Graco Trabon Modu Flo System Users Manual 42000Cov&TofC.PMD

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© LUBRIQUIP, INC., 1988. All Rights Reserved.

Modular

Pumping

Packages

Revised November 2005

LUBRIQUIP

BY ®

Bulletin 42000

Operation and Service Instructions

Modu-Flo® System

R

42000Modu-Flo® System

R

i

TABLE OF CONTENTS

Section/Para Page

1 INTRODUCTION .............................................. 1-1

1.1 GENERAL ............................................................. 1-1

1.2 GENERAL SYSTEM OPERATION ......................... 1-2

Section/Para Page

5.3 OIL TANK AND RESERVOIR 15 AMP

LOW-LEVEL ASSEMBLY MAINTENANCE

(OPTIONS L1, L2 and L3) .................................... 5-2

5.4 OIL TANK RESERVOIR 10-WATT LOW-LEVEL

ASSEMBLY MAINTENANCE (OPTIONS L5, L6

AND L7) ................................................................ 5-4

5.5 GREASE RESERVOIR LOW-LEVEL ASSEMBLY

MAINTENANCE (OPTION L4) ............................... 5-5

6 HIGH-PRESSURE AND BLOWOUT

SWITCHES ...................................................... 6-1

6.1 DESCRIPTION...................................................... 6-1

6.2 HIGH-PRESSURE SWITCH ADJUSTMENT ........ 6-2

6.3 MOUNTING INSTRUCTIONS ............................... 6-3

6.4 HIGH-PRESSURE SWITCH MAINTENANCE

(OPTION P1) ......................................................... 6-3

6.5 RESERVOIR BLOWOUT SWITCH MAINTE-

NANCE (OPTIONS P2 and P3) ............................ 6-4

6.6 TANK BLOWOUT SWITCH MAINTENANCE

(OPTION P4) ......................................................... 6-6

7 PNEUMATIC SOLENOID OPTIONS ................ 7-1

8 CONTROLLERS .............................................. 8-1

8.1 DESCRIPTION...................................................... 8-1

8.2 WIRING ................................................................. 8-2

9 SYSTEM OPERATION ..................................... 9-1

9.1 GENERAL ............................................................. 9-1

9.2 SYSTEM INFORMATION ....................................... 9-1

9.3 OPERATING TIPS ................................................. 9-1

9.4 MATERIAL CONSIDERATIONS ............................. 9-2

10 TROUBLESHOOTING ................................... 10-1

10.1 GENERAL ........................................................... 10-1

LIST OF ILLUSTRATIONS

Number Title Page Number Title Page

2 RESERVOIRS AND TANKS ............................. 2-1

2.1 DESCRIPTION...................................................... 2-1

2.2 MOUNTING INSTRUCTIONS ............................... 2-1

2.3 PREPARATION FOR USE ..................................... 2-2

2.4 GREASE RESERVOIR MAINTENANCE

(OPTIONS GP1 THROUGH GP5 AND GM1

THROUGH GM4) .................................................. 2-3

2.5 OIL RESERVOIR MAINTENANCE

(OPTIONS OP1 THROUGH OP4) ........................ 2-7

2.6 OIL TANK MAINTENANCE

(OPTIONS T1, T2 and T3) .................................. 2-11

3 PUMPS............................................................ 3-1

3.1 DESCRIPTION...................................................... 3-1

3.2 PREPARATION FOR USE ..................................... 3-3

3.3 PNEUMATIC PUMP MAINTENANCE

(OPTIONS A1 THROUGH A6) .............................. 3-3

3.4 HYDRAULIC PUMP MAINTENANCE

(OPTIONS H1 AND H3) ........................................ 3-9

3.5 HYDRAULIC PUMP MAINTENANCE

(OPTION H2)....................................................... 3-13

4 MANIFOLDS.................................................... 4-1

4.1 DESCRIPTION...................................................... 4-1

4.2 PREPARATION FOR USE ..................................... 4-1

4.3 MAINTENANCE ..................................................... 4-1

5 LOW-LEVEL SWITCHES ................................ 5-1

5.1 DESCRIPTION...................................................... 5-1

5.2. MOUNTING INSTRUCTIONS ............................... 5-1

1-1. Modu-Flo Functional Schematic ......................... 1-3

2-1. Grease Reservoir - Exploded View..................... 2-5

2-2. Oil Reservoir - Exploded View ............................ 2-9

2-3. Oil Tank - Exploded View .................................. 2-13

3-1. Typical Pump Operation ...................................... 3-2

3-2. Pneumatic Pump, Exploded View ...................... 3-7

3-3. Hydraulic Pump Options H1 and H3 -

Exploded View ................................................... 3-11

3-4. Hydraulic Pump Option H2 - Exploded View .... 3-15

4-1. Typical Manifold Assembly .................................. 4-3

5-1. Oil Tank and Reservoir 15 Amp Low-Level

Assembly ............................................................ 5-3

5-2. Oil Tank and Reservoir 10-Watt

Low-Level Assembly ........................................... 5-5

5-3. Grease Reservoir Low-Level Assembly ............. 5-6

6-1. High-Pressure Switch ......................................... 6-2

6-2. High-Pressure Switch (Rear View)..................... 6-4

6-3. Reservoir Blowout Switch Assembly (Front

View) .................................................................... 6-5

6-4. Tank Blowout Switch Assembly .......................... 6-7

7-1. Pneumatic Solenoid ........................................... 7-1

8-1. DC Timer Wiring Schematic ............................... 8-2

8-2. AC Timer Wiring Schematic ................................ 8-2

8-3. TC1000 Timer/Counter Wiring Schematic ......... 8-3

8-4. WMP Maxi-Monitor Wiring Schematic ................. 8-3

Modu-Flo® System 42000

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ii

LIST OF TABLES

Number Title Page

2-1. Reservoirs and Tanks ......................................... 2-2

2-2. Grease Reservoir Parts List ............................... 2-4

2-3. Oil Reservoir Parts Lists ..................................... 2-8

2-4. Oil Tank Parts List ............................................. 2-12

3-1. Pumps................................................................. 3-2

3-2. Pneumatic Pump Parts List ................................ 3-5

3-3. Hydraulic Pump Options H1 and H3

Parts List ........................................................... 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

Assemblies Parts List ........................................ 5-3

Number Title Page

5-3. Oil Tank and Reservoir 10-Watt Low-Level

Assemblies Parts List ........................................ 5-5

5-4. Grease Reservoir Low-Level Assembly

Parts List ............................................................. 5-6

6-1. Blowout Discs and Kits....................................... 6-1

6-2. High-Pressure and Blowout Switch

Assemblies ......................................................... 6-2

6-3. Pressure Switch Settings ................................... 6-3

6-4. High-Pressure Switch Parts List ........................ 6-4

6-5. Reservoir Blowout Switch Parts List .................. 6-5

6-6. Tank Blowout Switch Parts List........................... 6-6

7-1. Pneumatic Solenoid Parts List ........................... 7-1

10-1. Modu-Flo Troubleshooting ............................... 10-1

42000Modu-Flo® System

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OPERATION AND

SERVICE INSTRUCTIONS

Modu–Flo®

System

SECTION 1

INTRODUCTION

1.1 GENERAL................................................................... 1-1

1.1.1 Standard Components................................... 1-1

1.1.2 Modu-Flo Options ........................................... 1-1

1.2 GENERAL SYSTEM OPERATION .............................. 1-1

1.1 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. A reservoir 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.

b. 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.

c. 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.

1.1.2 Modu-Flo Options.

1.1.2.1 Options 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.

b. 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.

c. A 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.

d. 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) A WMP 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.

1-1

Modu-Flo® System 42000

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1.2 GENERAL SYSTEM OPERATION

1-2

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.

b. The manifold directs lubricant into the pump to fill the

pump chamber.

c. 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.

d. 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.

e. Lubricant from the reservoir flows through the manifold

and refills the empty chamber in the pump.

f. 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.

g. Low-level switch options are available for all tanks or

reservoirs. The switch provides an electrical signal

when lubricant level is low.

