User s Manua nstaation & Operating nstructions PRECSON PUMP APPLCATOR For Box, Junior, and Custom Appicators For questions and/or product support contact the TW ROCOL North America Customer Service Department at 8--8 ext..
ntroducng Accu-Lube History of Exceence Since 99 Accu-Lube has been the industry eader in manufacturing ubricants and equipment for Minimum Quantity Lubrication (MQL). Today Accu-Lube continues to be at the forefront of MQL and near-dry machining through a dedication to innovation, safety, and service. Quaity over Quantity Accu-Lube MQL precision pump appicators use advanced technoogy to focus dropets of ubricant directy onto the too s cutting edge, providing ubrication and protection precisey where it is needed. This minimum quantity approach aows manufacturers to conserve fuid and cut down on waste. By eiminating unneeded food cooant shops remain cean and fuid maintenance is no onger necessary. This process is caed Near-Dry Machining. TW ROCOL North America TW ROCOL North America, manufacturer of Accu-Lube products, is an industry eader in the deveopment and production of scientificay advanced fuid products for the metaworking industry. Precson PumP APPLcAtors Accu-Lube Precision Pump Appicators are positive dispacement ubrication systems for Minimum Quantity Lubrication that reguate the amount ubricant appied to a too s cutting edge in exact quantities. Accu-Lube precision pumps are designed to accuratey deiver a constant and consistent amount of ubricant from the instant the appicator is turned on unti the moment it is turned off. Unike cheap siphon-type imitators, which are negativey affected by sma variances in air pressure, room temperature, air hose ength, and ubricant viscosity, Accu-Lube precision pumps operate with accuracy and precision year after year to deiver ubricant to the cutting edge each time, every time. An Accu-Lube precision pump uses positive dispacement and air pressure to power the pump cyce. The back stroke of the cyce draws a precise, measured amount of ubricant into a chamber ike a syringe. nstanty the forward stroke forces the ubricant down a capiary tube inside an air hose up to ft. (8 m) ong. Since the pump cyce is automaticay reguated by a frequency generator it is not affected by ubricant viscosity, which changes with temperature. This is crucia for any appication operating in an environment without cimate contro since ubricants thicken in the cod. Accu-Lube precision pumps deiver instant performance, with every type of Accu-Lube ubricant, in a conditions. Precision Pump Appicator
table of contents Components... Preparing... nstaing... Nozze Positioning... - Operating... Setting the Lubricant Contro... 8-9 Setting the Frequency Generator... Re-Priming the Pump... Repacing the Hose Assemby... Repacement Parts... - Warranty... Troubeshooting... Technica Support... unpackng & nspectng Before beginning set-up make sure that you have the foowing items:..... Accu-Lube precision pump appicator (Box, Junior, or Custom Appicator) Liquid reservoir Nozzes and mounting camps (if appicabe) 8 oz. LB- sampe Warranty card, fi out and return within days of purchase f one of these items is missing do not continue with set-up. Contact Customer Service at 8--8 ext. regarding missing/damaged items. Precision Pump Appicator
components 8 ARFLOW + OL + 9 ARFLOW + OL + Figure. Two Nozze Auminum Pump Appicator with Manua Contro. Liquid Reservoir: Lightweight, durabe poycarbonate reservoir (severa sizes and designs are avaiabe, see page for information).. Reservoir Extension: Connects the iquid reservoir (#) to the appicator.. Braided Air Hose: Carries compressed air to the nozze.*. Lubricant Line: Capiary tube that runs inside the braided air hose.* *Hose Assemby: braided air hose (#) & ubricant ine (#).. Airfow Vave: Contros the amount of continuous air suppied to the nozze.. Security-Box (Box & Custom Appicators ony): Durabe stee box with ock. Separate front and back doors offer maximum access and protection.. Lubricant Contro: Secondary ubrication contro; adjusts the amount of ubricant deivered during each pump cyce. 8. Air Fiter Reguator/Pressure Gauge: Heps prevent partices and water from entering the appicator through the air suppy. 