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Owner Manual

Lincoln Auto Lubrication System


Hydraulic Operated Type

LINCOLN AUTO LUBRICATION


SINGLE LINE SYSTEM
ON MINING EQUIPMENT
INSTALLED BY
PT. FLUIDCON JAYA

MANUAL BOOK
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Owner Manual
Lincoln Auto Lubrication System
Hydraulic Operated Type

SPECIFICATIONS

Pump Model
High Chief Pump 03-000921

Hydraulic
Supply Inlet Pressure 20-200 BAR
Hydraulic Inlet Flow 0.25 3.0 L/min
Seals Viton
Operating Temperature -100 C to +600 C
Max. Hyd. Fluid Temp 980 C
Hydraulic Filtration 10 micron
Hydraulic Inlet Port ( P ) 7/16 JIC
Tank Return Port ( T ) 9/16 JIC
Pump Outlets NPT

Grease
For Container 40kg Tank
Output Pressure 242 Bar ( 3500 PSI )
Output Flow @ 15 cycles/mm 132cm3/min
Output per cycle 8.8cm3/min
Grease Output Port To System JIC
Grease Recommendation Min NLGI-2

Electric
Voltage Input 24V DC
Current 1.6 A max

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Owner Manual
Lincoln Auto Lubrication System
Hydraulic Operated Type

DESCRIPTION

The Hydraulic pump stations that is designed for use in bulk filling under pressure and is designed
to create centralized lubrication systems utilizing single line parallel grease injector components.
The units incorporate the High Chief Hydraulic Double Acting Pump, which dispenses lubricant on
both the up and down strokes.

The Pump stations have all the hydraulic control components to cycle a single line pararllel grease
injector system, EXLUDING THE TIMER CONTROLLER (Lubrication System Timer Controllers).

The main component are as follows :


High Chief (Hydraulic Double Acting) Grease Pump
Hydraulic Direct Acting Vent Valve
Grease Pressure Switch
Grease Pressure Gauge
3 Way Hydraulic Valve
Light weight metal reservoir for placing 40kg grease pump

High Chief Pump

Owner / Operator Responsibility


It is the owner/operator responsibility to properly use and maintain this
equipment. The instructions and warning contained in this manual shall be
read and understood by the owner/operator prior to operating equipment. If
an owner/operator does not understand English, a request must be made to
have the contents of this manual explained in the owner/operator native
language to maintain the legibility of all warning and instruction labels. The
owner/operator shall retain this manual for future reference to important
warning, operating and maintenance instructions.

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Owner Manual
Lincoln Auto Lubrication System
Hydraulic Operated Type

SAFETY INSTRUCTION

This equipment generates very high grease pressure. Extreme caution should be used when
operating this equipment as material leaks from loose or ruptured component can inject fluid
through the skin and into the body causing serious bodily injury including possible need for
amputation. Adequate protection is recommended to prevent splashing of material onto the skin or
into the eyes.

INSPECTION
If over pressurizing of the equipment is believed to have occurred, contact PT. FLUIDCON JAYA
or your nearest service center.

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Owner Manual
Lincoln Auto Lubrication System
Hydraulic Operated Type

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Owner Manual
Lincoln Auto Lubrication System
Hydraulic Operated Type

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Owner Manual
Lincoln Auto Lubrication System
Hydraulic Operated Type

G2 Pulse Lubrication Controller


The G2 Pulse Lubrication Controller is specifically designed for use on systems incorporating a
pumps well as a solenoid valve and pressure switch. The unit can be programmed for pause
cycles from 1 second to 50 hours, maximum pump cycle times of 1 to 50 minutes and solenoid
valve times of 1 to 50 seconds.
The systems can run from 10 to 30 volts DC making it suitable for 12 or 24 volt systems. Low level
monitoring is also available as well as an additional output to drive a fault lamp if required.

SET UP MODE

To enter setup mode apply power while holding the button down for 2 seconds. The fault led will
illuminate to indicate that the unit is in Setup Mode.

The first parameter is the Pause Time. This can be from 1 second to 50 hours. The range leds will
indicate the range of the current setting. To determine the exact setting turn the dial until the range
led starts to blink, this indicates that the dial and range leds are pointing to the current setting. To
select a different setting turn the dial until the range leds and the dial indicate the desired setting,
press and hold the button for 2 seconds. The range led will now start to blink indicating the new
setting has been accepted, This step can be repeated if necessary.

To move to the next parameter simply press the button briefly. Note that the position of the dial is
not significant when simply moving to the next parameter.

