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AutoLube III

Automated

Lubrication

System

Construction Products, LLC

TECHNICAL

MANUAL

Manual Part No. 102782

November 11, 2002

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Summary of Contents for AutoLube III

Page 1: ...AutoLube III Automated Lubrication System Construction Products LLC TECHNICAL MANUAL Manual Part No 102782 November 11 2002 ...

Page 2: ...Allied AutoLube III Allied AutoLube III Document Change Notice Date Page Change ...

Page 3: ...1 Follower Seal 10 7 2 Filling Pump with Grease 10 7 2 1 Remove Empty Cartridge 10 7 2 2 Install Grease Cartridge 11 7 2 3 Air Purging 11 7 2 4 Prefill Lubricant Line 11 7 2 5 Manual Bulk Filling 11 7 2 6 Manual Filling with Hand Pump 12 7 3 Maintenance Before Operation 12 7 4 Operation 12 7 4 1 Working In High Low Temperatures 12 7 4 2 Working Underwater 13 SECTION 8 0 TROUBLESHOOTING 14 AutoLube...

Page 4: ...Allied AutoLube III ii 11 11 02 This page intentionally left blank ...

Page 5: ... Lubrication System This technical manual describes in detail the procedures needed to operate the Allied AutoLube III Lubrication System on site Pay careful attention to all instructions and follow all governing regulations This pump is exclusively designed to dispense grease in Hydraulic Hammer applications and should be operated only with hydraulic power Any other use not in accordance with the...

Page 6: ...rregular pump refilling Damage caused by contaminated lubri cants Damage caused by improper disposal of used or contaminated lubricants Allied provides no warranty for the follow ing wear parts All seals O rings Hoses Allied AutoLube III 2 11 11 02 ...

Page 7: ...draulic hammers The Allied AutoLube III Lubrication Sys tem provides the following advantages Simple design Compact size mounts on hammer Supplied with all mounting hardware and adapter fittings Replaceable or refillable standard 12 ounce grease cartridge Bulk filling of cartridge canbe complete No tools required to change grease cartridge Primer releif valve Adjustable output by changing meter in...

Page 8: ...n when operating this equipment as ma terial leaks from loose or ruptured com ponents can inject fluid through the skin and into the body causing serious bodily injury Use adequate protection to prevent splashing of material onto the skin or into the eyes If any fluid appears to penetrate the skin get emergency medical attention immediately Do not treat as a simple cut Tell attending physician exa...

Page 9: ...k pressure is higher than 200 psi Pump output can be increased up to 0 072 in 3 1 2 cm3 by replacing the metering plug refer to Section 7 4 Metering Plugs 0 018 in 3 0 3 cm3 Part No 103057 0 060 in 3 1 0 cm3 Part No 103060 0 036 in 3 0 6 cm3 Part No 103508 0 072 in 3 1 2 cm3 Part No 103061 0 048 in 3 0 8 cm3 Part No 103059 Hose Inside Diameters Hydraulic Line 3 8 inch 9 53mm Lubricant Line 1 4 inc...

Page 10: ...cription A 14 91 379 Overall Height B 8 69 221 Overall Width C 3 00 76 Overall Depth D 3 00 76 Cylinder Block Height E 8 39 213 Cylinder Block Width F 5 64 143 Mounting Hole Location G 1 50 38 Low Level Indicator Cap extended H 1 40 36 Hydraulic Inlet Location J 50 13 56 14 Lube Outlet Location K ...

Page 11: ...REASE CARTRIDGE IS EMPTY WHEN INDICATOR SHOWN IS FULLY EXTENDED AS SAE 4 O RING PORT HYDRAULIC INLET VENT VALVE SAE 4 O RING PORT OR FILL FITTING LUBE OUTLET F E B C H NOTE J FULLY EXTENDED D K Figure 4 1 AutoLube III Dimension Drawing ...

Page 12: ...proper operation on older HyRams the inlet hy draulic back pressure is higher than 200 psi 14bar a pressure relief valve must be in stalled When the hammer is activated grease flows to the pump and the plunger opens the grease inlet port Grease is drawn into the pump head by the vacuum in the head This vacuum and the pressure of the car tridge follower spring force the grease into the lubricant pu...

Page 13: ...ant level Refer to Figure 6 1 Refer to Section 6 x to install Reservoir Retainer WARNING Disconnect the battery cables to pre vent electrical damage before perform ing any welding work CAUTION Shield all hydraulic hoses in the AutoLube III mounting vicinity during welding to avoid the risk of fire or dam age to the hoses from excessive heat 1 Determine location for AutoLube III Weld mounting brack...

Page 14: ... for hydraulic connection 8 Bolt AutoLube to Bracket with Hard ware provided 9 Refer to Section 7 1 and install Allied Chisel Paste cartridge into AutoLube III cartridge housing The cartridge can be refilled and re used 6 2 Installing the Reservoir Retainer The reservoir clip has fingers that fit into a groove at the lower end of the grease car tridge housing When the retainer is tight ened the ho...

Page 15: ...tall the spring clip 1 on the side of the pump head 2 with plate 3 cap screws 4 and lock washers 5 as shown in Figure 6 3 2 With Grease Housing 6 installed and tightened as required adjust the fingers of the spring clip 1 so that they firmly retain the housing 3 Tighten two cap screws 4 Allied AutoLube III 11 11 02 11 2 6 1 3 5 4 Figure 6 3 Reservoir Retainer ...