42000Modu-Flo® System

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1-3/(1-4 Blank)

LOW LEVEL

SWITCH

CONTROLLER

PRESSURE

SWITCH

SOLENOID

PNEUMATIC/

HYDRAULIC SUPPLY

RESERVOIR

OR TANK

MANIFOLD

LUBE OUTLET

CHECK

SYSTEM FILL

CHECK

BLOWOUT

ASSEMBLY

GAUGE

TEST/AIR

PURGE PORT

PUMP

LUBE LINES

PNEUMATIC/HYDRAULIC

LINES

ELECTRICAL LINES

Figure 1-1. Modu-Flo Functional Schematic

42000Modu-Flo® System

R

OPERATION AND

SERVICE INSTRUCTIONS

Modu–Flo®

System

2-1

SECTION 2

RESERVOIRS AND TANKS

2.1 DESCRIPTION .......................................................... 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

GM4) .......................................................................... 2-3

2.4.1 General .......................................................... 2-3

2.4.2 Grease Reservoir Maintenance .................... 2-3

2.4.3 Disassembly of Grease Reservoirs ............. 2-3

2.4.4 Assembly of Grease Reservoirs ................... 2-3

2.4.5 Grease Reservoir Parts Lists ....................... 2-3

2.1 DESCRIPTION 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 perform 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.

2.6 OIL TANK MAINTENANCE

(OPTIONS T1, T2 and T3) ....................................... 2-11

2.6.1 General ........................................................ 2-11

2.6.2 Oil Tank Maintenance .................................. 2-11

2.6.3 Disassembly of Oil Tanks ........................... 2-11

2.6.4 Assembly of Oil Tanks................................. 2-11

2.6.5 Oil Tank Parts List ....................................... 2-11

2.5 OIL RESERVOIR MAINTENANCE

(OPTIONS OP1 THROUGH OP4) ............................. 2-7

2.5.1 General .......................................................... 2-7

2.5.2 Oil Reservoir Maintenance ............................ 2-7

2.5.3 Disassembly of Oil Reservoir ....................... 2-7

2.5.4 Assembly of Oil Reservoir ............................. 2-7

2.5.5 Oil Reservoir Parts Lists ............................... 2-7

2.1.2 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

2.1.1 Reservoir Description. Reservoirs 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.

Modu-Flo® System 42000

R

2-2

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

petcock, 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

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.

WARNING

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 external

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

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) 5 lbs (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) 6 lbs (2.72 kg) GP4

185-101-080 Reservoir, Plastic (grease) 3 lbs (1.36 kg) GP5

185-100-050 Reservoir, Metal (grease) 5 lbs (2.27 kg) GM1

185-100-020 Reservoir, Metal (grease) 12 lbs (5.44 kg) GM2

185-100-030 Reservoir, Metal (grease) 20 lbs (9.07 kg) GM3

185-100-770 Reservoir, Metal (grease) 6 lbs (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, Plastic (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.

*

*

*

42000Modu-Flo® System

R

2-3

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.

the chance of spillage. The disassembly procedure is as

follows:

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 tight. Torque the nuts to 5 ft lbs. If the

leakage continues, replace gasket (9). Check for cracks

and nicks in tube (8). Replace the tube as required.

b. 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.

WARNING

Disconnect and lock out power before opening

electrical enclosures or conduit connections.

Serious injury may result from electrical shock.

2.4.3 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 restrictive 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

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).

WARNING

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).

c. 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 lubricant 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).

c. 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 lbs.

f. Install fill stud (15), dust cap (14) and petcock (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.

Modu-Flo® System 42000

R

2-4

Table 2-2. Grease Reservoir Parts List

Item

Number Part Number Description Quantity

185-100-040 RESERVOIR ASSEMBLY, 5 lbs (2.27 kg), plastic (GP1) --

185-100-000 RESERVOIR ASSEMBLY, 12 lbs (5.44 kg), plastic (GP2) --

185-100-010 RESERVOIR ASSEMBLY, 20 lbs (9.07 kg), plastic (GP3) --

185-100-760 RESERVOIR ASSEMBLY, 6 lbs (2.72 kg), plastic (GP4) --

185-101-080 RESERVOIR ASSEMBLY, 3 lbs (1.36 kg), plastic (GP5) --

185-100-050 RESERVOIR ASSEMBLY, 5 lbs (2.27 kg), metal (GM1) --

185-100-020 RESERVOIR ASSEMBLY, 12 lbs (5.44 kg), metal (GM2) --

185-100-030 RESERVOIR ASSEMBLY, 20 lbs (9.07 kg), metal (GM3) --

185-100-770 RESERVOIR ASSEMBLY, 6 lbs (2.72 kg), metal (GM4) --

1 415-700-272 BOLT, Tie (5 lb., 12 lb.) 3

415-700-271 BOLT, Tie (20 lb.) 3

415-700-273 BOLT, Tie (6 lb.) 3

415-020-190 BOLT, Tie (3 lb.) 3

2 RING, Retaining 1

3 CAP, Reservoir 1

4 SPRING 1

5 CABLE ASSEMBLY 1

GUIDE ROD 1

6 GUIDE, Follower 1

7 CUP Seal 1

9 501-423-001 GASKET (6” Tube) (3,6,12, 20 lb.) 1

501-414-000 GASKET (4” Tube) (5 lb.) 1

10 521-000-500 BASE, Aluminum (6” Tube) (6, 12, 20 lb.) 1

521-000-530 BASE (4” Tube) (5 lb.) 1

521-008-950 BASE, Black (6” Tube) (3 lb.) 1

11 501-970-000 PETCOCK 1

12 410-040-020 NUT, Hex, 5/16-18 3

13 421-010-020 LOCKWASHER, 5/16 inch 3

14 506-165-000 CAP, Dust 1

15 506-189-001 Reservoir Fill Stud 1

16 410-060-120 NUT, Hex, 5/16-18 1

17 511-041-000 PLATE, Backup 1

18 521-003-630 INDICATOR, Level (12 lb. Metal) 1

521-003-640 INDICATOR, Level (20 lb. Metal) 1

521-004-310 INDICATOR, Level (6 lb. Metal) 1

521-003-620 INDICATOR, Level (5 lb. Metal) 1

19 185-100-720+ TUBE, Reservoir, plastic, 13 inches (330.2mm) x 1

4 inches (100 mm) outer diameter (5 lb.)

185-100-730+ TUBE, Reservoir, plastic, 13 inches (330.2 mm) 1

x 6.0 inches (152.4 mm) outer diameter (12 lb.)

185-100-740+ TUBE, Reservoir, plastic, 20 inches (508 mm) x 6.0 1

inches (152.4 mm) outer diameter (20 lb.)

185-100-990+ TUBE, Reservoir, plastic, 8.5 inches (215.9 mm) x 6.0 1

inches (152.4 mm) outer diameter (6 lb.)

185-100-191+ TUBE, Reservoir, plastic, 5 inches (127 mm) x 6.0 1

inches (152.4 mm) outer diameter (3 lb.)

185-101-187+ TUBE, Reservoir, metal, 13 inches (330.2 mm) x 1

4 inches (100 mm) outer diameter (5 lb.)

185-101-188+ TUBE, Reservoir, metal, 13 inches (330.2 mm) x 6.0 1

inches (152.4 mm) outer diameter (12 lb.)

185-101-189+ TUBE, Reservoir, metal, 20 inches (508 mm) x 6.0 1

inches (152.4 mm) outer diameter (20 lb.)

185-101-190+ TUBE, Reservoir, metal, 8.5 inches (215.9 mm) x 6.0 1

inches (152.4 mm) outer diameter ( 6 lb.)

Items 2 through 7

are not serviceable

by the user; replace

entire reservoir.

Mating fill coupler 506-322-000 (order separately)

+ Reservoir Tube Kit includes gasket (item 9).

*

*

42000Modu-Flo® System

R

2-5/(2-6 Blank)

Table 2-2. Grease Reservoir Parts List - Continued

Item

Number Part Number Description Quantity

20 439-060-181 GASKET, Top Vent (3 lb.) 1

21 BUSHING, Follower 1

22 WASHER, Follower 1

23 WASHER, Support 1

24 NUT, Jam, 3/4-16 1

25 O-RING 1

26 RING, Retaining 1

27 527-000-230 PLUG, Low Level (3 lb.) 1

28 527-000-240 GASKET (3 lb.) 1

NOTE:

USED ON METAL

RESERVOIRS ONLY

FOR

OPTION

GP5

ONLY

3

4

5

22

7

23

26

21

25

24

20

2

3

4

5

6

7

8B

16

17

1

18

A

9

10

11

28

27

13

12

15*

14

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)

19+

Figure 2-1. Grease Reservoir - Exploded View

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).

WARNING

Items 21 through 26

are not serviceable

by the user; replace

entire reservoir.

