassembly procedures in Section 2 for draining techniques The pump does not need to be removed from the manifold but it may be desired if space is limited NOTE Ensure all lubricant is drained from reservoir before removing manifold LUBRIQUIP Lubrication amp Dispensing Solutions Modu Flo System Table 4 1 Port Name DA Double Acting GAUGE IND SYS FILL LUBE OUT SA Single Acting TEST LUBE IN Pump to Wall Re mote Mani fold Only Operating Ports on Modu Flo Manifolds Function Single acting model pumps Port is fitted with a plastic vent orifice plug so that air can be exhausted on piston return stroke Double acting model pumps Port has air or hydraulic supply conn
31. runs down and the assembly fails to perform as required the unit may have to be disassembled to replace a defective switch Before attempting disassembly check all electrical connections to make sure they are secure and check for any physical obstruction which might be preventing the float from operating 5 3 3 Disassembly of Oil Tank and Reservoir 15 Amp Low Level Assemblies 5 3 3 1 The disassembly procedure is as follows Disconnect and lock out all power from the assembly before attempting disassembly Serious injury may result from electrical shock LUBRIQUIP Lubrication amp Dispensing Solutions a Turn off all electrical power and all air supplies to the lube system b Remove cover from reservoir Refer to Section 2 Unscrew union nut 5 Figure 5 1 from switch adapter 2 d Unscrew switch adapter 2 from switch 1 e Remove actuating rod part of low level lower assembly 4 from remaining assembly f Unscrew low level lower assembly 4 from low level adapter 3 g Unscrew low level adapter 3 from the reservoir cover Remove low level adapter 3 from union nut 5 5 3 4 Assembly of Oil Tank and Reservoir 15 Amp Low Level Assemblies 5 3 4 4 The assembly procedure is as follows NOTE The procedure listed below is based on installing a new assembly in a tank or reservoir If your assembly was removed for repairs steps a and b do not apply p Remove cover from reservoir Ref
32. switch plunger housing before assembling switch to item 2 adapater Not available as replacement parts LOCKTITE USED AT ASSEMBLY ne ee ener ee ee NNA Figure 5 1 Oil Tank and Reservoir 15 Amp Low Level Assembly 5 3 LUBRIQUIP Lubrication amp Dispensing Solutions Modu Flo System 5 4 OIL TANK RESERVOIR 10 WATT LOW LEVEL ASSEMBLY MAINTE NANCE OPTIONS L5 L6 AND L7 5 4 1 General Maintenance tips disassembly and assembly procedures for low level options L5 L6 and L7 are discussed in Paragraphs 5 4 2 5 4 3 and 5 4 4 A sectional view of a low level assembly is shown in Figure 5 2 and should be referred to during the discussion 5 4 2 Oil Tank and Reservoir 10 Watt Low Level Assembly Maintenance Tips No maintenance is required on the 10 watt low level assemblies used on oil tanks and reservoirs If the oil level runs down and the assembly fails to perform as required the unit may have to be disas sembled to replace a defective switch Before attempting disassembly check all electrical connections to make sure they are secure and check for any physical obstructions which might be preventing the float from operating 5 4 3 Disassembly of Oil Tank and Reservoir 10 Watt Low Level Assemblies 5 4 3 1 The disassembly procedure for oil tank and reservoir 10 watt low level assemblies is as follows Disconnect and lock out all power from the assembly before attempting disassembly Serious injury may resul
33. the oil tanks according to the following procedure a Install one aluminum gasket 8 Figure 2 3 on each screw 7 and insert threads of screws through holes in bottom of tank weldment 9 o Install new o ring 13 in pump mounting pad 12 and align threaded holes in pump mounting pad with screws 7 protruding from bottom of tank weldment 9 Thread screws 7 into pump mounting pad 12 until pump mounting pad is snug against bottom of tank weldment 9 Torque screws 7 to 10 ft lbs E Position new gasket 10 on sight glass 11 and install sight glass on tank weldment 9 Secure sight glass 11 with four self threading nuts 14 Ie Install screen 4 into fill cup 5 Ie Position cover gasket 6 and cover 1 on tank weldment 9 and secure with self threading screws 2 ES Install pipe plug 3 in bottom of tank weldment 9 2 6 4 2 When the assembly steps listed in the above para graph have been completed any Modu Flo components which were removed to ease disassembly should be rein stalled on the tank 2 6 5 Oil Tank Parts List Table 2 4 identifies the parts indexed in Figure 2 3 LUBRIQUIP Lubrication amp Dispensing Solutions Modu Flo System Item Number 10 11 12 13 14 15 Part Number 521 001 060 521 001 070 521 001 080 521 000 810 521 000 830 521 000 850 415 640 040 415 640 040 508 975 000 534 304 003 534 147 000 521 003 420 521 003 380 521 003 340
34. tight Torque the nuts to 5 ft Ibs If the leakage continues replace gasket 9 Check for cracks and nicks in tube 8 Replace the tube as required P Visually inspect the reservoir tube 8 for dents which may restrict the movement of the follower cups 6 and 7 Replace the tube as required Disconnect and lock out power before opening electrical enclosures or conduit connections Serious injury may result from electrical shock 2 4 8 Disassembly of Grease Reservoirs Figure 2 1 shows a typical grease reservoir but does not include other Modu Flo components which may be mounted to the reser voir These components include the manifold pump level switches and high pressure blowout switches Disassembly of the reservoir may require that some of these components be removed The manifold and pump do not normally require removal but may be removed if desired The level and blow out switches may or may not require removal depending on the level of disassembly required The electrical connections to the switches probably should be disconnected in order to remove various parts without restriction of movement by the electrical cord The removal of these components is ex plained in other sections of the manual Refer to the table of contents to find where the components are discussed 2 4 3 1 The disassembly procedure may be performed with the reservoir mounted to the mounting surface However some mounting locations may be too restrict
35. tube INDICATOR ASSEMBLY Part of Part No 511 573 030 TUBING Copper 1 4 inch outer diameter x 0 030 wall SPUD Union NUT Union BODY Blowout ELBOW 1 4 inch NPT TEE 1 4 inch NPT CHECK VALVE ASSEMBLY FITTING Straight 1 4 tube x 1 4 inch NPT BLOWOUT AND SWITCH ASSEMBLY BLOWOUT DISCS Bag of 6 1450 psi FITTING Straight 1 4 inch tube x 1 8 inch NPT See Table 6 1 for other disc pressure ratings Tubing purchased separately Figure 6 3 Reservoir Blowout Switch Assembly Front View 6 5 PLUNGER Y CL 19 S 9 D o AN gen 1 H LEX ct 42000 Quantity hae 4 EA hb hihi hi E gt SH LUBRIQUIP Lubrication amp Dispensing Solutions Modu Flo System 6 6 TANK BLOWOUT SWITCH MAINTENANCE OPTION P4 6 6 1 General Maintenance tips disassembly and assembly instructions for tank blowout switches are dis cussed in Paragraphs 6 6 2 and 6 6 3 A typical tank with blowout switch is shown in Figure 6 4 and should be referred to during the discussion 6 6 2 Tank Blowout Switch Maintenance Tips maintenance is required on the blowout switch If this switch assembly is suspected to be defective check all wiring to the 42000 NOTE Relieve system pressure before removing any components 6 6 3 Assembly Disassembly of Blowout Switch Figure 6 4 shows a typical blowout switch mounted on a tank All components are connected by pipe threads and tubing and
36. 0 o Check jam nut 21 to make sure it is tight against adjustment screw body 19 If the jam nut is loose the adjustment screw 13 could rotate and cause the pump output to change This condition could also result in lubricant leakage or in air being sucked into the lubri cant 3 3 2 2 If internal components of the pump are defective it will usually result in erratic pump operation or output Section 9 of this manual lists causes and solutions for problems which could occur in the Modu Flo system Before disas sembling any pump refer to Section 10 The problem may be caused by other conditions which can be checked first before disassembling the pump 3 3 3 Disassembly of Pneumatic Pump The procedure below describes complete disassembly of a pump How ever you only need to disassemble to your specific area of concern 3 3 3 1 The disassembly procedure for the pneumatic pump is as follows NOTE Figure 3 2 shows air cylinder 7 separated from pump body 10 To achieve disassembly to this level requires special tools to remove air cylin der retainer 23 Normally this level of disas sembly is only performed at the factory If scoring or wear marks are evident on the inner diameter of air cylinder 7 or pump body 10 the pump assembly cannot be serviced and should be replaced Separate pump from manifold by removing four socket head screws 11 Figure 3 2 Remove and discard three o rings 9 and one o ring 18
37. 1 008 950 501 970 000 410 040 020 421 010 020 506 165 000 506 189 001 410 060 120 511 041 000 521 003 630 521 003 640 521 004 310 521 003 620 185 100 720 185 100 730 185 100 740 185 100 990 185 100 191 185 101 187 185 101 188 185 101 189 185 101 190 Table 2 2 Grease Reservoir Parts List Description RESERVOIR ASSEMBLY 5 lbs 2 27 kg plastic GP1 RESERVOIR ASSEMBLY 12 lbs 5 44 kg plastic GP2 RESERVOIR ASSEMBLY 20 Ibs 9 07 kg plastic GP3 RESERVOIR ASSEMBLY 6 Ibs 2 72 kg plastic GP4 RESERVOIR ASSEMBLY 3 Ibs 1 36 kg plastic GP5 RESERVOIR ASSEMBLY 5 lbs 2 27 kg metal GM1 RESERVOIR ASSEMBLY 12 lbs 5 44 kg metal GM2 RESERVOIR ASSEMBLY 20 lbs 9 07 kg metal GM3 RESERVOIR ASSEMBLY 6 Ibs 2 72 kg metal GM4 BOLT Tie 5 Ib 12 Ib BOLT Tie 20 lb BOLT Tie 6 Ib BOLT Tie 3 Ib RING Retaining CAP Reservoir SPRING Items 2 through 7 CABLE ASSEMBLY are not serviceable GUIDE ROD by the user replace GUIDE Follower entire reservoir CUP Seal GASKET 6 Tube 3 6 12 20 Ib GASKET 4 Tube 5 Ib BASE Aluminum 6 Tube 6 12 20 lb BASE 4 Tube 5 lb BASE Black 6 Tube 3 lb PETCOCK NUT Hex 5 16 18 LOCKWASHER 5 16 inch CAP Dust Reservoir Fill Stud NUT Hex 5 16 18 PLATE Backup INDICATOR Level 12 lb Metal INDICATOR Level 20 lb Metal INDICATOR Level 6 Ib Metal INDICATOR Lev
