FlowMaster II Rotary Driven Hydraulic Pump Series "A" User and Maintenance Instructions

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User and maintenance instructions

Models 85731, 5 U.S. gallons, 85732, 60 lbs (27 kg), 85733, 120 lbs (54 kg), 85734, 400 lbs (181 kg), 85138, 400 lbs (181 kg), 85144 (CAT branded)

FlowMaster II rotary driven hydraulic pump series “A”

Date of issue February 2023

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I, the undersigned of Lincoln Industrial Corporation, hereby declare that the equipment specified above, in its intended use, conforms with the Essential Health and Safety Requirements of U.K. legislation Supply of Machinery (Safety) Regulations 2008 No. 1597 Annex I, Declaration of Incorporation by the time of placing it on the market.

___________________________________

Robert Collins

Technical Compliance Manager St. Louis, MO, U.S.A.

The following EHSR (Essential Health and Safety Requirements) have been applied:

1.1.2a – 1.1.2b – 1.1.2c– 1.1.3 – 1.1.5 – 1.2.5 – 1.3.2 – 1.3.2 – 1.3.3 – 1.3.4 – 1.3.6 – 1.3.7 – 1.3.8 – 1.5.3 – 1.5.4 – 1.7 – 1.7.1 – 1.7.1.1 – 1.7.3 – 1.7.4

The manufacturer maintains a technical file summary sheet containing test reports and product documentation:

Technical file summary sheet number:

The partly completed machinery shown above should not be put into service until the final machinery into which it is to be

incorporated has been declared in conformity with the provisions of the directive, where appropriate.

RA402139 85144 (602-4050 CAT)

85731, 85732, 85733, 85734 and 85138 Rotary driven hydraulic pumps (series “A”)

2022/03/10 ^* Indicates change

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Safety*

The assembly must be installed, maintained and repaired exclusively by persons familiar with the instructions.

Always disconnect power source (electricity, air or hydraulic) from the equipment when it is not being used.

This equipment generates high pressure.

Extreme caution should be used when operating this equipment as material leaks from loose or ruptured components can inject fluid through the skin and into the body. If any fluid appears to penetrate the skin, seek attention from a doctor

immediately. Do not treat injury as a simple cut. Tell attending doctor exactly what type of fluid was injected.

Any other use not in accordance with instructions will result in loss of claim for warranty or liability.

• Do not misuse, over-pressurize, modify parts, use incompatible chemicals, fluids, or use worn and/or damaged parts.

• Do not exceed the stated maximum working pressure of the equipment or of the lowest rated component in your system.

• Always read and follow the manufacturer’s recommendations regarding fluid compatibility, and the use of protective clothing and equipment.

• Failure to comply may result in personal injury and/or damage to equipment.

C AUTION

Do not operate equipment without wearing personal protective gear.

Wear eye protection. Protective equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries.

Failure to comply may result in light personal injury.

WARNING

Do not allow any body part to be trapped by equipment.

Body parts can be crushed by subassemblies during operation.

Failure to comply may result in death or serious physical injury.

WARNING

Do not allow fluid to leak onto floor when operating equipment. If spill occurs, clean any fluid on floor before continuing operation.

Failure to comply may result in death or serious personal injury.

WARNING

Do not use this equipment to supply, transport, or store hazardous

substances and mixtures in accordance with annex I part 2-5 of the CLP regulation (EG 1272/2008) or HCS 29 CFR 1910.1200 marked with GHS01, GHS06 and GHS08 hazard pictograms shown:

Explanation of signal words for safety*

NOTE

Emphasizes useful hints and recommendations as well as

information to prevent property damage and ensure efficient trouble-free operation.

C AUTION

Indicates a dangerous situation that can lead to light personal injury if

precautionary measures are ignored.

WARNING

Indicates a dangerous situation that could lead to death or serious injury if precautionary measures are ignored.

DANGER

Indicates a dangerous situation that will lead to death or serious injury if precautionary measures are ignored.

WARNING

Do not operate equipment without reading and fully understanding safety warnings and instructions.

Failure to follow warnings and instructions may result in serious injury.

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Overview

This service page details the procedure that must be followed while installing, operating and repairing the FlowMaster II rotary driven hydraulic pump.