9. Precision Pump: Uses air pressure to power the pump cyce; provides consistent and accurate ubrication instanty.. On/Off Vave (Manua appicators ony): Contros the appicator by reguating airfow (eectronic soenoid contros are avaiabe, see page for information).. Air net: Accu-Lube precision pump appicators are pneumaticay powered.. Frequency Generator: Primary ubrication contro; reguates the pump cyce. Precision Pump Appicator
PrePArng... Remove the pastic shipping pug from the reservoir extension (Fig. #) on the top of the appicator and cean any debris from the threads and opening. Wrap the threads on the bottom of the reservoir (Fig. #) with Tefon tape (not incuded) and attach to the reservoir extension with a ¾" wrench. Connect the nozze to the end of the hose assemby: Copper/Stainess Stee Nozze: a. Cut the ubricant ine so that it wi stop ¾" to ½" from the end of the nozze when the tip is instaed.* ¾" to ½" Braided Air Hose Hose Camp Lubricant Line Magnetic Mount (optiona) Cut ubricant ine here b. Side the hose camp onto the air hose. nsert the end of the nozze " into the air hose. Side the camp ½" from the end of the air hose and secure. " ½" Loc-Line Nozze: a. Cut the ubricant ine back to the third knucke from the nozze tip.* Braided Air Hose Hose Camp Lubricant Line Magnetic Mount (optiona) Cut ubricant ine here b. Side the hose camp onto the air hose. nsert the end of the nozze into the air hose. Side the hose camp over the air hose and secure. Speciaty Sawing Nozzes: N-Nozze, V-Nozze, C-Nozze, R-Nozze: use Loc-Line nozze instructions. CM-Nozze, CL-Nozze: use copper/stainess stee nozze instructions. *NOTE: A ubricant ine that is onger or shorter than recommended wi resut in poor, inaccurate ubricant spray and decrease the appicator s effectiveness. Precision Pump Appicator
nstallng Mounting: Accu-Lube Box and Custom Appicators are mounted permanenty onto the machine. Optiona magnets mounts are avaiabe for - pump appicators.. Attach the appicator to the machine, make sure that it is as eve as possibe.. Position and attached the nozzes foowing the instructions beow.. Fi the reservoir (Fig. #) with ubricant. Refer to warranty information on page.. Eectric soenoid appicators ony: At this point a icensed eectrician shoud set-up the eectric soenoid contro.. Make sure the appicator is off, then the attach air suppy to the air inet (Fig. #). NOTE: f excessive oi, mist, or dirt is present in the air suppy an optiona coaescing fiter is highy recommended (see pages - for parts information). nozzle Postonng Nozze pacement is extremey important to effective Minimum Quantity Lubrication; they must be positioned so ubricant is appied to the cutting edge of the too BEFORE the cut is made (see Fig. ). For many machining operations mutipe nozzes are recommended for optima ubrication. Consut your Accu-Lube Saes Representative or the factory for recommendations. Speciaty Sawing Nozzes: Band Saw Nozzes; N-Nozze, RL-Nozze:. Position the nozze over the band saw bade and attach to the eading guide arm before the cutting point (see Fig. ).. Make sure the nozze is ½" to ¾" above the bottom of the bade; the ubricant stream shoud form a ange with the cutting edge (see Fig. ). Test the stream position with a piece of paper (see Step of Operations, page ). Figure. ½"-¾" Figure. Figure. work piece Precision Pump Appicator
