SMC AL40-D Lubricator Operation Manual PDF

1 of 35
1 of 35

Summary of Content for SMC AL40-D Lubricator Operation Manual PDF

Doc. No. AL-OMX0056-A

PRODUCT NAME

Lubricator

MODEL / Series / Product Number

AL20-(F,N)01(F,N)02(B)(-2,3,6,C,R,Z)-D

AL30-(F,N)02(F,N)03(B)(-2,3,6,8,R,W,Z)-D

AL40-(F,N)02(F,N)04(B)(-2,3,6,8,R,W,Z)-D

AL40-(F,N)06(B)(-2,3,6,8,R,W,Z)-D

AL50-(F,N)06(F,N)10(B)(-2,3,6,8,R,W,Z)-D

AL60-(F,N)10(B)(-2,3,6,8,R,W,Z)-D

Contents

Page

1. Safety Instructions 2-6

2. Application 7

3. Standard Specifications 7

4. How to Order 8

5. Structural Drawing, Option and Replacement Parts 9

6. Bowl Assembly Specifications 10-14

7. Assembly of Optional Parts 15

8. Operation and Adjustment 16-19

8-1. Adjustment of Dripping Amount 16

8-2. Lubrication 17-18

8-3. Oil Discharge from the Product with Drain Cock 19

9. Trouble Shooting 20

10. How to Replace the Components 21-30

10-1. Bowl Assembly Replacement 21-23

10-2. Bumper Retainer Assembly Replacement 24-27

10-3. Bumper and Sight Dome Assembly Replacement 28-30

11. Disassembly Drawing 31-32

12. Dimensions 33

-1-

Safety Instructions These safety instructions are intended to prevent hazardous situations and/or equipment damage. These instructions indicate the level of potential hazard with the labels of Caution, Warning or Danger. They are all important notes for safety and must be followed in addition to International Standards (ISO/IEC)*1) , and other safety regulations. *1) ISO 4414: Pneumatic fluid power -- General rules relating to systems. ISO 4413: Hydraulic fluid power -- General rules relating to systems. IEC 60204-1: Safety of machinery -- Electrical equipment of machines .(Part 1: General requirements) ISO 10218: Manipulating industrial robots -Safety. etc.

Caution Caution indicates a hazard with a low level of risk which, if not avoided, could result in minor or moderate injury.

Warning Warning indicates a hazard with a medium level of risk which, if not avoided, could result in death or serious injury.

Danger Danger indicates a hazard with a high level of risk which, if not avoided, will result in death or serious injury.

Warning 1. The compatibility of the product is the responsibility of the person who designs the equipment or

decides its specifications. Since the product specified here is used under various operating conditions, its compatibility with specific equipment must be decided by the person who designs the equipment or decides its specifications based on necessary analysis and test results. The expected performance and safety assurance of the equipment will be the responsibility of the person who has determined its compatibility with the product. This person should also continuously review all specifications of the product referring to its latest catalog information, with a view to giving due consideration to any possibility of equipment failure when configuring the equipment.

2. Only personnel with appropriate training should operate machinery and equipment. The product specified here may become unsafe if handled incorrectly. The assembly, operation and maintenance of machines or equipment including our products must be performed by an operator who is appropriately trained and experienced.

3. Do not service or attempt to remove product and machinery/equipment until safety is confirmed. 1.The inspection and maintenance of machinery/equipment should only be performed after measures to

prevent falling or runaway of the driven objects have been confirmed. 2.When the product is to be removed, confirm that the safety measures as mentioned above are implemented and the power from any appropriate source is cut, and read and understand the specific product precautions of all relevant products carefully. 3. Before machinery/equipment is restarted, take measures to prevent unexpected operation and malfunction.

4. Contact SMC beforehand and take special consideration of safety measures if the product is to be used in any of the following conditions. 1. Conditions and environments outside of the given specifications, or use outdoors or in a place exposed to direct sunlight. 2. Installation on equipment in conjunction with atomic energy, railways, air navigation, space, shipping,

vehicles, military, medical treatment, combustion and recreation, or equipment in contact with food and beverages, emergency stop circuits, clutch and brake circuits in press applications, safety equipment or other applications unsuitable for the standard specifications described in the product catalog.

3. An application which could have negative effects on people, property, or animals requiring special safety analysis.

4.Use in an interlock circuit, which requires the provision of double interlock for possible failure by using a mechanical protective function, and periodical checks to confirm proper operation.

-2-

Safety Instructions

Caution The product is provided for use in manufacturing industries.

The product herein described is basically provided for peaceful use in manufacturing industries. If considering using the product in other industries, consult SMC beforehand and exchange specifications or a contract if necessary.

If anything is unclear, contact your nearest sales branch.

Limited warranty and Disclaimer/Compliance Requirements The product used is subject to the following Limited warranty and Disclaimer and Compliance Requirements. Read and accept them before using the product.

Limited warranty and Disclaimer

1.The warranty period of the product is 1 year in service or 1.5 years after the product is

delivered,whichever is first.2) Also, the product may have specified durability, running distance or replacement parts. Please consult your nearest sales branch.

2. For any failure or damage reported within the warranty period which is clearly our responsibility, a replacement product or necessary parts will be provided. This limited warranty applies only to our product independently, and not to any other damage

incurred due to the failure of the product. 3. Prior to using SMC products, please read and understand the warranty terms and disclaimers

noted in the specified catalog for the particular products.

2) Vacuum pads are excluded from this 1 year warranty. A vacuum pad is a consumable part, so it is warranted for a year after it is delivered.

Also, even within the warranty period, the wear of a product due to the use of the vacuum pad or failure due to the deterioration of rubber material are not covered by the limited

warranty.

Compliance Requirements

1. The use of SMC products with production equipment for the manufacture of weapons of mass destruction(WMD) or any other weapon is strictly prohibited.

2. The exports of SMC products or technology from one country to another are governed by the relevant security laws and regulation of the countries involved in the transaction. Prior to the shipment of a SMC product to another country, assure that all local rules governing that export are known and followed.