All required parts, tools, and equipment needed to complete the operation of the FlowMaster II rotary driven hydraulic pump are defined and listed within this manual.

Review of the parts list and nomenclature is recommended before starting disassembly or operation.

Appropriate use

All models are designed to pump and dispense lubricants using hydraulic power.

Specifications are shown in Table 1, page 7 for pump.

Do not exceed maximum specification ratings.

Do not exceed 3 000 psi (206 bar) maximum supply inlet hydraulic pressure.

Exceeding rated pressure may result in personal injury or damage to system components.

Any other use not in accordance with instructions will result in loss of claims for warranty and liability.

Description

FlowMaster II rotary driven hydraulic pump is a fully hydraulically operated adjustable grease pump.

Grease output is proportional to hydraulic input flow. Pump is primarily designed for centralized lubrication systems such as single line parallel, single line progressive and two line systems. Integrated pump control manifold is incorporated with input flow and pressure.

Fig. 1, page 8 details grease output in proportion to the hydraulic input that is affected by temperature.

The models 85731 (5 gallon (18 liter)), 85732 (60 gallon (227 liter)), 85733 (120 lb (181 kg)), 85734 (400 lb (181 kg)), 85138 (400 lb (181 kg)), and 85144 (CAT branded) are similar, with main difference between length of housing tube.

24 V solenoid valve is also incorporated as a method to turn pump on and off.

Pump is driven by rotary motion of hydraulic motor. Rotary motion is converted to reciprocating motion through eccentric crank mechanism. Reciprocating action causes pump cylinder to move up and down.

Unit is a positive displacement double-acting pump, as grease output occurs during both up and down stroke.

During down stroke, pump cylinder is extended into grease. Through combination

Usage

of shovel action and vacuum generated in pump cylinder chamber, grease is forced into pump cylinder. Simultaneously, grease is discharged through outlet of pump. Volume of grease during intake is twice the amount of grease output during one cycle. During upstroke, inlet check closes, and one half of grease taken in during previous stroke is transferred through outlet check and discharged to outlet port.

Fig. 2, page 8 is the hydraulic schematic showing key sub-assemblies of the pump with actual location of those items shown in Fig. 3, page 9.

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Inspection

If over pressurizing of equipment is believed to have occurred, contact nearest factory authorized warranty and service center for inspection of pump. Specialized equipment and knowledge is required for repair of pump.

Annual inspection by nearest factory authorized warranty and service center is recommended.

Damaged pumps

Do not use any pump that appears to be damaged, badly worn or operates abnormally.

Remove pump from service and contact nearest factory authorized warranty and service center for repairs. Listing of authorized warranty and service centers is available upon request.

Table 1 Pump specifications

Hydraulic inlet flow 2 U.S. gpm (7,6 liters/min) Operating temperature –40 to 150 °F (–40 to 65 °C) Operating working hydraulic pressure 300 psi (21 bar)

Solenoid voltage, for the on/off solenoid 24 V

Hydraulic inlet port, in SAE 4

Tank return port, in SAE 6

Supply inlet hydraulic pressure Maximum 3 000 psi (206 bar)

Pump outlets, in ¹/4 in NPTF

Maximum hydraulic fluid temperature 250 °F (121 °C)

Pump ratio with manifold 10:1

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5 (81)

1.0 (3.7)

1.5 (5.6)

2.0 (7.5)

2.5 (9.4)

3.0 (11.3)

3.5 (13.2)

4.0 (15.1)

4.5 (17.0)

5.0 (18.9) 10 (163)

15 (245) 20 (327) 25 (409) 30 (491) 35 (573) 40 (655)

80 °F (27 °C)

20 °F (–2 °C) 0 °F (–18 °C)

–20 °F (–29 °C)

T

P 1

10

6 5

9 7

8 2

3 4

Fig. 1 Grease output vs. hydraulic input

Hydraulic input gpm (liter/min) Grease output

in³/min (cm³/min)

Fig. 2 Hydraulic schematic

Item Description

1 Hydraulic fluid inlet port SAE 4 ORB 2 Hydraulic fluid return to tank SAE 6 ORB 3 Hydraulic motor

4 Lube outlets ¹/4 in NPTF 5 Flow control valve

6 Pressure gauge

7 Hydraulic fluid to vent valve 8 Orifice 0.013 in (0.33 mm) diameter 9 Pressure reducing valve

10 Solenoid valve

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2.25 in (57 mm)

