HIGH CHIEF HYDRAULIC OPERATED GREASE PUMP - JSG Industrial · JSG INDUSTRIAL SYSTEMS PTY LTD Page 2...

JSG INDUSTRIAL SYSTEMS PTY LTD

HIGH CHIEF HYDRAULIC OPERATED GREASE PUMP

High Chief Models 03-000920, 03-000921, 03-000950-AUS, 03-000950-USA,

03-000951-AUS, 03-000951-USA, 03-000954, 03-000955, 03-000964 Revision 4.0, Jan 2017

DESCRIPTION Models 03-000920, 03-000950-AUS, 03-000950-USA, 03-000954, 03-000964 are hydraulically operated grease pumps using a reciprocation timer (03-000014-2). Models 03-000921, 03-000951-AUS, 03-000951-USA, 03-000955 are hydraulically operated grease pumps with no timer but designed to be used in conjunction with the JSG “G2” dual controller (13-002500) which has two control outputs, one output controlling the pump speed the second output controlling the pump on time and the lubrication cycle. All models are designed for centralised lubrication systems for any equipment which utilises 24VDC power source. (With “G2” Timer can use 12VDC)

OWNER/OPERATOR RESPONSIBILITY It is the owner/operator responsibility to properly use and maintain this equipment. The instructions and warnings 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 assure the owner/operator comprehends.

It is the owner / operator

responsibility to maintain the legibility of all warning and instruction labels. The owner/operator shall retain this manual for future reference to important warnings, operating and maintenance instructions.

FAILURE TO HEED THE FOLLOWING WARNINGS INCLUDING MISUSE, OVER PRESSURISING, MODIFYING PARTS, USING INCOMPATIBLE CHEMICALS AND FLUIDS, OR USING WORN OR DAMAGED PARTS, MAY RESULT IN EQUIPMENT DAMAGE AND/OR SERIOUS PERSONAL INJURY.

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

Do not alter or modify any part of this equipment.

Do not attempt to repair or disassemble the equipment while the system is pressurised.

Make sure all fluid connections are securely tightened before using this equipment.

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

Check all equipment regularly and repair or replace worn or damaged parts immediately.

WARNING

PART NUMBER: 03-000920, 03-000921 for 20kg pail 03-000950-USA, 03-000951-USA for 60kg drum 03-000950-AUS, 03-000951-AUS for 60kg drum 03-000954, 03-000955 for 180kg drum 03-000964 for mini drums SPECIFICATION: Supply Inlet Pressure: 20-200bar Hydraulic Inlet Flow: 0.25-3.0L/m Output Pressure: 300 bar Operating Temp: -100C to +600C Operating Voltage: 24VDC Hydraulic Inlet Port: 7/16” JIC Tank Return Port: 9/16” JIC Pump Outlets: ¼” NPT Max. Hyd. Fluid Temp: 980C Output per cycle: 8.8cm3/cycle FACTORY SETTINGS: Output: 132cm3/minute


Figure 1. General information

SAFETY INSTRUCTIONS

This equipment generates very high grease 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 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 pressurising of the equipment is believed to have occurred, contact JSG Industrial Systems or your nearest service centre.

Specialised equipment and knowledge is required for repair of this pump.

Contact JSG Industrial Systems or your nearest authorised JSG service centre for repairs or adjustments other than maintenance specified in this manual. Annual inspection by JSG Industrial Systems is recommended.

DAMAGED PUMPS

Any pump that appears to be damaged in any way, is badly worn or operates abnormally shall be removed from use until repairs are made. Contact JSG Industrial Systems for repairs.

BASIC PUMP DRUM SIZE DIMENSION A 03-000920, 03-000921 20kg 479 mm

03-000950-USA, 03-000951-USA 60kg 695 mm

03-000950-AUS, 03-000951-AUS 60kg 556 mm

03-000954, 03-000955 180kg 862mm

03-000964 Mini Pump 350mm

IMPORTANT If any fluid appears to penetrate the skin, get emergency medical care immediately. Do not treat as a simple cut. Tell attending physician exactly what fluid was injected.

DO NOT alter or modify any part of the equipment as this may cause a malfunction and result in serious bodily injury.

