Cautions on handling the pump, maintenance, and measures
MAINTENANCE & INSPECTION
Correct usage and handling leads to proper and efficient operation. Prevention of problems should be undertaken seriously, as faults and errors with the lubrication system can lead to a very expensive ordeal.
Prior to use, the pump units and distribution equipment should be checked and maintenance should be performed on a regular basis, as it will ensure effective operation of the lubrication system and target machinery.
NOTES ON USAGE
- Ensure appropriate oils and greases are used with the lubrication unit / system.
- Liquids other than the specified lubricating oils and greases, such as lamp oil, gasoline or water, should NOT be used and distributed through the system.
- Use new oil and greases which are pure and free of contaminants. In circulating oil lubrication systems, replace oils periodically to promote effective lubrication to take place.
- Refrain from using a combination of various oils, as it may lead to the formation of sludge, preventing proper operation of the lubrication equipment.
- Refrain from overfilling the oil or grease reservoirs by exceeding the “Full” line.
- Pumps and distribution apparatus are composed of various rubbers and nonferrous metals (Zinc, aluminum and brass) components. Do not use oils or grease that may erode or weaken the structure of the pump and distribution equipment.
NOTES ON PLACEMENT & INSTALLATION
- Install the pumps in a location free from falling debris (shavings, etc) and cutting fluids.
- Install pumps where vibration is minimal.
- Place pumps where maintenance, inspection and refilling can be performed easily, as these tasks should be performed regularly.
- Install manual pumps in a position easily accessible to the operator, promoting safe and efficient operation.
NOTES ON TEST RUNS & INITIAL OPERATION
- Ensure the motor’s electrical cover is in place before connecting power to the unit as this will help prevent the possibility of electrocution.
- Confirm the motor’s rotating direction. Running the motor in the reverse will result in substandard performance and possible damage to the unit.
- Expel all air from within the pump and distribution channels, then proceed to check the lubrication points to ensure correct operation.
- Ensure there are no oil or grease leaking from the distribution system, as this may allow air to enter the system.
NOTES ON MAINTENANCE & INSPECTION
- To allow effective operation of the lubrication system and to prevent major problems from occurring, routine maintenance and inspections of the equipment should be performed.
- Ensure the power has been disconnected from the unit prior to maintenance and inspection. In situations where power is required during tests and inspection, ensure the circuit board and IC timer (control board) covers are in place.
PERIODIC INSPECTION POINTS
|NO.||INSPECTION POINTS||INSPECTION DETAILS|
|1||Supply Filter (OIL SYSTEMS)||Check for tear and any foreign particles which may be attached or present in the filter. Ensure the filter is correctly in place.|
|2||Lubricant||Check for degradation, oxidization and impurity levels.|
|3||Reservoir / Tank||Check for foreign particles, sludge and leakages within the reservoir.|
|4||Connections / Connectors||Inspect piping connections to ensure there is no leakage and a firm connection is made.|
|5||Pipes & Tubes (Distribution Channels)||Check that the pipes or tubes have not split or deformed in any way.|
|6||Lubricant Usage||Ensure the consumption of oil and grease is appropriate and that neither too little nor too much has been used.|
|7||Pump Unit||Turn on the pump’s power and check the pressure gauge to confirm correct pressure levels are achieved.|
|8||Distribution Equipment (Distributors)||Confirm the distribution of oil and grease through each lubrication point.|
|9||Inspection & Monitoring Equipment||Inspection and monitoring equipment should be tested to ensure they operate correctly. Recalibrate or replace when necessary.|
- Ensure periodic cleansing and replacement of oil and filters are performed.
- To clean the tanks and filters, please use clean petroleum. Do not use gasoline / petrol, thinners or other fluids which are volatile in nature.
REVIEWING THE LUBRICATION SYSTEM
- As various types of machinery and environments in which they operate exists, one ideal lubrication system may not be appropriate for all. As such, it is good practice to monitor and log various internal & external effecting factors in conjunction with the lubrication system and target machine’s performance, as this will assist reevaluation and calibration processes at a later stage.
- Consultation with the machine operator, lubrication engineer and maintenance staff, will allow valuable information to be uncovered. Periodic reviewing and reevaluation of the lubrication system will assist in achieving the perfect lubrication system.
MANUAL PUMPS – PRECAUTIONARY NOTES & TROUBLESHOOTING
|Oil is not discharging||Motor’s rotating direction is reversed.||Stop the pump immediately and correct the rotating direction, as running the pump in reverse will damage the unit and may catch fire.|
|Low oil levels.
Supply line, strainer or filter is blocked.
|Fill the tank with the same type of oil currently in use, as mixing oils may lead to cavitation. Clean or replace the strainer. In a circulating oil system, flush the whole distribution system and replace with clean new oil. Replace filters if required.|
|Air is being drawn into the supply line or supply channel.
Air is seeping through the oil seal or O-ring.
|Check the oil level in the tank and fill if required. Check the washers and bushings at connection points and replace if required. Ensure a tight connection is achieved. Check the oil seals and O-rings and replace if necessary. For a temporary quick fix in emergency cases, apply grease to the seals, but keep in mind that replacement is a must.|
|Viscosity of the oil is too high.
