Hydraulic Mining Shovels

Cat® 6060/6060FS

12.0 Central Greasing System - Attachment

Dixio Torrerz - 2013

 280 ltr. Tank Service Training

One single 280 ltr. container is used as the basic version for central greasing system.
Available for machines CAT6018 - CAT6060.

If there is a second 280 ltr. Container mounted, this one is used weather for standby, or for undercarriage greasing.
Available for machines CAT6030 – CAT6060.

Attention: If you want to use the service lift to fill in grease,

please make sure the empty grease drum is removed
beforehand.

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500ltr. Tank Service Training

One single pump for

superstructure and
attachment.

Optional: Second pump

for standby or under-
carriage greasing.

Available for machines

CAT6030.

3
1000ltr. Tank Service Training

One single pump for

superstructure and
attachment.

Optional: Second pump

for standby or under-
carriage greasing.

Available for machines

CAT6040 – CAT6090.

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How comes the Grease into the Tank??? Service Training

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Tank with one Pump and 2 Line Control Panel Service Training

Grease Pump Breather Level Indicator

Servo Oil Supply „max“

Level Indicator
Tank
„min“

Grease Tank

Control Panel

Line A

Line B

Grease Filter
From Service Arm

Filter after
Grease Pump
Servo Oil
Filter
Emergency
Grease Nipple

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Filters Service Training

Breather Filter

(Clean Air can move in and out)

Grease Filter (200µm)

(Refill Line from Service Lift)

Servo Oil Filter (6µm)

Grease Filter (200µm)
with Contamination Switch
(Pump Line to Control Panel)
(Line from 50 bar Servo System
to supply the Greasing System)

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Level Switches – capacitive digital switches Service Training

brown blue brown blue

-5B15 -5B13

black white

Level - Full Level - Empty

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Control Panel Service Training

Unloader Valve
2 Line System
-5Y3
On/Off Solenoid
for Grease Pump
2 Line System
-5Y1

Pressure Sensor
2 Line System
-5B6

Grease Pressure Gage

Pressure Servo Oil
Gage

Grease Change Changeover

over Valve Solenoid
-5Y2

Servo Oil

Grease Supply
Grease
Grease from Tank
Grease to Distributors
Grease Pump Return
2 Line System
Tank Return Oil/Grease

Lines 1 / 2 9
Control Panel with second pump Service Training

-5Y1
-5Y5 -5Y3 -5Y4

-5B7 -5B6

-5Y2

-5B4

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Grease Pump Service Training

Quantity / Speed Pressure

Adjustment Adjustment

Active Oil
Pressure on
Grease Pump

Grease Pump Ratio:

Oil Piston : Grease Piston
6,6 : 1

Example:
Servo Pressure: 48 bar

Max. Grease Pressure:

6,6 x 48 bar = 316.8 bar

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Greasing System - Break Time Service Training

Grease
Pressure
Grease
Filter
Grease
Pump
Pressure
active
on Pump
-5B6
-5Y3
Unloader Grease
Valve Pressure
Sensor -5Y1
Pump
On /
Changeover Off
Valve Changeover
Solenoid

-5Y2

Line Line
1 2

Servo
Filter

Grease Tank Servo

Pump

Grease
Fill Line
with Filter
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Grease System – Break Time Service Training

Active in Break Time:

Initiator Line 2 -5B3

Lamp Line 2 -5H24
Initiator Line 1

Initiator Line 2

Additional:

No Grease Pressure
on Sensor -5B6

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Greasing System - Greasing Line 1 Service Training

Grease
Pressure
Grease
Filter
Grease
Pump
Pressure
-5Y3 active
on Pump
Unloader -5B6
Valve
Grease -5Y1
Pressure Pump
Sensor On /
Off

Changeover
Valve Changeover
Solenoid

-5Y2

Line Line
1 2

Servo
Filter

Grease Tank Servo

Pump

Grease
Fill Line
with Filter
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 Service Training
Lube Cycle Line 1

Distributors

Change Over

Valve

Line 1 (B)

Line 2 (A) Initiator 1

vented to Tank
50 bar Servo
Pressure

Sensor -5B6
Hydraulic

-5Y1 - ON/OFF Lube Pump

Solenoid

-5Y2 - Change
Auxiliary
Over Solenoid

BCS
Grease

Container

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Lube Cycle Line 1 Service Training

Active after completed cycle:

Initiator Line 1 -5B2

Lamp Line 1 -5H23

Additional:

250 bar Grease Pressure

on Sensor -5B6

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Grease System – Line 1 Service Training

Active after completed cycle:

Initiator Line 1 -5B2

Lamp Line 1 -5H23
Initiator Line 1

Initiator Line 2

Additional:

250 bar Grease Pressure

on Sensor -5B6

Line 1

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Greasing System - Greasing Line 2 Service Training

Grease
Pressure
Grease
Filter
Grease
Pump
Pressure
active
-5Y3 on Pump
Unloader -5B6
Valve
Grease -5Y1
Pressure Pump
Sensor On /
Off

Changeover
Valve

Changeover
Solenoid

-5Y2
Line Line
1 2

Servo
Filter

Grease Tank Servo

Pump

Grease
Fill Line
with Filter
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 Service Training
Lube cycle line 2

Distributors

Change Over
Line 1 (B)
vented to Tank Valve

Initiator 2
Line 2 (A)
50 bar Servo
Pressure

Sensor -5B6
Hydraulic
-5Y1 - ON/OFF
Lube Pump
Solenoid

-5Y2 - Change
Auxiliary
Over Solenoid

BCS
Grease

Container

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Lube Cycle Line 2 Service Training

Active after completed cycle:

Initiator Line 2 -5B3

Lamp Line 2 -5H24

Additional:

250 bar Grease Pressure

on Sensor -5B6

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Grease System – Line 2 Service Training

Active after completed cycle:

Initiator Line 2 -5B3

Lamp Line 2 -5H24
Initiator Line 1

Initiator Line 2

Additional:

250 bar Grease Pressure

on Sensor -5B6

Line 1

Line 2

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Greasing System - Break Time Service Training

Grease
Pressure
Grease
Filter
Grease
Pump
Pressure
active
on Pump
-5B6
-5Y3
Unloader Grease
Valve Pressure
Sensor -5Y1
Pump
On /
Changeover Off
Valve Changeover
Solenoid

-5Y2

Line Line
1 2

Servo
Filter

Grease Tank Servo

Pump

Grease
Fill Line
with Filter
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Time Adjustment and Grease Cycles Service Training

Adjusted Time (e.g. 1800 sec.)

1800 sec. → → → → → → → → → → → → → → → → → → → → → → → → → → → → → → → → → → → → 0 sec.

Lubrication Time (adjustable from 300sec. to 2400 sec.)

Greasing Line 1 4 sec. Greasing Line 2

Break Time
Greasing Time

If the operator starts the excavator and uses any attachment function, the greasing system also starts to lubricate the
machine.
At first line 1, then line 2 is lubricated:
Line 1:
The system is waiting for the indication of a fully lubricated line 1:
 Feedback from the “line 1 initiator” (-5B2) on the stick.
 250 bar pressure signal from the “grease pressure sensor” (-5B6).

Both conditions must be fulfilled before the system stops the lube pump for 4 sec. to allow the pump pressure to decrease.
Then the system switches over from line 1 to line 2, ready to grease line 2.

Line 2:
Then the system is waiting for the indication of a fully lubricated line 2:
 Feedback from the “line 2 initiator” (-5B3) on the stick.
 250 bar pressure signal from the “grease pressure sensor” (-5B6).

Both conditions must be fulfilled before the system stops the lube pump.
The system switches over from line 2 to line 1. => System is ready to grease line 1 again.

Greasing Time:
Time which is necessary to grease both lines.
This time can only be affected by: Temperature, Grease Pump Speed, Grease Type, Amount of Distributers.

Break Time: (Remaining time until the next lube cycle starts)
Remaining time is the result of Lubrication Time minus Greasing Time.

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Grease System – Easy to expand with an additional
Distributor Service Training

Single Dosing
Initiator Line 1

Initiator Line 2

Double Dosing

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Grease Distributor Service Training

Check Valves Rotary Valve

2 1
Directional Spool

Plugs

Pumping Piston

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Grease Distributors - Single Greasing - Line 1 Service Training

2 1

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Grease Distributors - Single Greasing - Line 2 Service Training

2 1

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Grease Distributors – Double Greasing - Line 1 Service Training

Valvula Giratoria

2 1

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Grease Distributors – Double Greasing - Line 2 Service Training

2 1

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Grease Distributors Service Training

Indicators pins to show

the movement of the spool. Valve Inlet Counter Nut
Closed with a removable brass cap

Double Single
Amount Amount

Double Single
Amount Amount

This side (with the directional valves)

is always mounted to the machine part!

