Installation and Maintenance For grease centralized lubrication system

 Installation and connection accessories

1) High-pressure resin hose and joint accessories

For the main oil pipe (connecting pump-distributor)  secondary oil pipe (connecting distributor-lubrication point), the outer diameter of the straight-through joint core ¢6.

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2)  Name  

.  1. High-pressure resin hose, supply of maximum length 50m high-pressure resin hose, maximum length of supply 50m

. 2. Connector jacket

. 3. Straight joint core, straight

. 4. Straight joint core, 45° bend type

.   Straight joint core, 90° bend type

3) Technical Parameters             

Resin tube:

Burst pressure ——-800bar

Minimum bending radius ——35mm

joint nut, straight joint core: —– steel, galvanized surface

Material: Hose: Lining tube ——-Nylon

Interlayer ———-Synthetic fiber braid

External layer——Resin

4) High-pressure resin hose joint assembly

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Product code : 30066+30067+51306+51106

 

5) High-pressure resin hose assembly

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Product code:56602-L

 

System Install

In most mechanical equipment, the main line between the lubrication pump and the distributor is connected by the outer diameter ¢6, ¢8 oil pipe; the branch line between the distributor oil outlet and the lubrication point, generally using the outer diameter ¢4, ¢6 tubing connection.rinciples

 

 

1) The lubrication pump (station) should be installed in a place that is easy to refuel, observe and maintain.

2) The main and branch lines should be as short as possible. The dispenser is installed as close as possible to the lubrication point, as conditions permit.

3) Before using the system, first fill the pipeline with grease to eliminate the air in the road.

4) All pipelines and control lines should be connected and positioned reliably, and protective measures should be taken at locations where there are collisions and contacts.

5) Protective measures should be used near heat sources.

Note  The lubrication system is a closed oil supply system, and care must be taken to keep the components and pipelines clean during installation. It is strictly forbidden to mix any debris. Otherwise may result in failure of the lubrication system, damage to the lubrication pump and distributor, and even accelerated wear and lubrication.

 

1) Diagram

DBS Please connect with proper power supply by a DIN adapter according to the following diagram

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2) Installation of the dispenser:

According to the size of the distributor installation, first make a mounting plate, then fix the mounting plate on the device (welding is recommended), and finally fix the distributor to the mounting plate with bolts. When fixing the screw hole of the distributor on the mounting plate, it is recommended to arrange the drilling with the mounting hole on the distributor to reduce the positioning error and facilitate the installation.

If the equipment conditions permit, you can also directly fix the dispenser to the device without installing the board. When soldering the installation, take care to protect the rubber seals and plastic parts in the dispenser and the travel switch.

THE MICRO-SWITCHING CYCLE INDICATOR IS A DEVICE THAT MONITORS THE FLOW OF LUBRICANT THROUGH THE SYSTEM. IT USES THE INDICATION RECIPROCATING MOTION ON THE PLUNGER IN THE PROGRESSIVE DISTRIBUTOR TO OPEN OR CLOSE THE MICROSWITCH ,TOUCH CYCLE INDICATOR TO SEND A SIGNAL TO THE HOST’S CONTROL SYSTEM. WHEN AN ABNORMALITY OCCURS IN THE LUBRICATION SYSTEM, THE HOST’S CONTROL SYSTEM WILL MAKE AN ALARM OR STOP THE MAIN ENGINE OPERATION FOR TIMELY MAINTENANCE.

   Note: The black line is the common end, the yellow line is normally closed, and the red line is normally open. 

3) Pipe connection

High pressure resin hose

1) Rotate the connector sleeve counterclockwise, put it on the hose, and try to screw it to the end. For easy of installation, apply a layer of oil or grease to the internal threads of the fitting or the surface of the hose.

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Screw the straight-through joint core clockwise from the other end of the joint casing, leaving a gap of about 1 mm between them, as shown. For ease of installation, apply a little oil or grease to the front surface of the joint core.

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After the ends of the hose are installed, confirm that the hose is not twisted. If the hose is found to be deformed, remove the hose from the deformed part and repeat the above steps to install it properly. Otherwise, when the system works normally and the oil pressure rises, the hose will first burst at the deformation point. Even if the system pressure does not reach the burst pressure value of the hose calibration.

 

Hard tube

2) Cut the copper tube with a copper tube cutter to ensure that the end of the copper tube is vertical, flat and free of burrs;

3) Put the tubing joint and the ferrule on the copper pipe separately;;

4) Insert the copper tube vertically into the straight-through (right-angle) joint and make close contact with the stop in the joint;;

5) Push in the ferrule and screw on the tubing connector. After feeling the oil pipe joint is stressed, screw the oil pipe joint into one turn to one and a half turns.

 

4) Pipe fixing

Use pipe clamps to secure the pipes to the frame, beam or other piping of the equipment, to minimize the suspended pipelines, and to protect them from collisions.

 

5) Electrical Installation

The electric control device is generally installed together with the operation  controller of the equipment to be lubricated, and the electric control device function can also be added to the control system of the lubricated device to be integrated with the equipment to be lubricated.

 

Connect the power supply line, control line and power line to the electronic control unit, sensor and lubrication pump according to the electrical principle or system wiring diagram, and wire and fix according to the wiring specifications and requirements of the lubricated equipment.

