Lubecore International Automated Lubrication System Inspection, Service & Repair - MLP/Spyder Pump MKI & MKI Rev-A

Lubecore International Automated Lubrication System Inspection, Service & Repair - MLP/Spyder Pump MKI & MKI Rev-A

System Inspection MKI & MKI Rev-A Spyder System Check Check for: Conclusion of Review Identifying Spyder Pumps Mk1 Mk1 Rev-A Power to pump turn on power source to pump. MKI (No LED power indicator) Use Multi-meter to test for voltage: Black Ignition Red Battery Brown Ground If no power/ground check wires and power source MK2 Rev-A LED left of the pushbutton must be on. Brown Ground Black Ignition If no power/ground check wires and power source Test operation of board and motor using supplied magnet Put magnet on here for MK1 MK1 If motor does not start, confirm voltage to motor at the board output to motor connections. Blue and Brown wires. If power not present. Possible Timer or motor issue, (see pg.5) Here for MK1 Rev-A MK1 Rev-A If cycle indicator LED comes on, and the motor does not, confirm voltage to motor at the board output to motor connections. Blue and Brown wires. If power not present, Possible Timer or motor issue, (see pg.5-6) Visual inspection of Pump Pump reservoir grease level Check appearance of pump looking for loose mounting bolts, loose connectors, etc. Is there sufficient grease in the reservoir? Repair as required When reservoir does not contain sufficient grease, (less than 1/4"), Proceed with refill procedure 2

Grease lines If pump has been operated with an empty reservoir Are there any leaks? Fill reservoir to MAX level and operate pump continuously, (see pg.8-9) Loosen all outlet tube fittings of elements and make sure air-free lubricant emerges. Re-tighten all tube fittings. Make required repair. (Lubrication point is not being lubricated until repaired.) Are there signs of wear due to rubbing or movement? Make repairs, re-route or protect tubing to prevent further damage. Are all grease point fittings Secure? Any signs of wear? Make repairs as necessary. Lubrication / Grease points Review if any of the following is applicable to the lubrication points: - Are points too dry (no grease visible) or too wet? (Large accumulation of grease at point) All points are dry: Timer interval too long or an electrical defect. With power on check with volt-meter for voltage at pump connector. If no voltage is measured, check fuse. When the fuse is defective, replace with a 5 amp rated fuse. For timing interval adjustment, please refer to appropriate manual. All points are too wet: Timer interval too short. (See pg.10-12). Note: Check for reverse polarity as the Mk1 pump will run continuously 1 or more points are too dry/wet: - Too wet: Confirm the correct elements have been installed. Please contact Lubecore for replacement instructions. - Too dry: Confirm elements are delivering grease & the correct elements have been installed. Please contact Lubecore for replacement instructions. Some pump elements do not dispense lubricant. Test for Air Lock around suction port of the element. Unscrew element from the pump housing, and start pump cycle. After grease starts to emerge, re-install the element and re-tighten. Start another pump cycle. If the element fails to dispense lubricant again, replace the element completely. *NOTE: Depending on temperature and/or type of lubricant, it can take up to 10 minutes till the pump elements commence full delivery. 3

MLP/Spyder System Identification (Eg.1) MKI - Timer Board with Dipswitches for trailer application Pin 30 Red Battery (+) Pin 87 Blue (+) Motor Pin 31 Brown (-) Motor Pin 31 Brown (-) Ground Pin 15 Black Jumper Wire to Pin 30 (Eg.2) MKI Timer Board with Dipswitches for truck application Pin 30 Red Battery (+) Pin 87 Blue (+) Motor Pin 31 Brown (-) Motor Pin 31 Brown (-) Ground Pin 15 Black Ignition (+) (Eg.3) MKI Rev-A - Timer Board with Rotary Dials & Push Button Pin 15 (+) Power Black Wire Pin 31 (-) Ground Brown Wire M (+) Motor Blue Wire M (-) Motor Brown Wire Power Indicator LED Manual Test Button Cycle Indicator LED 4