38. 20 68 8 A3 Double 100 8 28 135 7 521 000 041 AL 50 Single 0 060 to 0 240 0 983 to 3 933 20 8 40 137 6 A5 Double 60 16 56 271 4 B Hydraulic Pumps 521 000 011 HLJ 5 Double 0 010 to 0 030 0 164 to 0 492 100 0 35 5 7 H1 521 000 031 HLJ 25 Double 0 030 to 0 120 0 492 to 1 966 50 1 38 22 6 H2 521 005 900 HLJ 5X Double 0 030 to 0 092 0 492 to 1 51 100 1 28 21 0 H3 LUBRIQUIP 32 Lubrication amp Dispensing Solutions Modu Flo System 3 2 PREPARATION FOR USE 3 2 1 Mounting Any pump mounts directly to any manifold with four socket head capscrews Care must be taken to ensure that the outlet of the manifold is lined up with the inlet on the pump The face of the pump which mates with the manifold has several o rings When the pump is being installed care must be taken to ensure these o rings are not moved out of position The o rings provide a seal for the movement of air and lubricant between the manifold and pump If an o ring is missing air or lubricant may leak After being secured to the manifold no further connections can be made to the pump 3 2 2 Output Adjustment Adjustment of the pump output may be made with the pump removed from or still attached to the manifold 3 2 2 1 The procedure for output adjustment is listed below The items referenced are found in Figure 3 2 The adjust ment procedure is the same for both pneumatic and hydrau lic pumps a Remove adjustment cap 22 from adjustment screw
39. 93 Included in Repair Kit Refer to Page 3 6 Included in Pump Adjustment Assembly Refer to Page 3 6 SEE NOTE ON PAGE 4 2 Figure 3 2 Pneumatic Pump Exploded View smesBaw BRP Lubrication amp Dispensing Solutions Modu Flo System 3 4 HYDRAULIC PUMP MAINTENANCE OPTIONS H1 and H3 3 4 1 General Maintenance tips disassembly and assembly procedures for Options H1 and H3 hydraulic pump are discussed in Paragraphs 3 4 2 through 3 4 4 An exploded view of the pump is shown in Figure 3 3 and should be referred to during the discussion 3 4 2 Hydraulic Pump Options H1 and Maintenance Tips 3 4 2 1 The only maintenance required on the hydraulic pump Options H1 and is to check for the following a Check four socket head screws 8 Figure 3 3 to make sure they are tight Loose screws could allow hydraulic fluid and or lubricant to leak between the pump and the manifold This condition could result in erratic pump output b Check for leakage past gasket 12 Replace gasket if required Check jam nut 19 to make sure that it is tight against adjustment screw body 17 If the jam nut is loose the adjustment screw 10 could rotate and cause the pump output to change This condition could also result in lubricant leakage or in air being sucked into the lubri cant 3 4 2 2 If internal components of the pump are defective it will usually result in erratic pump operation or output Sect
40. 939 000 SPRING 1 Figure 5 3 Grease Reservoir Low Level Assembly STS SS 2 GREASE RESERVOIR CABLE ASSEMBLY REF GREASE RESERVOIR CAP REF LUBRIQUIP 56 Lubrication amp Dispensing Solutions Modu Flo System OPERATION AND SERVICE INSTRUCTIONS 42000 Modu Flo System SECTION 6 HIGH PRESSURE AND BLOWOUT SWITCHES 6 1 6 1 6 1 1 High Pressure 6 1 6 1 2 Blowout 6 1 6 1 3 Blowout Dec 6 1 6 1 4 High Pressure and Blowout Switch iris 6 2 6 2 HIGH PRESSURE SWITCH ADJUSTMENT 6 2 AN 6 2 6 2 2 High Pressure Switch Adjustment Procedur amp s E 6 2 6 3 MOUNTING INSTRUCTIONS 6 3 6 4 HIGH PRESSURE SWITCH MAINTENANCE OPTION BUT 2 iia a 6 3 6 4 1 General 6 3 6 4 2 High Pressure Switch Maintenance Tips 6 3 6 1 DESCRIPTION 6 1 1 High Pressure Switches High pressure switches may be plumbed into the lubricant output circuit to provide an electrical signal when excessive pressure is being approached The pressure switch is factory set at 1150 psig 79 bar and is used with a standard blowout disc rated at 1450 psig 100 bar When output pressure reaches 1150 psig 79 bar contacts on the switch will actuate and provide a warning signal to an external device I
41. DIMENSIONS OPTION A B C 42 T1 10 75 inches 7 25 inches 10 70 inches 273 mm 184 mm 272 mm T2 12 inches 13 22 inches 10 59 inches 305 mm 336mm 269 mm T3 17 25 inches 13 22 inches 10 59 inches 438 mm 336 mm 269 mm Figure 2 3 Oil Tank Exploded View 2 13 2 14 Blank LUBRIQUIP Lubrication amp Dispensing Solutions Modu Flo System 42000 OPERATION AND Modu Flo6 SERVICE INSTRUCTIONS System SECTION 3 PUMPS 3 1 DESCRIPTION ia 3 1 3 4 3 Disassembly of Hydraulic Pump 34 1 Contra iia 3 1 Options Hi and H9 3 9 8 2 PREPARATION FOR USE vsisi 3 3 3 4 4 Assembly of Hydraulic Pump Options H1 32A EE 3 3 et B 9m 3 2 2 Output Adlustmemt nennen 3 3 3 4 5 Hydrau ptions an 33 PNEUMATIC PUMP MAINTENANCE Parts Ust nn ga 3 10 OPTIONS A1 THROUGH 3 3 3 5 piles Seri PUMP MAINTENANCE MOMENT 3 3 is 3 3 2 Pneumatic Pump Maintenance Tips 3 3 3 3 3 Disassembly of Pneumatic Pump 3 3 3 5 2 es a Option H2 as 3 3 4 Assembly of Pneumatic Pump 3 4 2 es 3 3 5 Pneumatic Pump Parts List 3 4 3 5 3 isassembly SIS ECKER le Ee EE 3 13 3 4 HYDRAULIC PUMP MAINTENANCE 3 5 4 Assembly of Hydraulic Pump Option H2 3 13 OPTIONS H1 and H3 E 3 9 3 5 5 Hydraulic Pump Option H2 Parts List 3 14 3 4 1 Gener le 3 9 3 4 2 Hydraulic Pump Options H1 and
42. ERVOIR BLOWOUT SWITCH MAINTE EEN e NANCE OPTIONS P2 and 64 3 2 PREPARATION FOR 3 3 98 DS TICH MAINTENANCE 6 6 da PNEUMATICPUMPMAINTENANGE OPTION PA sss OPTIONS 1 THROUGH A6 3 3 7 PNEUMATIC SOLENOID OPTIONS 7 1 3 4 HYDRAULIC PUMP MAINTENANCE OPTIONS H1 AND 3 9 8 CONTROLLERS surta 8 1 9 O A MAINTENANCE 31 DESCRIPTION 8 1 O mus 32 WIRING EEN 8 2 4 MANIFOLDS rrr 4 1 41 DESCHIEPTION 4 1 9 SYSTEM OPERATION 4 9 1 4 2 PREPARATION FOR USE 4 1 9 1 GENERA T aaaea 9 1 A3 MAINTENANCE cette 4 1 9 2 SYSTEM INFORMATION 9 1 9 3 OPERATING TIPS ees 9 1 9 4 MATERIAL 9 2 5 LOW LEVEL SWITCHES 5 1 5 1 DESCRIPTION uses 5 1 10 TROUBLESHOOTING 10 1 5 2 MOUNTING INSTRUCTIONS 5 1 10 1 10 1 LIST OF ILLUSTRATIONS Number Title Page Number Title Page 1 1 Modu Flo Functional Schematic 1 3 5 2 Oil Tank and Reservoir 10 Watt 2 1 Grease Reservoir Exploded View 2 5 Low Level Assembly 4 2 2 5 5 2 2 Oil Reservoir Exploded View
43. INK SWITCH 2 2 OR 3 WIRE TYPE SUPPLEMENTAL WIRING FOR LOW LEVEL Figure 8 3 TC 1000 Timer Counter Wiring Schematic MAN SHD LOW eee CYCLE STROKE INPUT FAULT 2 SHD FAULT1 SHD jc SHD SW SWITCH agi PUMP SHOGNOPOWER min Von Vru mg Bt Von T OS F 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 4 3 l CO CD C2 C5 C5 C5 0009020000000 OHIO CONTACT as NO suasi n sel 22 a i INPUT POWER FUSED AT i 1 no 1 1 1 E 1 H THE BOARD Ne LESSE EXTERNAL SHOWN IN Nc Pe oa goa S peT Ma or POWER OFF ee ciales A s nn paski LUBE PUMP DE ENERGIZED Cn i 7 FUSED 2 AMP STATE N D 1 FAULT RELAY 1 STROKE SWITCH FROM MACHINE LUBE SYSTEM CYCLE SWITCH REMOTE MANUAL 7 9 0 5 5 5 5 5 Po RUN PUSH BUTTON i d LOW LEVEL Ers EE eebe ENEE i SWITCH eT GE a LUE PRESSURE SW ITCH THESE CONNECTIONS MUST BE MADE WHEN IN STROKE MODE Figure 8 4 WMP Maxi Monitor Wiring Schematic 8 3 8 4 Blank LUBRIQUIP Lubrication amp Dispensing Solutions Modu Flo System OPERATION AND SERVICE INSTRUCTIONS SECTION 9 SYSTEM OPERATION 9 15 GENERAL tii 9 1 9 2 SYSTEM INFORMATION 9 1 9 241 System Setup coercere erede 9 1 9 2 2 System Filling 9 1 9 2 3
44. KET Part of kits 560 001 051 and 560 001 940 1 13 511 893 000 SPRING Check valve part of kits 560 001 051 and 560 001 940 1 14 401 030 030 BALL Steel 3 16 inch part of kits 560 001 051 and 560 001 940 1 15 423 700 113 O RING Part of kits 560 001 051 and 560 001 940 3 16 423 700 114 O RING Part of kits 560 001 051 and 560 001 940 1 17 521 003 030 BODY Adjustment screw HLJ 5 1 521 005 710 BODY Adjustment screw HLJ 5X 1 18 439 040 050 GASKET Stat O Seal part of kit 560 001 051 HLJ 5 2 439 050 050 GASKET Stat O Seal part of kit 560 001 940 HLJ 5X 2 19 410 702 028 NUT Jam Part of Kit 560 001 051 1 20 521 002 970 Adjustment screw HLJ 5 1 521 010 360 CAP Adjustment screw HLJ 5X 1 21 527 000 790 O RING Part of kit 560 001 051 HLJ 5 1 22 521 008 450 SEAT Check valve part of kits 560 001 051 and 560 001 940 1 23 422 010 080 O RING Part of kits 560 001 051 and 560 001 940 1 25 423 700 057 RING Backup part of kit 560 001 940 HLJ 5X 2 26 423 700 060 O RING Part of kit 560 001 940 HLJ 5X 1 27 PISTON HLJ 5X 1 28 423 700 058 RING Backup part of kit 560 001 940 HLJ 5X 2 29 423 700 059 O RING Part of kit 560 001 940 HLJ 5X 1 30 521 000 050 SCREW Enclosure 1 31 401 010 010 BALL Steel 1 8 Dia Part of Kit 560 001 051 1 32 417 450 020 SCREW Set 10 32 x1 4 1 1 1 560 001 940 REPAIR consists of ltems 5 9 12 thru 16 18 22 thru 26 28 and 29 521 001 391 PUMP ADJ
45. L TANK RESERVOIR 10 WATT LOW LEVEL ASSEMBLY MAINTENANCE OPTIONS L5 L6 ANDIZ EE 5 4 5 1 DESCRIPTION 5 1 1 General Several varieties of assemblies are available to provide a signal when the lubricant level is low Low level switch assemblies used on oil tanks or reservoirs depend on floats that fall with the depletion of lubricant and actuate contacts on the switch Switch assemblies used on grease reservoirs are actuated when a cable attached to the grease follower is pulled away from the switch as the follower reaches the low position Switch assemblies used in oil reservoirs and grease reservoirs are rated 15 amps Optional 10 watt assemblies are available for oil tanks and reservoirs 5 1 1 1 The low level assemblies with a 15 amp rating are often used to activate a warning device such as a light or alarm The optional 10 watt assemblies are used to provide input to controllers which may be programmed to use the input signal as desired 5 1 1 2 Table 5 1 lists the low level assemblies available for use Listings in the option column are used to identify the assembly selected when a Modu Flo system is ordered 5 1 42000 Modu Flo amp System 5 4 1 General 5 4 5 4 2 Oil Tank and Reservoir 10 Watt Low Level Assembly Maintenance Tips 5 4 5 4 3 Disassembly of Oil Tank and Reservoir 10 Watt Low Level Assemblies 5 4 5 4 4 Assembly of Oil Tank and Reservoir 10 Watt Low Level Assemblies
