Page 3 - System; TABLE OF CONTENTS
42000 Modu-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 AN...
Page 4 - ii; LIST OF TABLES
Modu-Flo ® System 42000 R 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...
Page 5 - GENERAL; Standard Components.; A wide choice of modular
42000 Modu-Flo ® System R 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 ............................
Page 6 - GENERAL SYSTEM OPERATION; Figure 1-1 shows a functional schematic of a Modu-
Modu-Flo ® System 42000 R 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 themanifold. The manifold may be moun...
Page 9 - DESCRIPTION; Reservoir Option; MOUNTING INSTRUCTIONS; Reservoirs and tanks may be mounted to any; Reservoirs and Tanks Available.; Reservoirs are cylindrical in
42000 Modu-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 ...................
Page 10 - PREPARATION FOR USE
Modu-Flo ® System 42000 R 2-2 the reservoir without being disconnected. Operate the supplysource at a steady speed to allow air-free filling of the reser-voir. Too fast of a fill speed may result in air pockets. Thelevel of grease is checked by visual means. In reservoirswith plastic cylinders, the ...
Page 13 - Part Number; DIMENSIONS
42000 Modu-Flo ® System R 2-5/(2-6 Blank) Table 2-2. Grease Reservoir Parts List - Continued ItemNumber Part Number Description Quantity 2 0 439-060-181 GASKET, Top Vent (3 lb.) 1 2 1 BUSHING, Follower 1 2 2 WASHER, Follower 1 2 3 WASHER, Support 1 2 4 NUT, Jam, 3/4-16 1 2 5 O-RING 1 2 6 RING, Retai...
Page 19 - Maintenance on the oil tanks consists of the follow-
42000 Modu-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 oiltank is shown in Figure 2-3 and should be referred...
Page 21 - Reservoirs with separate aluminum
42000 Modu-Flo ® System R 2-13/(2-14 Blank) 3 4 5 7 * 8 * 9 2 1 1 4 A 1 0 11 13 * 12 * B 3 C 6 Figure 2-3. Oil Tank - Exploded View * Reservoirs with separate aluminum pump mounting pads only. Steel pumpmounting pads are welded in placeand are not replaceable. + Used on reservoirs with front pressur...
Page 23 - There are six models available for use.
42000 Modu-Flo ® System R OPERATION AND SERVICE INSTRUCTIONS Modu–Flo ® System 3-1 SECTION 3 PUMPS 3.1 DESCRIPTION .......................................................... 3-13.1.1 General .......................................................... 3-1 3.2 PREPARATION FOR USE .........................
Page 25 - Pneumatic Pump Maintenance Tips.
42000 Modu-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 toensure that the outlet of the manifold is lined up with the inleton the pump. The face of the pump which mates with themanifold has sev...
Page 26 - Assembly of Pneumatic Pump.; Assemble the pneumatic pump according to the; NOTE; When the assembly steps listed above have been; Pneumatic Pump Parts List.; Table 3-2 identifies
Modu-Flo ® System 42000 R 3-4 e. Insert wooden dowel or soft rod into pump body (10) andpush lube piston (5) until cylinder cap (3) is out of aircylinder (7). Remove and discard o-ring (2) from cylindercap (3). f. Continue to push lube piston (5) through pump body(10) until air piston (1) is exposed...
Page 29 - CHECK VALVE COMPONENTS
42000 Modu-Flo ® System R 3-7/(3-8 Blank) 5 * 6 + 24 + 2 3 7 4 + 3 2 + 1 1 9 20 + 21 + 20 + 2 2 28 + 27 + 2 6 25 + 8 + 9 + 18 + 1 4 15 + 16 + 17 + 30 + 29 + 9 + 17 + 16 + 15 + 3 3 10 * 12 + 13 ** 11 + CHECK VALVE COMPONENTS PREVIOUS TO L93 (December 1993) 35 + 34 + 6 6 ‘ Figure 3-2. Pneumatic Pump, ...
Page 31 - Hydraulic Pump Options H1 and H3 Maintenance
42000 Modu-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 pumpare discussed in Paragraphs 3.4.2 through 3.4.4. Anexploded view of the pump is shown in Figure 3-3 andshould be re...
Page 32 - Hydraulic Pump Options H1 and H3 Parts List.; Table 3-3. Hydraulic Pump Options H1 and H3 Parts List
Modu-Flo ® System 42000 R 3-10 f. Install jam nut (19) and two new gaskets (18), one oneach side of jam nut, on adjustment screw (10). Buttadjustment screw cap (20) against jam nut (19) andturn adjustment screw (10) until the length it extendsbeyond the jam nut is the same as the length recordedduri...
Page 33 - Figure 3-3. Hydraulic Pump Options H1 and H3 - Exploded View; Not Available as Replacement Parts.
42000 Modu-Flo ® System R 3-11/(3-12 Blank) 7 * CHECK VALVE COMPONENTS PREVIOUS TO L93 (December 1993) 27 * 28+ FOR H3OPTION(HLJ-5X) 25+ 26+ 6 5+ 4+ 3+ 2 FOR H1 OPTION (HLJ-5) 1 21+ 1 7 18+ 1 9 18+ 2 0 29+ 15+ 16+ 11 12+13+ 14+ 23+ 22+ 9+ 1 0 3 0 12+ 13+ 14+ 8 3 1 6 3 2 6 ‘ Figure 3-3. Hydraulic Pum...
Page 35 - Hydraulic Pump Option H2 Maintenance Tips.
