®

ISO
9001
Approved
Company NABCB
AN ISO 9001-2008 CO.

INSTRUCTION & OPERATION MANUAL

FOR
MOTORISED LUBRICATION UNIT
MODEL No.- DMCLU-2800 (DX) PS/FS

A SOURCE OF COMPLETE LUBRICATION SOLUTIONS

Website : www.dropco.com Ph. 0129-4191800 / 2307566-8
E-mail : [email protected], [email protected] Fax No. 0129 - 4191869
 MOTORISED LUBRICATION UNIT
DROPCO Motorised Lubrication Unit is a mini Hydraulic Power Pack where a rotary positive displacement pump of low discharge
is driven by an electric motor. This pump delivers lubricating oil to the machine. The unit is designed to run intermittently and is best
suited for single shot centralized lubrication system .The reservoir of lub. Unit is of Polycarbonate which is unbreakable and
transparent.

SCHEMATIC CIRCUIT 5

V 2
6 (1) Pump
4 (2) Motor
8
(3) Relief Valve
(4) Pressure Gauge Isolator
3 (5) Pressure Gauge
(6) Pressure Switch
10 (7) Float Switch
(8) Oil Filler cum Breather
(9) Suction Strainer
11 (10) Pressure Reducing Valve
1 (11) Bleed Valve
7 (12) Reservoir
9

12

During ON time of electric motor, pump coupled with the motor discharges oil under pressure immediately. After unit is switched off ,
oil pressure is brought down to approximately 1 Kg/Cm² with the help of pressure reducing valve .
To safeguard from overloading, a relief valve is incorporated in the line. Beside this, there is a bleed valve near the outlet port of the
unit to automatically bleed air in case air is entered in system (due to low oil level in reservoir).
Unit is equipped with a pressure switch. The function of the switch is to give electric signal when oil pressure exceeds the preset
value of the switch. This signal (change of contact) of pressure switch is an indication for completion of required pressure building
in lubrication line.
The float Switch incorporated in the unit is meant for sensing oil level. Electrical signal of float switch, when oil level becomes
critical, may be used as 'warning' for topping up the reservoir with oil.
For mounting the unit on machine wall, holes are provided on the back side. The unit shall be mounted in vertical position preferably
at a height where oil level can be checked and line pressure can be read on pressure gauge conveniently.
Unit is supplied with outlet port having tapping M 10 x 1 fitted with locking screw and cone (ferrule) for fitment of 6 mm OD tube .
Before operating Motorised Lubrication Unit following points should be noted :-
1. Direction of motor should be as indicated on the unit (Anti clockwise from top).
2. Oil should be absolutely clean (viscosity 32-68 Cst at 40 O C).
3. Check relief valve pressure setting as per recommendation. This can be adjusted by tightening/ loosing the relief valve through top opening.
4. Do not disturb pressure switch setting.

INSTRUCTIONAL LAYOUT
PRESSURE SWITCH
TO LUB. POINTS TO LUB. POINTS TO LUB. POINTS
RELIEF VALVE
CONTROLLER ELBOW
/ TIMER ELBOW BLOCK
STRAIGHT
CONNECTOR