46. STEM FILL CHECK VALVE BLOWOUT DOUBLE ACTING ASSEMBLY D A PORT YELLOW VENT PLUG TEST AIR PURGE PORT This port is used to manually fill system lube lines This is not the reservoir fill port See figure 2 1 on page 2 5 item 15 for location of grease reservoir fill On newer units the test port has been relocated to the adjustment end of the pump body The use and function of this port is the same in either location Figure 4 1 Typical Manifold Assembly AB Lubrication amp Dispensing Solutions Modu Flo System OPERATION AND SERVICE INSTRUCTIONS SECTION 5 LOW LEVEL SWITCHES 5 1 DESCRIPTION 5 1 54 WR ET 5 1 5 2 MOUNTING INSTRUCTIONS 5 1 5 2 1 Oil Reservoirs and 5 1 5 2 2 Grease Cylinders 5 1 5 3 OILTANK AND RESERVOIR 15 AMP LOW LEVEL ASSEMBLY MAINTENANCE OPTIONS L1 L2 and LO icono nica 5 2 5 31 Generali ni iniit em 5 2 5 3 2 Oil Tanks and Reservoir 15 Amp Low Level Assembly Maintenance Tips 5 2 5 3 8 Disassembly of Oil Tank and Reservoir 15 Amp Low Level Assemblies 5 2 5 3 4 Assembly of Oil Tank and Reservoir 15 Amp Low Level Assemblies 5 2 5 3 5 Tank and Reservoir 15 amp Low Level Assemblies Parts List 5 3 5 4 OI
47. TUBE Reservoir 13 inches 330 2 mm x 6 0 inches 152 4 mm outer diameter 12 pint TUBE Reservoir 20 inches 508 mm x 6 0 inches 1 152 4 mm outer diameter 20 pint GASKET 4 Tube 5 pint GASKET 6 Tube 6 12 20 pint BASE 4 Tube 5 pint BASE 6 Tube 6 12 20 pint NUT Hexagon 5 16 18 LOCKWASHER 5 16 inch Reservoir Tube Kit includes gasket Item 7 LUBRIQUIP Lubrication amp Dispensing Solutions plastic plastic plastic plastic A es Quantity NN 42000 28 Modu Flo System 42000 Te del ege e 1 UJ DIMENSIONS OPTION A B OP1 OP2 7 25 inches 15 inches 184 mm 381 mm OP3 7 25 inches 22 inches 184 mm 559 mm OP4 7 25 inches 10 5 inches 184 mm 267 mm Reservoir Tube Kit includes gasket Item 7 Figure 2 2 Oil Reservoir Exploded View 29308 Lubrication amp Dispensing Solutions Modu Flo System 2 6 OIL TANK MAINTENANCE OPTIONS T1 T2 and T3 2 6 1 General Maintenance tips disassembly and as sembly procedures for oil tanks are discussed in Para graphs 2 6 2 2 6 3 and 2 6 4 An exploded view of a typical oil tank is shown in Figure 2 3 and should be referred to during the discussion 2 6 2 Oil Tank Maintenance 2 6 2 1 Maintenance on the oil tanks consists of the follow ing a Visually check for oil leakage between the tank 9 Figure
48. The blowout body 14 is connected to the IND port on the manifold The return elbow 15 is piped into the fill port of the reservoir Normally the only components which may require removal are the switch 5 indicator assembly 10 and blowout disc Access to these components is easily achieved after removal of any connective tubing 6 5 4 Reservoir Blowout Switch Parts Lists Table 6 5 identifies the parts indexed on Figure 6 3 Modu Flo System Item Number Part Number 521 001 190 521 001 200 1 521 000 760 521 000 770 2 416 701 992 3 421 070 050 4 410 030 050 5 529 726 001 6 501 967 001 Ke 419 110 020 8 417 060 060 9 435 370 020 10 511 160 001 11 12 509 223 000 13 509 224 000 14 509 208 000 15 412 270 030 16 412 380 020 17 509 365 030 18 435 360 030 511 573 030 560 900 270 19 435 360 020 Table 6 5 Reservoir Blowout Switch Parts List Description HIGH PRESSURE BLOWOUT SWITCH ASSEMBLY 5 pint lb HIGH PRESSURE BLOWOUT SWITCH ASSEMBLY 6 12 or 20 pint Ib BRACKET Mounting for 5 lb and 5 pt BRACKET Mounting for 6 Ib 12 lb 20 Ib 6 pt 12 pt and 20 pt SCREW Round head 6 32 x 1 3 8 inch part of Part No 511 573 030 LOCKWASHER No 6 part of part No 511 573 030 NUT Hex 6 32 part of Part No 511 573 030 SWITCH Part of Part No 511 573 030 BRACKET Switch part of Part No 511 573 030 SCREW Socket head 10 24 x 1 2 inch SETSCREW 1 4 20 x 1 2 inch FITTING Elbow 1 8 NPT x 1 4 inch
49. a single pump cycle and chamber B is primed ready for the next cycle o The double acting models have an additional air or hydraulic supply line connected to port DA When the pistons have been moved to the right air or hydraulic supply to port SA is shut off and vented Then air or hydraulic fluid under pressure is supplied to port DA which returns the pistons to their original position This more powerful return action allows an increased cycle rate of the pump 3 1 1 3 All pneumatic pumps have a lube to air pressure ratio of 30 1 The pumps operate on input pressure ranging from 40 to 150 psi 3 to 10 bar The HLJ 5M and HLJ 25M hydraulic pumps have a lube to hydraulic ratio of 5 5 1 The HLJ 5X has a lube to hydraulic ratio of 2 2 1 The hydraulic pumps operate on input pressures ranging from 200 to 2000 psi 14 to 138 bar It should be noted that lower input pressures may prevent the pumps from building sufficient pressure to crack a rupture disc or activate a high pressure device In pneumatic systems with an inlet air pressure of 40 psi 3 bar only 1200 psi 83 bar could be developed In hydraulic systems with 200 psi 14 bar only 1100 psi 76 bar could be developed Neither of these pressures would be high enough to crack a 1450 psi disc The system could be blocked and not functioning without giving any indication to plant personnel The supply pressure either penumatic or hydraulic should be adjusted high
50. ace of the reservoir cap 5 e Install lockwashers 10 and hex nuts 9 on tie rods 1 Torque nuts to 5 ft Ibs f Install pipe plug 4 in base 8 2 5 4 2 When the assembly steps listed in the above para graph have been completed any Modu Flo components which were removed to ease disassembly should be rein stalled on the reservoir 2 5 5 Oil Reservoir Parts Lists Table 2 3 identifies the parts indexed in Figure 2 2 LUBRIQUIP Lubrication amp Dispensing Solutions Modu Flo System Item Number oR WP Part Number 185 100 080 185 100 060 185 100 070 185 100 750 415 700 272 415 700 273 415 700 271 534 304 003 534 147 000 508 975 000 521 000 600 501 474 029 185 100 720 185 100 990 185 100 730 185 100 740 501 414 000 501 423 001 521 000 530 521 000 500 410 040 020 421 010 020 Table 2 3 Oil Reservoir Parts Lists Description RESERVOIR ASSEMBLY 5 pint 2 37 liters RESERVOIR ASSEMBLY 12 pint 5 68 liters RESERVOIR ASSEMBLY 20 pint 9 46 liters RESERVOIR ASSEMBLY 6 pint 2 84 liters BOLT Tie 5 pint 12 pint BOLT Tie 6 pint BOLT Tie 20 pint SCREEN 40 Mesh CUP Fill PLUG Pipe 1 4 inch NPT CAP Reservoir 4 Tube 5 pint CAP Reservoir 6 Tube 6 12 20 pint TUBE Reservoir 13 inches 330 2 mm x 4 inches 1 100 mm outer diameter 5 pint TUBE Reservoir 8 5 inches 215 9 mm x 6 0 inches 152 4 mm outer diameter 6 pint
51. ainer ring 25 and spring retainer 26 from air piston 1 h Remove retainer ring 27 to separate lube piston 5 from air piston 1 Remove and discard o rings 6 and 28 3 3 4 Assembly of Pneumatic Pump 3 3 4 1 Assemble the pneumatic pump according to the following procedure NOTE Use new o rings gaskets and return spring when assembling pump Lubricate all o rings and sliding parts with the lubricant which is used in the system a Install new o ring 6 on lube piston 5 b Install new o ring 28 on air piston 1 Install lube piston 5 into air piston 1 and secure with retainer ring 27 c Install spring retainer 26 in air piston 1 and secure with retainer ring 25 d Install piston return spring 24 in air cylinder 7 Push air piston 1 through air cylinder 7 and into pump body 10 LUBRIQUIP Lubrication amp Dispensing Solutions 42000 Install new o ring 2 on cylinder cap 3 and secure in air cylinder 7 with retainer ring 4 Ie Insert smaller end of adjustment screw 13 into adjustment screw body 19 Rotate adjustment screw 13 until smaller end is protruding from hex portion of adjustment screw body 19 g Install new o ring 12 on adjustment screw body 19 and install adjustment screw body in pump body 10 Tighten securely E Install jam nut 21 and two new gaskets 20 one on each side of jam nut on adjustment screw 13 Butt adjustmen
52. are easily assembled or disassembled The blowout body 15 is connected to the IND port on the manifold The return elbow 12 is piped into the fill port of the reservoir Normally the only components which may require removal are the switch 6 indicator assembly 8 and blowout disc Access to these components is easily achieved after removal of any switch before removing any components connective tubing fies the parts indexed on Figure 6 4 Disconnect and lock out all power from the assembly before attempting disassembly Serious injury may result from electrical shock Item Number Part Number Description Quantity 521 001 210 BLOWOUT SWITCH ASSEMBLY Option P4 1 435 360 020 FITTING Straight 1 8 NPT x 1 4 inch tube 2 2 416 701 992 SCREW Round head 6 32 x 1 3 8 inch included in Part No 511 573 020 2 3 421 070 050 LOCKWASHER No 6 included in part Kit No 511 573 020 4 4 410 030 050 NUT Hex No 6 32 included in Part No 511 573 020 2 5 419 110 020 SCREW Socket head 10 24 x 1 2 inch 2 6 529 726 001 SWITCH Included in part No 511 573 020 1 7 501 967 001 BRACKET Switch included in part No 511 573 020 1 8 511 160 001 INDICATOR ASSEMBLY Included in part No 511 573 020 1 9 435 370 020 FITTING Elbow 1 8 x 1 4 inch tube 1 10 412 380 020 TEE 1 4 NPT 1 11 509 365 030 CHECK VALVE ASSEMBLY 1 12 435 370 030 FITTING Elbow 1 4 inch male pipe x 1 4 inch tube 1 13 509 223 000 SPUD Union 1 14 509 224 000 NUT Un
53. cations may be too restrictive to provide access to all components If your particular installation re quires dismounting of the reservoir make sure the reservoir 42000 is drained of lubricant before removing the attaching hard ware This will reduce the weight of the reservoir and reduce the chance of spillage The disassembly procedure is as follows a Remove pipe plug 4 Figure 2 2 from base 8 and allow oil to drain from reservoir into bucket or similar container Properly dispose of emptied oil b Remove three hex nuts 9 and three lockwashers 10 from tie rods 1 Remove tie rods 1 from reservoir cap 5 c Remove reservoir cap 5 from reservoir tube 6 d Remove fill screen 2 from fill cup 3 and clean screen e Remove reservoir tube 6 from base 8 ps Remove and discard gasket 7 from reservoir tube 6 2 5 4 Assembly of Oil Reservoir NOTE Before assembly lubricate followers and tube inner diameter with the lubricant which is used in the system 2 5 4 1 Assemble the oil reservoir according to the follow ing procedure a Install screen 2 Figure 2 2 in fill cup 3 b Install new gasket 7 on reservoir tube 6 c Position reservoir tube 6 on base 8 and position reservoir cap 5 on tube d Rotate reservoir cap 5 until tie rods 1 can be installed through holes in cap and in base 8 The heads of tie rods 1 must fit into the hexagon depressions on the upper surf