42000 Modu-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 arediscussed in Paragraphs 3.5.2 through 3.5.4. An explodedview of the pump is shown Figure 3-4 and should bereferred to during t...
Page 36 - Hydraulic Pump Option H2 Parts List.; Table 3-4. Hydraulic Pump Option H2 Parts List
Modu-Flo ® System 42000 R 3-14 Place new gasket (15) on enclosure screw (14). Screwenclosure screw (14) into body (10) and tighten securely. i. Install three new o-rings (9) and one new o-ring (18) intobody (10). Securely attach pump to manifold using foursocket-head screws (11). 3.5.4.2 When the as...
Page 39 - Two modular-design manifolds are; directly to the base of the reservoir or tank with two 3/8-16; Connection to Other Components.; MAINTENANCE; There is little maintenance required on the mani-
42000 Modu-Flo ® System R OPERATION AND SERVICE INSTRUCTIONS Modu–Flo ® System 4-1 SECTION 4 MANIFOLDS 4.1 DESCRIPTION ........................................................... 4-14.1.1 General ........................................................... 4-1 4.2 PREPARATION FOR USE ...................
Page 40 - Table 4-2. Manifolds and Manifold Accessories
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 sothat air can be exhausted on piston returnstroke.Double acting model pumps:Port has air or hydraulic supply connec...
Page 43 - Several varieties of assemblies are; Oil Reservoirs and Tanks.; To install any low-level
5-1 42000 Modu-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-WattLow-Level Assembly Maintenance Tips ....... 5-4 5.4.3 Disassembly of Oil Ta...
Page 45 - Oil Tank and Reservoir 15 Amp Low-Level Assem-; Figure 5-1. Oil Tank and Reservoir 15 Amp Low-Level Assembly; Not available as replacement parts.
5-3 42000 Modu-Flo ® System R c. Screw low-level lower assembly (4) into low-leveladapter (3) and tighten securely. e. Screw switch adapter (2) into switch (1) and tightensecurely. f. Screw union nut (5) onto switch adapter (2) and tightensecurely. g. Install cover on reservoir (Refer to Section 2.)...
Page 46 - Maintenance tips, disassembly and
Modu-Flo ® System 5-4 42000 R 5.4 OIL TANK RESERVOIR 10-WATTLOW-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 L7are discussed in Paragraphs 5.4.2, 5.4.3 and 5.4.4. Asectional view of a low-lev...
Page 47 - GREASE RESERVOIR LOW-LEVEL ASSEMBLY MAINTENANCE; Grease Reservoir Low-Level Assembly Mainte-
5-5 42000 Modu-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 arediscussed in Paragraphs 5.5.2, 5.5.3 and 5.5.4. A sectionalview of a typical assembly is shown in Fig...
Page 48 - Assembly of Grease Reservoir Low-Level; Table 5-4. Grease Reservoir 15 Amp Low-Level Assembly Parts List; Grease Reservoir Low-Level Assembly Parts List.
Modu-Flo ® System 5-6 42000 R a. Disconnect and lock out all electrical power and airsupplies 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...
Page 50 - High-Pressure and Blowout Switch Options.; High-Pressure Switch Adjustment Procedures.
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 discswhich have been ruptured will need to be replaced with anapproved disc. 6.1.4 High-Pressure and Bl...
Page 51 - WARNING
6-3 42000 Modu-Flo ® System R Table 6-3. Pressure Switch Settings MaximumRecommended 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 ...
Page 52 - Reservoir Blowout Switch Maintenance Tips.; Figure; Reservoir Blowout Switch Parts Lists.; identifies the parts indexed on Figure 6-3.
Modu-Flo ® System 6-4 42000 R Table 6-4. High-Pressure Switch Parts List IndexNumber 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 -- . F...
Page 53 - Table 6-5. Reservoir Blowout Switch Parts List; PLUNGER
6-5 42000 Modu-Flo ® System R Table 6-5. Reservoir Blowout Switch Parts List ItemNumber 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 ...
Page 54 - Tank Blowout Switch Maintenance Tips.; Table 6-6. Tank Blowout Switch Parts List
Modu-Flo ® System 6-6 42000 R 6.6 TANK BLOWOUT SWITCHMAINTENANCE (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 withblowout switch is shown in Figure 6-4 and should bereferred ...
Page 57 - Table 7-1. Pneumatic Solenoid Parts List
7-1/(7-2 Blank) 42000 Modu-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 INSTALLATI...
Page 59 - Refer to bulletin 14530 for additonal information.
8-1 42000 Modu-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 .............................
Page 60 - MANUAL RUN BUTTON
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 BOARD3. INSTALL 1/2“ CONDUIT CONNECTOR IN .840 DIAMETER HOLE. 4. CONNECT INPUT POWER LEDS TO INPUT TERMINALS. 110/220 VAC 50/60 HZ. 5. CONNEC...
Page 61 - OR 3 WIRE TYPE; DRY CONTACT SWITCH; : INPUT VOLTAGE WILL BE PRESENT ON
8-3 42000 Modu-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 LO...
Page 64 - If the reservoir or tank is not equipped with low-level; MATERIAL CONSIDERATIONS; Material Cleanliness.; System life and consistent; Temperature Effects.; Flow characteristics of the
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 alllubricant is used. If the reservoir or tank is allowed to run dry,air will be introduced into the system, requiring that thesystem be bled. 9....
Page 68 - ll
® 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 FIR...
