New Grease Pump Improvements Compatibility Mode

Joy Global
Wheel Loader
Auto Lube Pump
Wheel Loader Grease Pump History
• 4241080 Grease pump assembly
• Adjustable flow control
• Adjustable pressure reducing valve
• Ongoing internal improvements
• 4275729 Grease pump assembly

• Fixed 1.5 flow control
• Fixed pressure reducing valve 325 psi
• 4279093 Improved grease pump assembly

• New crankcase
• New mount base
• Improved check valves
• New connections to vent valve
• Fixed 1.5 flow control
• Fixed pressure reducing valve 325 psi
Wheel Loaders
│ 29 October 2014 │ Grease Pump - DRAFT DOCUMENT
Basic Grease Pump Operation
– Pump operation utilizes
rotating motion from a motor
– The eccentric pump
mechanism turns rotation
into reciprocating motion
(up-down)
– This motion drives the
reciprocating rod which
moves grease up through
the reciprocating tube
– The grease pump pumps
grease on both the up and
down strokes
– This is called a “double
acting” pump
– Grease out is .07 cu. in. per
RPM for all pumps
Wheel Loaders
Basic Grease Pump operation
• On the lower end of the pump
tube, grease is obtained from the
reservoir
• Two ball checks act together with
the reciprocating motion to move
grease up through the
reciprocating tube
• The upper ball check is held
closed and sealed by a spring
• The lower ball check is held
sealed in a steel ball cage
improved during Phase I
• These checks allow grease to
move during the up and down
strokes
Wheel Loaders
Features incorporated in the 4275729 pump
– Fitted upper and lower ceramic coated pump plungers to hardened

steel bushings
– Custom molded upper polyurethane U-cup seal
– Hardened and ground steel wrist pin anchor with polyurethane seal
– Custom pivot screw
– Ground and hardened reciprocating tube
– Hardened steel lower ball check cage
– Cast zinc crankcase cover with o-ring sealed oil dipstick
– Hydraulic motor bushings changed to needle bearings
– Hydraulic motor shaft and adapter hardened to Rc 48-53
– Follower plate wiper material changed to ‘super’ nitrile rubber
– Crankcase cover screws sealed with Loctite 222MS
Wheel Loaders
Original pump overview
Hardened wrist
Custom pivot
pin bushing
screws
Hardened wrist Fitted upper pump

pin anchor plunger & bushing
Custom
polyurethane seal*
*High temperature seal
available
Wheel Loaders
Issues & solutions
Issue with 4275729 pump Effect Solution on 4279093 pump
Pump can not be Labor intensive pump Redesign the pump housing
installed/removed without replacement/maintenance flange and reservoir lid so the
removing the lid from the and possible grease pump is mounted from the top
reservoir contamination of the lid
Labor intensive, pump and

Difficult to change the Add a drain plug at the
lid must be removed and
crankcase oil bottom of the crankcase
inverted
Pump tube can break away Potential for catastrophic Strengthened the pump
from the crankcase flange failure during shipping tube/housing interface
Increase the upper check

Contamination in grease can Prevents pump from
passage and relocate the
lodge in the upper check building pressure and stops
spring to allow contamination
assembly grease flow
to flow around the spring
Wheel Loaders
Issues & solutions
Improve pump housing with

Hydraulic motor separates Catastrophic failure – motor
four-bolt mounting for all
from pump housing separates from housing
motors
Leakage between hydraulic Crank case oil leaks on the Replace the gasket seal with
motor and pump housing reservoir lid & drains an O-ring seal
Design 2" follower plate

Grease builds up on top of wiper seal to improve the
Follower wiper seal allows
the follower plate reducing seal and significantly reduce
grease to bypass during
the useable volume of the chance of grease
filling
grease in the reservoir bypassing to the top side of
the follower
Wheel Loaders
Issues & solutions
Grease flows through Added a proven seal

Allows grease to build up
follower plate vent tube design for the vent tube in
on top of the follower plate
opening the follower plate
All follower plates and lids

Reservoirs can not be Impossible to add level
are level sensor ready for
retrofitted with level sensors sensor to older models
retrofit
Increase the overflow
Reservoir overflow outlet is Grease may not escape fast
outlet to 1 1/4" NPT from 1/2"
too small to handle enough and force grease to
NPT Inlet to be 1” NPT from
overfilling bypass follower plate
3/4” NPT
Reservoirs can not be lifted Add lifting eye bolts to all

Unsafe lifting conditions
safely reservoirs
Wheel Loaders
Wheel Loader Grease Pump –
4279092 pump and barrel assy
4279093 pump
Wheel Loaders
Improvement details
– A new, stronger crankcase