WARNING

HIGH CHIEF MANUAL Revision 4.0, Jan 2017


HYDRAULIC MOTOR OPERATION This section describes the operation of the hydraulic Motor Assembly. (See Figure 2)

The “P” port should be connected to a suitable hydraulic supply, preferably to a pilot system. The “T“ port is the return to tank line. The “P1” port is an auxiliary port, which is normally left plugged. It is suitable for use as a gauge port or if necessary to operate a hydraulic vent valve. If a gauge is connected to the “P1” port it will show the 20 bar setting of the integral pressure

reducing valve. During operation the pressure gauge reading will fluctuate in time with the reciprocating rate of the pump.

NOTE: If operating vent valve (01-084980) from auxiliary port “P1”, an orifice (03-247384) must be fitted. When ordering the orifice please state version of reciprocating assembly you have. With this setup an additional hydraulic 2/3 way shut off valve must be fitted in the hydraulic supply line. See Fig. 14 for wiring diagram.

The pump operates as follows: The reciprocation timer used in models 03-000920, 03-000950-AUS, 03-000950-USA, 03-000954, (03-000014-2) determines the number of cycles per minute. (The factory setting is 2 seconds on & 2 seconds off, which results in 15 cycles / minute.) By utilising the JSG “G2” timer with the High Chief Hydraulic Pump models 03-000921, 03-000951-AUS, 03-000951-USA & 03-000955 this cycle can be adjusted to whatever required reciprocation rate however

2 seconds on and 2 seconds off is the factory recommendations.

In the Rest State hydraulic pressure is normally applied to the top of the Motor, holding the piston at the end of its down stroke. Applying 24 volt DC Power to the reciprocation timer (03-000014-2) will start the reciprocating action by operating the solenoid valve, thus sending the piston to the top of its stroke and then back again, at the rate set by the timer. Turning the 24-volt supply off will stop the reciprocation timer thus interrupting the power to the solenoid and return the piston to its rest position at the bottom of its stroke.

Maximum allowable output pressure of this pump is 360 bar. Be sure that all system equipment and accessories are rated to withstand the maximum working pressure of this pump. DO NOT exceed the maximum working pressure of the lowest rated component in the system.

WARNING

A pressure switch and safety valve must be used in the lube system. The cylinder pressure must not exceed 20 bar. Failure to use these monitoring and safety devices may result in damage to system components and personal injury!

WARNING

NOTE:

THE THEORETICAL RATIO OF THIS PUMP IS 15:1

DEPENDANT ON THE APPLICATION AND

VARIABLE INTERNAL FRICTION; THE ACTUAL

RATIO MAY BE LESS.


Figure 2 – Pump

motor circuit

Reciprocation solenoid valve


Figure. 3 – Pump motor with reciprocating timer

There are two LED lights under the opaque cover of the reciprocation timer. (See figure 3) One indicates that power is applied the other blinks on and off as it operates the reciprocation solenoid valve.

TROUBLE SHOOTING

If the following procedures do not correct the problem, contact JSG Industrial Systems Pty Ltd or a JSG authorised 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.

PROBLEMS No or low hydraulic pressure at the Auxiliary port. A. No system pressure to the

pump.

B. Pressure reducing valve set to low. Increase setting by ½ turn to check operation.

Pump pressure builds very slowly or not at all

A. No pulsing signal from

reciprocation timer. B. Pressure reducing valve may be

set to low. C. Grease viscosity may be too

high for temperature at which pump is operating.

D. If pressure is not building at all,

the reciprocation solenoid may be inoperative.

E. Pump piston ball checks and inlet checks may have foreign matter trapped causing leakage. Remove, inspect and clean if necessary.

F. Inspect sealing surfaces

between upper and lower inlet checks. Replace if rough or pitted.

G. Replace shovel rod if rough or

pitted. Replace shovel rod packing.

H. Inspect lubricant supply line for

leaks or breaks. I. If hydraulic vent valve is used

then an orifice (03-247384) must be fitted in “P1” auxiliary port. Problem can be caused either by missing orifice or clog-ged orifice (see note page 3.)