Caution SMC products are not intended for use as instruments for legal metrology. Measurement instruments that SMC manufactures or sells have not been qualified by type approval tests relevant to the metrology (measurement) laws of each country.

Therefore, SMC products cannot be used for business or certification ordained by the metrology

(measurement) laws of each country.

-3-

Precautions for Design

Warning

(1) Consult SMC if no leakage is allowed due to the environment, or if the operating fluid is not air.

(2) Polycarbonate resin is used for external parts including the bowl and sight dome. Organic

solvents including thinner, acetone, alcohol and ethylene chloride; chemicals including sulphuric

acid, nitric acid and hydrochloric acid; cutting oil, synthetic oils, ester-based compressor oil, alkali,

kerosene, gasoline, lock material of screw are harmful. Do not use the product where these are

present.

Chemical resistance of polycarbonate and nylon used for the bowl and sight dome

When the above factors are present or there is some doubt, use a metal bowl for safety.

(3) Avoid the application where charge and discharge of pressure to/from a standard bowl is switched

frequently. This may damage the bowl. A metal bowl is recommended in these cases.

(4) Shield from ultra violet light and radiation with protective cover.

-4-

Polycarbonate Nylon

Hydrochloric acid

Sulfuric acid

Phosphoric acid

Chromic acid

Sodium hydroxide (Caustic soda)

Potash

Calcium hydroxide (Slack lime) Ammonia water

Carbotane of soda

Sodium sulfide

Potassium nitrate Sulfate of soda

Carbon tetrachloride

Chloroform

Ethylene chloride

Methylene chloride

Benzene

Toluene

Paint thinner

Acetone

Methyl ethyl ketone

Cyclohexane

Ethyl alcohol

IPA

Methyl alcohol

Gasoline

Kerosene

Phthalic acid dimethyl

Phthalic acid diethyl Acetic acid

Methyl ether

Ethyl ether

Thread-lock fluid

Sea water Leak tester

: Essentially safe.: Some effects may occur.: Effects will occur.

Amino Methyl amino

Cutting oil

Brake oil additives

Rubber accelerator

Others -

Ester Synthetic oil

Anti-rust additives

Ether Brake oil additives

Ketone

Photographic film

Dry cleaning

Textile industries

Alcohol Antifreeze

Adhesives

Oil -

Aromatic series Coatings

Dry cleaning

Alkaline

Degreasing of metals

Industrial salts

Water-soluble cutting oil

Inorganic salts -

Chlorine solvents

Cleaning liquid for metals

Printing ink

Dilution

Type Chemical name Application examples Material

Acid Acid washing liquid for metals

Selection

Warning

(1) Please consult SMC when the lubricator is used other than for lubricating pneumatic equipment.

(2) Please consult SMC when the lubricator is used at high frequency, such as press machine, as the

internal components may break or operation failure may occur on the outlet side equipment.

(3) If the air consumption is small, oil may not drip. Select a proper size of product according to the

minimum dripping flow rate.

(4) Do not flow from the outlet side (backflow) as it may cause breakage of the internal components.

(5) When the piping is branched on the inlet side, install a check valve on the inlet side of the lubricator

to prevent the lubricant from back flowing.

Installation

Warning

(1) Do not drop or apply impact during transportation or installation. It will cause damage to the product

and result in operation failure.

(2) Do not install in areas of high humidity or high temperature. Operation outside of the product

specification range may cause damage to the product or operation failure, or shorten the product

life.

(3) Connect the product ensuring the direction of "1"(IN) and "2"(OUT) for air direction and indicated

arrow. Incorrect connections may cause malfunction.

(4) Install with adequate space for maintenance beneath the product. Refer to section [12.

Dimensions] (P 33) for necessary space.

(5) Install the lubricator vertically so that the bowl is downward. It cannot be used in horizontal or

upward direction.

Piping

Warning

(1) Before piping is connected, it should be thoroughly blown out with air (flushing) or washed to

remove chips, cutting oil and solid foreign material from inside the pipe. Contamination of piping

may cause damage or malfunction.

(2) When screwing together pipes and fittings, etc., be certain that chips from the pipe threads and

sealant do not get inside the pipe. When a sealant tape is used, leave 1.5 to 2 thread ridges

exposed at the end of the threads.

(3) Connect piping/fittings using the recommended torque while holding the female thread side tightly.

Insufficient tightening torque leads to cause of loosening or sealing failure, and excessive

tightening torque leads to cause of breakage of screws. Tightening without holding female thread

applies an excessive force to the piping bracket directly, leading to breakage.

Recommended tightening torque Unit: N m

Thread size 1/8 1/4 3/8 1/2 3/4 1

Torque 7 to 9 12 to 14 22 to 24 28 to 30 28 to 30 36 to 38

(4) Before using an SMC fitting and S coupler, please refer to "Tightening the threaded portion of the

connection thread" of the Fittings & Tubing Precautions.

(5) Do not apply torsion or bending moment other than the weight of the product itself. External piping

needs to be supported separately as it may cause breakage. Non-flexible piping like steel tube is

susceptible to excessive moment load or vibration. Insert flexible tubes to prevent this.

(6) The cylinder volume should be larger than the piping volume between the solenoid valve and

cylinder. If the cylinder volume is smaller, operation oil may not be fed to the cylinder.

Caution

(1) Avoid rising piping and piping branches on the outlet piping. Otherwise, lubricating failure may

occur.

-5-

Air Source

Warning

(1) Use clean air. Do not use compressed air containing chemicals, organic solvent, synthetic oil or

corrosive gas as it may be cause of breakage of components or operation failure.

(2) Air containing too much moisture may cause malfunction. Install an air drier or aftercooler before

the lubricator.

Maintenance

Warning

(1) Release the pressure in the product to the atmosphere when replacing parts or removing piping.

(2) Maintenance and checks should be done by following the procedure in this operation manual.

Incorrect handling of the product may cause breakage or operation failure of the equipment or

device.

