Lincoln Quicklub Manuale utente

Quicklub®Maintenance

2/16/2009

ASC FORM# 80-1088

REV 7/11/2014

Contents

Pages

Introduction------------------------------------------------------------------------------------------ 3

Benefits from Automated Lubrication ------------------------------------------------------ 3

The Lincoln Quicklub Pump-------------------------------------------------------------------- 3

Glossary of Terms--------------------------------------------------------------------------------- 4 - 5

System Operation (Non-Monitored) --------------------------------------------------------- 6

System Operation (Monitored) ---------------------------------------------------------------- 7

Divider Valve Operation ------------------------------------------------------------------------- 8

System Startup ------------------------------------------------------------------------------------- 9

Daily Walk-Around Inspection----------------------------------------------------------------- 10

Troubleshooting Guide -------------------------------------------------------------------------- 11

Troubleshooting a Blockage ------------------------------------------------------------------- 12 – 13

Quick-Fill (Filling Reservoir) ------------------------------------------------------------------- 14

Monitored Pump PC Board indicator LED’s ---------------------------------------------- 15

Non-monitored Pump PC Board indicator LED’s --------------------------------------- 16

Pushbutton Fault Light Indicator ------------------------------------------------------------- 17

Manually Lubricating Bearings --------------------------------------------------------------- 18

Remote Lube Fitting ------------------------------------------------------------------------------ 19

Spiral Wrap (Protection for lube lines)------------------------------------------------------ 20

Special Guarding (Protection for lube lines)---------------------------------------------- 21- 22

Tapping Lubrication Points -------------------------------------------------------------------- 23

2/13/09

Introduction

This manual has been assembled to assist the operator in understanding and maintaining the Lincoln

Quicklub system. It should be reviewed periodically so the operator becomes familiar with the nuances

of the lube system. The manual shows some details about a typical installations followed by system

maintenance and trouble shooting techniques.

The manual has a section that shows how our progressive lube system operates. A schematic diagram

shows how the lube progresses from the pump to the primary valves, then to the secondary valves and

finally to the bearing points.

When a Lincoln lube system is installed, quality and system robustness is the number one priority.

Quicklub lubrication systems are proven to increase the life of pins and bushings, and decrease labor

costs associated with manual lubrication. When a system is installed, items such as machine

articulation, type of material machine handles, climate, and other operating conditions that could

damage the system are taking into consideration.

Benefits From Automatic Lubrication

•Gain 30 to 45 minutes per day of increased productivity for each machine by lubricating while

machine is in service.

•Improve bearing life and reduce maintenance downtime due to repairing damaged bearings.

•Reduce bearing wear by delivering smaller, more frequent amounts of grease to each bearing.

•Reduce grease consumption by delivering the required amount of grease.

•Improve safety by eliminating the daily practice of climbing all over machinery to lubricate

bearings. This can be extremely difficult in severe weather conditions.

The Lincoln Quicklub Pump

Designed for the harsh environment of the construction markets, Quicklub pumps are loaded with

features:

•Available in 12, 24 VDC and 120 VAC.

•Capable of dispensing #2 grease (oil systems available)

•Optional low-level alarms and system operation alarms with warning lights in the cab.

•Reservoir (2-, 4-, 8- or 15-Liter) can be refilled through a grease fitting, typically every 150-300

hours of operation.

•All pumps have high-pressure capability to ensure grease is delivered to each component.

•A blocked lube point can be detected at the pump or in the cab with the optional alarm and

warning light. A buzzer can also be added as an alarm.

•Pump controls run-time and built-in-timer.

•Data Logger models available that store information on system operation history and can be

connected to “Produce Link/GPS” to remotely notify if the system requires service.

2/13/09

Glossary of Terms

Automated Lubrication System (ALS) – A pump supplies a number of bearings with lubricant via a

system of transmission lines and divider valves.

Closure Plug – A threaded plug used to purposely block lubricant from exiting a valve outlet. This

lubricant will move down to the next outlet.

Cycle Indicator Pin – Visual indication pin attached to a valve piston on the divider valve (see below).

The pin is located on the side of the divider valve that moves in and out as grease flows within the

valve. A cycle indicator pin is not necessarily present on all divider valves. Divider valves without cycle

indicator pins are available.

Cycle Indicator Pin

Cycle Rate – Amount of time it takes for every valve to cycle at least once.