DISASSEMBLY

Refer to SERVICE PARTS for part numbers and location. Bleed all pressure from hydraulic and grease lines before disassembling pumps. A. Remove nut securing solenoid

coil. Remove the coil together with the reciprocation timer.

B. Remove socket head cap

screws securing reciprocation valve assembly and remove assembly.

C. Remove socket head screws

securing hydraulic cylinder top (03-000013-1) and remove top.

D. Remove hydraulic cylinder. E. Remove cylinder tie rods by

unscrewing them from outlet body.

F. The cylinder bottom will now be

partially free of the outlet body (03-001311)

G. Unscrew pump tube from outlet

body (03-001311). H. Extend pump piston rod (01-

011340) out of the bottom of outlet body (03-0001311). Place wrenches on piston rod end and flats of piston boss (03-000013-6) and flats of piston rod (01-011340) and unscrew piston rod. Thread the piston rod through the gland packing to allow removal of the pump tube.

I. Unscrew gland packing nut (01-

012333) from outlet body and remove all gland parts.

J. Remove the priming tube (01-

239719) from the bushing extension (01-061273).

K. Extend plunger rod (01-011723)

out of bushing extension and

unscrew priming extension (01-011724) to allow removal of priming check parts and plunger rod (01-011723).

L. Remove bushing extension (01-

061273) and unscrew plunger bushing assembly (01-090554) from pump tube. Unscrew coupling nut (01-011344) to allow removal of plunger and bushing assembly intact, reducing the chance of losing ball stop (01-057027) and check ball (01-066010).

ASSEMBLY To reassemble, perform DISASSEMBLY procedure in reverse.

IMPORTANT To prevent damage to pump gland

packing and to help increase packing life, lube pump piston rod

before assembly. Thread piston rod through gland packing when

assembling pump.

REPAIR Repair is limited to replacement of listed service parts. Special procedures and tools are required. Contact JSG Technical service for details and your nearest authorised service centre. When ordering replacement parts, list the part number, description, model number and series letter of the product to be repaired.

ACCESSORIES 01-245530 Viton / Teflon kit

(For Pumping Synthetic Lubricants)

01-083001 Lower Pump Tube repair Kit 03-000920-9V Hydraulic cylinder seal kit.

JSG OFFICE LOCATIONS Head Office Phone: (02) 9914 8720 Fax: (02) 9774 2321 Email: [email protected] Web: www.jsgindustrial.com Newcastle Office Phone: 0447 277 755 Email: [email protected] Brisbane Office Phone: (07) 3273 3433 Fax: (07) 3273 3369 Email: [email protected] Townsville Office Phone: (07) 4772 5454 Fax: (07) 4724 5951 Email: [email protected] North Mackay Office Mobile: 0448 022 886 Fax: (07) 4946 5466 Email: [email protected] Melbourne Office Phone: (03) 9762 4744 Fax: (03) 9762 4772 Email: [email protected] Perth Office Phone: (08) 9248 7311 Fax: (08) 9248 9817 Email: [email protected] Adelaide Office Phone: 0448 730 886 Fax: (08) 8240 3966 Email: [email protected]

AUTHORISED SERVICE CENTRES THROUGHOUT: New South Wales, Queensland, Victoria, South Australia, Western Australia, Tasmania, Northern Territory, Indonesia, Papua New Guinea, New Caledonia, Fiji, New Zealand


http://www.jsgindustrial.com/

mailto:jsgfnq

mailto:[email protected]


Service Replacement pump. Figure 4 & 5 Model 03-000921 Used only in conjunction with the G2 controller Service Replacement pump for: Pump station Model 03-000555BF Ref: Fig 4 shows pump with cover. Fitted & Fig 5 shows pump with cover removed. Service Replacement pump for: Pump station Model 03-000555BF Ref: Fig 4 shows pump with cover fitted. & Fig 7 shows pump with cover removed. Early Model Service Replacement pump for: Pump Station Model 03-000555 Ref Fig 4 shows pump with cover fitted & Fig 8 shows pump with cover removed.