54. ck close petcock and continue to fill the reservoir until follower is at vent hole in reservoir tube any remaining air and small amount of grease will exit vent Loosen system mainline connection at pump outlet Operate pump until lubricant free of air flows from outlet port Tighten mainline connec tion at pump Pump is now free of air Note for extreme cases where the pump will not take a prime it may be helpful to inject serveral Modu Flo System ounces of heavy oil through the grease fill quick disconnect The pump will then prime on oil pulling the grease behind it If it becomes nec essary to use this method all injected oil should be discharged at the loosened system supply connection along with any air Refer to bulletin 12411 Portable Filler Pak for manual operated fill pump 2 4 GREASE RESERVOIR MAINTENANCE OPTIONS GP1 THROUGH GP5 AND GM1 THROUGH GM4 2 4 1 General Maintenance tips disassembly and as sembly procedures for grease reservoirs are discussed in Paragraphs 2 4 2 2 4 3 and 2 4 4 An exploded view of a typical grease reservoir is shown in Figure 2 1 and should be referred to during the discussion 2 4 2 Grease Reservoir Maintenance 2 4 2 1 Maintenance on the grease reservoir consists of the steps described below a Visually inspect the reservoir for lubricant leaking between reservoir tube 8 Figure 2 1 and base 10 This may indicate a bad gasket 9 or that the hex nuts 12 are not
55. cycled by an external source such as a timer counter control package or customer supplied directional valve Once this external source is engaged the system will cycle as programmed 9 3 OPERATING TIPS 9 3 1 General While the system is operating the following components may be checked 9 3 1 1 Check that the pump is cycling according to schedule The solenoid or directional valve which operates the pumps should be actuated by the system controller 9 3 1 2 Visually check the system for leaks and loose fittings Make sure that hoses do not become kinked and are not rubbing on anything LUBRIQUIP Lubrication amp Dispensing Solutions Modu Flo System 9 3 1 3 If the reservoir or tank is not equipped with low level Switch visually check the lubricant level and refill before all lubricant is used If the reservoir or tank is allowed to run dry air will be introduced into the system requiring that the System be bled 9 4 MATERIAL CONSIDERATIONS 9 4 1 Material Cleanliness System life and consistent operation will both be improved by using only clean lubricant On all pumps the lube piston diameter is very close to the diameter of the chamber in the pump body Contaminants in the lubricant could cause scoring in this area resulting in LUBRIQUIP Lubrication amp Dispensing Solutions 42000 erratic pump operation and costly parts replacement Make sure that lubricant used to fill the system is clean If there
56. down and the assembly fails to perform as required the low level assembly may have to be disassembled to Disconnect and lock out all power from the assembly before attempting disassembly Serious injury may result from electrical shock 55 LUBRIQUIP Lubrication amp Dispensing Solutions Modu Flo System 42000 a Disconnect and lock out all electrical power and air a Attach bracket 2 to grease reservoir cover using three supplies to the lube system self tapping screws 4 b Disconnect switch 1 Figure 5 3 from terminal box b Place spring 5 over tip of level indicator Remove switch 1 from bracket 2 c Compress spring 5 and place retainer ring 3 be c Remove retainer ring 3 and spring 5 tween spring and tip of level indicator d Remove three self tapping screws 4 and bracket 2 d Attach switch 1 to bracket 2 5 5 4 Assembly of Grease Reservoir Low Level e Wire switch 1 in accordance with local electrical codes Assembly 5 5 4 1 The procedure for assembly of the grease reservoir 5 5 5 Grease Reservoir Low Level Assembly Parts List low level assembly is as follows Table 5 4 identifies the parts indexed in Figure 5 3 Table 5 4 Grease Reservoir 15 Amp Low Level Assembly Parts List Item Number Part Number Description Quantity 521 001 110 LOW LEVEL SWITCH ASSEMBLY Option L4 1 529 726 001 SWITCH 1 2 514 191 001 BRACKET 1 3 060251 RING Retainer 1 4 415 210 010 SCREW Self tapping 3 5 542
57. ected slide cover toward electrical terminations while twisting it to overcome friction e Connect power to terminals or leads p Insert screwdriver into adjustment slot and turn clock wise to increase setting or counter clockwise to de crease setting For setting on rise apply desired pressure and turn adjustment clockwise facing cable end of pressure switch until switch clicks and or tester confirms contact transfer Circuit across N O and COM terminals closes For setting on fall apply pressure equal to normal system operating pressure Reduce source pressure to set point value Turn adjustment counter clockwise until switch clicks and or tester confirms contact transfer circuit across N C and COM closes After completing adjustments slide cover closed order adjustment compartment Recheck set point 6 3 42000 6 3 MOUNTING INSTRUCTIONS 6 3 1 All high pressure switches and blowout options are connected to the outlet of the manifold and mounted to various locations on the reservoir or tank Refer to assembly Paragraphs 6 4 3 6 5 3 and 6 6 3 for specific assembly instructions 6 4 HIGH PRESSURE SWITCH MAINTENANCE OPTION P1 6 4 1 General Maintenance tips disassembly and assembly procedures for the high pressure switch are discussed in Paragraphs 6 4 2 and 6 4 3 A typical pressure Switch is shown in Figure 6 2 and should be referred to during the discussion 6 4 2 High Pressure Switch Main
58. ected to it Fluid directed to this port causes the pump to retract to the loading position Port for attaching a pressure gauge to indicate pump output pressure This port is common to the LUBE OUT port Port for attaching a blowout or pressure indicating assembly This port is common to the LUBE OUT port Port for attaching an inlet check valve This allows the lubrication lines to be filled by an outside source of lubricant so that the pump does not cycle excessively when filling the system Port that the system being lubricated is connected to An outlet check valve is installed here Port has a pneumatic or hydraulic supply source connected to it Fluid directed to this port causes the pump to dispense Port is used for bleeding air out of pump Back out setscrew one or two turns while pump is in the dispense stroke Close setscrew when pump is on return stroke to prevent air from being sucked in Repeat process until air free lubricant comes from vent hole Port that the lubricant reservoir or tank outlet is connected to On newer units the test port has been relocated to the adjustment end of the pump body The use and function of this port is the same in either location LUBRIQUIP Lubrication amp Dispensing Solutions 42000 Table 4 2 Manifolds and Manifold Accessories Item Pump to Reservoir Manifold Only Pump to Reservoir Manifold Assembly Includes outlet check valve System fill check valve
59. el 5 Ib Metal TUBE Reservoir plastic 13 inches 330 2mm x 4 inches 100 mm outer diameter 5 Ib TUBE Reservoir plastic 13 inches 330 2 mm x 6 0 inches 152 4 mm outer diameter 12 Ib TUBE Reservoir plastic 20 inches 508 mm x 6 0 inches 152 4 mm outer diameter 20 lb TUBE Reservoir plastic 8 5 inches 215 9 mm x 6 0 inches 152 4 mm outer diameter 6 lb TUBE Reservoir plastic 5 inches 127 mm x 6 0 inches 152 4 mm outer diameter 3 lb TUBE Reservoir metal 13 inches 330 2 mm x 4 inches 100 mm outer diameter 5 Ib TUBE Reservoir metal 13 inches 330 2 mm x 6 0 inches 152 4 mm outer diameter 12 lb TUBE Reservoir metal 20 inches 508 mm x 6 0 1 inches 152 4 mm outer diameter 20 lb TUBE Reservoir metal 8 5 inches 215 9 mm x 6 0 inches 152 4 mm outer diameter 6 Ib Mating fill coupler 506 322 000 order separately Reservoir Tube Kit includes gasket item 9 LUBRIQUIP Lubrication amp Dispensing Solutions Quantity a4 oo oa sch sch sch ck 9 ch sch sch oo sch sch ch EA EA ch sch 42000 2 4 Modu Flo System Item Number Part Number 439 060 181 527 000 230 527 000 240 42000 Table 2 2 Grease Reservoir Parts List Continued NOTE USED ON METAL RESERVOIRS ONLY 18 2 5 2 6 Blank Description Quantity GASKET Top Vent 3 Ib 1 BUSHING Follower 1 1
60. enough to ensure that a blocked line will cause sufficient pressure to be developed LUBRIQUIP Lubrication amp Dispensing Solutions Modu Flo System 3 1 1 4 In pneumatically operated systems pressure surges often occur when the solenoid is energized These surges can be minimized by installing air flow devices in the solenoid pneumatic lines 3 1 1 5 Table 3 1 lists the available pumps along with other data Note that the part number on the pneumatic pump is the same for two different pump models This is because any pneumatic pump may be used as either single or SINGLE ACTING S A PORT CHAMBER A 000000 42000 double acting Listings in the option column are used to identify the pump selected when a Modu Flo system is ordered The option used is designated by the entry in the ordering code as shown below MPP XXX XXX XX XX XX XX XX XXX XX Pump Option LUBE INLET PORT LUBE OUTLET PORT CHECK VALVE CHAMBER C CHAMBER B RETURN SPRING AIR PISTON LUBE PISTON DOUBLE ACTING D A PORT Figure 3 1 Typical Pump Operation Table 3 1 Pumps Input Volume Output Maximum Per Full Part Displacement Range Strokes Stroke Cycle Number Model Action in per stroke Minute cu in cm Option A Pneumatic Pumps 521 000 001 AL 5 Single 0 010 to 0 030 0 164 to 0 492 65 1 06 17 4 1 Double 100 2 09 34 3 521 000 021 AL 25 Single 0 030 to 0 120 0 492 to 1 966 25 4
61. er to Section 2 P Remove 1 4 inch pipe plug from reservoir cover Insert low level adapter 3 Figure 5 1 into union nut 5 Screw low level adapter 3 into the reservoir cover and tighten securely 5 2 Modu Flo System 42000 c Screw low level lower assembly 4 into low level e Screw switch adapter 2 into switch 1 and tighten adapter 3 and tighten securely securely f Screw union nut 5 onto switch adapter 2 and tighten NOTE securely If float portion of low level lower assembly was g Install cover on reservoir Refer to Section 2 removed during disassembly apply Locktite to the attaching bolt and securely attach the float to h Wire switch in accordance with local electrical codes the arm 5 3 5 Oil Tank and Reservoir 15 Amp Low Level Assem d Insert the actuating rod part of low level lower assembly blies Parts List Table 5 2 identifies the parts indexed in 4 into this assembly Figure 5 1 Table 5 2 Oil Tank and Reservoir 15 Amp Low Level Assemblies Parts List Item Number Part Number Description Quantity 521 001 030 LOW LEVEL ASSEMBLY 5 pint 12 pint 521 001 040 LOW LEVELASSEMBLY 20 pint 521 001 050 LOW LEVELASSEMBLY 6 pint 1 514 116 001 SWITCH 1 2 ADAPTER Switch 1 27 ADAPTER Low level 1 4 LOW LEVEL LOWER ASSEMBLY 1 5 NUT Union 1 ST AE f U 4 A t o 1 IN i L When replacing item 1 switch only remove lock nut from new