3.90 in (99 mm)

(4×) ∅ 0.28 in (7 mm) (4×) ¹/⁴-20

9.09 in (231 mm)

∅ 1.25 in (32 mm) A

B 9.37 in

(238 mm) 11.53 in (293 mm)

2.72 in (69 mm)

Fig. 3 Pump dimensions

Model Dimension A Dimension B

85731 25.08 in (637 mm) 13.74 in (349 mm) 85732 30.39 in (722 mm) 19.05 in (484 mm) 85733 38.90 in (988 mm) 27.56 in (700 mm) 85734 45.40 in (1 153 mm) 34.06 in (865 mm) 85138 45.40 in (1 153 mm) 34.06 in (865 mm) 85144 25.08 in (637 mm) 13.74 in (349 mm)

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A 69

66

37

70

67, 68 B

C

64

Fig. 4

Item Description

A Hydraulic fluid inlet port SAE 4 ORB B Hydraulic fluid return to tank SAE 6 ORB

C Gasket

37 Pump housing

64 Pressure gauge

66 Manifold

67 Solenoid valve 68 Solenoid coil (24 V ) 69 Flow regulator 70 Pressure reducing valve 72 Hydraulic motor

Installation and operation

Install pump

Pump was tested in lightweight oil that was left in to protect pump from corrosion. Flush pump before connecting it to system to prevent contamination of grease with residual oil.

Pump has flow and pressure controls integrated into manifold (66). Normally closed on/off solenoid valve (67 and 68) is also integrated into manifold and will start or stop pump operation.

NOTE

Refer to fig. 3, page 9 for hole pattern and dimensions if it is necessary to drill mounting holes into reservoir cover.

WARNING

Do not operate pump without shut-off valve in material supply line.

Failure to comply may lead to death or serious injury.

1 Mount pump securely on drum cover to prevent movement or vibration during operation (→ fig. 4).

2 Attach hydraulic supply line to inlet (A) and return line to tank ports.

3 Connect material supply line to pump outlet.

4 Plug unused outlet on opposite side of pump.

5 Install high pressure shut-off valve in material supply line (required).

6 Connect 24 V power supply to solenoid coil (74), using supplied plug.

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A 67, 68 69

66 37

70 B

64

Operation

NOTE

Do not change settings for pump until after start up procedure. All pumps are factory set at 320 psi (22 bar) working inlet hydraulic pressure with flow rate of 2.5 gallons/min (9.5 liters/min).

Failure to comply may result in damage to equipment.

NOTE

Do not exceed maximum operating temperature of hydraulic fluid 250 °F (121 °C).

Never allow pump to run dry of lubricant. Dry pump quickly speeds up, cre- ating friction heat that can damage seals. Monitor supply lubricant level and refill when necessary.

NOTE

Refer to Set pump manifold pressure and flow controls (page 12) for

instructions to adjust pressure and flow.

See fig. 5 for location of operating valves.

Do not exceed pump operating pressure of 400 psi (27 bar). Always use the lowest pump output pressure and hydraulic fluid flow to obtain desired results. This will reduce pump wear.

Pressure of 320 psi (22 bar) is recommended.

WARNING

Do not exceed 400 psi (27 bar) working hydraulic pressure. Use high pressure components to reduce risk of serious injury including fluid injection and splashing in eyes or on skin.

Do not connect accessories to pump outlet that are not approved for up to 5 000 psi (344 bar) minimum hydraulic operating pressure. Do not connect accessories that operate below 3 000 psi (206 bar) minimum working pressure.

Failure to comply may result in personal injury.

1 Shut off material supply line valve.

2 Turn on hydraulic pressure.

3 Energize solenoid on/off valve (67) (→ fig. 5).

4 Prime pump by slowly opening shut-off lubricant supply line valve.

5 Make sure all air has been expelled from pump and even lubricant flow is achieved.

6 Adjust pump pressure and flow to desired application requirements.

Fig. 5

Item Description

A Hydraulic fluid inlet port SAE 4 ORB B Hydraulic fluid return to tank SAE 6 ORB

37 Pump housing

64 Pressure gauge

66 Manifold

67 Solenoid valve 68 Solenoid coil (24 V ) 69 Flow regulator

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NOTE

Pressure must be adjusted to make sure desired flow setting is achieved.