Figure 4 Replacement pump

P/No. 03-000921

Figure 5: Close view of the head of the pump model 03-000921

In this we can see the plug is connected directly to the solenoid coil. This model pump is without reciprocation cycler. & therefore this pump must be controlled with G2 controller. The two outputs from a G2 controller can pulse the solenoid directly & control the vent valve at the same time. See Fig. 13 for wiring diagram.

Figure 6 P/No. 03-000920 shown with cover removed. This model includes a reciprocation cycler.(Ref : Fig 7). Pumps with reciprocation cycler can be controlled with a Lube Management controller. See Fig. 12 for wiring diagram.

Figure 7 P/No 03-000014-2 (includes plug connector) Shown above with-out plug connector.

Figure 8 P/No.03-000920 shown with cover removed. It is shown above with the early Model reciprocation cycler. Ref: Fig 9

Figure 9 P/No. 03-00014 now replaced by 03-000014-2 Ref: Fig 7


+ -


Figure.10 – Exploded BOM for pump

IMPORTANT

START FASTENERS BY HAND

TO AVOID STRIPPING

THREADS WHEN

REASSEMBLING.

PISTON

ROD

03-38165V 01-031050 01-034572 03-016576 01-034572 03-38165V 01-048213

01-012333 01-048213

PUMP

TUBE

BASIC PUMP PISTON ROD PUMP TUBE DRUM SIZE DIMENSION A 03-000920, 03-000921 01-011799 01-061293 20 kg 479 mm

03-000950-USA, 03-000951-USA 01-013020 03-000950-USATUBE 60 kg 695 mm

03-000950-AUS, 03-000951-AUS 01-011761 03-000950-AUSTUBE 60 kg 556 mm

03-000954, 03-000955 01-011761 01-246118 180kg 862 mm

03-000964 01-011064 01-061064 Mini Pump 350 mm

Note: 1. The Seal Kit Part No. 03-000920-9V is a combination of 7 seals for hydraulic cylinder. 2. Lower Pump Tube Kit Part No. 01-083001. 3. Gland Seals 1 x 01-031050, 2 x 03-038165V, 2 x 01-034572 not in kit. Order separately.

A

HIGH CHIEF MANUAL Revision 1, August 2005


Gland Assembly Note: 2 x thin washers P/No

01-048213 and 1 x copper gasket P/No 01-031050 must be assembled as shown in the diagram. After the nut P/No 01-012333 has been tightened check for proper compression of the copper gasket by trying to move the top thin washer P/No 01-048213 with a screw driver. It should be possible to just move the washer. If the thin washer cannot be moved check to see if the copper gasket P/No 01-031050 is in place or the correct thin washer P/No 01-048213 has been used.

01-011349 01-031048

01-061407 01-011346

01-011345

01-011344

01-031049 01-061273

USE LOCKTITE 510 GASKET ELIMINATOR ON THREADS

01-057027 01-066010

01-090554

01-057027

01-066010

01-31047

01-011726

01-011723

01-011722

01-035073

01-011702 01-011721 01-011725

01-011724

01-061275


TORQUE SPECIFICATIONS 1 14 Nm

2 41 Nm 3 61 Nm

4 108 Nm 5 122 Nm 6 136 Nm


Figure. 11 – Torque specification chart.