– Top mountable crankcase and reservoir lid design
 New pumps will also mount on current reservoirs
– Four bolt hydraulic motor design with dual bearing drive shaft
support
– O-ring seal on hydraulic motor replaces current paper gasket
– Fixed pressure and flow control valves – same as old pump
 Pressure set at 325 psi
 Flow control 1.5 GPM
Wheel Loaders
improvements detail
– New upper check assembly design increases annular grease flow

by 70%
– Bucket reservoir design incorporates larger 1” fill and 1 1/4”
overflow ports
– All bucket reservoirs will have the improved 2” foam follower
– All pump & bucket assemblies will be ready to accept the Lincoln
grease level sensor system
– New crankcase includes oil drain plug for easy oil changes
– Fluid connections will be SAE O-ring
– Electrical remains DIN
Wheel Loaders
improvements detail
– Reservoir design incorporates larger 1” fill and 1 1/4” overflow ports
Wheel Loaders
Improvements
A new, stronger crankcase
Wheel Loaders
Improvements
• New crankcase includes oil drain plug for easy oil changes
Wheel Loaders
Improvements
• New crankcase includes
• Threaded holes equivalent to earlier pump for bottom up mounting
• Through holes for top down bolting
Wheel Loaders
Unresolved compatibility question
• The 4275729 pump was mounted from the bottom to a plate
• The plate was bolted from the top to the cover with 3/8” bolts
• The 4279092 pump is bolted to the cover with ¼” bolts
• Waiting on Lincoln for advice
Wheel Loaders
Improvements
Crankcase changes
½” taller than current model
4‐bolt hole pattern
Dual support ribs for increased
strength
Wheel Loaders
Improvements
Crankcase changes
O‐ring seals for all motors
Dual bearing supports
Increased depth of pump
tube/crankcase interface for
added strength
Wheel Loaders © SKF Lubrication usiness Unit Slide 19

Improvements
Crankcase changes
Inner seal in crankcase
housing allows motor
replacement without loss of
crankcase oil
Wheel Loaders © SKF Lubrication Business Unit Slide 20

│ 29 October 2014 │ Grease Pump - DRAFT DOCUMENT 29 October 2014
Improvements
Crankcase changes
Drill through hole in a
wider bolt hole
pattern for mounting
from top. Lid has nuts
inside the lid
Oil drain plug to
change oil
Threaded holes
so can also mount
to current lids
Wheel Loaders
Improvements
Flow path through the upper check valve assemblies
Current design New design
• Grease flow is New spring location
restricted, flows
through the • Spring is removed
check spring from flow path
allowing 70% more
• This causes annular flow area
contamination
blocks, failure to • Contaminated
build pressure grease is not as
much of a problem

No changes in hydraulic manifold
• DIN connector
• Uses the same manifold as on current pumps
• Unchanged Fixed hydraulic oil flow of 1.5 gal/min. (FCV)
• Unchanged manifold pressure of 325 psi (PCV)

│ 29 October 2014 │ Grease Pump - DRAFT DOCUMENT 29 October 2014
Improvements
Current multiple coupler “daisy chain” New single hose connection
Wheel Loaders
Improvements
Two lifting eye bolts on reservoir for safety
Wheel Loaders
Improvements
2” follower plate
• Virtually eliminates ‘tilting’ of the follower plate
• Greatly enhances the sealing properties
• More than 3X the current design
All follower plates are
level sensor ready
Improved vent
tube seal 2” closed foam seal
resists grease by‐pass
Wheel Loaders
Improvements
Grease reservoirs
1 ¼” NPTF • All lids will be ready for
overflow vent top mounting pumps
• Lids fit current and older
reservoirs
• Lids will be grease level
system ready
1” NPTF grease • Older pumps will fit new
fill inlet reservoirs
• New pumps will fit older
reservoirs
•*
*With vent valve kit 278413
Wheel Loaders
Benefits
Benefits
• Longer operating life
• Simplified installation
• Reduced early failures in crank cases of
hydraulic pumps
• More robust design is less susceptible
to grease contamination
• Pump and reservoir combination models
are level sensor/shut-off system ready
Wheel Loaders

New Grease Pump Improvements Compatibility Mode

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Joy Global

• 4275729 Grease pump assembly

• 4279093 Improved grease pump assembly

– Fitted upper and lower ceramic coated pump plungers to hardened

Hardened wrist Fitted upper pump

Labor intensive, pump and

Increase the upper check

Improve pump housing with

Design 2" follower plate

Grease flows through Added a proven seal

All follower plates and lids

Reservoirs can not be lifted Add lifting eye bolts to all

– A new, stronger crankcase

– New upper check assembly design increases annular grease flow

– Reservoir design incorporates larger 1” fill and 1 1/4” overflow ports

Wheel Loaders © SKF Lubrication usiness Unit Slide 19

Wheel Loaders © SKF Lubrication Business Unit Slide 20

Wheel Loaders © SKF Lubrication Business Unit Slide 22

Wheel Loaders © SKF Lubrication Business Unit Slide 23

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