Fig. 5 (page 11) depicts location of valves.

NOTE

Do not exceed 400 psi (27 bar). Pressure of 320 psi (22 bar) is recommended.

Damage to equipment may occur.

NOTE

Adjustment screw will unscrew until it reaches stop. It will not come off. This is the minimum pressure setting, about 100 psi (6 bar).

NOTE

Flow control valve can be turned in until valve is completely closed and out to adjust pump speed.

Recommended flow control valve setting is ¹/⁴* turn counter clockwise.

Flow control valve adjustment

6 Loosen hex head cap and remove from flow regulator (69) (→ fig. 5).

7 Adjust flow by turning hex head screw clockwise to reduce flow and counter-clockwise to increase it.

8 Once flow rate is at desired level, install and tighten hex head cap on flow regulator (69).

Set pump manifold pressure and flow controls

Pressure control valve adjustment

1 With hydraulic pressure applied, stop pump by turning flow regulator (69) clockwise until completely closed.

2 Remove hex head cap from pressure reducing valve (70).

3 Turn hex head adjustment screw counter-clockwise until it stops.

4 With pump (37) stalled against pressure, turn pressure reducing valve (70) hex head clockwise until desired pressure is reached on manifold pressure gauge (64).

5 Install and tighten pressure reducing valve (70) hex head by turning lock nut clockwise.

Crankcase oil service interval

• Check oil level after every 750 hours of machine operation, or monthly.

• Change oil after every 2 000 hours of machine operation or every year.

• Use SAE 10W30 motor oil in all units used in an ambient temperature between -40 to 150 °F (-40 to 65 °C). For ambient temperatures between 50 to 70 °F (10 to 21 °C) , use low temperature oil.

• Oil level should be at indicating dot on dipstick (middle of crankshaft).

• Use 10W30 motor oil 15 oz (0.44 l).

* Indicates change.

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Maintenance and repair

Disassembly

Pump

1 Place pump into vise.

2 Remove dipstick (31) (→ fig. 6, page 14).

3 Drain crankcase oil.

4 Remove housing cover screws (33).

5 Remove housing cover (35) and gasket (36).

6 Remove hydraulic motor mounting screws (74) and lock washers (73).

7 Remove hydraulic motor (72).

8 Remove manifold mounting screws (65) and manifold assembly (66).

9 Remove pressure reducing valve (70).

10 Remove flow regulator (69).

11 Remove solenoid valve cartridge (67).

12 Remove outlet pin nuts (55) from both sides of pump housing (37).

13 Remove o-rings (54 and 53) and back-up washer (52) from outlet pin nuts (55).

23 Remove back-up washer (58) from tube housing (60).

24 Remove o-ring (59) from tube housing (60).

25 Using a rubber mallet and piece of brass or other suitable piece of soft metal, tap on crank rod (7) inside housing (37).

26 Pull eccentric (5) and crank rod (7) out of top of pump housing (37).

NOTE

Slight force may be necessary to remove eccentric (5) and crank rod (7) from housing (37). Tap on crank rod (7) until eccentric (5) is above pump housing (37) and can be pulled from pump

housing (37).

14 Loosen screws (44) holding shaft cover (46) on pump housing (37) (→ fig. 8, page 14).

15 Remove retaining ring (48) from pump shaft (40).

16 Remove pump shaft (40) by pushing pump shaft on retaining ring (48) side.

17 Remove retaining ring (63) from housing tube (60) (→ fig. 7, page 14).

18 Remove shovel plug (62) from housing tube (60).

19 Remove spiral retaining ring (61).

20 Loosen and remove tube housing (60).

21 Remove bronze bearing (56) from tube housing (60).

22 Remove o-ring (57) from tube housing (60).

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31

73, 74 33, 34

67

69 36

37 66

70 72 55

64 65 35

43

39 40 41 42

38 37

5 7

31 32

35 36

44 45 46 47 48 49 50 51

52 53

54 55

60 33

34

56 57 58 59

60

61 62 63

Fig. 6 Fig. 8

Fig. 7

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NOTE

Wrist pin bushings (12) often stick in wrist pin anchor (13). It may be necessary to use ⁵/16 – 24 bolt from kit 276275 to remove wrist pin bushings (12).