METERING
MOUNTING INJECTORS
HOLE MANIFOLD
MANIFOLD
RESERVOIR TEE BLOCK PLUG

DRAIN
01. INTRODUCTION :-
Any rotating or sliding parts may develop certain amount of heat due to friction of the moving parts and consequently,
there will be some wear and tear and loss of power. The most effective method of reducing friction to minimum and to
save the metals from wear and tear is efficient lubrication and the substance used for this purpose is called lubricant.
So proper lubrication system is the most important arrangement for efficient running of engines and machine parts.
02. ADVANTAGES OF LUBRICATION SYSTEMS :-
(1) To reduce friction between the moving surface of machine parts.
(2) To cool the parts by carrying away the heat generated due to friction.
(3) To clean the parts by washing away deposition of carbon and metal particles caused by wear.
(4) To cushion the parts against vibration and impact.
(5) Proper Lubrication can reduce the rate of break down of machine.
(6) Economic use of lubricant.
(7) Less wear & tear of machine parts.
03. CENTALISED LUBRICATION SYSTEMS :-
Motorised Lubrication System Model DMCLU-2800 (DX) /PS/FS, Three Phase.
Under centralized Lubrication system the oil is sent to different lubrication point after connecting all the lubrication
point provided at the machine by tube to lubrication System.
The main advantage of centralized lubrication system is that, after filling the oil in the Reservoir of lubrication system,
we can lubricate all the lubrication point of machine at the same time in the running condition of machine.
04. FUNCTION OF DIFFERENT COMPONENTS OF LUBRICATION SYSTEM :-
4.1 PUMP :-
It converts the mechanical energy in to flow energy or hydraulic energy. Oil pressure is created in the lubrication system with the
help of pump. It will work positively if the direction of rotation of pump will be in the correct direction. The pump used in this system is
a georator type having discharge 1 Lpm.
4.2 MOTOR :-
It converts the electrical energy in to mechanical energy and provides motion to pump. The following types of motor are use with
this model and can be supplied as per customer's requirement.
(a) Motor - 415V AC, Three Phase, 1440 RPM, 0.12 KW, 0.16 HP
The rating of Motor has been mentioned on the motor also.
4.3 RELIEF VALVE :-
To maintain the oil pressure constant, an oil pressure relief valve is placed in the circuit. When the pressure of the oil exceeds the
normal limit the oil returns to the oil reservoir through the relief valve, The setting of pressure relief valve can be adjusted by loosing
or tightening the split screw and nut of relief valve. Plug the outlet of lubrication system at the time of adjusting the relief valve.
4.4 PRESSURE GAUGE :-
It indicates the pressure in Kg/cm² which is developed by the system. Required pressure can be set with the help of relief valve
seeing the position of pointer on the dial scale of Pressure Gauge which is 0-28 Kg/Cm². The changing position of pointer confirms
that the system is working.
4.5 OIL FILLER CUM BREATHER :-
Used for filling the oil in the reservoir as well as filter the oil. Filter level is 300 micron.
4.6 SUCTION STRAINER :-
The function of strainer is to prevent admission of the impurities that may pan in to the oil system, made with SS Wiremesh, 149
micron.
4.7 METERING INJECTOR:-
The main function of metering injector is to inject metered amount of oil to the lubrication points. It works on stroke. The oil is
always stored in the metering injector. The stored oil is discharged to the end lubrication point through injector & are recharged with
fresh oil for next stroke when the motor of lubrication system OFF. It also works as a N.R.V. (non Return Valve). It comes with
dosage of 0.01, 0.03, 0.05, 0.10, 0.16, 0.25, 0.40, 1.00 & 1.60 cc. Made of Brass and EN-1A leaded material. Mounting thread is
M8 X 1 & M10 X 1. Outlet Port is for 4 MM O.D. Tube which connects to Lubrication Point.
4.8 PRESSURE SWITCH :-
Pressure Switch to sense Low Pressure of System during running to get alarm or interlock of machine. Pressure Switch
Range 8-30 Kg/Cm² or 0-20 Kg/Cm², Set pressure is 12 Kg/Cm², Switch Type with 1 NO + 1 NC or NO Contact used.
4.9 FLOAT SWITCH :-
Sense Low Oil Level in Reservoir of Lubrication System electrically. It is Vertical or Horizontal type with NO or NC Contact.
 TECHNICAL SPECIFICATIONS :-
MODEL OF UNIT DMCLU - 2800 (DX) /PS/FS
Reservoir Capacity 2.8 Ltrs. ( Transparent-Polycarbonate )
Discharge of pump 0.75 LPM
Motor 0.12 Kw., 1500 RPM, 3 Phase 415V AC, Face Mounting (B-14)
Pressure Switch 3 Amp. at 230V AC, Preset at 10 Kg/cm² with 1NO + 1NC Contact (Potential Free)
Float Switch 0.5 Amp. at 230V AC, TOP ON or BOTTOM ON (NO or NC Contact)
Relief Valve Preset at 15 Kg/cm²
All the above specifications are respect to Oil with viscosity 68 Cst / 40º C