Distribution block – See divider valve

Divider Valve – A Quicklub®divider valve is a proportioning device consisting of a minimum of three

pistons. A primary divider valve is the first divider valve downstream from the lube pump. A secondary

divider valve is any divider valve receiving lubricant from the primary divider valve. (A.k.a. distribution

block, metering valve or SSV valve)

Feed Line – Tubing or hose going from a divider valve directly into a terminating lubrication fitting.

Fitting – Hardware used to connect hose or tube to lubrication port on equipment.

Lube Event – Depending on the Quicklub®pump that is used, it is the duration the pump is pumping

grease. On a monitored pump, the lube event duration is controlled by a proximity switch. On the non-

monitored pumps, the lube event duration is controlled by setting the “on” and “off” times via the dials

on the PC board.

Metering Valve – See divider valve.

Monitored Pump – A Quicklub®pump that utilizes a proximity switch to monitor and end the lube

event. The pump requires that the “off time” be set on the PC board, which is accessible from the front

side of the pump. The “off time” is the length of time between lube events (pump operation).

2/13/09

Non-monitored pump - A Quicklub®pump that has it’s “on” and “off” time set by the red and blue dial

switches on the PC board, which is accessible from the front side of the pump. The operation of the

pump relies solely on the internal timer and its dial settings.

Outlet - Each outlet on a Quicklub®divider valve dispenses .012 in³ per cycle. If an outlet is plugged,

the lubricant will be diverted to the next outlet down allowing proper proportioning of lubricant to all

lubrication points.

Pressure Relief Valve – Located at the outlet side of each pump element. It is a valve that limits the

pressure in the system to a maximum value (3500psi). If pressure from the pump exceeds this value,

the valve opens and lubricant is bled off to the atmosphere. A blockage in the system will cause an

elevated pressure in the system.

Primary Divider Valve – First divider valve downstream from the lube pump, distributes lube to

secondary valves.

Proximity Switch – A switch device that can be inserted into a divider valve and triggered by the piston

movement inside the valve. A cycle consists of the piston moving two times (out and back).

Pushbutton – Optional accessory on Quicklub systems that alerts the operator of a fault and allows the

operator to trigger an additional lubrication cycle. Usually mounted in the cab for visibility.

Secondary divider valve – Any divider valve receiving lubricant from the primary divider valve.

SSV Valve – See divider valve.

SSV-D Valve – A divider valve with adjustable outputs.

Supply Line – Hose from the pump to primary valve and hose from the primary valve to any secondary

valve.

2/13/09

System Operation (Non-Monitored System)

The key components of the Quicklub Non-Monitored system are:

1. Pump with an Integrated Timer. The Integrated timer controls the “On Time” and “Off Time”

of the pump.

2. Divider valve network consisting of a Primary Valve and Secondary Valves with attached Cycle

Indicator Pin.

3. A lubrication event is initiated by actuating the pump via the Integrated Timer based on a

preset “pause time” or time between lubrication events.

4. The Pump dispenses lubricant to the primary divider valve.

5. The Primary Valve distributes the lubricant to the secondary valves.

6. The Secondary Valves distribute and dispense lubricant to the lubrication points.

7. Lubricant flow through the divider valves actuates the Cycle Indicator Pin for a visual

inspection of proper operation.

8. The pump will run for the preset On-Time

9. The controller now begins countdown for the next lubrication event.

2/13/09

Non-Monitored System

Secondary

Divider

Valves

Primary

Divider

Valve

Pump

Tubing

Lube Point

Hose

Outlet Fitting

Closure Plug

Cycle Indicator Pin

System Operation (Monitored System)

The key components of the Quicklub Monitored system are:

1. Pump with an Integrated Timer. The Integrated timer controls the “Off Time” of the pump.

2. Divider valve network consisting of a Primary Valve and Secondary Valves with attached Cycle

Indicator Pin.

3. A lubrication event is initiated by actuating the pump via the Integrated Timer based on a

preset “pause time” or time between lubrication events.

4. The Pump dispenses lubricant to the primary divider valve.

5. The Primary Valve distributes the lubricant to the secondary valves.

6. The Secondary Valves distribute and dispense lubricant to the lubrication points.

7. Lubricant flow through the divider valves actuates the Cycle Indicator Pin for a visual

inspection of proper operation.

8. The pump will run until the proximity switch reads one full cycle of the piston. The proximity

switch can be attached to any block outlet in the system.

9. The timer now begins countdown for the next lubrication event.

10. The Pushbutton/Fault light will blink if the pump reservoir is low on grease or if there is a

blockage in the system.