MLP/Spyder Cycle Test Turn the ignition on if pump is mounted on a truck. If pump is mounted on a trailer, ensure the 7 way trailer plug is inserted in the nose box on the front of the trailer. Remove the magnet from its holding position located on the side of the pump and place on the marked locations on the lid of the pump as shown below. 1. Mk1 Pump requires the magnet to sit directly over the front centre lid screw with part of the magnet touching the screw. Pump should activate between 10 and 15 seconds after contact. 2. Mk2-Rev-A Pump requires the magnet be placed just left of the raised logo on the lid, between the centre screw and the mounting screw to the far left. Pump should activate between 10 and 15 seconds after contact. 1 2 The pump should cycle for the manufacture specified time. MLP/Spyder Is Not Working 1. Always remove the DIN connector from the pump and check for power and ground at the plug end. The Mk1 DIN connector has one wiring configuration while the Mk1 Rev-A has two of its own configuration. You must verify which DIN connector configuration you have, as the pump power cables are not interchangeable with each other. Example: The system you are presently working on has already had its pump changed. However the mechanic did not verify the wire harness configuration for the pump that was installed. So the pump does not work. The solution to the issue is to open the DIN connector plug and reposition the wires within the DIN connector plug so the appropriate terminal sockets in the DIN plug match up to the correct DIN pins on the receptacle base. 5

These are the three wiring configurations for the Mk1 & Mk1 Rev-A pumps Mk1 MLP/Spyder DIP Switches Mk1 Rev-A MLP/Spyder Dials Mk1 Rev-A2 MLP/Spyder Dials 6

2. On a truck - check the fuse, all connections and the DIN plug. 3. On a trailer - If a set of audible clicking is heard from the trailer the ABS has power and so should the auto-lube system. If the ABS start up sequence is not heard, you must investigate to ensure that the ABS is working before proceeding with the inspection and testing of the auto-lube system. Check ABS connection to brake module Check the ABS Y connector and the wire extension to the pump Check for corrosion at the junction box Check for corrosion at all connections including the DIN connector These items must be repaired before proceeding with the auto-lube inspection and testing, as the auto-lube system is powered by the ABS control module main harness on a trailer installed system. Cables, connections and fuse are okay but pump does not cycle. Remove the timer cover from the pump using a No.#2 Philips screw driver and verify that the timer board does not show any signs of corrosion or contamination. Mk1 - Use a multi-meter to check for power, the Red wire (pin 30) is positive (+) the Brown wire (pin 31) is (-) if power is present, attempt to cycle the pump again using the magnet. If pump does not cycle - carefully remove the Red (pin 30) (+) positive lead from the timer board and touch the Blue (pin 87)(+) wire for the motor. The motor should run and the mixing paddle should be seen moving in the reservoir. If the motor runs change the timer board, if the motor does not turn change the pump. If corrosion is found - replace timer. Mk1 Rev-A - Observe the LED referred to in (Eg.3 Pg.4) it indicates that power is present at the timer board. The Mk1 Rev-A power wire is Black (pin 15) is positive (+), the Brown wire (pin 31) is negative (-) Push the manual test button, an LED should light up just right of the Red dial, signifying that the pump is cycling according to the manufacture specifications. 7