1 Remove pivot screws (11) from crank rod (7) (→ fig. 9, page 16).

2 Press out wrist pin bushing (12).

3 Loosen and remove wrist pin anchor (13) from reciprocating tube (25).

4 Pull cup seal (16) out of wrist pin anchor (13).

5 Remove steel back-up ring (17).

6 Place plunger link rod (20) in vise.

7 Loosen plunger link rod (20) and remove from outlet pin (8).

8 Remove plunger link rod (20).

9 Remove retainer clip (19) from plunger link rod (20).

10 Remove o-ring (18) from plunger link rod (20).

11 Remove back-up washer (15) from plunger link rod (20).

12 Remove o-ring (14) from plunger tube (25).

13 With crank rod in vise and using special tool (T1) provided in tool kit, 276275 remove plunger link rod (20).

14 Place end of plunger link rod (20) into hole of special tool (T1).

15 Align outlet hole of plunger link rod (20) with hole in special tool (T1).

16 Insert pin included in tool kit 276275 through tool and into plunger link rod (20) outlet hole.

17 Turn tool counter clockwise to loosen lower bushing and plunger (24) from plunger link rod (20).

18 Remove plunger (24).

19 Remove check rod from (22) lower bushing and plunger (24).

20 Remove ball (23) from lower bushing and plunger (24).

21 Remove spring (21) from link rod (20).

Crank rod and eccentric Reciprocating tube

1 Loosen check seat housing (30) with

3/8 in (9 mm) hex head wrench (→ fig. 9, page 16).

2 Remove check seat housing (30) from reciprocating tube (25).

3 Remove ball cage (28), check ball (29) and o-ring seal (27) from check seat housing (30).

4 Remove lower bushing (24) from reciprocating tube (25).

5 Remove lower cup seal (26) from reciprocating tube (25).

Crank rod

1 Loosen and remove two flat head screws (1) from eccentric (5) (→ fig. 9, page 16).

2 Remove counterbalance weights (2).

3 Remove outer (3) and inner (4) retaining ring from both sides of crank rod (7).

4 Place crank rod (7) on supplied 2 ¹/2 in (62 mm) diameter steel pipe.

5 Drive crank eccentric (5) out of ball bearing (6).

6 Drive ball bearing (6) out of crank rod (7).

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1 2

4 3

11 1 12

2 3

4 5

6

7

8 9

10 11 12

13 14 15 16 17 18 19 20 21 22 23

24

25

26

27

28 29 30 T1

Fig. 9

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1 2

4 3

11 1 12

2 3

4 5

6

7

8 9

10 11 12

13 14 15 16 17 18 19 20 21 22 23

24

25

26

27

28 29 30 T1

Assembly

Crank rod and eccentric

1 Place crank rod (7) on 2 ¹/² in (62 mm) diameter steel pipe, provided in tool kit 276275 (→ fig. 10).

2 Install ball bearing assembly (6) into crank rod (7).

3 Place eccentric (5) in ball bearing (6).

4 Place one end of inner retaining ring (4) on top of eccentric (5).

5 Squeeze other end of retaining ring (4) toward center and slide retaining ring (4) into place.

6 Place one end of outer retaining ring (3) on top of inner retaining ring (4).

7 Squeeze other end of retaining ring (3) toward center and slide retaining ring (3) into place.

8 Align holes of counter-balance weights (2) with threaded holes of eccentric (5) and place on eccentric (5).

9 Insert flat head screws (1) into counterbalance weight (2) and torque flat head screws (1) to a torque of

100 to 110 in-lbf (11.3 to 12.4 Nm).