62. f the problem causing the high pressure is not corrected the pressure will continue to rise When pressure reaches 1450 psig 100 bar the blowout disc will rupture and relieve the pressure The setting of the pressure switch is adjustable Adjustment procedures are discussed in Paragraph 6 2 2 6 1 2 Blowout Switches High pressure blowout switch assemblies may be plumbed into the lubricant circuit to provide an electrical signal when the blowout disc has ruptured On these assemblies a tubed blowout assembly is used The tubed blowout allows lubricant to flow from the ruptured blowout disc through tubing up to an indicator assembly The indicator assembly has a built in check valve which will allow the lubricant to reach a pressure sufficient enough to extend a plunger The extended plunger actuates a switch which will allow a signal to be sent to an alarm or other device Lubricant from the indicator is directed through tubing and is returned to the inlet port on the reservoir or 6 1 6 4 3 Assembly Disassembly of High Pressure SWIICH e id 6 3 6 4 4 High Pressure Switch Parts Lists 6 3 6 5 RESERVOIR BLOWOUT SWITCH MAINTENANCE OPTIONS P2 and 6 4 6 554 iia 6 4 6 5 2 Reservoir Blowout Switch Maintenance 6 4 6 5 3 Assembly Disassembly of Blowout Switch 6 4 6 5 4 Reservoir Blowout Switch Parts Lists
63. g of the system will reduce the chance of air entrapment The manifold pump 9 1 42000 Modu Flo amp System 9 3 OPERATING TIPS 9 1 9 3 1 General E 9 1 9 4 MATERIAL CONSIDERATIONS 9 2 9 4 1 Material Cleanliness 9 2 9 4 2 Temperature 2 9 2 assembly still must be bled to remove air which will be trapped inside the pump To do this loosen the setscrew in the TEST port while the pump is in the dispense stroke Tighten the setscrew before the pump reloads Lubricant should come out of the vent hole when the pump is dis pensing Cycle the pump several times until air free lubricant is dispensed out of the bleed hole then tighten the setscrew 9 2 4 System Start up Before starting any system make sure that all filling and bleeding steps have been com pleted Refer to Bulletin 30103 for filling and bleeding a series progressive system Check the pneumatic or hydraulic inlet pressure and verify that it is adjusted correctly The actual setting will vary from system to system depend ing on type of lubricant used and other system variables The correct pressure for any particular system will be determined during initial setup of the system and should not need to be changed 9 2 4 1 Check the output of the lubricant pump Adjust the output as described in Section 3 of this manual 9 2 4 2 The system is now ready to run The pump is
64. intenance 2 7 2 5 8 Disassembly of Oil Reservoir 2 7 2 5 4 Assembly of Oil Reservoir 2 7 2 5 5 Oil Reservoir Parts Lists 2 7 2 6 OILTANK MAINTENANCE OPTIONS T1 T2 and 2 11 26 1 General 2 2 2 11 2 6 2 Oil Tank Maintenance 2 11 2 6 3 Disassembly of Oil 2 11 2 6 4 Assembly of Oil 2 11 2 6 5 Oil Tank Parts Uert 2 11 designated by the entry in the ordering code as shown below MPP XXX XXX XX XX XX XX XX XXX XX Reservoir Option 2 2 MOUNTING INSTRUCTIONS 2 2 1 Reservoirs and tanks may be mounted to any vertical surface All units have 7 16 inch holes for attaching bolts or screws Cylindrical reservoirs have two holes six inches apart drilled in the base bracket All tanks have four holes drilled in flanges according to the following rectangu lar dimensions 9 7 8 wide by 7 inches high for T1 tanks 11 1 8 wide by 7 inches high for T2 tanks 16 3 8 wide by 7 inches high for T3 tanks 2 2 1 1 Make sure the mounting location allows clearance for any accessories attached to the tank or reservoir Oil reservoirs and all tanks have a fill cup on the top Make sure there is enough room above the fill cup to permit personnel to perfor
65. ion 10 of this manual lists causes and solutions for problems which could occur in the Modu Flo system Before disas sembling any pump refer to Section 10 The problem may be caused by other conditions which can be checked first before disassembling the pump 3 4 3 Disassembly of Hydraulic Pump Options H1 and H3 The procedure below describes complete disassembly of a pump However you only need to disassemble to your specific area of concern 3 4 3 1 The disassembly procedure for the hydraulic pump Options H1 and H3 is as follows a Separate pump from manifold by removing four socket head screws 8 Remove and discard three o rings 15 and one o ring 16 b Remove enclosure screw 11 Remove and discard gasket 12 check valve spring 13 steel ball 24 check seat 22 and o ring 23 Remove adjustment screw body 17 and o ring 9 from body 7 Discard o ring 9 Removal of adjustment screw 10 from adjustment screw body 17 will change output setting when pump is reassembled If adjust ment screw 10 requires removal perform the follow ing 1 Remove adjustment screw cap 20 from adjust ment screw 10 Butt the adjustment screw cap 20 against jam nut 19 and use the stamped numbers on the cap to measure how far the adjustment screw 10 extends from the jam nut Record this dimension p 3 9 42000 2 Remove jam nut 19 and two gaskets 18 Discard gaskets 18 3 Remove adjustment
66. ion 1 15 509 208 000 BODY Blowout 1 16 TUBING Copper 1 4 inch outer diameter x 0 030 wall 4 ft 511 573 020 BLOWOUT SWITCH ASSEMBLY 1 560 900 270 BLOWOUT DISCS Bag of 6 1450 psi 1 See Table 6 1 for other disc pressure ratings Tubing purchased separately 6 6 LUBRIQUIP Lubrication amp Dispensing Solutions Table 6 6 Tank Blowout Switch Parts List Tank Blowout Switch Parts List Table 6 6 identi 42000 Modu Flo System 6 PLUNGER NN E 9 AO 16 CNN NEM NAT GEO 1 13 14 15 12 11 10 Figure 6 4 Tank Blowout Switch Assembly Side View LUBRIQUIP Lubrication amp Dispensing Solutions 6 7 6 8 Blank Modu Flo System OPERATION AND SERVICE INSTRUCTIONS 42000 Modu Flo System SECTION 7 PNEUMATIC SOLENOID 7 1 DESCRIPTION 7 2 OPERATION 7 3 INSTALLATION 7 1 DESCRIPTION The Pneumatic Solenoid Valve option S1 is designed for use in 115 VAC applications while the S2 option is for 24 VDC applications The solenoid valve is supplied with the selection plate in a normally closed configuration making the solenoid a two way valve It comes equipped with a manual override operator and with 18 inch long 18 AWG coil lead wires 7 2 OPERATION When voltage is applied to the solenoid coil the valve is opened allowing air to flow through to the pump manifold and to the pneumatic piston in the pump As air is being supplied the pneumatic pi
67. is doubt about cleanliness lubricant should be filtered before being introduced into the system After filtering the system make sure the lubricant supply is protected from debris For protection of divider valves and the equipment being lubri cated an in line filter oil or strainer grease should be installed between this pump and the first stage master divider Lubriquip recommends a minimum oil cleanliness level of ISO 18 14 per ISO standard 4406 for all oil systems Lubriquip further recommends that all grease systems be equipped with a 100 mesh strainer Refer to bulletin 15200 for available lubricant filters and strainers 9 4 2 Temperature Effects Flow characteristics of the lubricant may change if the area the Modu Flo system is used in goes through drastic temperature changes Choose a lubricant that will flow properly at all temperatures expected in the system environment 9 2 Modu Flo System 10 1 GENERAL 10 1 1 Many system problems may be caused by loose connections or air trapped in the system Before removing system components it is a good practice to check all 10 1 GENERAL OPERATION AND SERVICE INSTRUCTIONS SECTION 10 TROUBLESHOOTING 42000 Modu Flo System system is properly bled Table 10 1 lists some of the problems which may occur in the Modu Flo system along with possible causes and corrective actions Disassembly connections to make sure they are tight Also make sure the P
68. ive to provide access to all components If your particular installation re quires dismounting of the reservoir make sure the reservoir is drained of lubricant before removing the attaching hard ware This will reduce the weight of the reservoir and reduce 23 42000 the chance of spillage The disassembly procedure is as m Do not attempt to remove retaining ring 2 or cable assembly 5 Figure 2 1 or retaining ring 25 or guide rod 5 for Option GP5 Injury could result from sudden expansion of spring 4 a Slowly open petcock 11 and allow lubricant to be forced from the reservoir into a bucket or similar container Remove fill stud 15 and petcock 11 if necessary Properly dispose of emptied grease b Remove hex nuts 12 and lockwashers 13 from tie rods 1 Remove tie rods 1 from cap 3 Lift reservoir tube 8 from base 10 keeping reservoir cap 3 in position on top of the tube d Slide reservoir tube 8 away from reservoir cap 3 until it is free of follower cup 7 e Remove gasket 9 from bottom of reservoir tube 8 f Further disassembly is only possible at the factory If damage is apparent on the follower cups 6 and 7 cable assembly or guide rod 5 spring 4 or reservoir cap 3 the unit cannot be serviced and the reservoir assembly must be replaced 2 4 4 Assembly of Grease Reservoirs NOTE Before assembly lubricate followers and tube inner diameter with the lubrica
69. l 29 check seat 25 and o ring 26 Remove adjustment screw body 19 and o ring 12 from body 10 Discard o ring 12 Removal of adjustment screw 13 from adjustment screw body 19 will change output setting when pump is reas E 3 13 42000 sembled If adjustment screw 13 requires removal perform the following 1 Remove adjustment screw cap 22 from adjust ment screw 13 Butt the adjustment screw cap 21 against jam nut 22 and use the stamped numbers on the cap to measure how far the adjustment screw 13 extends from the jam nut Record this dimension 2 Remove jam nut 21 and two gaskets 20 Discard gaskets 3 Remove adjustment screw 13 by screwing it towards the hex portion of the adjustment screw body 19 until it is free a Remove cylinder cap 6 Remove and discard o ring 5 Use wooden dowel or soft rod to push hydraulic piston 2 and lube piston 1 from hydraulic cylinder 7 Remove and discard o rings 4 and 9 and backup rings 24 f Separate hydraulic piston 2 from lube piston 1 by removing groove pin 3 o 3 5 4 Assembly of Hydraulic Pump Option H2 NOTE Use new o rings and gaskets when assem bling pump Lubricate all o rings and sliding parts with the lubricant which is used in the system 3 5 4 1 Assemble the hydraulic pump Option H2 according to the following procedure a Insert lube piston 1 into hydraulic piston 2 Insert groove pi