Band Saw Nozze; V-Nozze:. Mount the nozze on the door near the whee or on the back side of the machine so that the nozze faces into the teeth of the bade. Circuar Saw Nozzes; C-Nozze, CM-Nozze, CL-Nozze:. C-Nozze ony: f the saw has a covering use the mounting bracket as a tempate to cut a hoe in the covering for the nozze to go through, then side the main body of the nozze through the bracket and the hoe in the covering.. Mount the bracket where it won't obstruct the movement of the saw. NOTE: The C-Nozze comes with its own mounting bracket but the CM-Nozze and CL-Nozze wi need a mounting bracket.. Position the nozze within " of the bade. Make sure that the ubricant spray eveny covers the guet and both sides of the bade. Standard Nozzes Copper, stainess stee, Loc-Line:. Position the nozze ess than " from the cutting too making sure it is aimed towards the cutting edge (see Fig. ).. f the machine has moving parts make sure they don t interfere with the nozze. operatng A Accu-Lube pumps are primed and tested before shipping, however if the prime is ost see page for instructions on re-priming the pump before beginning Step.. Make sure the air suppy is connected and then turn the appicator on.. Check the ubricant fow by hoding a piece of paper where the work piece wi be for a minute then remove the paper, there shoud be a moist circe of ubricant roughy " (. cm) in diameter, about the size of a quarter. The paper shoud be damp but not soaked through. NOTE: f the paper is soaked through the ubricant contro is set too high.. Adjust the airfow vave (Fig. #) on each pump, turn countercockwise to increase air fow and cockwise to decrease the fow. The airfow shoud be just high enough to move the ubricant to the cutting edge. NOTE: Misting ubricant is often an indication that the airfow is too high.. Set the frequency generator (Fig. #), see instructions on page.. Set the ubricant contro (Fig. #), see instructions on pages 8-9.. Run the appicator for a few minutes and make sure fow of ubricant is stead and uninterrupted. Repeat Step and check spray pattern.. Make a test cut and then check the temperature of the too and work piece: The too shoud be at room temperature + F (8 C). Work piece shoud be sighty warmer than the too. Chips shoud be hot. WARNNG: Do not touch chips! Precision Pump Appicator
The ubricant contro is the secondary ubrication contro. t is used to fine-tuning the amount of ubricant in each pump cyce. To set the ubricant contro for genera operations see Standard Operation Setting beow, for more detaied settings see Operation-Specific Settings on the next page. Before the contro can be set the pump must first be set to the Zero Point: Stop Point:. Turn the ubricant contro cockwise as far as it wi go, the dia wi most ikey stop around or. NOTE: Never eave the contro at this setting because ubricant wi seep out of the appicator, even when the appicator isn't in operation. Zero Point:. Turn the ubricant contro countercockwise back to. settng the LubrcAnt control Standard Operation Setting: Start at the Zero Point and turn the contro countercockwise fu revoution, continue turning unti the contro is set at. a) Zero Point b) fu revoution c) Set at COUNTERCLOCKWSE COUNTERCLOCKWSE a) b) Stop Point or CLOCKWSE a) b) Zero Point COUNTERCLOCKWSE ARFLOW + OL + Figure. Lubricant Contro Side View CLOCKWSE COUNTERCLOCKWSE Figure. Lubricant Contro Front View Precision Pump Appicator 8
Operation-Specific Settings: NOTE: f these guideines aren't working for your operation try adjusting the amount of ubricant and/or the frequency generator (see page ). You can aso contact your Accu-Lube Saes Representative for Technica Support. a) Zero Point b) fu revoutions Band Sawing c) Set between & COUNTERCLOCKWSE COUNTERCLOCKWSE COUNTERCLOCKWSE a) Zero Point b) fu revoutions Broaching c) Set between & COUNTERCLOCKWSE COUNTERCLOCKWSE COUNTERCLOCKWSE a) Zero Point b) fu revoutions Circuar Sawing c) Set between & COUNTERCLOCKWSE COUNTERCLOCKWSE COUNTERCLOCKWSE a) Zero Point b) fu revoution Driing & Tapping c) Set between &. COUNTERCLOCKWSE COUNTERCLOCKWSE a) Zero Point Grinding b) Set between &. COUNTERCLOCKWSE a) Zero Point b) fu revoution Miing c) Set between & COUNTERCLOCKWSE COUNTERCLOCKWSE 9 Precision Pump Appicator