Page 16: ...pump the seal must be flipped so the lip is directed toward the pump head Refer to Figure 7 2 The illustration shows the seal in the cartridge position seal lip toward follower handle 7 2 Filling Pump with Grease 7 2 1 Remove Empty Cartridge 1 Disengage the retaining clip from the follower handle Refer to Figure 7 3 2 Pull finger tab on reservoir retainer to disengage clip fingers from the housing...

Page 17: ...etaining clip over the top of the follower handle 7 2 3 Air Purging 1 Engage the follower rod with the fol lower by lightly pulling up and rotating the follower handle M P I don t under stand this What is the follower 2 Push down on follower handle while pressing the button on Vent Valve to force any air pockets out of pump head Refer to Figure 7 4 3 Wipe excess grease from Vent Valve 7 2 4 Prefil...

Page 18: ...r handle 6 Push filler pump socket onto filler nip ple 7 While filling housing with hand pump watch follower rod When notch on fol lower rod is visible container is full 8 Disengage follower rod from follower and push follower rod into housing Air purging is not required unless the hous ing was removed from the pump head 7 3 Maintenance Before Operation WARNING Always relieve pressure from the pum...

Page 19: ... in temperatures below freezing a cold weather paste must be used In such cases please consult your Allied authorized dealer s service department for recom mended cold weather pastes 7 4 2 Working Underwater The entire AutoLube III and its holder must remain above the surface of the wa ter If the entire hammer is to be used under water the AutoLube III must be positioned high on the carrier stick ...

Page 20: ...n lubricant lines Purge air Section 7 2 3 Pressure oil line to system is blocked Open branch from hammer pressure line valve block on boom Pressure oil line to system leaks Check fittings and hose re place if necessary and tighten properly Refer to Section 6 0 Installation Lubricant line blocked or too long Check hose replace if nec essary maximum length 15 feet Perform functional test with hose u...

Page 21: ...Lubricant Supply too Low Wrong size metering plug Change to larger metering plug Section 7 4 Lubricant Supply too High Wrong size metering plug Change to smaller meter ing plug Section 7 4 Lubricant Supply Incor rect Wrong type of lubricant Observe lubricant recom mendations ...

Page 22: ... Remove the complete AutoLube III and store in a secure place 9 2 Removing Hoses Unscrew the AutoLube III hoses from the hydraulic and lubrication ports on the hammer Plug the ports and cap the hoses 9 3 Reattaching AutoLube III After Idle Periods 1 Clean the lubricant line which is still connected to the hammer and remove any blockages formed by residual lubri cant 2 Refer to SECTION 6 0 AutoLube...

Page 23: ...a wide range of operating tem peratures Ordering information Allied Part No 100057 Case 12 Tubes 100058 Box 36 Tubes 676698 Keg 35 lbs 679968 Keg 120 lbs Allied AutoLube III 11 11 02 19 AutoLube III Model Specific Part Numbers AutoLube III PART NO HY RAM MODEL PRESSURE CONNECTION 735 AutoLube III Port 740 AutoLube III Port 745 AutoLube III Port 102051 755 755B AutoLube III Port 775 775B AutoLube I...

Page 24: ...eal Kit O Ring nitrile 8 103065 Spring 9 103066 Spring 10 103067 Spring 11 103068 Pump Head 12 103069 Vent Valve 13 103070 Retaining Ring 14 103071 Indicator Rod 15 103072 Washer 16 103073 Spring 17 103074 Bushing 18 103075 Low Level Indicator Cap 19 103076 Outlet Housing 20 Seal Kit O Ring nitrile 21 103077 Spring 22 103078 Check Ball 23 103057 Metering Plug 0 3cc 24 Seal Kit O Ring nitrile 25 Se...

Page 25: ...Allied AutoLube III 11 11 02 21 1 4 6 15 14 19 17 18 16 29 12 11 13 21 20 24 22 23 9 2 5 3 8 7 27 10 26 25 32 33 34 31 28 30 Figure 10 1 AutoLube III Exploded View ...

Page 26: ... Sheet 2 of 2 ITEM NO QTY PART NO DESCRIPTION 28 1 103081 Grease Housing 29 1 798197 Fill Fitting 30 1 103087 Retainer Clip 31 1 103088 Spring Clip 32 1 103089 Plate 33 2 798220 Lockwasher 10 34 2 103090 10 32 x Button Head Cap Screw 1 103082 Seal Kit ...

Page 27: ...1 4 6 15 14 19 17 18 16 29 12 11 13 21 20 24 22 23 9 2 5 3 8 7 27 10 26 25 32 33 34 31 28 30 Figure 10 1 AutoLube III Exploded View 11 11 02 23 ...

Page 28: ...I 24 11 11 02 AutoLube III Seal Kit Part Number 103082 ITEM NO QTY PART NO DESCRIPTION 1 1 103091 U Cup polyurethane 2 1 103092 O Ring nitrile 3 1 103093 O Ring nitrile 4 1 103094 O Ring nitrile 5 2 103095 O Ring nitrile ...

Page 29: ...3 4 1 5 2 Figure 10 2 AutoLube III Seal Kit 25 11 11 02 ...

Page 30: ......

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