* Mating fill coupler 506-322-000 (order separately)

+ Reservoir Tube Kit includes gasket (item 9).

42000Modu-Flo® System

R

2-7

2.5 OIL 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 (9) are not tight.

Torque nuts (9) to 5 ft lbs. 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.

WARNING

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 locations may be too restrictive 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

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).

f. 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 surface of the reservoir cap (5).

e. Install lockwashers (10) and hex nuts (9) on tie rods (1).

Torque nuts to 5 ft lbs.

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.

Modu-Flo® System 42000

R

2-8

Table 2-3. Oil Reservoir Parts Lists

Item

Number Part Number Description Quantity

185-100-080 RESERVOIR ASSEMBLY, 5 pint (2.37 liters), plastic (OP1) --

185-100-060 RESERVOIR ASSEMBLY, 12 pint (5.68 liters), plastic (OP2) --

185-100-070 RESERVOIR ASSEMBLY, 20 pint (9.46 liters), plastic (OP3) --

185-100-750 RESERVOIR ASSEMBLY, 6 pint (2.84 liters), plastic (OP4) --

1 415-700-272 BOLT, Tie (5 pint, 12 pint) 3

415-700-273 BOLT, Tie (6 pint) 3

415-700-271 BOLT, Tie (20 pint) 3

2 534-304-003 SCREEN (40 Mesh) 1

3 534-147-000 CUP, Fill 1

4 508-975-000 PLUG, Pipe, 1/4 inch NPT 3

5 521-000-600 CAP, Reservoir (4” Tube) (5 pint) 1

501-474-029 CAP, Reservoir (6” Tube) (6,12, 20 pint) 1

6 185-100-720+ TUBE, Reservoir, 13 inches (330.2 mm) x 4 inches1

(100 mm) outer diameter (5 pint)

185-100-990+ TUBE, Reservoir, 8.5 inches (215.9 mm) x 6.0 inches 1

(152.4 mm) outer diameter (6 pint)

185-100-730+ TUBE, Reservoir, 13 inches (330.2 mm) x 6.0 inches 1

(152.4 mm) outer diameter (12 pint)

185-100-740+ TUBE, Reservoir, 20 inches (508 mm) x 6.0 inches1

(152.4 mm) outer diameter (20 pint)

7 501-414-000 GASKET (4” Tube) (5 pint) 1

501-423-001 GASKET (6” Tube) (6, 12, 20 pint) 1

8 521-000-530 BASE (4” Tube) (5 pint) 1

521-000-500 BASE (6” Tube) (6, 12, 20 pint) 1

9 410-040-020 NUT, Hexagon, 5/16-18 3

10 421-010-020 LOCKWASHER, 5/16 inch 3

+ Reservoir Tube Kit includes gasket (Item 7).

42000Modu-Flo® System

R

2-9/(2-10 Blank)

Figure 2-2. Oil Reservoir - Exploded View

2

1

3

4

6+

B

5

7

A

8

4

10

9

4

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).

42000Modu-Flo® System

R

2-11

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

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.

WARNING

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 components 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.

b. Remove self-threading screws (2) attaching cover (1) to

tank weldment (9) and remove cover and cover gasket

(6).

c. Remove fill screen (4) from fill cup (5) and clean screen.

d. 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).

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.

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.

e. 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 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).

b. 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.

c. 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).

d. Install screen (4) into fill cup (5).

e. Position cover gasket (6) and cover (1) on tank

weldment (9) and secure with self-threading screws (2).

f. Install pipe plug (3) in bottom of tank weldment (9).

Modu-Flo® System 42000

R

2-12

Table 2-4. Oil Tank Parts List

Item

Number Part Number Description Quantity

521-001-060 RESERVOIR ASSEMBLY, 12 pint, (5.68 liters) (T1) --

521-001-070 RESERVOIR ASSEMBLY, 24 pint, (11.4 liters) (T2) --

521-001-080 RESERVOIR ASSEMBLY, 40 pint, (18.9 liters) (T3) --

1 521-000-810 COVER, (12 pint) 1

521-000-830 COVER, (24 pint) 1

521-000-850 COVER, (40 pint) 1

2 415-640-040 SCREW, Self-threading, 1/4-28 x 5/16 inch (12 pint) 6

415-640-040 SCREW, Self-threading, 1/4-28 x 5/16 inch (24, 40 pint) 8

3 508-975-000 PLUG, Pipe, 1/4 inch NPT 2

4 534-304-003 SCREEN (40 Mesh) 1

5 534-147-000 CUP, Fill 1

6 521-003-420 GASKET, Cover, (12 pint) 1

521-003-380 GASKET, Cover, (24 pint) 1

521-003-340 GASKET, Cover, (40 pint) 1

7 419-170-010 SCREW, Socket-head, 3/8-16 x 1/2 inch 2

8 439-050-060 GASKET, 3/8 stat-o-seal 2

9 WELDMENT, Reservoir 1

10 439-060-110 GASKET 1

11 438-028-283 SIGHT GLASS 1

12 521-000-921 PAD, Pump mounting 1

13 423-700-096 O-RING 1

14 410-701-986 NUT, Self-threading 4

15 421-010-010 Lockwasher, 1/4 inch (12 pint) 6

421-010-010 Lockwasher, 1/4 inch (24, 40 pint) 8

16 412-150-040+ Plug, 3/8 NPT 1

*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.

Not available as a

item replacement

*

*

*

*

42000Modu-Flo® System

R

2-13/(2-14 Blank)

3

4

5

7*

8*

9

2

1

14

A

10 11

13*

12*

B

3

C

6

Figure 2-3. Oil Tank - Exploded View

* 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.

DIMENSIONS

OPTION A B C

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)

16+

15

42000Modu-Flo® System

R

OPERATION AND

SERVICE INSTRUCTIONS

Modu–Flo®

System

3-1

SECTION 3

PUMPS

3.1 DESCRIPTION .......................................................... 3-1

3.1.1 General .......................................................... 3-1

3.2 PREPARATION FOR USE ......................................... 3-3

3.2.1 Mounting ........................................................ 3-3

3.2.2 Output Adjustment ......................................... 3-3

3.3 PNEUMATIC PUMP MAINTENANCE

(OPTIONS A1 THROUGH A6) ................................... 3-3

3.3.1 General .......................................................... 3-3

3.3.2 Pneumatic Pump Maintenance Tips ............ 3-3

3.3.3 Disassembly of Pneumatic Pump ................ 3-3

3.3.4 Assembly of Pneumatic Pump ..................... 3-4

3.3.5 Pneumatic Pump Parts List .......................... 3-4

3.4 HYDRAULIC PUMP MAINTENANCE

(OPTIONS H1 and H3).............................................. 3-9

3.4.1 General .......................................................... 3-9

3.4.2 Hydraulic Pump Options H1 and H3

Maintenance Tips .......................................... 3-9

3.4.3 Disassembly of Hydraulic Pump

Options H1 and H3 ....................................... 3-9

3.4.4 Assembly of Hydraulic Pump Options H1

and H3 ........................................................... 3-9

3.4.5 Hydraulic Pump Options H1 and H3

Parts List ..................................................... 3-10

3.5 HYDRAULIC PUMP MAINTENANCE

(OPTION H2) ........................................................... 3-13

3.5.1 General ........................................................ 3-13

3.5.2 Hydraulic Pump Option H2

Maintenance Tips ........................................ 3-13

3.5.3 Disassembly of Hydraulic Pump

Option H2 .................................................... 3-13

3.5.4 Assembly of Hydraulic Pump Option H2 .... 3-13

3.5.5 Hydraulic Pump Option H2 Parts List ......... 3-14

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 a

single pump cycle and chamber (B) is primed, ready for

the next cycle.

b. 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 enough to

ensure that a blocked line will cause sufficient pressure to

be developed.

Modu-Flo® System 42000

R

3-2

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

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

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 cu in (cm3) per stroke Minute cu.in. (cm3) 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) A1

Double 100 2.09 (34.3)

521-000-021 AL-25 Single 0.030 to 0.120 (0.492 to 1.966) 25 4.20 (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

LUBE INLET

PORT

LUBE OUTLET

PORT

SINGLE ACTING

(S.A.) PORT

CHAMBER (A)

AIR PISTON

RETURN

SPRING

DOUBLE ACTING

(D.A.) PORT

LUBE PISTON

CHAMBER (B)

CHECK

VALVE

CHAMBER (C)

42000Modu-Flo® System

R

3-3

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

(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.

c. 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.