70. lastic grease w low level micro switch 40 lbs 18 14 kg These assemblies are not available through the normal MPP system only by ordering the full part number 2 3 PREPARATION FOR USE NOTE Before filling any reservoir or tank a manifold should be attached to the base The manifold has a check valve built into it which will prevent the lubricant from dripping out of the reservoir or tank If the system has a remote located mani fold make sure there is hose or tubing con nected from the bottom of the reservoir or tank to the remote manifold 2 3 1 Filling Oil Reservoirs and Tanks Reservoirs and tanks for oil have a fill cup mounted on top Wipe the area around the fill cup to avoid contamination during filling Open the fill cup cap and slowly pour the oil into the fill cup A strainer attached to the fill cup will remove large particles which may be present in the oil When filling is complete close fillcup cap and wipe any spillage 2 3 2 Filling Grease Reservoirs If a high pressure high volume supply pump is used to fill grease reservoirs excess pressure may not be completely released by the bleed hole in the reservoir wall This could cause the reservoir to fracture exposing personnel to flying particles and lubricant Safety glasses must be worn during filling operations and the supply pump must be turned off and disconnected when filling is complete 2 3 2 1 Filling of grease reservoirs requires that an exter
71. lernten 3 2 3 2 Pneumatic Pump Parts List 3 5 3 3 Hydraulic Pump Options H1 and H3 O 3 10 3 4 Hydraulic Pump Option H2 Parts List 3 14 4 1 Operating Ports on Modu Flo Manifolds 4 2 4 2 Manifolds and Manifold Accessories 4 2 5 1 Low Level Switch Assemblies 5 2 5 2 Oil Tank and Reservoir 15 Amp Low Level LUBRIQUIP Lubrication amp Dispensing Solutions Number 5 3 5 4 10 1 42000 Assemblies Parts 5 3 Title Page Oil Tank and Reservoir 10 Watt Low Level Assemblies Parts Uer 5 5 Grease Reservoir Low Level Assembly Parts Est an 5 6 Blowout Discs and 6 1 High Pressure and Blowout Switch ASSemDbIIGS itasse cie re a nen Pressure Switch Settings High Pressure Switch Parts List Reservoir Blowout Switch Parts List 6 5 Tank Blowout Switch Parts List 6 6 Pneumatic Solenoid Parts List 7 1 Modu Flo Troubleshooting 10 1 Modu Flo System OPERATION AND SERVICE INSTRUCTIONS 42000 Modu Flo System SECTION 1 INTRODUCTION del GENERAL cT 1 1 1 1 1 Standard 1 1 1 1 2 Modu Flo
72. m 2 Disassemble pump and replace defective components Refer to Section 3 3 Tighten components of the adjustment assembly 4 Repair pump or manifold Refer to Sections 3 and 4 5 Tighten setscrew LUBRIQUIP Lubrication amp Dispensing Solutions Modu Flo System 42000 Table 10 1 Modu Flo Troubleshooting Continued Problem Possible Cause Corrective Action D Pump is not receiving 1 Electrical connections to solenoid or 1 Check all connections and tighten signal to operate timer are defective securely 2 Timer or controller is set incorrectly 2 Set timer or controller to correct or is defective setting If unit is still not functioning consult factory for assistance 3 Pneumatic or hydraulic power supply 3 Turn on power supply is turned off LUBRIQUIP 102 Lubrication amp Dispensing Solutions Bulletin 42000 Trabon Modu Flo Sy www lubriquip com pdf 42000 pdf Look to LUBRIQUIP Inc for all of your Centralized Lubrication System needs Products include DIVIDER VALVES for oil and grease to 7500 PSI 1 to 20 points form 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 hydraulaic electric motor or mechanically driven TIMERS AUTOMATIC CONTROLS from simple on off to complete flow and pressure monitoring either timer or machine actuated
73. m a filling operation without difficulty Drill the re quired holes and attach the reservoir or tank to the vertical surface Securely tighten all attaching hardware Make sure that the reservoir or tank is level LUBRIQUIP Lubrication amp Dispensing Solutions Modu Flo System 42000 Table 2 1 Reservoirs and Tanks Part Number Type Use Reservoir Capacity Option 521 001 060 Tank oil 12 pint 5 68 liters T1 521 001 070 Tank oil 24 pint 11 4 liters T2 521 001 080 Tank oil 40 pint 18 9 liters T3 185 100 080 Reservoir Plastic oil 5 pint 2 37 liters OP1 185 100 060 Reservoir Plastic oil 12 pint 5 68 liters OP2 185 100 070 Reservoir Plastic oil 20 pint 9 46 liters OP3 185 100 750 Reservoir Plastic oil 6 pint 2 84 liters OP4 185 100 040 Reservoir Plastic grease 5lbs 2 27 kg GP1 185 100 000 Reservoir Plastic grease 12 lbs 5 44 kg GP2 185 100 010 Reservoir Plastic grease 20 lbs 9 07 kg GP3 185 100 760 Reservoir Plastic grease 6lbs 2 72 kg GP4 185 101 080 Reservoir Plastic grease 3lbs 1 36 kg GP5 185 100 050 Reservoir Metal grease 5lbs 2 27 kg GM1 185 100 020 Reservoir Metal grease 12 Ibs 5 44 kg GM2 185 100 030 Reservoir Metal grease 20 Ibs 9 07 kg GM3 185 100 770 Reservoir Metal grease 6lbs 2 72 kg GM4 185 101 100 Reservoir Plastic grease 40 lbs 18 14 kg 185 101 110 Reservoir Plastic grease w low level indicator 40 lbs 18 14 kg 185 100 120 Reservoir P
74. n 3 to secure the assembly b Install new o ring 4 and backup rings 24 on hydraulic piston 2 Install new o ring 9 on lube piston 1 Push piston assembly through hydraulic cylinder 7 into body 10 Install new o ring 5 on cylinder cap 6 Screw cylinder cap into hydraulic cylinder 7 and tighten securely Ie E Insert smaller end of adjustment screw 13 into adjustment screw body 19 Rotate adjustment screw 13 until smaller end is protruding from hex portion of adjustment screw body 19 o Install new o ring 12 on adjustment screw body 19 and install adjustment screw body in body 10 Tighten securely f Install jam nut 21 and two new gaskets 20 one on each side of jam nut on adjustment screw 13 Butt adjustment screw cap 22 against jam nut 21 and turn adjustment screw 13 until the length it extends beyond the jam nut is the same as the length recorded during disassembly g Install adjustment screw cap 22 on adjustment screw 13 Install new o ring 26 on check seat 25 and install check seat assembly into pump body Install new ball 29 and new check valve spring 16 into body 10 LUBRIQUIP Lubrication amp Dispensing Solutions Modu Flo System Place new gasket 15 on enclosure screw 14 Screw enclosure screw 14 into body 10 and tighten securely Install three new o rings 9 and one new o ring 18 into graph 3 2 2 42000 3 5 4 2 Whe
75. n the assembly steps listed above have been completed adjust the pump output as described in Para body 10 Securely attach pump to manifold using four 3 5 5 Hydraulic Pump Option H2 Parts List Table 3 4 socket head screws 11 Item Number identifies the parts indexed in Figure 3 4 Table 3 4 Hydraulic Pump Option H2 Parts List Part Number 521 000 031 521 000 310 411 101 6604 422 021 1604 422 011 2204 521 000 300 521 000 290 422 010 2004 423 700 1114 419 130 0704 422 011 1404 521 003 010 521 008 460 500 132 000 511 893 000 401 030 030 423 700 114 521 003 040 439 040 070 410 702 033 521 002 980 521 000 330 423 700 063 521 008 450 422 010 080 423 700 113 521 000 050 401 010 010 417 450 020 411 700 763 560 001 061 521 001 401 Not Available as Replacement Parts Included in Repair Kit LUBRIQUIP Lubrication amp Dispensing Solutions Description PUMP ASSEMBLY HL 25 Option H2 PISTON Lube PISTON Hydraulic PIN Groove part of kit 521 001 061 O RING Part of kit 521 001 061 O RING Part of kit 521 001 061 CAP Cylinder CYLINDER Hydraulic O RING Part of kit 521 001 061 O RING Part of kit 521 001 061 BODY Pump SCREW Socket head 1 4 20 x 1 1 4 inch O RING Part of kit 521 001 061 SCREW Adjustment SCREW Enclosure GASKET Part of kit 521 001 061 SPRING Check valve part of kit 521 001 061 BALL Steel 3 16 inch part of kit 521 001 061 O
76. nal supply source be connected to the fill stud located in the base of the reservoir To avoid introducing air into the system make sure there is enough grease in the supply source to fill LUBRIQUIP Lubrication amp Dispensing Solutions the reservoir without being disconnected Operate the supply Source at a steady speed to allow air free filling of the reser voir Too fast of a fill speed may result in air pockets The level of grease is checked by visual means In reservoirs with plastic cylinders the grease level may be seen through the cylinder Reservoirs with metal cylinders have a level indicator rod mounted on the cap which will indicate when the fill is complete NOTE Excess lube forced into the reservoir after it has reached full level will be vented from a bleed hole in the reservoir tube See Warning above 2 3 2 2 When filling is complete turn off the supply source and disconnect it from the fill stud A check valve in the fill stud will prevent lubricant from being forced back out A plastic dust cap is attached to the fill stud and should be installed over the fill stud to keep dirt from entering the system NOTE For first time grease filling or if the grease res ervoir has been allowed to go empty open the petcock in the bottom right side of the reservoir Slowly begin to fill the reservoir allowing air trapped under follower to exhaust out the open petcock When grease free of air flows from the petco
77. nents are discussed 2 6 3 1 The disassembly procedure may be performed with the tank mounted to the mounting surface However some mounting locations may be too restrictive to provide access to all components If your particular installation requires dismounting of the tank make sure the tank is drained of lubricant before removing the attaching hardware This will reduce the weight of the tank and reduce the chance of spill age The disassembly procedure is as follows a Remove pipe plug 3 Figure 2 3 from base of tank weldment 9 and allow oil to drain into bucket or similar container Properly dispose of emptied oil 2 11 42000 o Remove self threading screws 2 attaching cover 1 to tank weldment 9 and remove cover and cover gasket 6 Remove fill screen 4 from fill cup 5 and clean screen Ie a Remove two screws 7 and aluminum gaskets 8 to release pump mounting pad 12 from tank weldment 9 Remove and discard o ring 13 from pump mount ing pad 12 NOTE Step e should be performed only if the sight glass is dirty or leaking Threads cut on nylon studs of sight glass may prevent the sight glass from being used Remove four self threading nuts 14 and remove sight glass 11 and gasket 10 Discard gasket 10 and sight glass 11 2 6 4 Assembly of Oil Tanks NOTE Before assembly lubricate all o rings with the lubricant which is used in the system 2 6 4 1 Assemble