Fig. 10

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7

12

13 11

56 57 58 59

60

61 62 63

Pump

1 Install ball (23) into lower bushing and plunger (24) (→ Fig. 10, page 17).

2 Insert check rod (22) into pump plunger (23).

3 Place spring (21) onto check rod (22).

4 Thread plunger link rod (20) into pump plunger (24).

5 Insert lower bushing pump plunger (24) into tool (T1).

6 Align hole in lower bushing pump plunger (24) with hole in tool (T1).

7 Insert pin provided in tool kit 276275 into hole of tool (T1) and into lower bushing pump plunger (24).

8 Torque lower bushing pump plunger (24) to 110 to 125 in-lbf (12.4 to 14.1 Nm).

9 Install steel back-up ring (17) onto threads of upper bushing and plunger end (10).

10 Slide o-ring (18) onto upper bushing and plunger end (10).

11 Install retaining clip (19) on upper bushing and plunger end (10).

12 Install o-ring (9) on upper bushing and plunger end (10).

13 Place outlet pin (8) into a vise.

14 Apply thread locker to the threads of the upper bushing and plunger end (10).

15 Thread the upper bushing and plunger end (10) into the outlet pin (8).

16 Torque to 110 to 125 in-lbf (12.4 to 14.1 Nm).

17 Install the back-up washer (15) in the wrist pin anchor (13).

18 Place a new cup seal (16) inside the wrist pin anchor (13).

19 Clean threads of wrist pin anchor (13).

20 Install o-ring (14) on wrist pin anchor (13).

21 Insert upper bushing and plunger end (10) into wrist pin anchor (13) and tighten.

22 Place wrist pin anchor (13) in a vise.

23 Tighten wrist pin anchor (13) to torque of 20 to 25 ft-lbf (27 to 34 Nm).

24 With wrist pin anchor (13) still in vise, align crankrod/eccentric assembly (7) holes with wrist pin anchor (13) (→ fig. 11).

25 Install wrist pin bushings (12) through crank rod (7) and into wrist pin anchor (13).

26 Apply thread locker to threads of wrist pin bushing screws (11).

27 Insert and thread wrist pin bushing screws (11) into crankrod (7).

28 Tighten bushing screws (11) to torque of 110 to 125 in-lbf (12.4 to 14.1 Nm).

Fig. 11

32 Install steel check cage (28) into reciprocating tube (25).

33 Install ball (29) into steel check cage (28).

34 Apply thread locker to threads of check seat housing (30).

35 Thread check seat housing (30) into reciprocating tube (25) and tighten using

3/⁸ in (9 mm) hex key.

36 Torque to 20 to 25 ft-lbf (27 to 33 Nm).

37 Remove crank rod (7) from vise.

38 Insert o-ring (59) into housing tube (60) (→ Fig. 12, page 18).

39 Place back-up washer (58) into housing tube (60).

40 Insert o-ring (57) into housing tube (60).

41 Insert bronze bearing (56) into housing tube (60).

NOTE

For ease of installation of lower cup, use small piece of tubing to slide lower up into reciprocating tube and over pump plunger.

Fig. 12

29 Install cup seal (26) with slotted side toward center of reciprocating tube (25) (→ fig. 10, page 17).

30 Place new o-ring (27) on lower bushing and plunger (24).

31 Slide lower bushing and plunger (24) into reciprocating tube (25) with o-ring (27) near bottom of reciprocating tube (25).

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43

39 40 41 42

38 37

5 7

31 32

35 36

44 45 46 47 48 49 50 51

52 53

54 55

60 33

34

5 43 Align crank rod (7) with shaft (40)

mounting hole.

44 While aligning key (39) on shaft (40) with eccentric key way (5), slide shaft (40) into eccentric (5) (→ fig. 14).

45 Install retaining ring (48) on shaft (40).

46 Install shaft cover (46) on pump (37).

47 Insert and thread screws (44) with lockwashers (45) into shaft cover (46) and pump housing (37).

NOTE

Failure to align key on shaft and key way in eccentric will result in damage to equipment.

Fig. 13 Fig. 14

42 Position crankrod assembly (7) over top of pump housing (37) and lower into pump housing (37) (→ fig. 13).

48 Install new cover gasket (36) on pump housing (37).

49 Install pump cover (35).

50 Install screws (33) with o-rings (34) into pump cover (35).

51 Tighten screws (33) to a torque of 10 to 15 in-lbf (1.1 to 1.6 Nm).

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65 66 64

60

63 62 61 72

70

71

69 68

67

73, 74

75

37

52 53 54

55 Fig. 15 52 Insert and thread the housing tube (60)

into pump housing (37).

53 Install hydraulic motor (72) on pump housing (37) (→ fig. 15).

54 Thread hydraulic motor mounting screws (74) with lock washers (73) into pump housing (37).

55 Tighten mounting screws (74) to a torque of 50 to 55 ft-lbf

(67.8 to 74.5 Nm).