The next parameter is the Solenoid Cycle Time. This is the seconds of the solenoids on and off
cycles (e.g. if this is set to 1.5 seconds the solenoid will switch at a rate of 1.5 seconds on and 1.5
seconds off). This setting can be from 1 second to 50 seconds and can be changed as with the
Pause Time.

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Owner Manual
Lincoln Auto Lubrication System
Hydraulic Operated Type

To move to the next parameter again press the button briefly.

The last parameter is the Pressure Timeout. This is the maximum time the system can take to
build up pressure. If the pressure switch does not close within this time the unit will assume there
is a fault and go into Fault Mode. Valid range for this setting is from 1 minute to 50 minutes.
Change as per Pause Time. This value must be suitably longer than the maximum possible
pressurizing time of the system to ensure no false alarm.

To move past this parameter press the button briefly.

The last stage of Setup Mode is a Test Mode, this is indicated by the Fault led flashing. The level
and pressure leds will indicate if the level or pressure switches are closed. Holding the button
down will drive the solenoid and pump. CAUTION, note that this will continue for as long as the
button is pressed, regardless of whether the pressure switch is closed or not.

To exit Setup Mode remove power.

OPERATING MODE

RUN
During a run cycle the pump is on continuously while the solenoid cycles at the rate
specified in Setup. The dial and range leds can be used to determine how much time has
elapsed. Once the pressure switch contact closes the unit will enter a Pause cycle. If
however, the pressure switch contact has not closed before the Pressure Time out expires,
the unit will enter a Fault Mode. Pressing the button at any point will terminate the Run
cycle and initiate a Pause cycle.

PAUSE
During a pause cycle the pumo and solenoid are off and the unit counts down to zero
starting from the Pause Time specified in Setup. The dial and range leds can be used to
determine how much pause time remains. Once the time counts to zero the unit will
attempt to start a new Run cycle. If the pressure contact is still closed, however, the unit
will enter a Fault mode instead.

Pressing the button will terminate the Pause cycle and start a Run cycle only if the
pressure switch contact is open. If the pressure switch contact is still closed pressing the
button will have no effect. The Pressure led will remain lit so long as the pressure switch
contact is closed.

FAULT
The are three possible fault conditions
1. Reservoir low level indicated by the level led being on. This occurs if the Level switch
contact is closed at any point during a Run cycle after the initial four seconds have
elapsed.
2. Cycle Timeout indicated by the Pressure led being on. This occurs if the pressure
switch contact does not close within the period specified by the Pressure Timeout in
Setup.
3. Pressure Fault indicated by the pressure led blinking. This occurs if the Pressure
Switch contact has not opened before the end of a Pause cycle.

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Owner Manual
Lincoln Auto Lubrication System
Hydraulic Operated Type

In fault mode the dial and range leds can be used to determine how long the fault has
existed (up to 50 hours max). Note that pressing the button will terminate the Fault mode
and start a Pause cycle. The unit must go through a complete Run and Pause cycle first
before the fault time will be reset to zero. If another fault occurs first, the fault time will
continue counting from where it left off.

G2 PULSE WIRING
The G2 incorporates a fuse on the negative supply line. This has been done deliberately as most
applications are automotive and the majority of vehicles are positive earthed. This configuration
ensures that any wiring shorts to earth will draw current through the fuse and thus protect the
system. Note that on negative earth systems it is possible to have a short circuit that by passes the
fuse and may cause damage to the unit. It is recommended to incorporate an external 8 Amp fuse
on the positive supply line on installations on negative earth machines. Also be sure to use the
return wiring points provided and do not introduce negative or positive circuits from other points to
attempts to simplify the wiring, doing so would create alternate paths can by pass the fuse in event
of short circuits.

The low level switch and the pressure switch circuit will work off normally open contact as well as
NPN N/O two and three wire proximity switches. If a three wire proximity switch is used take the
proximity supply from the fault lamp positive terminal. If low level monitoring is not needed simply
leave unconnected.

NB : This unit incorporates MOSFET transistor to drive the pump, solenoid and lamp. Excessive
short circuits on these could destroy the MOSFETs before the fuse blows. Take extra precaution
to avoid the possibility of short circuits. Damage to the MOSFETs from short circuits is not covered
by warranty.

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Owner Manual
Lincoln Auto Lubrication System
Hydraulic Operated Type

INJECTOR
SL-1 INJECTOR series H
SINGLE AND MANIFOLD TYPE
For Dispensing Fluid Lubricant and Grease
Not to Exceed N.L.G.I.#1 Grade

SPECIFICATIONS

Minimum operating pressure 1,850 PSI


Maximum operating pressure 3,500 PSI
Recommended operating pressure 2,500 PSI
Maximum vent (Recharge) pressure 600 PSI
Lubricant output is adjustable 0.008 cu.in to 0.08 cu.in
Injectors can be mounted in any position and can be used in circuits with SL-32 and/or SL-33
Injectors.