78. nt which is used in the system 2 4 4 1 Assemble the grease reservoir according to the following procedure a Slide reservoir tube 8 Figure 2 1 over follower cup 7 being careful not to distort the follower cup lips Slide reservoir tube 8 up until it contacts reservoir cap 3 b Install new gasket 9 on bottom of reservoir tube 8 Place reservoir tube 8 with gasket 9 on base 10 and rotate reservoir cap 3 until holes in the cap line up with holes in the base 10 d Install tie rods 1 through holes in reservoir cap 3 and base 10 e Install lockwashers 13 and hex nuts 12 on tie rods 1 and torque to 5 ft Ibs Install fill stud 15 dust 14 11 in base Make sure petcock 11 is in the closed position 2 4 4 2 When the assembly steps listed in the above para graph have been completed any Modu Flo components which were removed to ease disassembly should be rein stalled on the reservoir 2 4 5 Grease Reservoir Parts Lists Table 2 2 identifies the parts indexed in Figure 2 1 LUBRIQUIP Lubrication amp Dispensing Solutions Modu Flo System Item Number OND 11 12 13 14 15 16 17 18 Part Number 185 100 040 185 100 000 185 100 010 185 100 760 185 101 080 185 100 050 185 100 020 185 100 030 185 100 770 415 700 272 415 700 271 415 700 273 415 020 190 501 423 001 501 414 000 521 000 500 521 000 530 52
79. o System 42000 LOW LEVEL SWITCH i 1 CONTROLLER RESERVOIR OR TANK Espora idad PNEUMATIC HYDRAULIC SUPPLY H H T H SYSTEMFILL PRESSURE MANIFOLD CHECK SWITCH 11 PUMP LUBE OUTLET e ma SOLENOID u a ER BLOWOUT ASSEMBLY GAUGE mae LUPE LINES TEST AIR PURGE PORT ELECTRICAL LINES Figure 1 1 Modu Flo Functional Schematic 1 3 1 4 Blank LUBRIQUIP Lubrication amp Dispensing Solutions Modu Flo System OPERATION AND SERVICE INSTRUCTIONS SECTION 2 RESERVOIRS AND TANKS 21 DESCRIPTION issues ee 2 1 2 1 1 Reservoir Description 2 1 2 1 2 Tank Description 2 1 2 1 3 Reservoirs and Tanks Available 2 1 2 2 MOUNTING INSTRUCTIONS 2 1 2 3 PREPARATION FOR USE 2 2 2 3 1 Filling Oil Reservoirs and Tanks 2 2 2 3 2 Filling Grease Reservoirs 2 2 2 4 GREASE RESERVOIR MAINTENANCE OPTIONS GP1 THROUGH GP5 AND GM1 THROUGH E EE 2 3 2 41 General iit nee icti peces 2 3 2 4 2 Grease Reservoir Maintenance 2 3 2 4 8 Disassembly of Grease Reservoirs 2 3 2 4 4 Assembly of Grease 2 3 2 1 DESCRIPTION 2 1 1 Reservoir Description Reservoirs
80. oose the adjustment screw 13 could rotate and cause the pump output to change This condition could also result in lubricant leakage or in air being sucked into the lubricant 3 5 2 2 If internal components of the pump are defective it will usually result in erratic pump operation or output Section 9 of the manual lists causes and solutions for problems which could occur in the Modu Flo system Before disassembling any pump refer to Section 9 The problem may be caused by other conditions which can be checked first before breaking down the pump 3 5 3 Disassembly of Hydraulic Pump Option H2 The procedure below describes complete disassembly of a pump However you only need to disassemble to your specific area of concern 3 5 3 1 The disassembly procedure for the hydraulic pump Option H2 is as follows NOTE Figure 3 4 shows hydraulic cylinder 7 sepa rated from body 10 To achieve disassembly to this level requires special tools to remove hydraulic cylinder retainer 23 Normally this level of disassembly is only performed at the factory If scoring or wear marks are evident on the inner diameter of hydraulic cylinder 7 or body 10 the pump cannot be serviced and should be replaced Separate pump from manifold by removing four socket head screws 11 Remove and discard three o rings 9 and one o ring 18 p o Remove enclosure screw 14 Remove and discard gasket 15 check valve spring 16 steel bal
81. ounter 8 3 el I 1000 Timer GOUNEN 8 1 8 24 Maxi Monitors aussen 8 3 8 1 4 WMP Maxi Monitor 8 1 81 DESCRIPTION 8 1 1 DC Timer The DC timer is a solid state 12 to 32 VDC unit that energizes a DC solenoid when it is time to start a lubrication cycle The solenoid actuates the lubrica tion pump The interval between cycles is adjustable from 1 to 10 minutes in eight steps The duration of the lubrication cycle is not adjustable and is 30 seconds long The DC Timer also features elapsed time memory to ensure that the interval between cycles is maintained during equipment shutdown A manual run button simplifies startup testing and venting of lubrication lines and points The manual run button initiates one 30 second cycle each time it is de pressed Refer to Paragraph 8 2 1 for installation instruc tions Refer to bulletin 14511 for additional information 8 1 2 AC Timer The AC timer is a solid state 115 230 VAC 50 60 Hz unit that energizes a solenoid valve when it is time to start a lubrication cycle The solenoid valve See Paragraph 8 1 1 activates the lubrication pump The total cycle time is adjustable from 0 5 minute to 32 hours The duration of the lubrication pump cycle is adjustable from 12 seconds to 13 minutes The AC timer has a built in memory to keep the timer active for 1 1 2 hours during power failures and machine shutdowns This
82. r Components 4 1 4 3 MAINTENANCE sisirin sissioni eerte tennis 4 1 4 4 DESCRIPTION 4 1 1 General Two modular design manifolds are available Either manifold is designed to have any of the pneumatic or hydraulic pumps mount directly to it The pump to reservoir manifold attaches directly to the base of the lubricant reservoir or tank The pump to wall manifold is used to mount the lubricant pump in a remote location separate from the lubricant reservoir or tank 4 1 1 1 The manifolds contain the pneumatic or hydraulic porting and lubricant lines necessary to operate the pump and to direct the lubricant flow A shutoff is built into the manifold to prevent lubricant from leaking from the reservoir or tank when the pump is removed 4 1 1 2 Table 4 1 lists the operating ports used on the manifolds Each port is identified by stamped lettering Table 4 2 lists the part numbers of the manifolds accesso ries Manifolds and accessories can be ordered separately or as a combination package Figure 4 1 shows a typical manifold with various accessories connected to the lube ports 4 2 PREPARATION FOR USE 4 2 1 Mounting Pump to reservoir manifolds mount directly to the base of the reservoir or tank with two 3 8 16 4 1 Socket head screws Pump to wall manifolds require that the surface that the manifold will be attached to has two 3 8 16 tapped holes 2 1 4 inches apart The manifold must be mounted so that when the pump
83. roblem A No lube is dispensed from pump but pump is receiving air or hydraulic operating signals B Blow out disc has ruptured C Pump output is erratic 10 1 and assembly procedures for the system components are contained in other sections of this manual and should be referred to if a component needs servicing Table 10 1 Modu Flo Troubleshooting Possible Cause 1 Reservoir or tank is empty 2 Air or hydraulic pressure is inadequate 3 If pump is single acting return spring may be defective 4 Pump needs servicing 5 Pump adjustment screw is turned in too far 6 Pump is air bound 1 High pressure exists in the system 2 Excessive air or hydraulic flow to pump 1 System is not properly bled 2 Pump needs servicing 3 Pump adjustment assembly is leaking or sucking air during return stroke 4 Defective o ring 5 Setscrew and ball are loose in TEST port Corrective Action 1 Refill as required 2 Set pressure to proper setting 3 Replace spring or change pump to double acting Refer to Section 3 4 Disassemble pump and replace defective components Refer to Section 3 5 Adjust pump Refer to Section 3 6 Bleed air through test port Refer to Figure 4 1 1 Inspect dividers lines fittings and lube points to determine the source of high pres sure Correct problem and replace disc 2 Install a restrictor in the air or hydraulic lines 1 Bleed syste
84. screw 10 by screwing it towards the hex portion of the adjustment screw body 17 until it is free d Remove cylinder cap 6 from body 7 Remove and discard o ring 5 e Removal of the piston and its associated components is different for each option Perform the appropriate following steps 1 For Option H1 use a wood dowel or a soft rod to push hydraulic piston 2 and lube piston 1 from pump body 7 Remove and discard o rings 4 and 21 Inspect piston 2 and pump bogy 7 inner diameter for scoring or wear marks If damage is present the pump assembly cannot be serviced and should be replaced 2 For Option H3 use a wood dowel or a soft rod to push the piston 27 from the pump body 7 Remove and discard o rings 26 and 29 and backup rings 25 and 28 Inspect piston 27 and pump 7 inner diameter for scoring or wear marks If damage is present the pump assembly cannot be serviced and should be replaced For the H1 option only separate hydraulic piston 2 and lube piston 1 by removing groove pin 3 3 4 4 Assembly of Hydraulic Pump Options H1 and NOTE Use new o rings and gaskets when assembling pump Lubricate all o rings and sliding parts with the lubricant which is used in the system 3 4 4 1 Assemble the hydraulic pump Options H1 and H3 according to the following procedure a Forthe H1 option only insert lube piston 1 into hydrau lic piston 2 Install groove pin 3