(3) Perform periodical check to find cracks, flaws or other deterioration on resin bowl. If any of these

appear, replace with a new or metal bowl. Otherwise, breakage may occur. Investigate and/or

review the operating conditions if necessary.

(4) Check for dirt in resin bowl periodically. If any dirt is seen, replace with new bowl. If removing dirt by

washing the resin bowl, never use washing material other than neutral detergent. Otherwise, the

bowl is damaged.

(5) Open and close the drain cock manually. The use of tools can result in damage to the product.

(6) Use class 1 turbine oil (with no additives) ISO VG32. Using other lubricant can cause damage to

devices and result in malfunction.

(7) Adjustment of the oil regulating valve should be carried out manually, the use of tools etc. can

result in damage to the unit. Refer to section [8. Operation and Adjustment] (P16-19) for

adjustment of the amount of oil.

(8) AL20-D cannot replenish lubricant while being pressurized. Before lubrication, exhaust the inlet

pressure and make sure that there is no pressure in the bowl. Refer to section [8. Operation and

Adjustment] (P16-19) for the oil supply method.

(9) Loosen the lubrication plug and release the pressure in the bowl before lubricating using AL30-D,

AL40-D, AL50-D or AL60-D. As air containing oil may come out, be sure to wear protective glasses

when lubricating. Refer to section [8. Operation and Adjustment] (P16-19) for the oil supply

method.

Caution

(1) Check the dripping amount once a day. Drip failure can cause damage to the components that

need lubrication.

(2) Use clean oil. Otherwise, it may cause dripping failure or clogging.

(3) The lubrication amount should be less than the upper limit of oil level of the bowl.

(4) Discharge drain periodically so that the drain is not accumulated beyond the upper limit of the drain

level of the bowl. If a large amount of drain enters lubricator, it may cause dripping failure.

-6-

2. Application

3. Standard Specifications

-7-

This product aims at lubricating air-driven equipment and solenoid operated directional control valves

and supplying oil into compressed air.

Model AL20-D AL30-D AL40-D AL40-06-D AL50-D AL60-D

Port size 1/8, 1/4 1/4, 3/8 1/4, 3/8, 1/2 3/4 3/4, 1 1

Fluid

Ambient and fluid temperature

Proof pressure

Max. operating pressure

Min. dripping flow rate Note 1) 15 L/min (ANR) Port size 1/4: 30 L/min(ANR)

Port size 3/8: 40 L/min(ANR)

Port size 1/4: 30 L/min(ANR)

Port size 3/8: 40 L/min(ANR)

Port size 1/2: 50 L/min(ANR)

50 L/min(ANR) 190 L/min(ANR) 220 L/min(ANR)

Oil capacity 25 cm3 55 cm3

Recommended lubricant

Bowl material

Bowl guard Semi-standard (Steel)

Weight 0.10 kg 0.18 kg 0.37 kg 0.41 kg 0.92 kg 0.99 kg

Air

-5 to 60 oC (with no freezing)

1.5 MPa

- For a circuit that repeatedly turns ON and OFF on the outlet side, make the adjustment so that the average air consumption per minute becomes equal to

the minimum dripping flowrate or more.

Note 1) - The flow rate is 5 drops/min under the following conditions: Inlet pressure of 0.5 MPa; Class 1 turbine oil (ISO VG32); Temperature at 20oC; Oil adjustment valve

fully open.

1.0 MPa

135 cm3

Class 1 turbine oil (ISO VG32)

Polycarbonate

Standard (Polycarbonate)

4. How to Order

AL - - - D

-8-

30 03 BE

Note 1) Semi-standard: Select one each for a to d. Note 2) : For NPT thread type only.

20 30 40 50 60

Nil N F 01

02

03

04

06

10 Nil Without mounting option B With bracket Nil Polycarbonate bowl 2 Metal bowl 6 Nylon bowl 8 Metal bowl with level gauge C With bowl guard

6C With bowl guard (Nylon bowl)

Nil Without drain cock 3 With drain cock

3 Drain cock with barb fitting Nil Flow direction: Left to right R Flow direction: Right to left Nil Pressure unit: MPa Temp. unit: oC Z Pressure unit: psi Temp. unit: oF Note 2) Note 2) Note 2) Note 2) Note 2)

d Pressure unit

Temp. unit

Option (Mounting)

S e m

i- s ta

n d a rd

a Bowl

b

Lubricant

exhaust

port

Thread type

Rc

NPT

G

c Flow

direction

1/8

1/4

3/8

1/2

Body size

Port size

3/4

1

Symbol Description

5. Structural Drawing, Option and Replacement Parts

-9-

Structural drawing / Option / Replacement parts

AL30-D / AL40-D AL50-D / AL60-D

(2)

(3)

(1)

(5)

(4)

(6)

(7)

Option

AL20-D AL30-D AL40-D AL40-06-D AL50-D AL60-D

(1) Bracket assembly Note2) AF24P-070AS AF34P-070AS AF44P-070AS AF49P-070AS

Note 1)

Note 2)

The number in the table and structural drawing is consistent with the number in [10. How to Replace the Components] (P21-30and

[11. Disassembly Drawing] (P31-32).

Assembly of 2 types of bracket and 2 set screws.

DescriptionNo. Note 1) Part No.

AF54P-070AS

AL20-D

(5)

(3)

(6)

(1)

(2)

(4)

(7)

Replacement part

AL20-D AL30-D AL40-D AL40-06-D AL50-D AL60-D

(2) Sight dome assembly Note 2)

(3) Lubrication plug assembly AL24P-060AS AL34P-060AS

Bumper retainer assembly Note 3) AL20P-030AS AL30P-030AS

Bumper seat retainer assembly Note 3) - - AL54P-030AS AL60P-030AS

Bumper AL20P-040S AL30P-040S

Bumper assembly - -

(6) Bowl seal C2SFP-260S C32FP-260S

(7) Bowl assembly

Note 1)

Note 2)

Note 3)

The numbers in the table and structural drawing are consistent with the numbers in [10. How to Replace the Components] (P21-30and

[11. Disassembly Drawing] (P31-32).