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Owner Manual
Lincoln Auto Lubrication System
Hydraulic Operated Type

SYSTEM OPERATION

STAGE 1
The injector piston is in its normal or rest position. The
discharge chamber is filled with lubricant from the
previous cycle. Under the pressure of incoming
lubricant, the slide valve is about to open the passage
leading to the measuring chamber above the injector
piston.

STAGE 2
When the slide valve uncovers the passage, lubricant
is admitted to the measuring chamber above the
injector piston which forces lubricant from the
discharge chamber through the outlet port to bearing.

STAGE 3
As the injector piston completes its stroke, it pushes
the slide valve past the passage, cutting off further
admission of lubricant to the passage and measuring
chamber. The measuring injector piston and slide
valve remain in this position until lubricant pressure in
the supply line is vented (relieved at the pump).

STAGE 4
After venting, the injector spring expands, causing the
slide valve to move, so that the passage and discharge
chamber are connected by a valve port. Further
expansion of the spring causes the piston to move
upward, forcing the lubricant in the measuring
chamber through the passage and valve port to refill
the discharge chamber.

Injector is now ready for next cycle.

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Owner Manual
Lincoln Auto Lubrication System
Hydraulic Operated Type

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Owner Manual
Lincoln Auto Lubrication System
Hydraulic Operated Type

Adjustments and Priming

Initial Priming of Lubricant Supply Lines (After Installation)


A Remove plug from tee or injector manifold
closest to the pump
B Start pump operation
C When lubricant begins to flow freely from Tee
or injector manifold opening, stop pump
operation and replace plug
D Follow same procedure for Tee or injector
manifold on the next shortest supply line, or
branch supply line
E Follow same procedure for remaining supply
lines and the branch lines, progressively
working to the last and longest supply line run

After all air is expelled and all plugs replaced the pump will build up lubricant pressure and
complete its operation cycle

To prime feed lines

Use a manual or power operated grease gun to prime the feed line.
NOTE : The same lubricant used in the centromatic system must be used in the grease gun.

A Remove filter fitting cap


B Contact injector filler fitting with the grease gun
nozzle. Pump lubricant through the injector and feed
line until there is evidence if lubricant flow at the
bearing
C Replace filler fitting cap. Repeat procedure for each
injector in the system

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Owner Manual
Lincoln Auto Lubrication System
Hydraulic Operated Type

SYSTEM OPERATION
This system describes the operation of the Hydraulic Pump Station and how it function with order
component in the system.

The system operates as follows :


A The Lubricant System controlled by a timer controller.
Whatever timer controller is used it must have a variable pause time and run time and have an
input for a pressure switch.
B The High chief and 3 Way Valve are connected electrically in parallel. When the system
controller pause time is completed, a 24V DC signal (pulse) is supplied to High Chief and 3
Way Valve. This will closes the Vent Valve by oil from the pump (P1) and begins the
reciprocating action of the pump, building grease pressure in the system until the pressure
switch set pressure is reached (170 to 200 bar). The grease will be direct to all injector and
injector will be deliver grease to each of pin or bearing who covered in the system.
C The pump will continue to reciprocate until the system timer operating period ceases or the
grease pressure switch is activated. This will terminate the signal (pulse) de-energizing the
pump and the vent valve. Thus stopping the reciprocating action of the pump and opening the
vent valve.
D As the vent valve opens, grease pressure in the system main line is vented back to the tank.
E The system is now at rest, ready for another lube cycle and the sequence repeats it self.

Adjustment of the Pump Reciprocating Rate


The pump reciprocating cycle timer is factory set at 2 seconds ON and 2 seconds OFF, which
results in a cycle rate 15 cycles/minute.
For information on the High Chief and Vent Valve, see the relevant service sheet

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Owner Manual
Lincoln Auto Lubrication System
Hydraulic Operated Type

Sample System Layout on Grader

Sample System Layout on Dozer

Sample System Layout on Excavator

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Owner Manual
Lincoln Auto Lubrication System
Hydraulic Operated Type

Sample System Layout on Truck

Sample System Layout on Loader

Sample System Layout on Articulated Truck

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Owner Manual
Lincoln Auto Lubrication System
Hydraulic Operated Type

Pump Grease Set 03-000555FJ

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Owner Manual
Lincoln Auto Lubrication System
Hydraulic Operated Type

TROUBLE SHOOTING

If the following procedures do not correct the problem, contact PT. FLUIDCON JAYA or a
FLUIDCON JAYA authorized service centre. When submitting equipment to be repaired, be sure
to state the nature of the problem and indicate if a repair cost estimate is required.