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.

c. 0.009 cubic inch for pump options A5 and A6.

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.

b. 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.

a. 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).

b. 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).

c. 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:

(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.

d. Remove retainer ring (4).

Modu-Flo® System 42000

R

3-4

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).

f. 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 retainer 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).

e. Install new o-ring (2) on cylinder cap (3) and secure in

air cylinder (7) with retainer ring (4).

f. 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.

h. 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.

i. Install adjustment screw cap (22) on adjustment screw

(13).

j. 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.

l Install three new o-rings (9) and one new o-ring (18) into

pump body (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.

42000Modu-Flo® System

R

3-5

Table 3-2. Pneumatic Pump Parts List

Item

Number Part Number Description Quantity

521-000-001 PUMP ASSEMBLY (AL5) --

521-000-021 PUMP ASSEMBLY (AL25) --

521-000-041 PUMP ASSEMBLY (AL50) --

1 521-000-110 PISTON, Air (AL5) 1

521-000-220 PISTON, Air (AL25) 1

521-000-400 PISTON, Air (AL50) 1

2 422-010-290+ O-RING, Part of kit 560-001-021 (AL5) 1

422-010-350+ O-RING, Part of kit 560-001-031 (AL25) 1

422-010-380+ O-RING, Part of kit 560-001-041 (AL50) 1

3 521-000-100 CAP, Cylinder (AL5) 1

521-000-210 CAP, Cylinder (AL25) 1

521-000-390 CAP, Cylinder (AL50) 1

4 418-050-310+ RING, Retainer, part of kit 560-001-021 (AL5) 1

418-050-450+ RING, Retainer, part of kit 560-001-031 (AL25) 1

418-050-520+ RING, Retainer, part of kit 560-001-041 (AL50) 1

5 PISTON, Lube 1

6 527-000-790+ O-RING, Part of kit 560-001-021 (AL5) 1

423-700-111+ O-RING, Part of kit 560-001-031 (AL25) 1

423-700-112+ O-RING, Part of kit 560-001-041 (AL50) 1

7 521-000-080 CYLINDER, Air (AL5) 1

521-000-200 CYLINDER, Air (AL25) 1

521-000-450 CYLINDER, Air (AL50) 1

8 422-010-200+ O-RING, Part of kits 560-001-021, 560-001-031 and 560-001-041 1

9 423-700-113+ O-RING, Part of kits 560-001-021, 560-001-031 and 560-001-041 5

10 BODY, Pump 1

11 419-130-070+ SCREW, Socket-head, 1/4-20 x 1-1/4 inch 4

12 422-011-140+ O-RING, Part of kits 560-001-021, 560-001-031 and 560-001-041 1

13 521-003-000 SCREW, Adjustment (AL5) 1

521-003-010 SCREW, Adjustment (AL25) 1

521-003-020 SCREW, Adjustment (AL50) 1

14 521-008-460 SCREW, Enclosure 1

15 500-132-000+ GASKET, Part of kits 560-001-021, 560-001-031 and 560-001-041 1

16 511-893-000+ SPRING, Check valve, part of kits 1

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 1

19 521-003-030 BODY, Adjustment screw (AL5) 1

521-003-040 BODY, Adjustment screw (AL25) 1

521-003-050 BODY, Adjustment screw (AL50) 1

20 439-040-050+ GASKET, Part of kit 560-001-021 (AL5) 2

439-040-070+ GASKET, Part of kit 560-001-031 (AL25) 2

439-040-080+ GASKET, Part of kit 560-001-041 (AL50) 2

21 410-702-028+ NUT, Jam, hexagon, 5/16-24 (AL5) 1

410-702-033+ NUT, Jam, hexagon, 7/16-20 (AL25) 1

410-702-034+ NUT, Jam, hexagon, 1/2-20 (AL50) 1

22 521-002-970 CAP, Adjustment screw (AL5) 1

521-002-980 CAP, Adjustment screw (AL25) 1

521-002-990 CAP, Adjustment screw (AL50) 1

23 521-000-150 RETAINER, Air cylinder 1

24 521-000-070+ SPRING, Piston return, part of kit 560-001-021 (AL5) 1

521-000-480+ SPRING, Piston return, part of kit 560-001-031 (AL25) 1

521-000-420+ SPRING, Piston return, part of kit 560-001-041 (AL50) 1

25 418-050-110+ RING, Retainer, part of kit 560-001-021 (AL5) 1

418-050-160+ RING, Retainer, part of kits 560-001-031 and 560-001-041 (AL25 AL50) 1

26 521-000-520 RETAINER, Spring (AL5) 1

521-000-510 RETAINER, Spring (AL25) 1

521-000-430 RETAINER, Spring (AL50) 1

+ Included in Repair Kit. Refer to Page 3-6

* Not Available as Replacement Parts.

*

*

Modu-Flo® System 42000

R

3-6

Table 3-2. Pneumatic Pump Parts List - Continued

Item

Number Part Number Description Quantity

27 418-150-050+ RING, Retainer, part of kit 560-001-021 (AL5) 1

418-150-070+ RING, Retainer, part of kit 560-001-031 (AL25) 1

418-150-080+ RING, Retainer, part of kit 560-001-041 (AL50) 1

28 423-700-118+ O-RING, Part of kit 560-001-021 (AL5) 1

423-700-119+ O-RING, Part of kit 560-001-031 (AL25) 1

423-700-120+ O-RING, Part of kit 560-001-041 (AL50) 1

29 521-008-450+ SEAT, Check valve, part of kits 560-001-021, 560-001-031, and 1

560-001-041

30 422-010-080+ O-RING, Part of kits 560-001-021, 560-001-031, and 560-001-041 1

33 521-000-050 SCREW, Enclosure 1

34 401-010-010+ BALL, Steel 1/8” Dia. 1

35 417-450-020+ SCREW, Set 10-32”x1/4” 1

36 411-700-763+ ROLL PIN 1

-- 560-001-021 REPAIR KIT (consists of Items 2, 4, 6, 8, 9, 11, 12, 15 thru 18, 1

20, 21, 24, 25, 27 thru 30 and 34 thru 36) (AL5)

560-001-031 REPAIR KIT (consists of Items 2, 4, 6, 8, 9, 11, 12, 15 thru 18, 1

20, 21, 24, 25, 27 thru 30 and 34 thru 36) (AL25)

560-001-041 REPAIR KIT (consists of Items 2, 4, 6, 8, 9, 11, 12, 15 thru 18, 1

20, 21, 24, 25, 27 thru 30 and 34 thru 36) (AL50)

-- 521-001-391 PUMP ADJUSTMENT ASSEMBLY (consists of Items 13 and 19 thru 22) (AL5) 1

-- 521-001-401 PUMP ADJUSTMENT ASSEMBLY (consists of Items 13 and 19 thru 22) (AL25) 1

-- 521-001-411 PUMP ADJUSTMENT ASSEMBLY (consists of Items 13 and 19 thru 22) (AL50) 1

+ Included in Repair Kit. Refer to Repair Kits above.

42000Modu-Flo® System

R

3-7/(3-8 Blank)

5*

6+

24+

23

7

4+

3

2+

1

19

20+

21+

20+

22

28+

27+

26

25+

8+

9+

18+

14 15+

16+17+30+29+

9+

17+

16+

15+

33

10*

12+

13**

11+

CHECK VALVE COMPONENTS

PREVIOUS TO L93

(December 1993)

35+

34+

6

6

‘

Figure 3-2. Pneumatic Pump, Exploded View

** 36+

*Not Available as Replacement Parts.

+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

TEST/AIR

PURGE PORT

***

42000Modu-Flo® System

R

3-9

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 H3 Maintenance

Tips.

3.4.2.1 The only maintenance required on the hydraulic

pump Options H1 and H3 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.

c. 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. Section

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.

(2) Remove jam nut (19) and two gaskets (18). Discard

gaskets (18).

(3) Remove adjustment 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 body (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 body (7) inner diameter for scoring or wear

marks. If damage is present, the pump assembly

cannot be serviced and should be replaced.

f. 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 H3.

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. For the H1 option only, insert lube piston (1) into hydrau-

lic piston (2). Install groove pin (3) to secure the assem-

bly.

b. 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).

c. Install new o-ring (5) on cylinder cap (6). Screw cylinder

cap (6) into body (7) and securely tighten it.

d. 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).

e. Install new o-ring (9) on adjustment screw body (17) and

install adjustment screw body in body (7). Tighten

securely.