For the bumper retainer assembly and bumper seat retainer assembly for the metal bowl with level gauge, add -8 to the end of the product number.

Example: AL30P-030AS-8

Refer to section [6. Bowl Assembly Specifications] (P10-P14).

For nylon type (material: PA), add -6 to the end of the product number. Example: AL20P-080AS-6

Part No.

C42FP-260S

-

AL60P-040AS

(4) -

AL20P-080AS

AL44P-060AS

-AL40P-030AS

(5) AL44P-040S

-

No. Note 1) Description

6. Bowl Assembly Specifications

6-1. Bowl assembly for AL20-D

Semi-standard symbol 6 C 6C

Semi-standard symbol 3 36 3C 36C

Semi-standard symbol

Note 1) Part No. (7) includes Bowl seal (6). Refer to section [11. Disassembly Drawing] (P31).

Note 2) "Z" in Part No. (7) indicates semi-standard specifications. The pressure unit: psi. The temperature unit: o F.

Note 3) Refer to section [4. How to Order] (P8) for option and semi-standard symbols.

-10-

Appearance and

part No.

Appearance and

part No.

2 23

Appearance and

part No.

Semi-standard: - (Standard)

Rc

G

NPT C2SL(-Z)-D

Semi-standard: 6

Rc

G

NPT C2SL-6(Z)-A

C2SL-D

C2SL-6-A

Piping port

thread ty pe (7) Part No.

(7) Part No. Piping port

thread ty pe

Semi-standard: C

Rc

G

NPT C2SL-C(Z)-D

Semi-standard: 6C

Rc

G

NPT C2SL-6C(Z)-A

C2SL-C-D

C2SL-6C-A

Piping port

thread ty pe (7) Part No.

(7) Part No. Piping port

thread ty pe

Semi-standard: 3

Rc

G

NPT C2SL-3(Z)-D

Semi-standard: 36

Rc

G

NPT C2SL-36(Z)-A

C2SL-3-D

C2SL-36-A

(7) Part No.

(7) Part No. Piping port

thread ty pe

Piping port

thread ty pe

Semi-standard: 3C

Rc

G

NPT C2SL-3C(Z)-D

Semi-standard: 36C

Rc

G

NPT C2SL-36C(Z)-A

C2SL-3C-D

(7) Part No.

(7) Part No.

C2SL-36C-A

Piping port

thread ty pe

Piping port

thread ty pe

Semi-standard: 2

Rc

G

NPT C2SL-2(Z)-A

C2SL-2-A

Piping port

thread ty pe (7) Part No.

Semi-standard: 23

Rc

G

NPT C2SL-23(Z)-A

C2SL-23-A

(7) Part No. Piping port

thread ty pe

6-2. Bowl assembly for AL30-D

Semi-standard symbol 6 3 36

Semi-standard symbol 3W 36W

Semi-standard symbol

-11-

Appearance and

part No.

Appearance and

part No.

Appearance and

part No.

2 23

Semi-standard: - (Standard)

Rc

G

NPT C3SL(-Z)-D

Semi-standard: 6

Rc

G

NPT C3SL-6(Z)-A

C3SL-D

(7) Part No.

C3SL-6-A

(7) Part No. Piping port

thread ty pe

Piping port

thread ty pe

Semi-standard: 3

Rc

G

NPT C3SL-3(Z)-D

Semi-standard: 36

Rc

G

NPT C3SL-36(Z)-A

(7) Part No.

(7) Part No.

C3SL-3-D

C3SL-36-A

Piping port

thread ty pe

Piping port

thread ty pe

Semi-standard: 3W

Rc

G

NPT C3SL-3W(Z)-D

Semi-standard: 36W

Rc

G

NPT C3SL-36W(Z)-A

C3SL-36W-A

(7) Part No.

(7) Part No. Piping port

thread ty pe

C3SL-3W-D

Piping port

thread ty pe

Semi-standard: 2

Rc

G

NPT C3SL-2(Z)-A

Piping port

thread ty pe

C3SL-2-A

(7) Part No.

Semi-standard: 23

Rc

G

NPT C3SL-23(Z)-A

C3SL-23-A

Piping port

thread ty pe (7) Part No.

Semi-standard symbol

Note 1) Part No. (7) includes Bowl seal (6). Refer to section [11. Disassembly Drawing] (P31).

Note 2) "Z" in Part No. (7) indicates semi-standard specifications. The pressure unit: psi. The temperature unit: o F.

Note 3) Refer to section [4. How to Order] (P8) for option and semi-standard symbols.

-12-

Appearance and

part No.

8 38

Semi-standard: 8

Rc

G

NPT C3LL-8(Z)-A

C3LL-8-A

Piping port

thread ty pe (7) Part No.

Semi-standard: 38

Rc

G

NPT C3LL-38(Z)-A

(7) Part No.

C3LL-38-A

Piping port

thread ty pe

6-3. Bowl assembly for AL40, 50, 60-D

Semi-standard symbol 6 3 36

Semi-standard symbol 3W 36W

Semi-standard symbol

-13-

Appearance and

part No.

Appearance and

part No.

2 23

Appearance and

part No.

Semi-standard: (Standard)

Rc

G

NPT C4SL(-Z)-D

Semi-standard: 6

Rc

G

NPT C4SL-6(Z)-A

(7) Part No.

C4SL-D

(7) Part No.

C4SL-6-A

Piping port

thread ty pe

Piping port

thread ty pe

Semi-standard: 3

Rc

G

NPT C4SL-3(Z)-D

Semi-standard: 36

Rc

G

NPT C4SL-36(Z)-A

(7) Part No.

(7) Part No.

C4SL-3-D

Piping port

thread ty pe

Piping port

thread ty pe

C4SL-36-A

Semi-standard: 3W

Rc

G

NPT C4SL-3W(Z)-D

Semi-standard: 36W

Rc

G

NPT C4SL-36W(Z)-A

(7) Part No.

