AC1 - AC2 - AC3 PUMPS - Interlube Systems

1 AC1 - AC2 - AC3 PUMPS12/24v PUMPSSERVIC E AND MAINTENANCE MANUAL FOR Interlube MULTI-LINE LUBRICATION SYSTEM Issue 1 SAFETYAs with all equipment, all due care must be used when servicing the AC chassis lubrication this manual there will be information provided which requires special attention. This information will be displayed under the headings of WARNING, CAUTION, or Headquarters: Interlube Systems LtdSt Modwen Road, Parkway Industrial Estate, Plymouth, Devon, England PL6 8 LHTel: +44 (0)1752 676000 Fax: +44 (0)1752 676001 e-mail: Web Site: Headquarters: Interlube Systems Inc4696 Wadsworth Road, Dayton, Ohio, 45414, USATel: + 1 937 276 4507 Fax: + 1 937 276 4518 e-mail: Systems (Malaysia) Sdn.

2 Bhd:30, Jalan Appollo U5/189, Bandar Pinggiran Subang Seksye n U5, 40150 Shah Alam, Selangor, Malaysia. Te l: (603) 7845 6577 Fax: (603) 7845 5377 Email: OF CONTENTS 1. INTRODUCTION 22. GENERAL DESCRIPTION 23. SYSTEM PLANNING 3 Pump Preparation 3 Pump Elements 3 Pump Mounting 3 Pump Settings 34. INSTALLATION 4 Looms 4 Connecting Looms 4 Fitting Looms 4 Test System 45. AC1 + AC2 Controller 56. AC1 + AC2 Test Procedure 67. AC1 + AC2 Wiring Diagram 68. AC3 Controller 79. AC3 Test Procedure 810. AC3 Witing Diagram 811. AC1 + AC2 Wiring Dimensions 912. AC3 Dimensions 1013. Pump Filling 1114. Pump Elements 1215.

3 Troubleshooting 1316. Parts Breakdown 15 Parts List 16 Grease Consumption 1617. AC3 Parts Breakdown 17 Parts List 18 Grease Consumption 1818. Pump Service Procedure 1919. AC3 Pump Service Procedure 2220. Accessories 2321. Grease Filler PUMPS 2422. Lubricants 2523. ORDERING METHOD 26 21. INTRODUCTIONThis manual gives instructions for operating, maintaining, installing and servicing the Interlube AC multi-line lubrication system. Because of the importance of providing the correct lubricant amount to the moving parts of the equipment, read this manual to become familiar with your AC lubrication and follow the procedures given before attempting installation maintenance or service.

4 Illustrations are provided to aid in disassembly and there are questions not answered by this manual, contact your Interlube distributor, dealer, or Interlube GENERAL DESCRIPTIONA typical AC Multi-line lubrication system includes the following components: Pump with Plastic Reservoir Adjustable Controller Pump Elements Tubing directly to lubrication points FittingsThe AC family of PUMPS have a range of 12 to 60 outlets each outlet can be fitted with a pump element. There are six elements to choose from, each having different output capacities (see page 12).Each pump element feeds directly the lubrication point via a pipe which can be numbered at the pump and bearing to assure accurate lubrication + identification 3kg maximum outputsAC1 PUMPAC2 PUMPAC3 kg ( ) Reservoir maximum outputs 122 kg ( ) Reservoir maximum outputs 363 kg ( ) Reservoir maximum outputs 603 The AC Multi-Line Pump is used on chassis and Industrial the case of a chassis fitment (TILT CAB when applicable): Flush out all bearings to be connected to the system and clean the bearing surfaces.

5 Remove grease nipples and insert connectors to establish the number of bearings being lubricated. Note the list of bearings to be connected to and choose relevant pump element to directly feed that SYSTEM PLANNINGL ubrication Syst ems for Vehicles& PlantISSUE 09/2010 ISF295UK Headquarters: Interlube Systems Ltd:St Modwen Road, Parkway Industrial Estate, Plymouth, Devon, England, PL6 8LH. Tel: +44 (0)1752 676000 Fax: +44 (0)1752 676001 Email: Division:InterlubeSy stemsInc:4696 Wadsw or th Road, Da yt on, Ohio 45414,US A Tel: (937)2764507 Fax: (937)2764518 Email:nmackay@int er stems(Malaysia)SDNBHD:30, Jalan Appollo U5/189, Bandar Pinggiran Subang Sesyen, 40150 Shah Alam, Selangor, Malaysia.