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).

c. 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.

Modu-Flo® System 42000

R

3-10

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).

h. Install new o-ring (23) on check seat (22) and install

seat assembly into pump body.

i. Install steel ball (24) and check valve spring (13) into

body (7). Place new gasket (12) on enclosure screw

(11). Screw enclosure screw into body (7) and tighten

securely.

j. 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-

graph 3.2.2.

3.4.5 Hydraulic Pump Options H1 and H3 Parts List.

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 Quantity

521-000-011 PUMP ASSEMBLY, HLJ-5 (Option H1) --

521-005-900 PUMP ASSEMBLY, HLJ-5X (Option H3) --

1 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+ GASKET, 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 CAP, 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

-- 560-001-051 REPAIR KIT (consists of Items 3, 4, 5, 8, 9, 12 thru 16, 18, and 21 thru 23) 1

-- 560-001-940 REPAIR KIT (consists of Items 5, 9, 12 thru 16, 18, 22 thru 26, 28 1

and 29)

-- 521-001-391 PUMP ADJ. ASSEMBLY (consists of Items 10 & 17 thru 20) (HLJ-5) 1

* Not Available as Replacement Parts.

+ Included in Repair Kit.

*

*

*

42000Modu-Flo® System

R

3-11/(3-12 Blank)

7*

CHECK VALVE COMPONENTS

PREVIOUS TO L93

(December 1993)

27*

28+ FOR H3

OPTION

(HLJ-5X)

25+

26+

6

5+

4+

3+

2

FOR H1

OPTION

(HLJ-5)

1

21+

17

18+

19

18+

20

29+

15+

16+

11 12+

13+

14+ 23+ 22+

9+

10

30 12+ 13+ 14+

8

31

6

32

6

‘

Figure 3-3. Hydraulic Pump Options H1 and H3 - Exploded View

* Not Available as Replacement Parts.

+ Included in Repair Kit. Refer to Page 3-10 for Repair Kits

*** SEE NOTE ON PAGE 4.2

TEST/AIR

PURGE PORT

***

42000Modu-Flo® System

R

3-13

3.5 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.

3.5.2.1 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.

c. 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 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:

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.

d. Remove cylinder cap (6). Remove and discard o-ring

(5).

e. 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).

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 pin (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).

c. Install new o-ring (5) on cylinder cap (6). Screw cylinder

cap into hydraulic cylinder (7) and tighten securely.

d. 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).

e. 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).

h. 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).

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.

a. Separate pump from manifold by removing four socket-

head screws (11). Remove and discard three o-rings

(9) and one o-ring (18).

b. Remove enclosure screw (14). Remove and discard

gasket (15), check valve spring (16), steel ball (29),

check seat (25), and o-ring (26).

c. 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-

Modu-Flo® System 42000

R

3-14

Place new gasket (15) on enclosure screw (14). Screw

enclosure screw (14) into body (10) and tighten securely.

i. Install three new o-rings (9) and one new o-ring (18) into

body (10). Securely attach pump to manifold using four

socket-head screws (11).

3.5.4.2 When the assembly steps listed above have been

completed, adjust the pump output as described in Para-

graph 3.2.2.

3.5.5 Hydraulic Pump Option H2 Parts List. Table 3-4

identifies the parts indexed in Figure 3-4.

Table 3-4. Hydraulic Pump Option H2 Parts List

Item

Number Part Number Description Quantity

521-000-031 PUMP ASSEMBLY, HL-25 (Option H2) --

1 PISTON, Lube 1

2 521-000-310 PISTON, Hydraulic 1

3 411-101-660+ PIN, Groove, part of kit 521-001-061 1

4 422-021-160+ O-RING, Part of kit 521-001-061 1

5 422-011-220+ O-RING, Part of kit 521-001-061 1

6 521-000-300 CAP, Cylinder 1

7 521-000-290 CYLINDER, Hydraulic 1

8 422-010-200+ O-RING, Part of kit 521-001-061 1

9 423-700-111+ O-RING, Part of kit 521-001-061 1

10 BODY, Pump 1

11 419-130-070+ SCREW, Socket-head, 1/4-20 x 1-1/4 inch 4

12 422-011-140+ O-RING, Part of kit 521-001-061 1

13 521-003-010 SCREW, Adjustment 1

14 521-008-460 SCREW, Enclosure 1

15 500-132-000+ GASKET, Part of kit 521-001-061 1

16 511-893-000+ SPRING, Check valve, part of kit 521-001-061 1

17 401-030-030+ BALL, Steel, 3/16 inch, part of kit 521-001-061 1

18 423-700-114+ O-RING, Part of kit 560-001-061 1

19 521-003-040 BODY, Adjustment screw 1

20 439-040-070+ GASKET, Stat-O-Seal, part of kit 521-001-061 2

21 410-702-033+ NUT, Jam, 7/16-20 1

22 521-002-980 CAP, Adjustment screw 1

23 521-000-330 RETAINER 1

24 423-700-063+ RING, Backup, part of kit 560-001-061 1

25 521-008-450+ SEAT, Check valve, part of kit 560-001-061 1

26 422-010-080+ O-RING, Part of kit 560-001-061 1

27 423-700-113+ O-RING, Part of kit 560-001-061 5

30 521-000-050 SCREW, Enclosure 1

31 401-010-010+ BALL, Steel 1/8” Dia. 1

32 417-450-020+ SCREW, Set 10-32”x1/4” 1

33 411-700-763+ ROLL PIN 1

-- 560-001-061 REPAIR KIT (consists of Items 3, 4, 5, 8, 9, 11,12, 15 thru 18, 1

20, 21, 24 thru 27 and 31 thru 33)

-- 521-001-401 PUMP ADJUSTMENT ASSEMBLY (consists of 1

Items 13 and 19 thru 22)

* Not Available as Replacement Parts

+ Included in Repair Kit.

*

*

42000Modu-Flo® System

R

3-15/(3-16 Blank)

CHECK VALVE COMPONENTS

PREVIOUS TO L93

(December 1993)

7

8+

27+

12+

13

10*

17+

16+

15+

18+

27+

14 15+

17+ 25+

26+

16+

30

11+

9+

23

22

20+

21+

20+

19

1*

2

3+ 4+

5+

6

24+

32+

31+

6

6

‘

Figure 3-4. Hydraulic Pump Option H2 - Exploded View

33+

* Not Available as Replacement Parts.

+ Included in Repair Kit. Refer to Page 3-14 for Repair Kits

*** SEE NOTE ON PAGE 4.2

TEST/AIR

PURGE PORT

***

42000Modu-Flo® System

R

OPERATION AND

SERVICE INSTRUCTIONS

Modu–Flo®

System

4-1

SECTION 4

MANIFOLDS

4.1 DESCRIPTION ........................................................... 4-1

4.1.1 General ........................................................... 4-1

4.2 PREPARATION FOR USE .......................................... 4-1

4.2.1 Mounting ......................................................... 4-1

4.2.2 Connection to Other Components ................. 4-1

4.3 MAINTENANCE .......................................................... 4-1

4.1 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

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 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.

Modu-Flo® System 42000

R

4-2

Table 4-1. Operating Ports on Modu-Flo Manifolds

Port Name Function

DA Single-acting model pumps:

(Double 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 connected to it.

Fluid directed to this port causes the pump to

retract to the loading position.

GAUGE Port for attaching a pressure gauge to indicate

pump output pressure. This port is common to

the LUBE OUT port.

IND Port for attaching a blowout or pressure

indicating assembly. This port is common to

the LUBE OUT port.

SYS FILL 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.

LUBE OUT Port that the system being lubricated is

connected to. An outlet check valve is installed

here.

SA Port has a pneumatic or hydraulic supply

(Single source connected to it. Fluid directed to this

Acting) port causes the pump to dispense.

TEST 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.

LUBE IN Port that the lubricant reservoir or tank outlet

Pump-to- is connected to.

Wall (Re-

mote) Mani-

fold Only

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.

Table 4-2. Manifolds and Manifold Accessories

Item Part Number

Pump-to-Reservoir Manifold Only 521-001-540

Pump-to-Reservoir Manifold Assembly: 521-001-180

Includes outlet check valve, System

fill check valve,blowout assembly,

and pressure gauge

Pump-to-Wall (Remote) Manifold Assembly: 521-001-170

Includes outlet check valve, system

fill check valve, and blowout assembly

Pump-to-Reservoir Manifold Combination: 521-001-790

Includes outlet check valve, system fill

check valve, tubed blowout assembly,

and pressure gauge

Pump-to-Wall (Remote) Manifold

Combination: 521-001-780

Includes outlet check valve, system fill

check valve, and blowout assembly

for high pressure alarm.