C4SL-3W-D

(7) Part No.

C4SL-36W-A

Piping port

thread ty pe

Piping port

thread ty pe

Semi-standard: 2

Rc

G

NPT C4SL-2(Z)-A

(7) Part No. Piping port

thread ty pe

C4SL-2-A

Semi-standard: 23

Rc

G

NPT C4SL-23(Z)-A

Piping port

thread ty pe

C4SL-23-A

(7) Part No.

Semi-standard symbol

Note 1) Part No. (7) includes Bowl seal (6). Refer to section [11. Disassembly Drawing] (P31-32).

Note 2) "Z" in Part No. (7) indicates semi-standard specifications. The pressure unit: psi. The temperature unit: o F.

Note 3) Refer to section [4. How to Order] (P8) for option and semi-standard symbols.

-14-

8 38

Appearance and

part No.

Semi-standard: 8

Rc

G

NPT C4LL-8(Z)-A

(7) Part No.

C4LL-8-A

Piping port

thread ty pe

Semi-standard: 38

Rc

G

NPT C4LL-38(Z)-A

(7) Part No. Piping port

thread ty pe

C4LL-38-A

7. Assembly of Optional Parts

7-1. Bracket

1) Mounting of bracket A

2) Mounting of bracket B

-15-

Insert bracket A from the front of the lubricator so that

the fingers of the bracket A hold the lubricator at the

groove and the bottom of the body.

Fix the bracket B with the set screw (2 pcs.) included

in the package. Refer to the table below for the

tightening torque.

Lubricator

Bracket A

Bracket B

Set screw (2 pcs.)

Groove

Fingers

Bottom of the body

Model Tool Tightening torque

AL20-D

AL30-D

AL40-D

AL50-D

AL60-D

0.75+/-0.2 N m Phillips

screw driver

1.5+/-0.2 N m

8. Operation and Adjustment

8-1. Adjustment of Dripping Amount

-16-

Oil regulating valve

While supplying air, rotate the oil regulating valve to adjust the amount of oil. Rotate the valve in the arrow direction shown in the figure to increase the amount of oil supplied. (The amount of oil decreases when rotated in reverse.) From the fully closed position, three rotations will bring it to the fully opened position. Do not rotate it any further than this. Note that the numbered scale markings are guidelines for adjusting the position, and not indicators of the dripping amount. Furthermore, oil may drip even when the oil regulating valve is at a fully closed position. If dripping is not acceptable, please stop using the lubricator.

8-2. Lubrication

-17-

AL20-D cannot replenish lubricant while being pressurized.

Be sure to release the internal pressure before starting lubrication.

AL20-D

Lubrication plug

Remove the lubrication plug. Tool: Screwdriver (-)

Lubrication

Supply lubricant up to the threaded part (A) of the bowl. Note) If an oil film appears on the lubrication port, oil may overflow. Supply lubricant slowly so that the oil film is not generated.

After supplying lubricant, check the mounting condition of

the lubrication plug O-ring and screw it in gently.

Because of the O-ring seal structure, it is not necessary to screw strongly. 0.3 +/- 0.05 N m

Make sure that no air is

coming out of the gap.

Loosen for approx. 1 turn.

Make sure that no air exists in the bowl by checking the lubrication plug.

Remove the lubrication plug.

A

AL30-D, AL40-D, AL50-D, AL60-D

-18-

AL30-D, AL40-D, AL50-D and AL60-D can replenish lubricant while being pressurized. When supplying

lubricant under pressure, loosen the lubrication plug slowly by approximately one turn to exhaust the air in the

bowl. After confirming that the exhaust is complete, remove the lubrication plug (there is a small leakage even

after the exhaust is complete). There is always a small leakage from the lubrication port. Supply lubricant

slowly up to the oil level limit so that an oil film is not generated.

Supply lubricant until the oil surface comes between the lower and upper limits of the oil level of the bowl. Note) If an oil film appears on the lubrication port, oil may overflow. Supply lubricant slowly so that an oil film is not generated. Air containing oil may come out. Be sure to wear protective glasses when supplying lubricant.

Exhaust internal

pressure from the gap.

Exhaust internal air from the lubrication plug.

Max. oil level

Min. oil level

Lubrication plug

Loosen for approx. 1 turn.

Remove the lubrication plug. Tool: Screwdriver (-)

Remove the lubrication plug.

Lubrication

After supplying lubricant, check the mounting condition of the lubrication plug O-ring and screw it in gently. Because of the O-ring seal structure, it is not necessary to screw strongly. AL30-D: 0.4+/-0.05 N m AL40-D, AL50-D, AL60-D: 0.55+/-0.05 N m

8-3. Oil Discharge from the Product with Drain Cock

-

-

-19-

Pressurize the inside of the lubricator when discharging oil. Oil will not be discharged properly if not pressurized.

Oil discharge mechanism is different depending on the bowl assembly. Check the bowl assembly and discharge the oil

following the method below.

Rotation type: After discharging the oil, tighten the drain cock to the opposite direction by hand until the seal inside seals

correctly. Use of a tool can damage the product.

Drain cock OPEN

(discharging oil)

PUSH

(discharging oil)

AL20-D: Drain cock (rotation type)

(Polycarbonate bowl / Nylon bowl)

AL30-D/ AL40-D/ AL50-D/ AL60-D: Drain cock / with barb fitting (push type)

(Polycarbonate bowl / Nylon bowl)

Drain cock with barb

fitting

OPEN

(discharging oil)

PUSH

(discharging oil)

AL20-D: Drain cock (push type)

(Metal bowl)

AL30-D/ AL40-D/ AL50-D/ AL60-D: Drain cock (rotation type)

(Metal bowl / Metal bowl with level gauge)

Drain cock

Drain cock

Drain cock

Drain cock

9. Trouble Shooting

Category Failure

Oil does not drip. 1. The product is installed opposite to the

flow direction.

