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LUBMANN ALP81 Product Manual

Progressive lubrication pump-bayonet connector version
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PRODUCT MANUAL
ALP81 Progressive
Lubrication Pump
- Bayonet Connector Version

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Summary of Contents for LUBMANN ALP81

  • Page 1 PRODUCT MANUAL ALP81 Progressive Lubrication Pump - Bayonet Connector Version...
  • Page 2 ALP81 BYN Ver. Pump Index Declaration of incorporation CE certification Legal disclosure Safety instructions 8-10 Lubricant Technical data 11-32 Overview 11-12 Working Principle Pump element 14-15 Safety valve SV - C / SV - A 16-18 Installation dimensions 19-20 Low level indication...
  • Page 3 The special documentation that responds to the machine, has been prepared according to annex VII- part B. The manufacturer (documentation department, phone +49 9241 80 89 87 00, email: info@lubmann- gmbh.de) obliges itself to pass on electronically the special documentation for partly completed machinery to individual national authorities upon request.
  • Page 4 ALP81 BYN Ver. Pump CE certification Page 1...
  • Page 5 ALP81 BYN Ver. Pump CE certification Page 2...
  • Page 6 ALP81 BYN Ver. Pump CE certification Page 3...

  • Page 7: Legal Disclosure

    E-Mail: info@lubmann-gmbh.de Website: www.lubmann-gmbh.de Training courses In order to provide a maximum of safety and economic viability, Lubmann GmbH carries out detailed training courses. It is recommended that the training courses are attended. For more information, please contact Lubmann GmbH.

  • Page 8: Safety Instructions

    ▪ Unauthorized modifications of the product ▪ Intent or negligence ▪ Use of non-original Lubmann spare parts ▪ Faulty planning or layout of the centralized lubrication system Liability for loss or damage resulting from the use of our products is limited to the maximum purchase price.

  • Page 9: Assembly And Maintenance

    Use in conformity with the intended purpose: The pumps of the series ALP81 serve only for the supply of central lubrication pumps at vehicles, systems and machines. Any use beyond this scope is regarded as being not in conformity with the intended purpose.
  • Page 10 Transport and storage of the pump The pumps of the series ALP81 are packed commercially, according to the regulations of the recipient country and to the wish of the customer. There are no limitations with respect to land, air or sea...

  • Page 11: Technical Data

    ALP81 BYN Ver. Pump Technical data Overview Lubmann progressive centralized lubrication pump type - ALP81 has been widely used in industries like wind power, mining, metallurgy, machine tools, textiles, food, ports, commercial vehicles, construction machinery, and heavy mechanical equipment, etc.
  • Page 12 Dia. 12.1 ALP81 3D view The ALP81 series pumps differ in reservoir size and control type. It can be controlled by the standard integrated controller with current version AK09* with LED display AK06, or externally by PLC, board computer or external controller from Lubmann.