If there are two LEDs lit on the timer board, but the motor is not turning. Use a piece of wire stripped at both ends and insert one end in to the back of the Molex connector behind the Blue (+) wire and the other end into the Black wire (pin 15)(+) (Eg.3 Pg.4). The motor should start running and the paddle should be seen rotating in the reservoir. If the motor runs change the timer board, if the motor does not run change the pump. MLP/Spyder Is Working But Equipment Is Dry Verify that you have power and ground at the pump DIN connector Verify time settings are correct for the installed system. Turn the ignition on if pump is mounted on a truck. If pump is mounted on a trailer, ensure the 7 way, trailer plug is inserted in the nose box on the front of the trailer and is supplying power. On the Mk1 (DIP Switch model) there is no way of causing the pump to run continually by using the magnet or the timer board. But there is an alternative way of causing the pump to run continually. Remove the Lid from the pump and using 1 pair of alligator test leads clip one end of the test lead on A which is pin 30 on the timer board or Battery and connect the other end of the test lead on B which is pin 87 on the timer board, which is motor positive. The motor will run until you remove your test leads if there is a good ground. Run the pump this way until fresh grease is visible at all grease points. B A If grease is not visible after 10-15 minutes at a particular grease point, trace the secondary line back to the pump looking for leaks along the line. If no leaks are found, remove and replace the pump element with the same volumetric specifications. (Ensure that the element comes out completely intact) 8

On the Mk1 Rev-A pump, place the magnet over the designated area on the timer cover as shown on page 3. Leave the magnet in place and the pump will continually run until the magnet is removed. An alternative way of having the pump run continually is to insert a 3 wire, with stripped ends into the backside of the Molex connector, connecting the Black wire (+) (pin 15) to the Blue wire (Motor +). If grease is not visible after 10-15 minutes at a particular grease point, trace the secondary line back to the pump looking for leaks along the line. If no leaks are found, remove and change the pump element with the same volumetric specifications. (Ensure that the element comes out completely intact) MLP/Spyder Element When removing a MLP/Spyder element from a pump for inspection, or replacement. It must come out complete, as the picture above shows. If the piston or spring is missing from the end of the element, a magnet will have to be used to retrieve the missing pieces from inside the pump housing. NOTE: Do not run the pump until the missing pieces are recovered as this will severely damage the pump!!! 9

MLP/Spyder Timer Settings Mk1 Time Settings 8 Position DIP Switch Settings Pause/Dwell Time (Only 1 switch can be ON pos. Except No.8) Time In Minutes No.1 No.2 No.3 No.4 No.5 No.6 No.7 No.8 ON Range 1 1.9 3.8 7.5 15 30 60 120 240 OFF Range 2 101.9 103.8 107.5 115 130 160 220 340 Working Time Setting (in seconds) Switch No.1 No.2 No.3 No.4 Time 10 sec. 20 sec. 40 sec. 80 sec. OFF ON 1 2 3 4 5 6 7 8 1.9 Min. OFF ON 1 2 3 4 5 6 7 8 3.8 Min. OFF ON 1 2 3 4 5 6 7 8 --- Min. OFF ON 1 2 3 4 5 6 7 8 7.5 Min. OFF ON 1 2 3 4 5 6 7 8 101.9 Min. OFF ON 1 2 3 4 5 6 7 8 130 Min. OFF ON 1 2 3 4 5 6 7 8 107.5 Min. OFF ON 1 2 3 4 5 6 7 8 340 Min. 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 10 Sec. 20 Sec. 30 Sec. 40 Sec. --- Sec. 10

Mk1 Rev-A Time Settings 11

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Lubecore Service Guide Infield Repair of Loose MLP/Spyder Pump Motor Mounting Bolts LCI recently discovered a possible issue pertaining to the torque settings on the three bolts that hold the motor assembly to the MLP/Spyder pump body, this issue may result in a leaking pump and possible damage to the pump elements if not rectified. This LCC (Lube Core Communication) will guide you through an infield repair of the MLP/Spyder Pump. This repair should be able to be carried out while the MLP/Spyder pump is still mounted on the equipment in question. (NOTE: When you are looking directly at the pump, verify whether there is a serial number plate mounted on the left hand side of the green pump bracket. If there is no serial tag please contact the Lubecore International Warranty Administrator for directions on how to proceed) 5mm x 7.5mm Ball End Allen Key socket You will need a cam clamp similar to this, You will also require: 1. Inch pound torque wrench 2. Brake cleaner 3. shop rags 4. 12mm wrench 5. 14mm Deep socket 13