Install the product correctly after confirming

the flow direction. "1 indicates the IN and

"2 indicates the OUT. -

2. Oil level in the bowl is low. Supply lubricant so that the oil surface

appears above the "MIN. OIL LEVEL"

display on the bowl. P17-18

3. The flow rate is insufficient. Supply air more than the minimum dripping

flow rate. If the flow rate cannot be

increased, select the model based on the

minimum dripping flow rate.

P7

4. Bumper is damaged. Replace the bumper.

P28-30

5. Oil regulating valve is closed. While supplying air, open the oil regulating

valve to adjust the dripping amount. Refer

to section [8. Operation and Adjustment]

(P16) for the adjustment of the dripping

amount.

P16

6. Air leakage from the bowl or lubrication

plug.

Replace the bowl seal or lubrication plug

assembly. P18

P21-23

7. Element at the end of the siphon tube is

clogged.

Replace the damper retainer assembly.

P24-27

8. Air leakage from the sight dome. Replace the sight dome assembly.

P28-30

Bubble exists in

an oil droplet.

1. Seal of the siphon tube is damaged. Replace the damper retainer assembly.

P24-27

2. Oil level in the bowl is low. Supply lubricant so that the oil surface

appears above the "MIN. OIL LEVEL"

display on the bowl. P17-18

Air or oil leaks

from the sight

dome.

1. The sight dome or O-ring is damaged. Replace the sight dome assembly.

P28-30

Air leaks from

the lubrication

plug.

2. O-ring is damaged. Replace the lubrication plug assembly.

Refer to section [8-2 Lubrication] of [8.

Operation and Adjustment] for the

replacement of the lubrication plug.

P17-18

Air leaks from

the gap between

the bowl and

body.

3. Bowl seal is damaged. Replace the bowl seal.

Apply grease before replacing the bowl

seal. Note)

P21-23

Air leaks from

the bowl.

4. The bowl is damaged. Replace the bowl assembly.

(If the solvent is considered to be harmful,

replacement to the metal bowl is

recommended)

P21-23

-20-

Refer to sections [8. Operation and Adjustment] (P16-P19), [10. How to Replace the Components] (P21-30) and [11. Disassembly

Drawing] (P31-32). A

ir l e a k a g e

Page for

reference

Note) Fluorine grease is recommended.

Trouble CountermeasurePossible cause

O il

d ro

p le

ts

10. How to Replace the Components

Warning Before replacement, make sure that no pressure remains in the product.

After replacement, confirm that the product satisfies specific functions and no external leakage occurs before operating it.

10-1. Bowl Assembly Replacement

Applicable

model

Work

category Tool Criteria

Disassembly 1) Remove the bowl assembly from the product. If

the bowl assembly is tightened too much to be

removed, use a hook spanner until it can be

loosened by hand.

Spanner specified for SMC

Product No.: 1129129

Work

category Tool Criteria

Assembly 2) Screw the bowl assembly into the product.

Tighten it referring to the specified torque.

Reference

tightening

torque: 2.2 N m

-21-

Procedure

AL20

Procedure

(7) Bowl assembly

Product

(7) Bowl assembly

Product

(6) Bowl seal

Applicable

model

Work

category Tool Criteria

Disassembly 1) Remove the bowl assembly from the product.

While the lock button is held down, rotate the

bowl assembly by approx. 30 degrees so that

the mating marks of the body and bowl

assembly meet each other. Then remove the

bowl assembly by pulling it downward.

Work

category Tool Criteria

Assembly 1) Mount the bowl assembly to the product and

rotate the bowl assembly until the lock button is

locked in position as shown in the figure below.

-22-

Procedure

AL30

AL40

Procedure

Align the mating marks

Lock button

Step 1

Step 2

Mating mark of the bowl assembly

Mating mark of the body

Make sure that the lock button

is locked to the flute of the

product before pressurising it.

Caution Step 2

Step 1

Product

Product

Lock button

Rotate 30 degrees

Pull downward

Rotate 30 degrees

Insert upward

(6) Bowl seal

(7) Bowl assembly

(7) Bowl assembly

Applicable

model

Work

category Tool Criteria

Disassembly 1) Remove the bowl assembly from the product.

While the lock button is held down, rotate the

bowl assembly by approx. 30 degrees so that

the mating marks of the body and bowl

assembly meet each other. Then remove the

bowl assembly by pulling it downward.

Work

category Tool Criteria

Assembly 1) Mount the bowl assembly to the product and

rotate the bowl assembly until the lock button is

locked in position as shown in the figure below.

-23-

Procedure

AL50

AL60

Procedure

(6) Bowl seal

Lock button

Product

(7) Bowl assembly

Align the mating marks

Mating mark of the body

Mating mark of the bowl assembly

Step 1

Step 2

Rotate 30 degrees

Pull downward

Product

Lock button

(7) Bowl assembly

Step 2

Rotate 30 degrees

Step 1

Insert upward

Make sure that the lock button

is locked to the flute of the

product before pressurising it.

Caution

10-2. Bumper Retainer Assembly Replacement

Applicable

model

Work

category Tool Criteria

Disassembly 1) Remove the bowl assembly referring to section [10-1.

Bowl Assembly Replacement] (P21). After removing

the bowl assembly, rotate the oil regulating valve by

hand to close the valve fully before disassembly.

Remove the bumper retainer assembly by hooking the

round nose pliers to the holes and turning them in the

direction of the figure.

Round nose pliers

(125 or 150)

Work

category Tool Criteria

Assembly 2) Screw the damper retainer assembly into the product.

After assembling, mount the bowl assembly referring

to section [10-1. Bowl Assembly Replacement] (P21). Round nose pliers

(125 or 150)

-24-

Procedure

AL20

Procedure

Product

Round nose plier hole

Product

(4) Bumper retainer assembly

(4) Bumper retainer assemblyOil regulating valve

Tightening torque [N m]

Model Torque

AL20-D 1.4+/-0.1

Round nose plier hole

Applicable

model

Work

category Tool Criteria

Disassembly 1) Remove the bowl assembly referring to section [10-1.