settng the frequency generator The frequency generator contros the pump cyce and is the primary ubrication contro. t is used to make major ubricant adjustments, fine tuning is done with the ubricant contro.... With a stop watch determine the ength of the pump cyce in seconds. Each pump cyce consists of two strokes, a back stroke and a forward stroke. Use a sma fat screwdriver to adjust the frequency generator, countercockwise increases the cyce speed and cockwise decreases the speed. With the stop watch continue to monitor the pump cyce unti the desired cyce rate is reached. NOTE: Use the chart beow as a ROUGH guideine. Contact the factory or your Accu-Lube Saes Representative for more detaied recommendations. Appication Cyce time (sec.) Cyces per min. Fuid used* (oz.) Circuar sawing - -.-.8 Band sawing.- -.-. Broaching.- -.-. Miing - -.-. Driing.- -. Tapping.- -. Grinding - -.-. * Daiy fuid use amount per nozze during an eight-hour shift. re-prmng the PumP f the Accu-Lube appicator has ost its prime it wi be necessary to re-prime the pump before it wi operate propery..... 8. Make sure the appicator is turned off with the air suppy disconnected and the reservoir is fied with ubricant. Turn the ubricant contro countercockwise as far as it wi go. NOTE: This is the maximum setting and shoud ONLY be used during priming. Attach the air suppy and turn the appicator on. Set the frequency generator to cyce every second ( cyces per minute). Let the appicator cyce unti fuid begins to fow through the ubricant ine and out the tip of the nozze. NOTE: This process usuay ony takes a few minutes, if the appicator has cyced for more than five minutes without any progress refer to Troubeshooting on page for additiona hep. Precision Pump Appicator
replacng the hose AssembLy Hose Barb Outet Rubber Grommet Lubricant Line Braided Air Hose Hose Barb O-Ring Lubricant Line O-Ring ARFLOW + OL + Refer to pages - for repacement parts information, make sure you have a the necessary components before starting to repace the hose assemby.. Cut the od hose assemby (braided air hose & ubricant ine) off just past the end of the hose barb outet and then carefuy pu or cut the remaining air hose off the barb.. Unscrew the hose barb outet from the pump.. Remove the o-ring from the ubricant ine and set it to the side.. Remove the remaining ubricant ine from the hose barb outet.. Cut the new hose assemby to the appropriate ength.. Thread the new ubricant ine through the grommet and into the hose barb outet unti ¼" of the ine is visibe on the inner side.. Put the o-ring on the inner end of the ubricant ine. 8. Screw the hose barb outet back into the pump being carefu not to over-tighten the hose barb outet. Continue to feed the hose assemby through the grommet whie screwing in the hose barb outet. NOTE: f the hose barb is over-tightened it wi compress the o-ring round the ubricant ine and constrict the ine. ARFLOW + OL + ¼" 9. Once the hose barb outet is secured genty pu the ubricant ine, if the ine is correcty instaed it wi not come out when pued.. Thread the new air hose over the new ubricant ine and secure the air hose over the end of the hose barb outet. Precision Pump Appicator
replacement PArts For more information on repacement parts contact your Accu-Lube Saes Representative or visit www.roconorthamerica.com. 9 8 ARFLOW + ARFLOW + OL + 8 9 OL + Part # Description 98 oz. reservoir (⅞" x 9 ", ¼" NPT) 98 qt. reservoir (½" x ¾", ¼" NPT) 98 ½ ga. reservoir (½" x 9 ", ¼ NPT) 98 ga. reservoir (½" x ", ¼" NPT) 98 qt. reservoir w/ow-eve switch 98 ga. reservoir w/ow-eve switch 98 Reservoir extension 9A ¼- x ⅝ THMS (screw) 9 Hose assemby*, ft. 9 Hose assemby*, ft. 9 Hose assemby*, ft. 9 Hose assemby*, ft. 9 Hose assemby*, ft. * Braided air hose + Lubricant ine 9 Braided air hose (sod by the ft.) 9 Lubricant ine (sod by the ft.) 9 Rubber grommet 9 Quick reease (¼" x ⅛" NPT) 98 Pug Part # Description 8 9 Quick reease ( " x ⅛" NPT) 9 9 Stee security box (- nozzes) 9 Stee security box (- nozzes) 9 Stee security box (-8 nozzes) 9 Stee security box (9- nozzes) 9 Back poy hose ¼" OD (sod by the ft.) 9 Back poy hose " OD (sod by the ft.) 9 Frequency generator and base pate 9 Frequency generator 9 Base pate for frequency generator 9 - x ½ phi (screw) 9 8 x ½ pan phi s/m (screw) 999 Shut-off vave (¼" mae x ¼" femae) 98 Shut-off vave (⅜" femae x ⅜" femae) 9 Ebow - street ¼ 9 ¼ cose nippe 8 9 ¼ NPT bukhead fitting 9 99 ¼ bukhead washer 9 Mae run tee, ¼" x " x ¼" NPT Precision Pump Appicator