6) Adjust the system

Before using the centralized lubrication system after the initial or overhaul, please follow the steps below to debug the system:

 

1. Fill the lubrication pump tank with the clean grease from the specified fuel filler using the specified fueling tool.

2. Loosen the distributor inlet port fitting and start the lubrication pump till clean grease output.

3. Intall and tighten the distributor inlet port fittings and loosen the lubrication port fittings at the same time. Start the lubrication pump until each output have grease .

4. Connect and tighten the oil inlet pipe fitting to start the lubrication pump. Observe the operating condition of the lubrication pump and check that the pipe joints have no leakage and timely disposal.

5. Start the lubrication pump and the lubrication system should be according to the predetermined procedure.

6. Turn off the power switch and the lubrication system stops working.

Note: The system is a closed oil supply system, so you must pay attention to the cleaning of each component during installation and commissioning. Foreign objects and impurities will affect and damage the lubrication pump and distributor.

Note: The system is a closed oil supply system, so you must pay attention to the cleaning of each component during installation and commissioning. Foreign objects and impurities will affect and damage the lubrication pump and distributor.

 

Repair and maintenance

Note: The grease added to the tank must be clean.

1. After running for a certain period of time, check all pipelines and joints for oil leakage and appearance damage. If problems are found, they should be repaired immediately and replaced. If a section of pipeline needs to be replaced, the new pipe must be pre-filled with grease before it is installed (our company has a high-pressure resin hose filled with grease);

For the removal and installation of the pump unit, see “How to Repair the Pump Unit with Seal Failure” ;

2. Maintenance regulations for lubrication systems:

- General inspection, in accordance with the above procedures;

- Users should not disassemble the electric pump body by themselves;

- please contact the company in time if the cause of the malfunction or maintenance is required.

3. In daily use, the oil quantity of the lubrication pump should be checked regularly, and the clean grease should be added in time;

4. When the oil supply pump is filled with grease, unscrew the grease plug on the pump body of the pump, with Manual greaser into the tank fill in the clean grease;

5. Check the lubrication point for insufficient lubrication or excessive lubrication during overhaul or regular maintenance of the equipment.

6. If the equipment is not used for a long time, please remove the grease in the system to avoid the normal operation of the system due to the deterioration of the grease.

 

Common faults and troubleshooting methods

Fault Reason Maintenance method
The pump make oil, but all the outlets of the main distributor are not oiled, and the safety valve does not spray oil. The rubber seal of the one-way valve body assembly in the pump unit fails, and the oil pressure is too low. Replace the new rubber mat. For details, see “How to repair a damaged pump unit”
Pump can run, but no grease output No oil in the tank Fill the grease port with clean grease;
Air entering the plunger Continuously operate the pump and exhaust;
Pump unit damage Replace the new pump unit;
Safety valve injection System blockage Check system
Dispenser blocked Clean or replace the dispenser;
There is a problem with the safety valve Repair or replace the safety valve
The power is on, but the pump is not working The power is not connected to the motor a) Check the wires for damage;
b) Check that the wire connections are reliable; c) Check that the wiring is correct;
d) check the power supply voltage;
Controller has a problem Replace the programmer
Pump damage Replace the new pump
The dispenser is not working properly There is debris in the dispenser Disassembly  and clean
Input pressure is not enough Check lubrication pump
Distributor damage Replacement dispenser

error alarm 

 

 

No oil in the tank Fill the grease to the filler port
Lubrication point blocked Unblock the blocked lubrication points and piping
There is debris in the dispenser Disassembly and clean 
Lubrication pump have error Check or replace the lubrication pump
Pump operation is difficult or the speed is decreasing 

 

(See “Maintenance, Repair and Maintenance”) Replace the grease system, first, emptyold grease and clean it in the right way;
The pressure is too high  Thoroughly check whether the distributors and pipelines are blocked.Make sure that the lubrication points are clear.
The pump or motor is stuck Clean the pump or overhaul the equipment

How to repair pump unit:

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When the pump is connected to the power supply, the motor runs normally, but the oil flow rate and pressure are almost zero (the oil outlet is swallowed and swallowed, and the thumb can block the oil), indicating that the foreign matter in the grease is stuck in the check valve core 5 ‘s sealing cone, or at the bottom of the valve plug. Simply remove the 1, 2, 3, 4, and 5 with the opener, wipe off the foreign matter on the bottom of the valve core 5 and the sealing cone with a cloth, and then reinstall it, and the fault can be eliminated. The specific method is as follows:

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1. Remove the pump unit in the correct way, making sure that the plunger does not remain in the pump body;

2. Unscrew the joint body between the safety valve and the pump unit, then insert it into the oil outlet of the pump unit with a flat-blade screwdriver, screw out the adjustment valve 1, and take out the adjustment seat 1, the valve spring 2, the spring seat 3, and the gasket 4 in turn valve core 5 and other parts, wipe the bottom of the valve core 5 and the sealing cone surface with a cloth;

3. Clean all parts of the pump unit with diesel or kerosene;

4. If the gasket has worn out, replace it with a new one and return it in the correct position;

5. Install the pump unit into the pump body.

Note: The above operations should be carried out in a clean environment.


Post time: Aug-11-2020