Bowl Assembly Replacement] (P22). After removing

the bowl assembly, rotate the oil regulating valve by

hand to close the valve fully before disassembly.

Remove the four screws, and then remove the bumper

retainer assembly. There is an O-ring between the

bumper retainer assembly and the holder assembly. Be

careful not to miss it.

Phillips

screwdriver

Work

category Tool Criteria

Assembly 2) Ensure that the O-ring is mounted correctly. Mate the

holders and the positioning holes on the bumper

retainer assembly. Tighten the bumper retainer

assembly with 4 screws as in the figure below. After

assembling, mount the bowl assembly referring to

section [10-1. Bowl Assembly Replacement] (P22).

Phillips

screwdriver

-25-

Procedure

AL30

AL40

Procedure

Product

Product

O-ring

Positioning holes

2 places

Holder

(4) Bumper retainer

assembly

(4) Bumper retainer assembly

Oil regulating valve

Screw (4 pcs. Tool: Phillips screwdriver

Screw (4 pcs. Tool: Phillips screwdriver

Tightening torque [N m]

Model Torque

AL30-D 0.4+/-0.1

AL40-D 0.7+/-0.2

Applicable

model

Work

category Tool Criteria

Disassembly 1) Remove the bowl assembly referring to section [10-1.

Bowl Assembly Replacement] (P23). After removing

the bowl assembly, rotate the oil regulating valve by

hand to close the valve fully before disassembly.

Remove 4 screws. Remove the housing and O-ring.

Hexagon wrench

(Nominal size: 5)

Work

category Tool Criteria

Disassembly 2) Remove the four screws and then remove the bumper

retainer. There is an O-ring between the bumper

retainer assembly and the holder assembly. Be careful

not to miss it.

Phillips

screwdriver

-26-

Procedure

AL50

AL60

Procedure

(4) Retainer assembly

Oil regulating valve

Screw (4 pcs. Tool: Hexagon wrench

(Nominal size: 5)

Housing

Screws (4 pcs.)

O-ring

Product

Product

Screw (4 pcs. Tool: Phillips screwdriver

Screws (4 pcs.)

O-ring

Holder

Applicable

model

Work

category Tool Criteria

Assembly 1) Ensure that the O-ring is mounted correctly. Match the

position of the oil passage tube on the retainer

assembly with the protruded guide around the oil

passage on the holder. Mount the retainer assembly to

the holder in the direction shown in the drawing below

and tighten it with 4 screws.

Phillips

screwdriver

Work

category Tool Criteria

Assembly 2) Mount the O-ring and housing to the body. Assemble

them with 4 screws. After assembling, mount the bowl

assembly referring to section [10-1. Bowl Assembly

Replacement] (P23).

Hexagon wrench

(Nominal size: 5)

-27-

Procedure

AL50

AL60

Procedure

Screw (4 pcs. Tool: Phillips screwdriver

Product

O-ringHolder

Screw (4 pcs. Tool: Hexagon wrench

(Nominal size: 5)

Housing

O-ring

Product

Oil passage tube

(4) Retainer assembly

Protruded guide around the oil passage

Tightening torque [N m]

Model Torque

AL50-D

AL60-D 1.4+/-0.1

Tightening torque [N m]

Model Torque

AL50-D

AL60-D 3.5+/-0.3

10-3. Bumper and Sight Dome Assembly Replacement

Applicable

model

Work

category Tool Criteria

Disassembly 1) Remove the bumper retainer assembly referring to section [10-2.

Bumper Retainer Assembly Replacement] (P24). After removing the

bumper retainer assembly, remove the holder assembly by pushing

the oil regulating value (sight dome assembly) into the body.

Separate the holder assembly and sight dome assembly by hand.

There is a steel ball inside. Please take care not to miss it.

Work

category Tool Criteria

Assembly 2) Assemble the spacer, sight dome assembly, steel ball and holder.

Place the steel ball in the oil inlet of the holder assembly and

assemble the sight dome assembly by aligning the zero point

alignment mark of the sight dome assembly with the zero point

alignment mark of the holder assembly. Next, install the bumper in

the holder assembly. Assemble them in a direction that matches the

shape of the bumper and the protrusion of the holder assembly.

Lastly, assemble the holder assembly to the body. When the holder

assembly and body are assembled with correct positioning, the end

surfaces of the holder and body become flat. After assembling the O-

ring, assemble the bumper retainer assembly referring to section [10-

2. Bumper Retainer Assembly Replacement] (P24).

-28-

Procedure

AL20

Procedure

Insert upward

Oil regulating valve

Product

Product

Holder assembly

Positioning groove (different width)

Positioning protrusion (different width)

Steel ball

(2) Sight dome

assembly

Holder assembly

(5) Bumper

O-ring

Spacer

Zero point alignment mark

Zero point

alignment

mark

Spacer

Sight dome assembly

Holder

Joint

Bumper

Steel ball

O-ring

I N

Holder assembly

Applicable

model

Work

category Tool Criteria

Disassembly 1) Remove the bumper retainer assembly referring to section [10-

2. Bumper Retainer Assembly Replacement] (P25).

Remove the sight dome assembly by pushing it in the arrow

direction. Separate the holder assembly and sight dome

assembly by hand. Remove the bumper using tweezers so that

it is not damaged.

Tweezers

Work

category Tool Criteria

Assembly 2) Assemble the spacer, sight dome assembly and holder.

Assemble the sight dome assembly by aligning the zero point

alignment mark of the sight dome assembly with the zero point

alignment mark of the holder assembly. Next, install the

bumper in the holder assembly. Assemble them in a direction

that matches the shape of the bumper and the concave of the

holder assembly. Lastly, assemble the holder assembly to the

body. When the holder assembly and body are assembled with

correct positioning, the end surfaces of the holder and body

become flat. After assembling, mount the bumper retainer

assembly referring to section [10-2. Bumper Retainer

Assembly Replacement] (P25).