replacement PArts contnued... 8 Not shown: Part # Description 9 Magnetic mount (nut & bot incuded) 9 Coaescing fiter, ¼" (- nozze units) 9 Coaescing fiter, ⅜" 99 Air fiter w/gauge (- nozze units) 998 Air fiter w/gauge (+ nozze units) 9 Frequency generator repair kit 98 Eectric soenoid, VAC (¼" NPT) 9 Eectric soenoid, VAC (¼" NPT) 9 Eectric soenoid, VAC 9 Eectric soenoid, VAC (stacking) 99 Eectric soenoid, VAC 9 Eectric soenoid, VDC (¼" NPT) 9 Compete ock assemby WArrAnty 9 Pump Repair Kit (#98) Pump Repair Kit w/piston (#9) Hose Barb Repair Kit (#9) Part # Description Qty. Qty. Qty. 99 Hose barb, ¼" x ⅛" NPT 9 O-ring barb sea 99A O-ring for ubricant ine N/A Lubricant ine seeve O-ring (. D x.) Conica evac spring Evac vave 8 O-ring (. D x.) 9 Same as # N/A Retaining ring for o-ring Return spring U-cup, viton (. D x /) ⅛" stainess stee piston O-ring, viton (. D x.) N/A Lubricant contro Parts,, and can not be repaced Parts -8 and - are ony avaiabe in kits A Accu-Lube precision pump appicators are backed with a Two-Year Limited Warranty against defects in workmanship and/or materias. Warranty appies ony when used under norma operating conditions. Any part which is returned to TW ROCOL North America Accu-Lube that is determined to be defective in workmanship and/or materias wi be repaired or repaced by TW ROCOL North America. A minimum abor fee of one hour wi be charged. Additiona shipping charges may appy. A Warranties, expressed and impied, are nu and void if the equipment is subject to improper instaation/appication, misuse, negect, and/or accident or if a ubricant other than Accu-Lube brand ubricant is used in the warrantied equipment. For more information on warranties, service, and repairs contact Customer Service. Returned equipment wi not be accepted without prior approva and a Return Merchandise Authorization (RMA) form. Precision Pump Appicator
troubleshootng Probem Reduced/no fuid output Reduced/no air output Fuid eaking Frequency generator mafunctioning Appicator is on but not operating Soution. Make sure air is being suppied to the appicator.. Check pressure gauge, operating range is 8- psi.. Check reservoir eve, fi if needed.. Make sure the ubricant ine is cut and instaed correcty, see page and page.. Check the frequency generator, see page to reset.. Make sure the ubricant contro is not at the zero point, see page 8 to reset.. Make sure the hose bard outet isn't over-tightened, see page.. Make sure air is being suppied to the appicator.. Check pressure gauge, operating range is 8- psi.. Check airfow vave, see page to reset.. Make sure the ubricant contro is not set to the stop point, see page 8 to reset.. Make the ubricant ine is cut and instaed correcty, see page and page.. Check frequency generator, see page to reset.. Dirty/oiy air can damage the frequency generator, repace damaged interna components with the Frequency Generator Repair Kit (#9), see pages -.. To prevent future probems add a coaescing fiter to the air fiter reguator/pressure gauge, see pages -.. Check on/off vave or eectronic soenoid.. Make sure air is being suppied to the appicator.. Make sure the air hose and ubricant ine are securey instaed, see page. Misting ubricant. Make sure the airfow vave isn't set too high, see page. techncal support For Accu-Lube Technica Support contact your Accu-Lube Saes Representative or TW ROCOL North America Accu-Lube Customer Service. Saes Representative contact information is avaiabe on our website. TW ROCOL North America Accu-Lube Te: 8--8 ext. or 8--8 Fax: 8-9-8 or 8--89 E-mai: info@roconorthamerica.com URL: www.roconorthamerica.com Precision Pump Appicator
notes Mode Number: Seria Number: Purchase Date: Distributor: Precision Pump Appicator
User s Manua nstaation & Operating nstructions PRECSON PUMP APPLCATOR West Lake Avenue, Genview, inois Phone: 8--8/8--8 Fax: 8-9-8/8--89 info@roconorthamerica.com www.roconorthamerica.com Revised 8/9