Outlet Check Valve 509-360-030

System Fill Check Valve 509-365-030

Elbow, 1/4 inch pipe 509-113-000

Pipe Plug, 1/4 inch 508-975-000

Plastic Vent Plug, 1/4 inch 521-001-160

(Located in D.A. Port) (Yellow)

Standard Blowout Assembly (1450 psi) 509-206-100

Tubed Blowout Assembly (1450 psi) 509-220-101

Bag of 6 Discs (1450 psi) 560-900-270

Standard Pressure Gauge (0-3,000 psi) 543-362-000

Liquid-filled Pressure Gauge (0-3,000 psi) 543-711-380

Manifold to Reservoir

O-Ring (Buna-N) 422-010-210

(Included with pump to reservoir manifold assemblies)

* Refer to Section 6 for kits in other pressure ranges.

Acting)

Above items are for manifolds with 1/4” NPSF ports.

Consult factory for manifolds and accessories with SAE,

BSPP, and metric threads.

**

**

*

42000Modu-Flo® System

R

4-3/(4-4 Blank)

DOUBLE ACTING

(D.A.) PORT

YELLOW VENT PLUG

TEST/AIR

PURGE PORT

BLOWOUT

ASSEMBLY

LUBE

SYSTEM

OUTLET

SINGLE ACTING

(S.A.) PORT

PLUNGER

O-RING

P/N 422-010-210

* 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.

LUBE SYSTEM

FILL

CHECK VALVE *

**

Figure 4-1. Typical Manifold Assembly

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.

**

5-1

42000Modu-Flo® System

R

OPERATION AND

SERVICE INSTRUCTIONS

Modu–Flo®

System

SECTION 5

LOW-LEVEL SWITCHES

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 .................... 5-4

5.4.5 Oil Tank and Reservoir 10-Watt

Low-Level Assemblies Parts List ................. 5-4

5.5 GREASE RESERVOIR LOW-LEVEL ASSEMBLY

MAINTENANCE (OPTION L4) ................................... 5-5

5.5.1 General .......................................................... 5-5

5.5.2 Grease Reservoir Low-Level Assembly

Maintenance Tips .......................................... 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 List ....................................................... 5-6

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 DESCRIPTION .......................................................... 5-1

5.1.1 General .......................................................... 5-1

5.2. MOUNTING INSTRUCTIONS ................................... 5-1

5.2.1 Oil Reservoirs and Tanks.............................. 5-1

5.2.2 Grease Cylinders .......................................... 5-1

5.3 OIL TANK AND RESERVOIR 15 AMP

LOW-LEVEL ASSEMBLY MAINTENANCE

(OPTIONS L1, L2 and L3) ......................................... 5-2

5.3.1 General .......................................................... 5-2

5.3.2 Oil Tanks and Reservoir 15 Amp

Low-Level Assembly Maintenance Tips ....... 5-2

5.3.3 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 Oil Tank and Reservoir 15 amp

Low-Level Assemblies Parts List ................. 5-3

5.4 OIL TANK RESERVOIR 10-WATT LOW-LEVEL

ASSEMBLY MAINTENANCE (OPTIONS L5, L6

AND L7)..................................................................... 5-4

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.

Modu-Flo® System

5-2

42000

R

Table 5-1. Low-Level Switch Assemblies

Part Number Switch Type Switch Rating AC Used On Option

521-001-030 Single-pole, double-throw 15 amps at 115, 230 5- and 12-pint oil L1

or 480 VAC cylindrical reservoirs

521-001-040 Single-pole, double-throw 15 amps at 115, 230 20-pint oil cylindrical L2

or 480 VAC reservoir

521-001-050 Single-pole, double-throw 15 amps at 115, 230 6-pint oil cylindrical L3

or 480 VAC reservoir and all tanks

456-010-171 Single-pole, single-throw 10 watts at 115 VAC 6-pint oil cylindrical L7

reservoir and oil tanks

456-010-172 Single-pole, single-throw 10 watts at 115 VAC 5- and 12-pint oil L5

cylindrical reservoir

456-010-173 Single-pole, single-throw 10 watts at 115 VAC 20 pint oil cylindrical reservoir L6

521-001-110 Single-pole, double-throw 15 amps at 115, 230 All grease cylindrical reservoirs L4

or 480 VAC, 0.5 amp

at 115 VDC, 0.25 amp

at 230 VDC

5.3 OIL TANK AND RESERVOIR 15 AMP

LOW-LEVEL ASSEMBLY MAINTE-

NANCE (OPTIONS L1, L2 and L3)

a. Turn off all electrical power and all air supplies to the

lube system.

b. Remove cover from reservoir (Refer to Section 2.).

c. 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.

5.3.4.1 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 cover from reservoir (Refer to Section 2.).

b. 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.

WARNING

Disconnect and lock out all power from the

assembly before attempting disassembly.

Serious injury may result from electrical shock.

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 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:

5-3

42000Modu-Flo® System

R

c. Screw low-level lower assembly (4) into low-level

adapter (3) and tighten securely. e. Screw switch adapter (2) into switch (1) and tighten

securely.

f. Screw union nut (5) onto switch adapter (2) and tighten

securely.

g. Install cover on reservoir (Refer to Section 2.).

h. Wire switch in accordance with local electrical codes.

5.3.5 Oil Tank and Reservoir 15 Amp Low-Level Assem-

blies Parts List. Table 5-2 identifies the parts indexed in

Figure 5-1.

NOTE

If float portion of low-level lower assembly was

removed during disassembly, apply Locktite to

the attaching bolt and securely attach the float to

the arm.

d. Insert the actuating rod, part of low-level lower assembly

(4), into this assembly.

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-LEVEL ASSEMBLY (20 pint) --

521-001-050 LOW-LEVEL ASSEMBLY (6 pint) --

1 514-116-001+ SWITCH 1

2 ADAPTER, Switch 1

3 ADAPTER, Low-level 1

4 LOW-LEVEL LOWER ASSEMBLY 1

5 NUT, Union 1

*

*

*

*

2

3

5

1

COVER (REF)

4

LOCKTITE

USED AT

ASSEMBLY

+ When replacing item (1)

switch only, remove lock

nut from new switch

plunger housing before

assembling switch to

item (2) adapater.

Figure 5-1. Oil Tank and Reservoir 15 Amp Low-Level Assembly

* Not available as replacement parts.

Modu-Flo® System

5-4

42000

R

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:

WARNING

Disconnect and lock out all power from the

assembly before attempting disassembly.

Serious injury may result 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.

c. Remove the cover from the tank or reservoir (Refer to

Section 2.).

d. Unscrew nipple (2) from adapter (1). Be careful not to

twist the wires too much.

e. 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.

c. 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.

f. Connect switch (4) in accordance with local electrical

codes.

5.4.5 Oil Tank and Reservoir 10-Watt Low-Level

Assemblies Parts List. Table 5-3 identifies the parts

indexed in Figure 5-2.

5-5

42000Modu-Flo® System

R

5.5 GREASE RESERVOIR LOW-LEVEL ASSEMBLY MAINTENANCE

(OPTION L4)

5.5.1 General. Maintenance tips, disassembly and

assembly procedures for low-level assembly option L4 are

discussed in Paragraphs 5.5.2, 5.5.3 and 5.5.4. A sectional

view of a typical assembly is shown in Figure 5-3 and should

be referred to during the discussion.

5.5.2 Grease Reservoir Low-Level Assembly Mainte-

nance Tips. No maintenance is required on the low-level

assemblies used on grease reservoirs. If the grease level

runs down and the assembly fails to perform as required,

the low level assembly 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 switch from operating.

5.5.3 Disassembly of Grease Reservoir Low-Level

Assembly.

5.5.3.1 The disassembly procedure for the grease reservoir

low-level assembly is as follows:

4

RESERVOIR

COVER (REF)

3

2

1

WARNING

Disconnect and lock out all power from the

assembly before attempting disassembly.

Serious injury may result from electrical shock.

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-LEVEL ASSEMBLY (20 pint) --

456-010-171 LOW-LEVEL ASSEMBLY (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

*

*

*

* Not available as replacement parts.