56 Install o-rings (71) in motor (72).

57 Place manifold (66) on hydraulic motor (72).

58 Thread four manifold mounting screws (65) into manifold (66).

59 Torque screws to 20 to 25 ft-lbf (27.1 to 33.9 Nm).

60 Install solenoid valve (67) into manifold (66).

61 Tighten solenoid valve (67) to torque of 25 to 30 ft-lbf (33 to 40 Nm).

62 Install pressure reducing valve (70) in manifold (66).

63 Tighten pressure reducing valve (70) to torque of 35 to 40 ft-lbf (47 to 54 Nm).

64 Install flow regulator (69) into manifold (66).

65 Tighten flow regulator (69) to torque of 35 to 40 ft-lbf (47 to 54 Nm).

66 Tighten housing tube (60) to torque of 20 to 25 ft-lbf (27 to 33 Nm).

67 Insert retaining ring (61) into second groove of housing tube (60).

68 Install shovel plug (62) into housing tube (60).

69 Install spiral retaining ring (63).

70 Install o-ring (54) in outlet pin mounting hole groove of pump housing (37).

71 Install back-up washer (52) inside outlet pin nut (55).

72 Install o-ring (53) inside outlet pin nut (55).

73 Line up outlet pin and thread outlet pin nut (55) into pump housing (37).

74 Torque to 30 to 35 ft-lbf (40 to 47 Nm).

75 Fill crankcase with SAE 10W30.

76 Install crank case oil dip stick (31) (→ fig. 13, page 19).

77 Torque to 10 to 15 in-lbf (1.1 to 1.7 Nm).

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Troubleshooting

Condition Possible cause Corrective action

Pump does not run No pressure on gauge (64) Open shut off valve

Closed supply line shut off valve

• No power to solenoid valve (68) Correct electrical fault

• Faulty solenoid (68) Replace solenoid (68)

• Pressure reducing valve (70) is set too low Reset pressure reducing valve (70)

• Insufficient hydraulic fluid supply Check hydraulic supply for proper pressure and flow Pressure is shown on gauge (64)

• Closed fluid outlet line Check outlet line and clear obstructions

• Flow control valve is fully closed Readjust valve to ¹/4* turn open

• Pump is stalled due to grease backpressure Check vent valve in system

• Pump is seized or damaged Dismantle the pump and repair defective or seized component; See disassembly and assembly procedure Pump speeds up or runs erratically Low level of grease or reservoir is empty Refill reservoir

Follower plate is stuck and separated from grease Check follower plate and container for damage Pump piston or checks are worn Disassemble the pump and repair

Pump runs, but output is low Insufficient hydraulic fluid supply Check hydraulic supply and adjust flow using valve (69)

Inlet pressure low Increase pressure using valve (70)

Faulty inlet (29, 30), faulty discharge check (23, 24) or damaged o-ring (27)

Replace faulty components

Leakage from housing cover (35) Cup seal (16) or o-ring (14) wore out Check seals and replace if necessary Pump becomes noisy Crankcase needs oil Check dipstick (31) and fill with oil as required Pump does not build pressure Worn wrist pin bushing (12) Check the bushings and replace if necessary

Foreign material holding lower check open Dismantle and clear check

Consider adding grease filter to system

* Indicates change.