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Grease Distributors Service Training

Counter Nut
Valve Inlet

Spare part distributers need to be adjusted

to the condition of the original.
They are always delivered in a
“single amount” condition.
Pleas find also a description in the
technical handbook.

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Grease Distributors Service Training

VSG 4 - Distributor Connection

Lines A+B

VSL 2 - Distributor
s
oni
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te
Ex

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VSG 8 Distributor with only 2 Outlets Service Training

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ig
t ra
S

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What is shown? …. VSL or VSG??? Service Training

VSG 2 - Distributor VSL 2 - Distributor

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Distributors Service Training

VSG 4 - Distributor VSL 4 - Distributor

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Distributors Service Training

VSG 6 - Distributor VSL 6 - Distributor

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Distributors Service Training

VSG 8 - Distributor VSL 8 - Distributor

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Distributors and Adjustment Screws Service Training

VSG 8 - Distributor

The distributor spools are machined very precise.

If not really necessary, do not open plugs of spools,
specially not in dirty environment!
If you have to control the movement of the spools,
you have to have a look at the telltale indicators.
For this you have to remove the brass or plexiglas cap.

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Information Screen Service Training

 Start Page

 Click “Service” Button

 Click the “Greasing System”

 Information Screen opens.

39
Settings Screen Service Training

 Start Page

 Click “Settings” Button => Enter Code

 Click the “Controller” Button

 Click on “Auxiliary Controller”

 Click on “Settings”

 Settings Screen opens.

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Example: Distributors A-Frame Service Training

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Example: Distributors Swing Bearing / Greasing Pinion Service Training

42
Example: Distributors Boom (FS) Service Training

43
Example: Distributors on Stick Rear Wall (FS) Service Training

Standard
Version

Initiators

Extended
Version

44
Auxiliary Controller Service Training

I/O module

The auxiliary controller is fully

interchangeable with the drive controller. Only
the software needs to be changed. The
hardware set up is identical.
The auxiliary controllers consist of a CPU
module and an I/O module

CPU module

45
System Monitoring Service Training

Auxiliary Controller

Pressure Sensor -8B6

Proximity Switches -5B2 and -5B3

46
Superstructure Greasing System: Reset Function Service Training

47
Superstructure Greasing System: Reset Function Service Training

Test Cycles

The conditions of greasing (superstructure and undercarriage) in the normal and in the test mode:
As well in the normal mode as in the test mode the following conditions must be given:

 The engine must be in operation.

 The grease drum must not be empty.
 There may not be any fault message.

The functions of the reset button:

Press button: Function:

1 sec resets values and deletes fault messages
2 sec + starts one single greasing cycle (also done upon engine start!)
5 times shortly (within 5 sec) Starts the test mode (3 ongoing greasing cycles)
1 sec Stops the test mode (ongoing greasing cycle continues)

Test mode 1 cycle:

One separate cycle is started and operated by pressing the re-set button for 2 sec.

Test mode 3 cycles:

The test mode is initiated by pressing five times within 5 sec the re-set button. 3 complete grease cycles are run.
The test mode can be stopped by pressing the re-set button for 1 sec during the test mode. The current cycle, however, is finished.
(The number of the cycles to be run during the test mode is pre-set in the Auxiliary controller.)

48
Superstructure Greasing System: Fault Messages Service Training

Fault messages (and switch-off of the grease pump) in the superstructure:

 When pressure exceeding 350bar is built up.

 After 2 min. each if one of the two initiators does not switch over
 After 4 minutes, if the pressure of 250 bar can not be reached in one main line.

Fault messages can only be deleted by pressing the reset button (1 sec).

The fault message is suppressed 3 min after starting the engine (i.e. during the first greasing) in order to prevent possible faults
(e.g. a longer greasing because of cold oil or grease)!

Switch-off of the bucket cylinder:

After a fault message persisting during 15 min in the superstructure the bucket switches off.
BCS fault messages (without grease pump being switched off) superstructure:

 When a cable of the pressure sensor is broken

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More Information? Service Training

Hey Fellows,

Please find more Information

in the Technical Handbook!

Chapter 11.4: Function of Central Lubrication System

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