Modu-Flo® System

5-6

42000

R

a. Disconnect and lock out all electrical power and air

supplies to the lube system.

b. Disconnect switch (1, Figure 5-3) from terminal box.

Remove switch (1) from bracket (2).

c. Remove retainer ring (3) and spring (5).

d. Remove three self-tapping screws (4) and bracket (2).

5.5.4 Assembly of Grease Reservoir Low-Level

Assembly.

5.5.4.1 The procedure for assembly of the grease reservoir

low-level assembly is as follows:

a. Attach bracket (2) to grease reservoir cover using three

self-tapping screws (4).

b. Place spring (5) over tip of level indicator.

c. Compress spring (5) and place retainer ring (3) be-

tween spring and tip of level indicator.

d. Attach switch (1) to bracket (2).

e. Wire switch (1) in accordance with local electrical codes.

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

5 542-939-000 SPRING 1

Figure 5-3. Grease Reservoir Low-Level Assembly

2

GREASE RESERVOIR

CABLE ASSEMBLY (REF) GREASE RESERVOIR

CAP (REF)

3

1

5

4

5.5.5 Grease Reservoir Low-Level Assembly Parts List.

Table 5-4 identifies the parts indexed in Figure 5-3.

6-1

42000Modu-Flo® System

R

OPERATION AND

SERVICE INSTRUCTIONS

Modu–Flo®

System

SECTION 6

HIGH-PRESSURE AND BLOWOUT SWITCHES

6.4.3 Assembly/Disassembly of High-Pressure

Switch ............................................................ 6-3

6.4.4 High-Pressure Switch Parts Lists ................ 6-3

6.5 RESERVOIR BLOWOUT SWITCH MAINTENANCE

(OPTIONS P2 and P3) .............................................. 6-4

6.5.1 General .......................................................... 6-4

6.5.2 Reservoir Blowout Switch

Maintenance Tips .......................................... 6-4

6.5.3 Assembly/Disassembly of Blowout Switch .. 6-4

6.5.4 Reservoir Blowout Switch Parts Lists........... 6-4

6.6 TANK BLOWOUT SWITCH MAINTENANCE

(OPTION P4) ............................................................. 6-6

6.6.1 General .......................................................... 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

6.1 DESCRIPTION .......................................................... 6-1

6.1.1 High-Pressure Switches ............................... 6-1

6.1.2 Blowout Switches .......................................... 6-1

6.1.3 Blowout Disc ................................................. 6-1

6.1.4 High-Pressure and Blowout Switch

Options .......................................................... 6-2

6.2 HIGH-PRESSURE SWITCH ADJUSTMENT............. 6-2

6.2.1 General .......................................................... 6-2

6.2.2 High-Pressure Switch Adjustment

Procedures .................................................... 6-2

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. If 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

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.

6.3 MOUNTING INSTRUCTIONS ................................... 6-3

6.4 HIGH-PRESSURE SWITCH MAINTENANCE

(OPTION P1) ............................................................. 6-3

6.4.1 General .......................................................... 6-3

6.4.2 High-Pressure Switch Maintenance Tips ..... 6-3

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

Modu-Flo® System

6-2

42000

R

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

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 P1

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 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

Figure 6-1. High-Pressure Switch

FACTORY SEALED

3 WIRE CABLE

16 AWG

5 FT. LG.

RED N.O.

BLACK N. C.

WHITE COM.

1/4 NPT

1/2" FEMALE

CONNECTOR

CONDUIT

CAUTION LABEL

PRESSURE SWITCH

LUBRIQUIP, INC. A Unit of IDEX

18901 Cranwood Pkwy, Cleveland Oh

(216) 581-2000 1-800-USA-

FAX 216) 581-8945

LUBRIQUIP

542-210-120

ADJUSTMENT

COVER

MOVE

TO

ACCESS

ADJ.

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.

6.2.2 High-Pressure Switch Adjustment Procedures.

6-3

42000Modu-Flo® System

R

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:

WARNING

•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.)

a. Turn off electrical power to the lube system.

b. Connect control to pressure source.

c. With power disconnected, slide cover toward electrical

terminations while twisting it to overcome friction.

d. Connect power to terminals or leads.

e. 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).

f. After completing adjustments, slide cover closed order

adjustment compartment. Recheck set point.

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 Maintenance 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.

6.4.3 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).

c. Install new blowout disc (5) in pressure relief nut (6).

d. Install pressure relief nut (6) on adapter fitting (4) and

torque to 5 ft lbs.

6.4.4 Pressure Switch Parts Lists. Table 6-4 identifies

the parts indexed in Figure 6-2.

Modu-Flo® System

6-4

42000

R

Table 6-4. High-Pressure Switch Parts List

Index

Number Part Number Description Quantity

521-001-220 HIGH-PRESSURE SWITCH ASSEMBLY (Option P1) --

1 542-210-120 SWITCH, Pressure 1

2 412-380-020 TEE, Male, 1/4 inch pipe 1

3 509-206-100 BLOWOUT ASSEMBLY, 1450 psi 1

4 -- . FITTING, Adapter 1

5 -- . DISC, Blowout 1

6 -- . NUT, Pressure relief 1

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.

WARNING

Disconnect and lock out all power from the

assembly before attempting disassembly.

Serious injury may result from electrical shock.

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. 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.

TANK OR

RESERVOIR

MANIFOLD

(REF)

LUBE OUTLET

EXISTING

LUBE

OUTLET

ELBOW

IND PORT

1

2

3

654

S.A.

Figure 6-2. High-Pressure

Switch (Rear View)

4-3/4”

6-5

42000Modu-Flo® System

R

Table 6-5. Reservoir Blowout Switch Parts List

Item

Number Part Number Description Quantity

521-001-190 HIGH-PRESSURE BLOWOUT SWITCH ASSEMBLY (5 pint/lb) --

521-001-200 HIGH-PRESSURE BLOWOUT SWITCH ASSEMBLY (6, 12 or 20 pint/lb) --

1 521-000-760 BRACKET, Mounting, for 5 lb and 5 pt 1

521-000-770 BRACKET, Mounting, for 6 lb, 12 lb, 20 lb, 6 pt, 12 pt, and 20 pt 1

2 416-701-992 SCREW, Round head, 6-32 x 1-3/8 inch, part of 2

Part No. 511-573-030

3 421-070-050 LOCKWASHER, No. 6, part of part No. 511-573-030 4

4 410-030-050 NUT, Hex, 6-32, part of Part No. 511-573-030 2

5 529-726-001 SWITCH, Part of Part No. 511-573-030 1

6 501-967-001 BRACKET, Switch, part of Part No. 511-573-030 1

7 419-110-020 SCREW, Socket-head, 10-24 x 1/2 inch 2

8 417-060-060 SETSCREW, 1/4-20 x 1/2 inch 2

9 435-370-020 FITTING, Elbow, 1/8 NPT x 1/4 inch tube 2

10 511-160-001 INDICATOR ASSEMBLY, Part of Part No. 511-573-030 1

11+ TUBING, Copper, 1/4 inch outer diameter x 0.030 wall 3 ft

12 509-223-000 SPUD, Union 1

13 509-224-000 NUT, Union 1

14 509-208-000 BODY, Blowout 1

15 412-270-030 ELBOW, 1/4 inch NPT 1

16 412-380-020 TEE, 1/4 inch NPT 1

17 509-365-030 CHECK VALVE ASSEMBLY 1

18 435-360-030 FITTING, Straight, 1/4 tube x 1/4 inch NPT 1

-- 511-573-030 BLOWOUT AND SWITCH ASSEMBLY 1

-- 560-900-270 BLOWOUT DISCS, Bag of 6, 1450 psi 1

19 435-360-020 FITTING, Straight, 1/4 inch tube x 1/8 inch NPT 1

* See Table 6-1 for other disc pressure ratings.

+ Tubing purchased separately

Figure 6-3. Reservoir Blowout Switch

Assembly (Front View)

PLUNGER

1

19

18

17

16

2,3,4 5

14 13 12

11

10

9

8

7

6

15

9

*

Modu-Flo® System

6-6

42000

R

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. No

maintenance is required on the blowout switch. If this switch

assembly is suspected to be defective, check all wiring to the

switch before removing any components.

WARNING

Disconnect and lock out all power from the

assembly before attempting disassembly.

Serious injury may result from electrical shock.

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

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

connective tubing.

6.6.4 Tank Blowout Switch Parts List. Table 6-6 identi-

fies the parts indexed on Figure 6-4.