Firmly grasp the lid of the pump and turn either clockwise or counter clockwise depended on pump mounting location and/or space afforded to move freely. Position the cam clamp directly under the corner of the lid and activate the lever so that the cam bar causes pressure between the lid and the green bracket. Consistent pressure will cause the lid to pop off the pump. Note: Do not use anything other than a cam clamp to perform this function, otherwise you will crack the reservoir and/or lid Clean out any grease that remains in the reservoir until you can see the bottom of the reservoir. Turn the stir arm clockwise (its LH thread) and it should break loose and unthread. No tools are required to perform this. 14

Once the grease has been removed, this is the view you will have of the inside of the MLP/Spyder pump This is a view of the inside of the pump when the reservoir is removed, DO NOT REMOVE THE RESERVOIR A A C B A A (A) Represents the bolts that you need to tighten to 7.5 ft/lbs. As you can see from the picture to the right you may have to remove a number of piston elements (B) from the pump (Pg.15-16) so you can get access to the motor mounting bolts located at the bottom of the pump. When removing these piston elements ensure they are kept in a clean location to prevent contamination which could cause premature failure of the piston element, pump or lubrication point. Slots ( C ) (Pg.15-16) located at the bottom of the reservoir will allow you access to the bolts, so you will not have to remove the reservoir from the pump body or mounting bracket to properly torque the bolts. Prior to removing the piston elements, use the 12mm wrench to release the compression nut on the lines leading to the piston element. Label these lines so you can identify which line goes to which piston element. (Colored electrical tape or masking tape and pen work) To remove the piston element slide the 14mm 12 point deep socket all the way in, until the socket is either touching the pump housing or is on the piston element body, dependant on the length of the socket. Remove piston element and store in a safe, clean location until reassembly. Insert the 5mm x 7.5mm Ball End Allen Key wrench or socket through the appropriate slot, located at the bottom of the reservoir. Lightly snug up all the bolts by hand prior to using the ft/lb torque wrench. Carefully torque the motor mounting bolts to 7.5 ft/lbs When reinserting the piston elements into the pump body ensure that all springs and piston tips are present and assembled. The springs should be holding the piston tips to the body of the element and the whole unit should be inserted as a single piece. If the springs are not holding the piston tips to the body a new piston element will be required. Reverse the procedure for re-assembly. Caution: Do Not Mix & Match Element Pins & Bodies!!!! 15

6 7 3 10 2 11 A light shining through the motor mounting holes show the motor mounting bolt locations with the elements in place. The yellow circle signifies the front of the pump. The Red Trapezoids show the location of the slots that can be used to access the motor mounting bolts This yellow circle signifies the front of the pump 16

17 16 15 14 13 ELEMENT HOLE 1 TOP ROW 2 MIDDLE ROW 3 BOTTOM ROW 20 19 18 12 10 11 21 9 23 22 7 8 24 6 Element Removal Combination to allow access to the motor 5 6 14 15 25 26 4 13 24 Right of front centre Back Left of front centre 25 26 27 1 2 3 4 5 Torque bolts to 7.5 ft/lbs Once you have tightened up the motor mounting bolts, position the lid on top of the pump making sure that the groove in the lid matches up with the ridge of the reservoir. When you are sure that the pump lid and reservoir ridge are in line with each other. Give the lid a quick rap. The lid will then snap down onto the reservoir. Fill pump using the fill connector (DO NOT FILL THE PUMP FROM THE TOP) Test the pump. 17

Lubecore International 7065 Twiss Road Campbellville, ON L0P 1B0 CANADA Phone: (905) 864-3110 Fax: (905) 878-6935 Tech Assistance: support@lubecore.com Website: www.lubecore.com MLP Parts Catalogue Lubecore_PC_003_MLP rev02 18