Description 3

Grease lubrication system 3.15

3.15 Grease lubrication system

The machine is equipped with an automatically operating grease lubrication
system which is based on the oil-loss lubrication principle.
The used lubricant which is pressed out of the lubrication points is not retur-
ned to the tank.

The used lubricant must be disposed of in accordance with the

applicable guidelines and provisions.

The grease lubrication unit provides the different lubricating points of the
machine with the required lubricant.
The lubricant is conveyed to the lubricating points in pulses. The time bet-
ween the lubrication intervals is monitored by the machine control system.
Any malfunctions of the lubrication system are displayed by the control sys-
tem. In serious cases, malfunctions can result in the machine being switched
off.

In the event of repair work to be carried out at the grease

lubrication system, the compressed-air supply must be
interrupted. The shut-off valve must be closed for this purpose.

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3 Description
3.15 Grease lubrication system

3.15.1 Grease lubrication diagram

The drawings supplied

include the original-size
grease lubrication chart.

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Grease lubrication system 3.15

3.15.2 Function
While the machine is switched on, a pump delivers lubricant in a pulsed
manner from the tank to one or several lubricant metering blocks.
The lubricant metering blocks deliver the lubricant in a pulsed manner and in
metered quantities to the connected points of lubrication. Various pistons are
installed in the lubricant distributors which are pushed back and forth by the
available grease pressure in a sequence of operations. The volume displa-
ced in each case corresponds to the amount of grease supplied to the lubri-
cation point with each lubrication pulse.
The sequence control guarantees that each lubrication point is automatically
supplied with the lubricant quantity allocated to it. A sensor which is arran-
ged immediately at the main lubricant metering block and which is dampe-
ned during each lubrication pulse, monitors the lubrication system.
In the event of system failures (e.g. squeezed line, no grease pressure avai-
lable in the feed line between the pump and the main distributor) the se-
quence of operations is interrupted. The lack of the signal from the sensor is
evaluated by the machine as a fault.
When the value set at the pressure switch is exceeded, this information is
also evaluated as a fault.
The lubricant filling level in the tank is monitored via a level switch. As soon
as the minimum level is reached, a message requesting the exchange of the
barrel is displayed by the control system.

When the message "barrel empty" is given, the barrel must be

changed.
We recommend to deposit a full barrel in the immediate vicinity
of the machine.

For details on the lubricating intervals and the type of lubricants, please refer
to Section "Maintenance", Chapter "Lubrication chart".
The lubrication pulse is automatically triggered by the machine control sys-
tem. Each time the machine is switched on, a lubrication pulse is initiated.

Lubrication pulse: 38 cycles per hour (basic setting)

The grease lubrication system comes perfectly set by the

manufacturer. Changes of grease quantities can result in
malfunctions and may only be made by qualified staff.

3.15.3 Grease pump

The grease pump is pneumatically operated. The pump is pressurised du-
ring each lubrication cycle.
The lubrication pulses are triggered by switching a 3/2-way solenoid valve.

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3.15 Grease lubrication system

3.15.4 Barrel change

The lubricant tank is designed as exchangeable tank (barrel).
Different barrel types are available. The barrel type used for your machine is
indicated in the Section "Maintenance", Chapter "Lubrication chart".

Only clean and fresh grease must be used. When changing the
barrel make sure that no dirt and/or objects get into the barrel.

3.15.5 Monitoring device

Number Function Effect Eliminate the cause/fault

of
pulses
per hour
< 38 Failure of the Display of a warning Lubricant line between the metering block
lubrication system message at the control ant the lubricating points squeezed, replace
system the line.

The piston in the metering block jams,

remove the metering block, clean it and/or
replace it, if necessary.

Defective sensor, to be exchanged.

Notes on troubleshooting

Condition at the Possible fault Remedy

machine
Dry guides (some). Defective lubrication lines Check the lines, replace damaged
(interrupted and/or squeezed). lines

Lubricant metering block defective Check lubricant metering block and

or contaminated (clogged). replace, if necessary.

Dry guides (all). Lubricant tank empty. Filling of lubricant tank

Lubricant metering block defective. Check lubricant metering block and

replace, if necessary.

The lubricant pump is defective Check the lubricant pump.

and/or is not activated. Check the control system.

In the event of a damage, a defective metering block must be

exchanged against a metering block which is identical in
construction.
The connections may not be exchanged during erecti-
on/assembly.

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