Hydraulic Mining Excavator

CAT 6040

13.1 Central Greasing System – 2 Line Style

Matthias Aust - 2012

280 ltr. Tank Service Training

One single 280 ltr. container is used as the basic version for central greasing system.
Available for machines RH 90 – RH 340.

If there is a second 280 ltr. Container mounted, this one is used weather for standby, or for undercarriage greasing.
Available for machines RH 120 – RH 340.

Attention: If you want to use the service lift to fill in grease, please
make sure the empty grease drum is removed beforehand.

2
500 ltr. Tank Service Training

One single pump for

superstructure and
attachment.

Optional: Second pump

for standby or under-
carriage greasing.

Available for machines

RH 120E.

3
1000 ltr. Tank Service Training

One single pump for

superstructure and
attachment.

Optional: Second pump

for standby or under-
carriage greasing.

Available for machines

RH 170 – RH 400.

4
How comes the Grease into the Tank??? Service Training

!
d ed!!
n
m me
o
t r ec
No

5
Tank with one Pump and 2 Line Control Panel Service Training

Servo Oil Supply Grease Pump Breather Level Indicator

„max“
Tank
Level Indicator
„min“
Grease Tank

Control Panel

Line A

Line B

Grease Filter
From Service Arm

Filter after
Grease Pump
Servo Oil
Filter Emergency
Grease Nipple

6
Filters Service Training

Breather Filter
(Clean Air can
move in and out)

Grease Filter
(200 µm)
(Refill Line from
Service Lift)

Grease Filter
Servo Oil Filter (6 µm) (200 µm)
with Contamination (Pump Line to
Switch S257 Control Panel)
(Line from 50 bar Servo
System
to supply the Greasing
System)

7
Level Switches – capacitive digital switches Service Training

brown blue brown blue

black white

Level - Full Level - Empty

8
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
Grease Supply
Tank
Return Grease to Distributors
Grease from
Grease Pump
2 Line System Tank Return Oil/Grease
Lines A / B 9
Control Panel Service Training

-5Y3
-5Y1

-5B6

-5Y2

-5B4

10
Grease Pump Service Training

Quantity / Speed Pressure

Active Oil Adjustment Adjustment
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

11
Greasing System – Break Time Service Training

Grease
Pressure
Grease
Filter
Grease
Pump
Pressure
active
on Pump
-5B6
-5Y3
Unloader Grease
Valve Pressure -5Y1
Sensor
Pump
Changeover On / Off
Changeover
Valve
Solenoid
-5Y2

Line Line
1 2

Servo
Filter

Grease Tank Servo

Pump

Grease
Fill Line
with Filter 12
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

13
Greasing System – Greasing Line 1 Service Training

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

Changeover
Changeover
Valve
Solenoid
-5Y2

Line Line
1 2

Servo
Filter

Grease Tank Servo

Pump

Grease
Fill Line
with Filter 14
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

15
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

16
Greasing System – Greasing Line 2 Service Training

Grease
Pressure
Grease
Filter
Grease
Pump
Pressure
active
-5Y3 on Pump
-5B6
Unloader
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 17
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

18
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

19
Greasing System – Break Time Service Training

Grease
Pressure
Grease
Filter
Grease
Pump
Pressure
active
on Pump
-5B6
-5Y3
Unloader Grease
Valve Pressure -5Y1
Sensor
Pump
Changeover On / Off
Valve Changeover
Solenoid
-5Y2

Line Line
1 2

Servo
Filter

Grease Tank Servo

Pump

Grease
Fill Line
with Filter 20
Time Adjustment and Grease Cycles Service Training

Adjusted Time (e.g. 1800 sec)

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

Lubrication Time (adjustable from 300 sec 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.
21
Grease System – Easy to expand with an additional Distributor Service Training

Single Dosing
Initiator Line 1

Initiator Line 2

Double Dosing

22
Grease Distributor Service Training

Check Valves Rotary Valve

2 1
Directional Spool

Plugs

Pumping Piston

23
Grease Distributors – Single Greasing – Line 1 Service Training

2 1

24
Grease Distributors – Single Greasing – Line 2 Service Training

2 1

25
Grease Distributors – Double Greasing – Line 1 Service Training

Rotary Valve

2 11

26
Grease Distributors – Double Greasing – Line 2 Service Training

2 1

27
Grease Distributors Service Training

Indicators pins to show Valve Counter

the movement of the spool. Inlet 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!

28
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.

29
Grease Distributors Service Training

VSG 4 - Distributor

Connection
Lines A+B

ns
io
ns
te
Ex

VSL 2 - Distributor

30
VSG 8 Distributor with only 2 Outlets Service Training

a lve
V
e ck
Ch

n
ctio
e
o nn
htC
ig
tra
S

31
What is shown? …. VSL or VSG??? Service Training

VSG 2 - Distributor VSL 2 - Distributor

32
Distributors Service Training

VSG 4 - Distributor VSL 4 - Distributor

33
Distributors Service Training

VSG 6 - Distributor VSL 6 - Distributor

34
Distributors Service Training

VSG 8 - Distributor VSL 8 - Distributor

35
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.
36
Information Screen Service Training

 Start Page
 Click “Service” Button
 Click the “Greasing System”
 Information Screen opens

37
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

38
Example: Distributors A-Frame Service Training

39
Example: Distributors Swing Bearing / Gearbox Pinion Service Training

40
Example: Distributors Boom (FS) Service Training

41
Example: Distributors on Stick Rear Wall (FS) Service Training

Standard
Version

Initiators

Extended
Version

42
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

43
System Monitoring Service Training

Auxiliary Controller

Pressure Sensor B 36

Proximity Switches B 336 and B 336.1

44
Superstructure Greasing System: Reset Function Service Training

45
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 PLC.)

46
Superstructure Greasing System: Fault Messages Service Training

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

 When pressure exceeding 350 bar is built up.

 After 2 min each if one of the two initiators does not switch over.
 After 4 min, 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

47
More Information? Service Training

Hey Fellows,

Please find more Information

in the Technical Handbook!

Chapter 11.4: Function of Central Lubrication System

48