PROBLEM

No or Low hydraulic pressure at auxiliary port


1 No system pressure to the pump
2 Pressure reducing valve set to low. Increase setting by turn to check operation.

Pump pressure build very slowly or not at all


1 No pulsing signal from reciprocation timer
2 Pressure reducing valve may be set to low
3 Grease viscosity may be to high for temperature at which pump is operating
4 If pressure is not building at all, the reciprocation solenoid may be inoperative
5 Pump piston ball check and inlet checks may have foreign matter trapped causing leakage.
Remove, inspect and clean if necessary.
6 Inspect sealing surfaces between upper and lower inlet checks. Replace if rough or pitted
7 Replace shovel rod if rough or fitted. Replace shovel rod packing
8 Inspect lubricant supply line for leaks or breaks.

Lubricant volume to bearing LOW


1 Output adjustment screw injector setting incorrect
2 Worn or damaged LOWER slide valve seal injector
3 Worn or damaged LOWER slide valve body o-ring injector
4 Plunger spring injector broken or worn

Lubricant volume to bearing too High


1 Output adjustment screw injector setting incorrect
2 Worn or damaged UPPER slide valve seal injector
3 Worn or damaged UPPER slide valve body o-ring injector
4 Plunger spring injector broken or worn
5 Worn or damaged slide valve injector assy

External leakage at body injector


1 Damaged or worn body o-ring

External leakage at fitting assembly injector


2 Loose cap
3 Damaged fitting

External leakage at indicator rod injector


1 Worn or damaged indicator rod packing
2 Worn or damaged indicator rod

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Owner Manual
Lincoln Auto Lubrication System
Hydraulic Operated Type

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Owner Manual
Lincoln Auto Lubrication System
Hydraulic Operated Type

FLUIDCON CONTACT ADDRESS:

HEAD OFFICE

JAKARTA SATELITE SUPPORT FACILITIES


Cilandak Commercial Estate
Building 111 M3 - Gunung Bayan Coal Mine
Jl Raya Cilandak KKO, - Drillshop Newmont Sumbawa
Jakarta 12560 - Bengalon KPC Mine Site
Tel :(+62-21)7890550 (hunting) - Bontang PT.Banpu Kitadin
Fax :(+62-21)7890549 Mine Site
E-Mail :jktbrn@fluidcon.co.id
Webpage :www.fluidcon.co.id

OUR BRANCHES

BALIKPAPAN: SUMBAWA:
PT Fluidcon Jaya Concentrator Area Buin Batu
Hidup Baru Industrial Estate Batu Hijau Project Newmont Nusa
Jl.Mulawarman No 21 Rt 023 Rw 007 Tenggara Sumbawa NTB
Manggar -Balikpapan 76116 Ph :(+62 372))635012
East kalimantan Fax :(+62 372))635013
Tel :(+62 542))743389 (hunting) Email :sbwbrn@fluidcon.co.id
Fax :(+62 542))743383 Newmont Extension
Email :bpnbrn@fluidcon.co.id Tel :(+62-21)5799 4600 ext :47364
Email :PT.FluidconJaya@Newmont.com
SAMARINDA:
Jl.Ir. Sutami Blok LL No. 9-10 GOSOWONG:
Kelurahan Karang Asem Gosowong Gold Project
Samarinda 75126 PT.Nusa Halmahera Mineral,Gosowong
East Kalimantan Tel.:(+62-21)788 46967 ext :4793
Tel :(+62-541) 270909 (Hunting) Email :fluidcon@nhm.co.id
Fax :(+62-541) 272625
Email :smdbrn@fluidcon.co.id BANJAR BARU:
Jl.A.Yani Km.33,5
SANGATTA: Banjar Baru -South Kalimantan
Road 9 Area PT.Kaltim Prima Coal Phone :(+62-511)4774843
Swarga Bara,Sangatta 75387 Fax :(+62-511)4777630
Kab.Kutai Timur -East Kalimantan Email :bjmbrn@fluidcon.co.id
Phone :(+62 -549 )21103
Fax :(+62 -549 )21778
E-mail :sgtbrn@fluidcon.co.id

ADARO:
Adaro Site KM7.3
Tanjung
South Kalimantan
Tel/fax :(+62-526)2707774

Email :adarosite@fluidcon.co.id

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