DIMENSIONAL DIAGRAM

J
H
C I E
DROPCO
F OUTLET PORT
M10X1
MOUNTING HOLES
G 205 2 nos ø7
B 180
305

®
DROPCO

5
C E N T RA L I S E D LU B R I C AT I O N S Y S T E M
170

130
A

190 L

PART NAME
A RESERVOIR D OIL LEVEL GAUG G JUNCTION BLOCK J FLOAT SWITCH
B TOP PLATE E PRESSURE GAUGE H RELIEF VALVE K RETURN LINE FILTER
C MOTOR F OIL FILLER CUM BREATHER I PRESSURE SWITCH L DRAIN PLUG

05. MAINTENANCE & TROUBLE SHOOTING OF LUBRICATION SYSTEM :-

5.1 STANDARD MAINTENANCE PRACTICES :-

n Periodic checking of oil level in the reservoir.

n Periodic cleaning of suction strainer.

n Flushing of the system after major break down and restart.

n Do not mix two different grades / makes of oil.

n Check minimum required pressure on the pressure gauge i. e. 12 15 Kg/cm².

n Fill lubricant in the unit before reaching the Oil Level below marked (MIN. OIL LEVEL)

n Check required OFF time setting of lubrication timer. / PLC.

5.2 TROUBLE SHOOTING: -
Sr. Probable Cause Remedy
1. Motor running but not * Check oil level in reservoir
developing Pressure * Ensure that all lubrication lines are in ok Position i.e. there is no
Leakage in lubrication circuit.
* Check Pressure Relief Valve Setting.
2. Motor not running * Check Output Voltage of Timer / Controller
* Check supply Voltage of motor.
* Check Motor direction, it should be anti-Clockwise from top.
* Check if pump is jammed.
* Check input and output supply of Timer / Controller.
3. Excessive oil viscosity * Chose Oil with suitable Viscosity Grade it should be generally
SAE 40 to 60 grade.
4. Motor running and developing * If everything is ok i.e. oil is coming at the inlet of metering injector
Required pressure but metering with pr. And not giving the discharge from the outlet, then replace
injector not discharging the oil. the metering injector.
5. Clogged Strainer / Filter * Clean or replace the Strainer / Filter.
6. Oil is not coming at the end * If oil is coming at the outlet of metering injector, but not providing
lubrication point of machine the oil at the end lubrication point of the m/c. Then check the oil
line provided in the bushes or m/c parts.

RECOMMENDED SPARES LIST (FOR 1 YEAR TROUBLE FREE OPERATION) :-

Sr. ITEMS QTY.
1. Motor 0.12 KW, 1500 RPM, 3 Phase, Flange Mounting. 01 No.
2. Float Switch 0.5 Amp, 220V AC, “TOP ON” Vertical. 01 No.
3. Pressure Switch 3 Amp., 220V AC with 1 NO + 1 NC Range - 0-30 Kg/Cm². 01 No.
4. Pressure Gauge 0-28 Kg/Cm² , 50 MM Dial Size 01 No.
5. Oil Filler cum Air Breather 01 No.
6. Rotary Pump with Discharge 1.25 LPM, Flange Mount 01 No.
7. Pressure Relief Valve (M 16 X 1.5) 01 No.
8. Suction Strainer Ø10 X 50 MM 01 No.

DROPCO MULTILUB SYSTEMS PVT. LTD.

Plot No. 152 Sector-58, Behind JCB India Ltd. FARIDABAD-121 004 (Haryana) INDIA
Phones : 0129-4191800, 2307568, 2307868, Fax : 0129-4191869, 2307869
E-mail : [email protected], [email protected] Visit us at : www.dropco.com