2/13/09

Primary

Divider

Valve

R3 Valve Secondary

Divider

Valves

Pushbutton/

Fault Light

Pump

Proximity

Sensor

Hose

Monitored System

Lube Point

Hose

Divider Valve Operation

At the heart of every Quicklub System is the metering valve or progressive distributor block, designed

to positively meter the input of lubricant (oil up to NLGI #2 greases) out to the connected number of

lubrication points irrespective of distance and back pressure. The inlet passageway is connected to all

piston chambers at all times with only one piston free to move at any one time.

•With all pistons at the far right, lubricant from the inlet flows against the right end of piston A (fig. 1).

•Lubricant flow shifts piston A from right to left, dispensing piston A output through connecting

passages to outlet 2. Piston A shift directs flow against right side of piston B (fig. 2).

•Lubricant flow shifts piston B from right to left, dispensing piston B output through valve ports of

piston A and through outlet 7 (fig. 3).

•Lubricant flow shifts piston C from right to left dispensing piston C output through valve ports of

piston B and through outlet 5.

•Piston C shift directs lubricant flow against right side of piston D (not illus.)

•Lubricant flow shifts piston D from right to left, dispensing piston D output through valve ports of

piston C and through outlet 3.

•Piston D shift directs lubricant through connecting passage to the left side of piston A (fig. 4).

•Lubricant flow against left side of piston A begins the second half cycle which shifts pistons from left

to right, dispensing lubricant through outlets 1, 8, 6 and 4 of the divider valve.

2/13/09

System Start-up

The following checklist has been developed as an aid in verifying proper installation and

operation of the Quicklub Onboard Grease System. By completing the steps outlined below,

the operational readiness of the system and resulting extension of the component life of all

points connected to the system will be insured.

•Apply grease gun (manual or pneumatic) to the grease fitting located on the Primary valve and each

secondary valve inlet. While pumping grease through the system, cycle the indicator pin on the

primary metering valve a minimum of 15 times. NOTE: Grease gun nozzle and grease fitting should

be thoroughly cleaned before lubricating to prevent flow of contaminants into the lube system.

•Inspect primary valve supply and outlets for grease discharge. If leakage is detected, tighten the

fittings.

•Continue to cycle the system until fresh grease appears at each lube point.

•Inspect each lube point fitting for leaks. Correct any leaks by firmly pushing tube into the fitting until

seating occurs, or tighten the threaded fittings for components connected with hose.

•Operate the equipment through its complete range of motion, inspecting for unrestricted movement

of tube and hose. Correct any problems of rubbing, chaffing or kinking.

•Inspect all hose and tube that is not covered with some type of protective wrap. Wrap any tube or

hose that would be susceptible to damage from rubbing or chaffing.

•Inspect all hose and tube connected to moving components. Insure that adequate hose or tube is

provided to allow unrestricted movement to these moving lube points.

•Verify proper pump operation and verify time setting by activating pump with the green activation

button located on the face of the pump control panel. Activate the pump at least three times to

insure proper operation.

•After the machine is in operation for a period of time (approx. 80 hours), you may find you need to

adjust timing to a shorter or longer period based on the operating conditions.

•Fill the reservoir with selected grease by filling at the grease fitting located on the face of the pump

reservoir.

2/13/09

Daily Walk-Around Inspection

The Lincoln Industrial Quicklub automated lube system components are designed, engineered,

manufactured and assembled to the highest or quality standards. This lube system requires little or nor

maintenance, however, to ensure maximum reliability and to realize maximum service life of all

components, it is recommended that a daily walk-around inspection be performed.

The daily walk-around inspection should include the following:

•Observe lubricant level in reservoir. Fill reservoir if it is low.

•Inspect high pressure relief at pump element, noting any lubricant buildup. If buildup is observed,

correct this problem by determining cause of blockage.

•Inspect all valve and lube point connections to verify that no leaks are occurring.

•Inspect supply/feed lines to insure that no breaks or leaks have occurred.

•Inspect lube points to ensure that all lube points have a “fresh grease appearance.”

•Check pump operation by depressing push-button located in base of pump for two seconds to

initiate a manual lube event. This will verify that pump is working (ignition switch must be on).

•Report or repair any problems found in this walk-around inspection immediately.

NOTE: Operator to confirm operation of electric pump while machine is in service.

NOTE: Report or repair any problem detected from daily inspection.

2/13/09

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