6 Tel: (603) 7845 5377 Fax: (603) 7845 5977 Email:acllube@str eam w w . i n t e r l u b e s y s t e m s . c o mPartoftheMULTI-L INEBEARING REQUIREMENTS & er (SplitFeed*- seeno te) Fro *SplitFeedsare nnectedtothelubricatio n system:BalanceBeamBearings (2feeds)2 x x th Wheel CouplingPivot th Wheel PumpTypicaIBearingChartPumpingUnitElbowC onnectorsStraightConnectorsACCESSORIESPM 904121/ 8 PTFSAEPM904841/ 4 -28 UNFPM904855/ 16-24 UNFPM904871/ 8 BSPTPM90489M6X1 PPM90490M8X1 PPM90491M8X1,25 PPM90492M1OX1 PPM90493M10X1,5 PPar t NumberThreadSizeElbowsPM804121/ 8 PTF SAEPM804841/ 4 -28 UNFPM804855/ 16-24 UNFPM804871/ 8 BSPTPM80489M6X1 PPM80490M8X1 PPM80491M8X1,25PM80492M1OX1 PPM80493M10X1,5P25478-0564mmto4mmPar t NumberThreadSizeLoomingAccessoriesPlasti ctape1 Black.

7 1755-830 SpiralBinding(1-2lines) ..1837-001 SpiralBinding8mmI/ D (3-4lines)..1837-002 SpiralBinding10mmI/ D (5-7lines)..1837-003 SpiralBinding14mmI/ D (8-12lines).. 1837-004 PremiumGradeNGLI000/ FG3,025717-28412x 1 LitreBottles25717-284/ 25K25 KGPail25717-284/ 50K50 KGPail25717-284/ 180K180 KGPailGreaseSpecificationsNGLI000/ FG3,0 Colour.. AmberTexture.. Fluid,TackyNLGI.. CalciumPenetration @25 C.. 445-475 BaseViscosi ty @40 C.. 35to45 CSTDrop Point.. N/ AGR EASENLGIG rade2 Colo ur.. PaleAmberTexture.. Slightly FibrousNLGI.. 2 SoapType.. LithiumPenetration @25 C.. 265-295 BaseViscosity@40 C.. 125cStDrop Point.. 185 CAccessories152823.

8 4mmODso ft greasefilledtubex 25M152823 ..4mmODso ft greasefilledtubex 50M152824 ..4mmODHeavygreasefilledtubex ..CabletiesOA50397/12 offNumberedsleeves1 12OA50397/22 offNumberedsleeves1 24OA50397/32 offNumberedsleeves1 36OA50397/42 offNumberedsleeves1 48OA50397/52 offNumberedsleeves1 60 NLGIG rade225717-270/ Replacement of Motor Assembly AC1 & 2. Fit the relevant pump elements chosen for each bearing feed into the pump carcass ring (take care not to overtighten). if any outlet positions are unused, blank using blanking plugs shown on page Pumping Elements (see page 12) Each bearing requires a measured amount of grease this is determined by size and function.

9 To meet this requirement there are a range of six pumping units to choose Mounting of the Pump (see pages 9 + 10) Select a suitable mounting point for the pump on the chassis or machine, preferably in a position where it is protected from debris. Ensure adequate clearance for re-filling is made (see page XX). Do not mount the pump on ancillary equipment, such as battery covers etc. Using the pump mounting adhesive template supplied, position and drill the bracket holes (mounting positions are detailed on page 9 + 10). Use bolts/nuts and spring washers to securely mount the pump in Pump Settings (see pages 5 + 7)Lubrication Syst ems for Vehicles& PlantISSUE 09/2010 ISF295UK Headquarters: Interlube Systems Ltd:St Modwen Road, Parkway Industrial Estate, Plymouth, Devon, England, PL6 8LH.

10 Tel: +44 (0)1752 676000 Fax: +44 (0)1752 676001 Email: Division:InterlubeSy stemsInc:4696 Wadsw or th Road, Da yt on, Ohio 45414,US A Tel: (937)2764507 Fax: (937)2764518 Email:nmackay@int er stems(Malaysia)SDNBHD:30, Jalan Appollo U5/189, Bandar Pinggiran Subang Sesyen, 40150 Shah Alam, Selangor, Malaysia. Tel: (603) 7845 5377 Fax: (603) 7845 5977 Email:acllube@str eam w w . i n t e r l u b e s y s t e m s . c o mPartoftheMULTI-L INEBEARING REQUIREMENTS & er (SplitFeed*- seeno te) Fro *SplitFeedsare nnectedtothelubricatio n system:BalanceBeamBearings (2feeds)2 x x th Wheel CouplingPivot th Wheel PumpTypicaIBearingChartPumpingUnitElbowC onnectorsStraightConnectorsACCESSORIESPM 904121/ 8 PTFSAEPM904841/ 4 -28 UNFPM904855/ 16-24 UNFPM904871/ 8 BSPTPM90489M6X1 PPM90490M8X1 PPM90491M8X1,25 PPM90492M1OX1 PPM90493M10X1,5 PPar t NumberThreadSizeElbowsPM804121/ 8 PTF SAEPM804841/ 4 -28 UNFPM804855/ 16-24 UNFPM804871/ 8 BSPTPM80489M6X1 PPM80490M8X1 PPM80491M8X1,25PM80492M1OX1 PPM80493M10X1,5P25478-0564mmto4mmPar t NumberThreadSizeLoomingAccessoriesPlasti ctape1 Black.