PARTS LIST

PART NO. QTY DESCRIPTION PART NO. QTY DESCRIPTION

03-000013-1 1 Cylinder Top 01-011721 * 1 Priming check

03-000013-2 1 Cylinder 01-011722 1 Check stop

03-000013-3 1 Cylinder Base 01-011723 * 1 Plunger rod

03-000013-5 1 Valve Reciprocating Assy 01-011724 * 1 Priming plunger

03-000013-5-CS 1 Complete cartridge 2/4 way & 24VDC Solenoid

01-011725 * 1 Priming check seat

03-000013-5-PRC 1 Pressure Reducing Valve 01-011726 * 1 Check seat

03-000013-6 1 Piston (long boss) 01-031047 * 1 Check seat gasket

03-000013-7-2 4 Cylinder tie rods 01-031048 1 Connector gasket

03-000014-2 1 Reciprocation timer 01-031049 2 Bushing gasket

03-001311 1 Outlet steel body 01-031050 1 Gland gasket

03-016576 1 Gland packing spacer 01-031054 1 Pump tube gasket

03-0185-5704 6+ Set screws ¼” x 3/4” 01-034572 2 O-ring

03-0185-6606 2 Set screws ¼” x 2 3/4” 01-035073 * 1 Priming check pack’g

03-000920-9V 1 Seal kit (cylinder) 03-38165V 2 U-packing

01-011340 1 Piston rod 01-048213 2 Gland packing washer

01-011344 1 Plunger adaptor 01-057027 2 Ball stop

01-011345 1 Coupling nut 01-061273 1 Bushing extension

01-011346 1 Coupling nut 01-066010 * 4 Ball

01-011349 1 Piston rod connector 01-090554 1 Plunger & bushing assy

01-011702 * 1 Check washer 01-239719 1 Priming tube

* Included in 01-083001 Lower Pump Tube Repair Kit.

+ 4 off required for Tie Rods, 2 off required for bottom section of valve


UPGRADE KIT 03-000940

from PILOT CHIEF to HIGH CHIEF

Hydraulic Motor End Only

PART NO. QTY DESCRIPTION

01-031050 1 Gland Gasket

01-031054 1 Copper Gasket

01-034572 2 O-Ring

01-048213 2 Packing Washer

01-083001 1 Repair Kit

03-001311 1 Outlet Steel Body

03-016576 1 Gland Spacer

03-038165V 2 U-Packing

03-000013-9V1 2 Viton O-Ring

03-000013-9V2 4 Viton O-Ring

03-000013-9V4 1 Viton O-Ring

03-000013-7-2 4 Tie Rods 3/8” UNC

NOTE: Kit does not include Cylinder or piston



Figure. 12 - Detailed wiring diagram for the connection of the Lube Management controller to the High Chief Pump.



Figure. 13 - Detailed wiring diagram for the connection of the JSG “G2” Timer to the High Chief Pump.



Figure. 14 - Detailed wiring diagram for the connection with hydraulic vent valve using JSG “G2” Timer.


PRODUCT DETAILS USING JSG “G2” TIMER

For more technical detail on the JSG “G2” timer please refer to the “G2” manual.

JSG Industrial Systems Pty Ltd (hereinafter called “JSG”) warrants that all products marketed by

JSG will be free from defects in material and workmanship during one (1) year period following

the date of purchase. If the equipment is deemed to be defective during this warranty

period, it will be repaired or replaced without charge, providing examination proved the

equipment to be defective. To obtain repair or replacement if must be shipped

”transportation charges prepaid”, with proof of date of purchase, to either JSG or one of its

authorised Service Centres within one (1) year following the date of purchase.

This warrant is extended to the original retail purchaser only. This warranty does not apply to

equipment damaged by accident, overload, abuse, misuse, negligence, faulty installation or

abrasive or corrosive materials, or to equipment repaired or altered by anyone not authorised

by JSG to repair to alter the equipment. This warranty applies only to equipment specified,

approved installed and operated according to the recommendations of JSG. No other

express warranty applies to lubrication equipment, material dispensing equipment, hose and

cable management equipment, or other related equipment supplied by JSG.

In no event shall JSG be liable for incidental or consequential damages. The liability of JSG on

any claim for loss or damage arising out of the sale, resale, or use of lubrication equipment,

material dispensing equipment, hose and cable management equipment, or other related

equipment shall in no event exceed the purchase price.

Product Warranty

HIGH CHIEF PUMP

– NO TIMER

HIGH CHIEF PUMP –

WITH “G2” TIMER

COMPLETE TIMER

WITH 5M CABLE

“G2” TIMER

ONLY

5 METRE

CABLE ONLY

03-000921 03-000921-T 13-002500 13-002500-1 13-002500-2

03-000951-### 03-000951-###-T 13-002500 13-002500-1 13-002500-2

03-000955 03-000955-T 13-002500 13-002500-1 13-002500-2

Note: Models 03-000920, 03-000950-AUS, 03-000950-USA & 03-000954 come fitted with a reciprocating timer 03-000014-2


HIGH CHIEF HYDRAULIC OPERATED GREASE PUMP - JSG Industrial · JSG INDUSTRIAL SYSTEMS PTY LTD Page 2...

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