Table 6-6. Tank Blowout Switch Parts List

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 NPT 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, Union 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

*

6-7

42000Modu-Flo® System

R

/(6-8 Blank)

Figure 6-4. Tank Blowout Switch Assembly (Side View)

PLUNGER

6

78

9

10

11

12

1,13,14,15

1 2,3,4 5

16

7-1/(7-2 Blank)

42000Modu-Flo® System

R

OPERATION AND

SERVICE INSTRUCTIONS

Modu–Flo®

System

SECTION 7

PNEUMATIC SOLENOID

7.1 DESCRIPTION ........................................................... 7-1

7.2 OPERATION ............................................................... 7-1

7.3 INSTALLATION ........................................................... 7-1

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 piston 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

Item 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

Figure 7-1. Pneumatic Solenoid

1/4-18 NPSF

THREAD

TORQUE

10-15 FT. LBS

352

1

2

4

55

1/2 NPSM

CONDUIT

CONNECTION

MANUAL

OVERRIDE

1/4 NPSF

"AIR INLET"

2.188

3.312

6

8-1

42000Modu-Flo® System

R

OPERATION AND

SERVICE INSTRUCTIONS

Modu–Flo®

System

SECTION 8

CONTROLLERS

8.1 DESCRIPTION .......................................................... 8-1

8.1.1 DC Timer ....................................................... 8-1

8.1.2 AC Timer........................................................ 8-1

8.1.3 TC-1000 Timer/Counter ................................ 8-1

8.1.4 WMP Maxi-Monitor ......................................... 8-1

8.2 WIRING ..................................................................... 8-2

8.2.1 DC Timer ....................................................... 8-2

8.2.2 AC Timer........................................................ 8-2

8.2.3 TC-1000 Timer/Counter ................................ 8-3

8.2.4 Maxi-Monitors ................................................ 8-3

8.1 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 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 TC-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.

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

accessories. 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.

Modu-Flo® System

8-2

42000

R

INSTALLATION INSTRUCTIONS

1. DISCONNECT INPUT AND LOAD POWER SUPPLIES

AT THEIR SOURCE.

2. REMOVE (2) SCREWS AND LIFT OUT CIRCUIT BOARD

3. 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)

7. INSTALL TIMER BOARD WITH (2) =6 X 1/2“ SCREWS

SUPPLIED MAX. TIGHTENING TORQUE 5 IN. LBS.

8. SET TIMER ON AND OFF TIMERS

9. CLOSE AND FASTEN COVER WITH 2 =10 X 3/4“

SCREWS SUPPLIED MAX. TIGHTENING TORQUE 7 IN

LBS AND APPLY POWER.

1/2 AMP

3 AMP

INPUT LOAD

0.2

1

2

57

10

13

ON TIME

MINUTES

CAUTION

DISCONNECT A LOCK

OUT POWER PRIOR

TO SERVICING TO AVOID

POSSIBLE ELECTRICAL

SHOCK.

INPUT

115/230V

50/60 HZ

LOAD

3 AMP

MAX.

MAN

RUN

LOAD ENERGIZED

LUBRIQUIP

TOTAL CYCLE TIME

HOURS

MINUTES

TOTAL CYCLE TIME

MINUTES’ HOURS

5

2

4

8

16

24

32

30

24

16

8

4

2

5

ASSY NO

572-142-590

MANUAL RUN BUTTON

Figure 8-2. AC Timer Wiring Schematic

12 to 32 VDC

POWER SOURCE

ORANGE

(MEMORY)

RED (+)

BLUE (+)

SWITCH

SOLENOIDBLACK

TIMER

GROUND

( – ) ( + )

YELLOW ( – )

Figure 8-1. DC Timer Wiring Schematic

8-3

42000Modu-Flo® System

R

8-3/(8-4 Blank)

Figure 8-3. TC-1000 Timer/Counter Wiring Schematic

Figure 8-4. WMP Maxi-Monitor Wiring Schematic

10

11

12

13

SOURCE SWITCH -

2 OR 3 WIRE TYPE

10

11

12

13

SINK SWITCH -

2 OR 3 WIRE TYPE

10

11

12

13

DRY CONTACT SWITCH

10

11

12

13

SUPPLEMENTAL

WIRING FOR LOW LEVEL

1

2

R

Caution: Voltage will be present at low

level switch and may be

present at lamp when power

to TC-1000 is on

DO NOT USE

HOT

NEU

PUMP

PUMP

1234567

89

MACHINE COUNT

(SEE BELOW)

MANUAL

RUN

SW

SENSE

10 11 12 13 14 15 16 17 18 19

JOG ENABLE

+

-

+

--

+

-

+

-

+

SW IN

SW

-

ADD JUMPER

IF ENABLE

FEATURE IS

NOT USED

CAUTION: INPUT VOLTAGE WILL BE PRESENT ON

TERMINAL - 5 FOR DC MODELS ONLY.

INPUT

OUTPUT

9-1

42000Modu-Flo® System

R

OPERATION AND

SERVICE INSTRUCTIONS

Modu–Flo®

System

SECTION 9

SYSTEM OPERATION

9.1 GENERAL ................................................................. 9-1

9.2 SYSTEM INFORMATION ........................................... 9-1

9.2.1 System Setup ................................................ 9-1

9.2.2 System Filling ................................................ 9-1

9.2.3 System Bleeding ........................................... 9-1

9.2.4 System Start-up ............................................. 9-1

9.3 OPERATING TIPS ..................................................... 9-1

9.3.1 General .......................................................... 9-1

9.4 MATERIAL CONSIDERATIONS ................................. 9-2

9.4.1 Material Cleanliness ..................................... 9-2

9.4.2 Temperature Effects ...................................... 9-2

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.

b. 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.

c. Check that the pump is securely fastened to the

manifold.

d. Check all electrical connections to any solenoids,

controllers, level switches or pressure switches used

on the system.

e. 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 filling of the system will

reduce the chance of air entrapment. The manifold/pump

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

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.

Modu-Flo® System

9-2

42000

R

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

erratic pump operation and costly parts replacement. Make

sure that lubricant used to fill the system is clean. If there 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.

10-1

42000Modu-Flo® System

R

OPERATION AND

SERVICE INSTRUCTIONS

Modu–Flo®

System

SECTION 10

TROUBLESHOOTING

10.1 GENERAL ............................................................... 10-1

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

connections to make sure they are tight. Also make sure the

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

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

Problem Possible Cause Corrective Action

A. No lube is dispensed 1. Reservoir or tank is empty. 1. Refill as required.

from pump, but pump is

receiving air or hydraulic 2. Air or hydraulic pressure is inadequate. 2. Set pressure to proper setting.

operating signals. 3. If pump is single-acting, return 3. Replace spring or change pump

spring may be defective. to double-acting. (Refer to Section 3.)

4. Pump needs servicing. 4. Disassemble pump and replace

defective components. (Refer to Section 3.)

5. Pump adjustment screw is turned in 5. Adjust pump. (Refer to Section 3.)

too far.

6. Pump is air bound. 6. Bleed air through test port. (Refer to

Figure 4-1).

B. Blow-out disc has ruptured. 1. High pressure exists in the system. 1. Inspect dividers, lines, fittings, and lube

points to determine the source of high pres-

sure. Correct problem and replace disc.

2. Excessive air or hydraulic flow to pump. 2. Install a restrictor in the air or hydraulic

lines.

C. Pump output is erratic. 1. System is not properly bled. 1. Bleed system.

2. Pump needs servicing. 2. Disassemble pump and replace

defective components. (Refer to Section 3.)

3. Pump adjustment assembly is leaking 3. Tighten components of the adjustment

or sucking air during return stroke. assembly.

4. Defective o-ring. 4. Repair pump or manifold. (Refer to

Sections 3 and 4.)

5. Setscrew and ball are loose in TEST 5. Tighten setscrew.

port.

Modu-Flo® System

10-2

42000

R

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.

® Registered trademark of LUBRIQUIP, INC.,

Printed in U.S.A.

LUBRIQUIP, INC., 18901 Cranwood Pkwy.



Cleveland, Ohio 44128



Phone: 216-581-2000 or 800-USA-LUBE



FAX: 216-581-8945

R

Bulletin 42000

www.lubriquip.com/pdf/42000.pdf

Trabon® Modu-Flo® System

ISO 9001

REGISTERED FIRM

ISO 14001

REGISTERED FIRM

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