-29-

Procedure

AL30

AL40

Procedure

(5) Bumper

Holder

(2) Sight dome assembly

Spacer

Push upward

Holder assembly

Product

Joint

Product

Positioning protrusion

Positioning concave

I N

Spacer (5) Bumper

Holder assembly

(2) Sight

dome

assembly

Holder assembly

Holder

Zero point

alignment

mark

Zero point alignment mark

Applicable

model

Work

category Tool Criteria

Disassembly 1) Remove the retainer assembly referring to section 10-2.

Retainer Assembly Replacement] (P26 to 27).

Remove the sight dome assembly by pushing it in the

arrow direction. Separate the holder assembly and sight

dome assembly by hand. Remove the bumper assembly

using tweezers so that it is not damaged.

Tweezers

Work

category Tool Criteria

Assembly 2) Assemble the spacer, sight dome assembly and holder.

Assemble the sight dome assembly by aligning the zero

point alignment mark of the sight dome assembly with the

zero point alignment mark of the holder assembly. Next,

install the bumper assembly in the holder assembly.

Assemble the bumper assembly and holder assembly

when their positioning hole match. Be careful with the

side of the protrusion. Lastly, assemble the holder

assembly and O-ring to the body. When the holder

assembly and body are assembled with correct

positioning, the end surfaces of the holder and body

become flat. After assembling, mount the retainer

assembly referring to section 10-2. Retainer Assembly

Replacement] (P26 to 27).

-30-

Procedure

AL50

AL60

Procedure

I N

Holder assembly

Product

Push upward

(5) Bumper assembly

Holder

(2) Sight dome assembly

Spacer

O-ring

Holder

Spacer

Zero point alignment mark

(5) Bumper assembly

Holder assembly

Zero point

alignment

mark

Product

Positioning protrusion

Positioning concave

Holder assembly

O-ring

Positioning hole

Positioning hole (protruded)

(2) Sight

dome

assembly

11. Disassembly Drawing

-31-

Body

I N

OUT

AL30-D, AL40-DAL20-D

Body

I N

OUT

(4) Bumper retainer assembly

(5) Bumper

(6) Bowl seal

Spacer

Holder

(7) Bowl assembly

(2) Sight dome assembly

O-ring

(3) Lubrication plug assembly

cross recessed round head screws

(3) Lubrication plug assembly

(7) Bowl assembly

(6) Bowl seal

(4) Bumper retainer assembly

(5) Bumper

Holder

(2) Sight dome assembly

Spacer

-32-

I N

OUT

AL50-D, AL60-D

Body

cross recessed round head screws

(3) Lubrication plug assembly

(6) Bowl seal

(5) Bumper assembly

Holder

(2) Sight dome assembly

Spacer

Housing

O-ring

O-ring

(7) Bowl assembly

(4) Retainer assembly

Hexagon socket

head cap screws

12Dimensions

-33-

(Port size)

C le

a ra

n c e f

o r

m a in

te n a n c e

Standard specifications Bracket mount

P A B C D E G J M N Q R S T U V

AL20-D 1/8, 1/4 40 79.3 35.9 21 60 21 30 27 22 5.4 8.4 60 2.3 28

AL30-D 1/4, 3/8 53 104.3 38.1 26.5 30 80 26.5 41 35 25 6.5 13 71 2.3 32

AL40-D 1/4, 3/8, 1/2 70 136.1 44 35.5 38.4 110 35.5 50 52 30 8.5 12.5 88 2.3 39

AL40-06-D 3/4 75 138.1 44 35.5 38.4 110 35.5 50 52 34 8.5 12.5 88 2.3 43

AL50-D 3/4, 1 90 209.1 48 45 110 45 70 66 40.5 11 13 113 3.2 52.5

AL60-D 1 95 223.1 48 45 110 45 70 66 40.5 11 13 113 3.2 52.5

Model

Semi-standard bowl

Semi-standard specifications

With drain

cock

With barb

fitting

Without

drain cock

With drain

cock

Without

drain cock

With drain

cock

B B B B B B

AL20-D 87.6 84.5 87.4 AL30-D 115.4 123.9 104.3 117.8 124.3 137.8

AL40-D 147.1 155.6 136 149.5 156.1 169.5

AL40-06-D 149.1 157.6 138 151.5 158.1 171.5

AL50-D 220.1 228.6 209 222.5 229 242.5

AL60-D 234.1 242.6 223 236.5 243 256.5

Metal bowl

with level gauge PC/PA bowl

Model

Metal bowl

Revision history

40-06,50,60 size added.

Dec. 2020.

4-14-1, Sotokanda, Chiyoda-ku, Tokyo 101-0021 JAPAN Tel: + 81 3 5207 8249 Fax: +81 3 5298 5362 URL https://www.smcworld.com Note: Specifications are subject to change

Manualsnet FAQs

If you want to find out how the AL40-D SMC works, you can view and download the SMC AL40-D Lubricator Operation Manual on the Manualsnet website.

Yes, we have the Operation Manual for SMC AL40-D as well as other SMC manuals. All you need to do is to use our search bar and find the user manual that you are looking for.

The Operation Manual should include all the details that are needed to use a SMC AL40-D. Full manuals and user guide PDFs can be downloaded from Manualsnet.com.

The best way to navigate the SMC AL40-D Lubricator Operation Manual is by checking the Table of Contents at the top of the page where available. This allows you to navigate a manual by jumping to the section you are looking for.

This SMC AL40-D Lubricator Operation Manual consists of sections like Table of Contents, to name a few. For easier navigation, use the Table of Contents in the upper left corner.

You can download SMC AL40-D Lubricator Operation Manual free of charge simply by clicking the “download” button in the upper right corner of any manuals page. This feature allows you to download any manual in a couple of seconds and is generally in PDF format. You can also save a manual for later by adding it to your saved documents in the user profile.

To be able to print SMC AL40-D Lubricator Operation Manual, simply download the document to your computer. Once downloaded, open the PDF file and print the SMC AL40-D Lubricator Operation Manual as you would any other document. This can usually be achieved by clicking on “File” and then “Print” from the menu bar.