  • Page 13: Working Principle

    ALP81 BYN Ver. Pump Working Principle A gear DC motor ⑨ continually operates eccentric pressure disc ⑤. This eccentricity effects the suction and pressure strokes of the delivery piston ⑥, whereby the integrated non-return valve ⑦ prevents the delivery media from being sucked back out of the main line.
  • Page 14 ALP81 BYN Ver. Pump Pump Element ALP81 series pumps can be installed - max. 3 pump elements with type C safety valve (SV-C without bypass) on the pump outlet position 1/2/3 max. 2 pump elements with type A safety valve (SV-A with bypass) on the pump outlet position 1/3*.
  • Page 15 ALP81 BYN Ver. Pump Pump Element Function of Pump Element 15.1-1 On the vertical shaft of the geared DC motor an eccentric pressure disc EPD with eccentric hole in the centre is mounted. When the pump starts running the EPD will make a back-and-forth movement (X1, X2, X3).
  • Page 16 ALP81 BYN Ver. Pump Safety Valve Type C: SV-C for PE (Standard Version) Safety valve Type C: without bypass function Safety valve Type C: Pre-set to 300 bar When the system pressure is higher than the pre-set valve (300 bar), the safety valve opens, lubricant flows from the safety valve overflow port out.
  • Page 17 ALP81 BYN Ver. Pump Safety Valve Type A: SV-A for PE Safety valve Type A (SV-A): with bypass function Safety valve Type A (SV-A): Pre-set to 300 bar When the system pressure is higher than the pre-set valve (300 bar), the safety valve opens, lubricant flows from the bypass of the safety valve and back to pump reservoir.
  • Page 18 ALP81 BYN Ver. Pump Grease Bypass Kit for Safety Valve Type A Single Bypass（Order No. 2011222820） In Dia. 18.4 shows the pump with safety valve type A and single bypass, which mainly used for Windmill application. When the pressure is higher than the pre-set max. value of the safety valve, the grease flows back through the pump element - safety valve - single bypass - pump reservoir.
  • Page 19 ALP81 BYN Ver. Pump Installation Dimensions for ALP81 - 1 Liter Dia. 19.1 Dimension of ALP81 – 1 Liter Reservoir with Pump Bracket (Order No. for Pump Bracket: 3010102600)
  • Page 20 ALP81 BYN Ver. Pump Installation Dimensions for ALP81 - 2 Liter Dia. 20.1 Dimension of ALP81 – 2 Liter Reservoir with Pump Bracket (Order No. for Pump Bracket: 3010102600)
  • Page 21 ALP81 BYN Ver. Pump Low-level Indication Functioning principle of the intermittent grease low-level indication The intermittent low-level indication operates free of contact. Its main components are the following: 1. firmly positioned magnetic switch A inside of the reservoir bottom 2. flexible guide plate E connected to the stirring paddle B with a magnet C 3.A control curved track D fixed on the perforated base plate...
  • Page 22 LED Display AK06 with Integrated Controller AK09 Dia. 22.1 AK06 LED- Display Our AK09 V5.3 controller / print board is the integrated setting adjustable controller for ALP81 BYN Ver. pumps series. The AK06 LED – Monitor / Display Universal works only in combination with the AK09 Setting adjustable controller which can be programmed with different program codes depending on the version (Standard Program Code for ALP81 BYN Ver.
  • Page 23 Click Down Arrow no matter during the pause time or lube time, can enter the status checking interface to check the following data: D-XX: Program Code of the pump (for ALP81 Pump regular program, XX=61) EE-X: Error Code in the last cycle X (X= 0, 1, 2) t XX: Environment Temperature is XX°C...
  • Page 24 LED Display AK06 with Integrated Controller AK09 Parameter Setting – First connecting to power For first time connecting the power on the pump, the display shows Dia. 24.1 Controller program code the program code “d-61” up like (Dia. 24.1) or other pump pre-set program code, depends on pump and software type.
  • Page 25 ALP81 BYN Ver. Pump LED Display AK06 with Integrated Controller AK09 Parameter Setting – Setup new parameter Press �� button to switch to 4P Low temperature setting. With this parameter you can stop the pump working at low temperatures. Dia. 25.1 Setting of 4P - Pre-set temperature is –...
  • Page 26 ALP81 BYN Ver. Pump LED Display AK06 with Integrated Controller AK09 Restart of controller by switching off the machine In case power/machine is switched off during a lube Dia. 26.1 Cycle changing when power time P1 or pause time P3 following happens:...
  • Page 27 ALP81 BYN Ver. Pump Wiring Connection (With integrated Controller) ALP81 pump with Bayonet 7 Pin connectors – Solution for Divider Monitoring and External Test Button and Indication Light * The pump is supplied with 12/24V DC via the Bayonet 7-pin plug via Pos. A.
  • Page 28 ALP81 BYN Ver. Pump Wiring Connection (With non-Controller) ALP81 pump with Bayonet 7 Pin connectors – Solution for External Low Grease Level Indication Light * The pump is supplied with 12/24V DC via the Bayonet 7-pin plug via Pos. A and the pump is not programable with lube time and pause time.
  • Page 29 5. Only fill in clean lubricants! The service life of the pump elements highly depends on the quality of the used lubricants. Grease refilling Nipple M10x1 Part No. 2031001509 Pneumatic Filling Machine* * Multiple types depends on the applications, please contact us for more order info. Dia. 29.1 Optional refilling devices for ALP81 Pump...
  • Page 30 ALP81 BYN Ver. Pump Explosion Drawing – ALP81 Pump BYN 7 Pin Connector 12/24 VDC Power & AK09 Controller 1 Liter & 2 Liter Reservoir Dia. 30.1 ALP81 Pump – Explosion Drawing...
  • Page 31 1.18-1 1 Pump bottom cover - ALP81 205x130x20 3020101170 1.18-2 1 Seal ring - pump bottom cover - ALP81 202x132x2​ 3020200470 1.19 Set - cylinder screw with inner hex M4 L20 with flat and spring washer 3040104370 Divider monitoring input socket and cap with internal wirings and cap 12/24V DC, 1.20...
  • Page 32 Connecting Rods (ALP81 2L) D7 M6 L236 3010402391 2.05-1 4 Flat Washer D6 3040101080 2.05-2 4 Spring Washer D6 3040101090 2.05-3 4 Acorn Nut M6 3040102200 2.06 Ventilation Unit 2090121660 2.07 Hex Nut M8 3040102510 2.08 T-Type Rod for Grease Mixing (ALP81 2L) D10 L162 3010106150...

  • Page 33: Delivery, Returns And Storage

    Protect the product against mechanical influences such as impacts. There are no restrictions for land, sea or air transport. Storage Lubmann products are subject to the following storage conditions: ▪ dry, dust- and vibration-free in closed premises ▪ no corrosive, aggressive materials are allowed to be nearby (ozone) ▪...

  • Page 34: Place Of Installation

    ALP81 BYN Ver. Pump Step for Storage period from 6 to 18 months - Hose 1. Dismantle preassembled hose 2. Ensure that both sides of the hose remain open 3. Fill hose with new lubricant Storage period exceeding 18 months To avoid dysfunctions, consult the manufacturer before commissioning.
  • Page 35 ALP81 BYN Ver. Pump - Electrical connection Electric shock Make sure to disconnect the product from the power supply before carrying out any works on electrical components. Carry out the electrical connection according to the connection type of the pump, 1.

  • Page 36: Troubleshooting

    ALP81 BYN Ver. Pump Trouble shooting Fault Possible cause Solution Pump does not run ▪ Power supply to pump interrupted Check whether one of the indicated faults is present and − Superior machine is switched off remedy it in the frame of −...

  • Page 37: Shutdown And Disposal

    ALP81 BYN Ver. Pump Defect of the safety valve • Signal for a defected safety valve – the lubricant comes out from the safety valve. Dismount the main hose from the outlet of the safety valve and use a blind plug on the outlet. Check the pressure of the manometer, if the safety valve opens under 180bar, replace the safety valve.
  • Page 38 ALP81 BYN Ver. Pump Order Key...

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