Viscosity of the oil is too low.
|Adjust the temperature of the oil or change the type of oil used. When changing oils, ensure the whole system is cleaned before the new oil is utilized with the system.|
|Internal component of the pump has worn.||Fix or replace the worn parts or replace the pump unit.|
|Pressure will not rise||Relief valve is not operating properly.
1) Inappropriate pressure settings.
2) Contaminants present or parts have worn.
|Check the pressure gauge and adjust the pressure to the correct levels. Incorrect pressure settings may lead to chattering. If the valve is worn or has been damaged, replace the valve. Clean the valve if unclean.|
|Suction filter is blocked.||Clean or replace the suction filter.|
|The pump is emitting irregular noises|
1) Oil in the reservoir has become white and bubbles are present.
|Water or high levels of moisture has entered the tank. 200 ～ 300p.p.m. can turn the oil cloudy and at 1000p.p.m. the lubricant will start to oxidize.||Eliminate possible entry points for moisture / water and install the unit away from areas where water and high levels of humidity are present. Limit temperature differences to prevent condensation from occurring.|
2) Cavitation is occurring.
|Filter or strainer is blocked.
Oil’s temperature is too low or the viscosity is too high.
|Inspect the components and clean or replace if necessary. Check the oil’s purity. Inspect the oil and change the type of oil used if necessary.|
|3) Pump’s component has broken.||Pump has been misused or used in a way that does not conform to the operational usage guidelines.||Confirm the pump matches the lubrication requirements and the type of system. Review and replace the unit with an appropriate pump. If the pump has been misused and a component has broken, replace with a new part and review operation.|
|Substantial heat produced.|
1) Pump’s temperature is excessively hot (Oil temp + 30 o C).
|Excessive friction is being produced and chafing and wear is occurring within the pump.||Recalibrate moving components or replace parts if required.|
2) Lubrication points on target machinery are excessively hot or burnt.
|Lubricant is not being discharged or an inadequate amount is being applied.||Check all components to the lubrication point for blockages and malfunctions. If the oil is contaminated, flush the lubrication system and replace with clean new oil. Adjust the oil’s discharge volume to an appropriate level (Increase).|
3) Excessive heat from bearings / spindles.
|Viscosity level is inappropriate. Highly viscous oils applied to points of high speed motion can produce considerable heat from liquid friction.||Try increasing the temperature of the oil to decrease it’s viscosity. If the oil is too viscous, replace with a different oil of lower viscosity.|
MANUAL PUMPS – PRECAUTIONARY NOTES & TROUBLESHOOTING
- Manual pumps will expel a specified amount of oil with a simple action, regardless of being either a lever type or a handle type pump. There is no need to stop midway or to exert excessive force when using
the pump. By releasing the lever, it will return to the original position. There is no need to push the lever or handle back with excessive force.
- If a noise can be heard during operation directly after replenishing the unit with oil, it is highly possible that air has entered into the pump’s system. Allow the oil to settle so that it is free from bubbles before pulling the lever or handle repetitively until the noise can be heard no more.
- Regardless of the pump type (Complete unit or a separated pump and reservoir type), make sure the intake port (opening located within the reservoir) faces downwards.
- When installing a pump which will utilize oil from an oil tank already in use (on the target machine or installed for other lubrication systems), ensure to use a filter or a strainer to prevent foreign matter and contaminants from entering the pump and the lubrication system.
|Oil is not discharging||Low oil Level||Fill the tank with oil up to the “FULL” line. Ensure the same type of oil currently in use is added.|
|Air has been drawn into the pump||Remove the main distribution pipe and continue to operate the pump until air is expelled and oil is discharged.|
|Incorrect operation of the pump||Do not pull the handle or lever too quickly or apply excessive force when operating. Ensure a complete motion is achieved.|
|Pump is emitting irregular / abnormal noises||Air has been drawn into the pump||Check to see if there is sufficient oil within the reservoir and replenish if required. Remove the main distribution pipe and continue to operate the pump until air is expelled and oil is discharged.|
|The handle or lever returns to its original position extremely slow or slower than usual||The filter is blocked||Remove the filter and clean or replace if necessary.|
|Is the pump operating properly?||Check to see if the pump itself is the cause of the problem by attaching a pressure gauge to the main distribution pipe and checking the discharge pressure and volumes.|
|Piping has been squashed||Inspect piping and replace if necessary.|
|Leaking oil from joints and connectors||Connections are loose and have not been tightened adequately||Inspect the connector components for damage. Tighten connection properly if loose.|
|Connections have been over-tightened and the pipe ends (Nylon, etc) have been squashed||Remove the pipe sleeve (PB), trim the squashed ends and reconnect with a new sleeve.|
|Oil is leaking from the lubrication points||Excessive pressure from the pump||Check the pump’s discharge pressure and ensure correct pressure is being produced. If pressures are to specification, check other lubrication points for possible problems.|