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1 2

4 3

11 1 12

2 3

4 5

6

7

8 9

10 11 12

13 14 15 16 17 18 19 20 21 22 23

24

25

26

27

28 29 30

Fig. IPB 1

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43

39 40 41 42

38 37

31 32

33 34

35 36

44 45

46 47 48 49 50 51

52 53

54 55

56 57 58 59

60

61 62 63

Fig. IPB 2

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67

68

69

75 66

71

72

74

73 70

64

65

Fig. IPB 3

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Parts list

Item Description Part number Quantity Item Description Part number Quantity

1 Flat head screw (¹/4–28 × 1 ³/4) 270635 2 40 Pump shaft 277397 1

2 Counter weight 272197 2 41 Retaining ring 272561 1

3 Retaining ring 270609 2 42 Ball bearing 272556 1

4 Retaining ring 270608 2 43 Shaft seal 272554²⁾ 1

5 Crank eccentric 270666 1 44 Screws 272557 4

6 Ball bearing 270607 1 45 Lock washer 66051 4

7 Crank rod 270665 1 46 Bearing cover 272549 1

8 Outlet pin 270670 1 47 O-ring 272559²⁾ 1

9 O-ring 34255^{1) 2)} 1 48 Retaining ring 272563 1

10 Upper bushing and plunger 275000¹⁾ 1 49 Ball bearing 272555 1

11 Pivot screw 275006 2 50 Retaining ring 272562 1

12 Wrist pin bushing 275005 2 51 Drain plug 244752 1

13 Wrist pin anchor 274992 1 52 Back-up washer 249837²⁾ 2

14 O-ring 275015²⁾ 1 53 O-ring 249838²⁾ 2

15 Back-up washer 274998^{1) 2)} 1 54 O-ring 270719²⁾ 2

16 Cup seal 274999^{1) 2)} 1 55 Outlet pin nut 270619 2

17 Steel back-up ring 274997^{1) 2)} 1 56 Bronze bearing 270674 1

18 O-ring 272791^{1) 2)} 1 57 O-ring 249839²⁾ 1

19 Retainer clip 274996^{1) 2)} 1 58 Back-up washer 270652²⁾ 1

20 Plunger link rod See chart 1 59 O-ring 34431²⁾ 1

21 Spring 277168²⁾ 1 60 Housing tube See chart 1

22 Check rod 277167 1 61 Retaining ring 277398 1

23 Ball 66010²⁾ 1 62 Shovel plug 270707 1

24 Lower bushing and plunger 275002 1 63 Retaining ring 270705 1

25 Reciprocating tube See chart 1 64 Pressure gauge 270768 1

26 Cup seal 270625²⁾ 1 65 Socket head screw (⁵/16-18 × 1 ¹/4) 270680 4

27 O-ring 275011²⁾ 2 66 Manifold 270771 1

28 Ball cage 272179 1 67 Solenoid valve cartridge 270690 1

29 Ball 66001²⁾ 1 68 Solenoid coil (24 V ) 270691³⁾ 1

30 Check seat 270664 1 69 Flow regulator 270693 1

31 Dipstick with o-ring 275369 1 70 Pressure reducing valve 270692 1

32 O-ring 275015²⁾ 1 71 O-ring 271236²⁾ 2

33 Self-threading screw #8 × ¹/2 270633 6 72 Hydraulic motor with o-rings 277740 1

34 Gasket (screw) 252986²⁾ 6 73 Lock washer (³/8) 272566 4

35 Housing cover 275009 1 74 Socket head screw (³/8-16 × 1 ¹/2) 277405 4

36 Cover gasket 270630²⁾ 1 75 Orifice fitting 270735 1

37 Pump housing 278230 1 76 Solenoid, cable 277427⁴⁾ 1

38 O-ring 272567²⁾ 1

39 Woodruff key 272560 1

Non-common repair parts

Item Description Model 85731 Model 85732 Model 85733 Model 85734 Model 85138 Model 85144

20 Plunger link rod 277381 277382 277383 277384 277384 277381

25 Reciprocating tube 277732 277733 277734 277735 277735 277732

60 Housing tube 277736 277737 277738 277739 277739 277736

72 Hydraulic motor with o-rings 277740 277740 277740 277740 277740 279517

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® SKF and Lincoln are registered trademarks of the SKF Group.

The contents of this publication are the copyright of the publisher and may not be reproduced (even extracts) unless prior written permission is granted. Every care has been taken to ensure the accuracy of the information contained in this publication but no liability can be accepted for any loss or damage whether direct, indirect or consequential arising out of the use of the information contained herein.

February 2023 · Form 404554 Version 6

Warranty

The instructions do not contain any information on the warranty.

This can be found in the General Conditions of Sales, available at:

www.lincolnindustrial.com/technicalservice or www.skf.com/lubrication.

FlowMaster II Rotary Driven Hydraulic Pump Series "A" User and Maintenance Instructions

User and maintenance instructions

Models 85731, 5 U.S. gallons, 85732, 60 lbs (27 kg), 85733, 120 lbs (54 kg), 85734, 400 lbs (181 kg), 85138, 400 lbs (181 kg), 85144 (CAT branded)