85. screw AL50 20 439 040 050 GASKET Part of kit 560 001 021 AL5 439 040 070 GASKET Part of kit 560 001 031 AL25 439 040 080 GASKET Part of kit 560 001 041 AL50 21 410 702 028 NUT Jam hexagon 5 16 24 AL5 410 702 033 NUT Jam hexagon 7 16 20 AL25 410 702 034 NUT Jam hexagon 1 2 20 AL50 22 521 002 970 CAP Adjustment screw AL5 521 002 980 Adjustment screw AL25 521 002 990 CAP Adjustment screw AL50 23 521 000 150 RETAINER Air cylinder 24 521 000 070 SPRING Piston return part of kit 560 001 021 AL5 521 000 480 SPRING Piston return part of kit 560 001 031 AL25 521 000 420 SPRING Piston return part of kit 560 001 041 AL50 25 418 050 110 RING Retainer part of kit 560 001 021 AL5 418 050 160 RING Retainer part of kits 560 001 031 and 560 001 041 AL25 AL50 26 521 000 520 RETAINER Spring AL5 521 000 510 RETAINER Spring AL25 521 000 430 RETAINER Spring AL50 JE ch vk ch ch ch ch 4 IN A ch Included in Repair Kit Refer to Page 3 6 Not Available as Replacement Parts 35 LUBRIQUIP Lubrication amp Dispensing Solutions Modu Flo System Item Number 27 28 29 Part Number 418 150 0504 418 150 0704 418 150 0804 423 700 1184 423 700 1194 423 700 1204 521 008 4504 422 010 0804 521 000 050 401 010 0104 417 450 0204 411 700 7634 560 001 021 560 001 031 560 001 041 521 001 391 521 001 401 521 001 411 Table 3
86. ssories It can be used to schedule and monitor the operation of lubrication pumps and divider valves in automatic lubrication systems The WMP is available in AC or DC power source models 8 1 4 1 The WMP Maxi Monitor controls lubrication sched ules on either a time or a machine cycle stroke count basis It will also continuously monitor and display the status of the lubrication system it is controlling It is capable of shutting down a machine and lubrication system to protect it from a loss of lubrication 8 1 4 2 The WMP Maxi Monitor is easily programmed No special training or knowledge of computer languages is needed Programming is done through a membrane keypad located on the enclosure door Refer to bulletins 14750 and 14752 for additional information LUBRIQUIP Lubrication Dispensing Solutions 42000 Modu Flo System 12 to 32 VDC POWER SOURCE SWITCH ORANGE MEMORY YELLOW BLACK SOLENOID GROUND Figure 8 1 DC Timer Wiring Schematic INSTALLATION INSTRUCTIONS DISCONNECT INPUT AND LOAD POWER SUPPLIES AT THEIR SOURCE REMOVE 2 SCREWS AND LIFT OUT CIRCUIT BOARD INSTALL 1 2 CONDUIT CONNECTOR IN 840 DIAMETER HOLE 4 CONNECT INPUT POWER LEDS TO INPUT TERMINALS 110 220 VAC 50 60 HZ 5 CONNECT LOAD LEADS TO LOAD TERMINALS 110 220 VAC 50 60 HZ 3 AMP MAX 6 CONNECT REMOTE MANUAL RUN IF DESIRED CONTACT ONLY INSTALL TIMER BOARD WITH 2 6 X 1 2 SCREWS
87. ston moves forward and pushes the lube piston forward which discharges lubricant to the system When voltage is dropped out air flow is stopped The pneumatic and lube piston are returned by the piston return spring thus allowing the pump to reprime for the next cycle 7 3 INSTALLATION Installing the solenoid valve to the pump manifold requires making sure the o rings 4 are in place Mount the solenoid valve to the pump manifold port stamped SA with the valve bolt Torque to 10 15 ft lbs Table 7 1 Pneumatic Solenoid Parts List Number Part Number Description Quantity 521 001 020 115 VAC SOLENOID ASSEMBLY S1 521 002 100 24 VDC SOLENOID ASSEMBLY S2 1 521 000 540 115 VAC SOLENOID VALVE WITH COIL 1 521 004 550 24 VDC SOLENOID VALVE WITH COIL 1 2 521 000 550 MANIFOLD BLOCK 1 3 521 000 560 BOLT MOUNTING 1 4 422 010 160 O RING 2 5 416 060 120 SCREW 8 32 X 1 1 4 2 6 521 000 542 NO NC PORT PLATE PART OF ITEM 1 1 5 5 1 4 18 NPSF THREAD 3 TORQUE 10 15 FT LBS MANUAL OVERRIDE 2 188 1 4 NPSF AIR INLET 1 2 NPSM CONDUIT CONNECTION Figure 7 1 Pneumatic Solenoid 7 1 7 2 Blank LUBRIQUIP Lubrication amp Dispensing Solutions Modu Flo System 42000 OPERATION AND Modu Flo amp SERVICE INSTRUCTIONS System SECTION 8 CONTROLLERS 8 1 5 275 8 1 8 2 WIRING BH 8 2 BIT DG e e 8 1 8 1 2 AC Timer n 8 1 82 3 TC 1000 Timer C
88. t from electrical shock a Turn off all electrical power and air supplies to the lube System b Disconnect the two 22 AWG wires from the terminal box Disconnect adapter 1 Figure 5 2 from the conduit Remove the cover from the tank or reservoir Refer to Section 2 LUBRIQUIP Lubrication amp Dispensing Solutions 42000 d Unscrew nipple 2 from adapter 1 Be careful not to twist the wires too much Unscrew nipple 2 from coupling 3 f Unscrew coupling 3 from switch 4 g Unscrew adapter 1 from the reservoir cover 5 4 4 Assembly of Oil Tank and Reservoir 10 Watt Low Level Assemblies 5 4 4 1 The assembly procedure is as follows NOTE The procedure listed below is based on installing a new assembly in a tank or reservoir If your assembly was removed for repairs steps a and b do not apply a Remove the cover from the reservoir Refer to Section 2 b Remove the 1 4 inch pipe plug from the cover Screw adapter 1 Figure 5 2 in and tighten it securely Guide the two 22 AWG wires from switch 4 through coupling 3 Screw coupling 3 onto switch 4 and tighten securely d Guide two 22 AWG wires through nipple 2 Screw nipple into coupling 3 e Guide the two 22 AWG wires through adapter 1 Screw nipple into adapter 1 Be careful not to twist the wires too much Tighten the connection Connect switch 4 in accordance with local electrical codes 5 4
89. t screw cap 22 against jam nut 21 and turn adjustment screw 13 until the length it extends beyond the jam nut is the same as the length recorded during disassembly Install adjustment screw cap 22 on adjustment screw 13 Install new o ring 30 on check seat 29 and install seat into pump body k Install steel ball 32 and check valve spring 16 into pump body 10 Place new gasket 15 on enclosure screw 14 Install enclosure screw 14 into pump body 10 and tighten securely Install three new o rings 9 and one new o ring 18 into pump 10 Securely attach to manifold with four Socket head screws 11 3 3 4 2 When the assembly steps listed above have been completed adjust the pump output as described in Para graph 3 2 2 3 3 5 Pneumatic Pump Parts List Table 3 2 identifies the parts indexed in Figure 3 2 34 Modu Flo System 42000 Table 3 2 Pneumatic Pump Parts List Item Number Part Number Description Quantity 521 000 001 PUMP ASSEMBLY AL5 521 000 021 PUMP ASSEMBLY AL 25 521 000 041 PUMP ASSEMBLY AL50 1 521 000 110 PISTON Air AL5 521 000 220 PISTON Air AL25 521 000 400 PISTON Air AL50 2 422 010 2904 O RING Part of kit 560 001 021 AL5 422 010 350 O RING Part of kit 560 001 031 AL25 422 010 380 O RING Part of kit 560 001 041 AL50 3 521 000 100 Cylinder AL5 521 000 210 Cylinder AL25 521 000 390 Cylinder AL50
90. tenance Tips No maintenance is required on the high pressure switch If the Switch is suspected to be defective check all wiring to the switch before removing any components NOTE Relieve system pressure before removing any components 6 43 Assembly Disassembly of High Pressure Switch Figure 6 2 shows a typical high pressure switch mounted to a manifold All components of the unit are connected by pipe threads and are easily assembled or disassembled The blowout assembly 3 is connected to the IND port of the manifold and the pressure switch 1 is connected by fittings to the LUBE OUT port of the manifold Normally the only components which may require removal or replacement are the pressure switch 1 and the blowout disc 5 The pressure switch 1 is easily screwed out after all electrical connections are removed 6 4 3 1 The blowout disc replacement procedure is as follows a Remove pressure relief nut 6 from adapter fitting 4 b Remove blowout disc 5 E Install new blowout disc 5 in pressure relief nut 6 e Install pressure relief nut 6 on adapter fitting 4 and torque to 5 ft Ibs 6 4 4 Pressure Switch Parts Lists Table 6 4 identifies the parts indexed in Figure 6 2 LUBRIQUIP Lubrication amp Dispensing Solutions Modu Flo System 42000 Table 6 4 High Pressure Switch Parts List Index Number Part Number 521 001 220 542 210 120 412 380 020 509 206 100 OO P
91. tions which are available for any system include the following a Low level switches which mount to the reservoir or tank and provide a low level fault signal to a customer designated component Level switch options are described in Section 5 o High pressure indicators which are installed into the pump outlet circuit and provide an over pressure signal to external components Pressure switch options are discussed in Section 6 pneumatic solenoid valve which mounts directly to the manifold The solenoid valve is a three way normally closed type Use of the solenoid allows the pump to be cycled by various controller options The solenoid is equipped with a manual override button which may be used to simplify system testing line filling and line bleeding e Several types of controllers are used which can be adapted to the system Controller options are dis cussed in Section 8 Controllers available are as follows 1 Timers which may be set to cycle the pump at given intervals Both AC and DC models are available 2 A TC 1000 timer can operate the lube system on either a time or machine cycle basis It is available in 12 or 24 VDC or 115 or 230 VAC 3 AWMP Maxi Monitor which provides a dispense signal on either a time or machine cycle basis The WMP also monitors and displays the status of the lube system it is controlling The Maxi Monitor is available in either 115 or 230 VAC LUBRIQUIP Lubrication
92. to secure the assem bly Assembly of the piston and its associated components is different for each option Perform the appropriate following steps 1 For Option H1 install new o ring 4 on hydraulic piston 2 Install new o ring 21 on lube piston 1 Insert pistons into body 7 2 For Option H3 install new o ring 26 and backup rings 25 on cylinder cap end of piston 27 Install new o ring 29 and backup rings 28 on the other end of the piston 27 Install new o ring 5 on cylinder cap 6 Screw cylinder cap 6 into body 7 and securely tighten it a Insert smaller end of adjustment screw 10 into adjustment screw body 17 Rotate adjustment screw 10 until smaller end is protruding from hex portion of adjustment screw body 17 Install new o ring 9 on adjustment screw body 17 and install adjustment screw body in body 7 Tighten securely o LUBRIQUIP Lubrication amp Dispensing Solutions Modu Flo System f Install jam nut 19 and two new gaskets 18 one on each side of jam nut on adjustment screw 10 Butt adjustment screw cap 20 against jam nut 19 and turn adjustment screw 10 until the length it extends beyond the jam nut is the same as the length recorded during disassembly g Install adjustment screw cap 20 on adjustment screw 10 42000 body 7 Place new gasket 12 on enclosure screw 11 Screw enclosure screw into body 7 and tighten securely

Graco Trabon Modu-Flo System User's Manual

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