- Pump assembly
- Injector banks
- Automatic lubrication injectors
Pump Assembly
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| Illustration 1 | g00609335 |
View of the Automatic Lubrication System (1) Air signal line. (2) Pump assembly. (3) Check valve. (4) Vent line. (5) Vent valve assembly. (6) Air regulator. (7) Pressure sensor. | |
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| Illustration 2 | g00609337 |
Automatic Lubrication System (1) Air signal line. (2) Pump assembly. (3) Check valve. (4) Vent line. (5) Vent valve assembly. (6) Air regulator. (8) Outlet for the lubricant. (9) Unloader valve. | |
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| Illustration 3 | g00609338 |
(2) Pump assembly. (4) Vent line. (5) Vent valve assembly. (10) Tube. | |
Air signal line (1) provides system air pressure to air regulator (6). The air regulator limits the air pressure to pump assembly (2). This regulated air pressure operates pump assembly (2) and vent valve assembly (5). The air regulator (6) limits the air pressure to 500 ± 20 kPa (73.0 ± 3.0 psi).
Pump assembly (2) draws lubricant through tube (10). The lubricant passes through check valve (3) to vent valve assembly (5). The regulated air supply closes the vent valve assembly. This allows the lubricant to flow through outlet (8). The lubricant then flows to the automatic lubrication injectors.
The pump assembly has a cycle for both the intake and for the discharge of lubricant. During the pump intake, check valve (3) closes. This prevents the pressurized lubricant from flowing back into the pump assembly. This allows the pump assembly to fill with lubricant from tube (10). The pump assembly then forces the lubricant through check valve (3). This flow of lubricant pressurizes the lubrication lines through outlet (8) .
Pump assembly (2) provides pressurized lubricant to the automatic lubrication system at approximately 17200 kPa (2500 psi).
After the lubrication injectors have cycled, the injectors will block the flow of lubricant. At this time, the pressure in the lubrication line increases until pump assembly (2) stalls or until the electronic control turns off the air supply. When the air pressure is removed, the pump stops operating and vent valve assembly (5) opens. Opening the vent valve allows the pressurized lubricant that is in the lubrication lines to return to the container through vent line (4). Check valve (3) prevents lubricant from flowing back into the pump assembly.
Unloader valve (9) protects the lubrication lines and the lubrication injectors. If the pressure in the lubrication lines exceeds 18600 kPa (2700 psi), unloader valve (9) will open. This allows the pressurized lubricant to release. The unloader valve is preset and the unloader valve is not adjustable.
There is a pressure sensor (7) that monitors the pressure of the lubricant. The actual pressure of the lubricant can be viewed on the message center module for the VIMS. In order to view the pressure of the lubricant, the operator must enter "749" on the keypad. Then, the operator must press the "gauge" key that is on the keypad. This will display the actual pressure of the lubricant.
The pressure sensor is monitored by the VIMS. When the pressure of the lubricant is not correct, the VIMS will display a warning. The possible warnings for the automatic lubrication system that can be displayed on the message center module for the VIMS are shown below.
"AUTO LUBE PRES HI CALL SHOP"
If the pressure of the lubricant exceeds 27586 kPa (4000 psi), the VIMS will display a warning category 2. This indicates that unloader valve (9) may not be functioning properly. "AUTO LUBE PRES HI CALL SHOP" will be displayed on the message center module for the VIMS.
"AUTO LUBE PRES ERR CALL SHOP"
The pressure of the lubricant must decrease to less than 3446 kPa (500 psi) within 300 seconds after the cycle of the automatic lubrication system. If the pressure of the lubricant does not decrease to less than 3446 kPa (500 psi), the VIMS will display a warning category 3. This indicates that vent valve (5) may not be functioning properly. "AUTO LUBE PRES ERR CALL SHOP" will be displayed on the message center module for the VIMS.
For additional information on the VIMS, refer to the Service Manual, SENR6059, "Vital Information Management System (VIMS)".
Injector Banks
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| Illustration 4 | g00465511 |
Injector Bank (Typical Example) (12) Lubrication line. (13) Outlet port. (14) Valve manifold. (15) Automatic lubrication injectors. | |
The injector banks are mounted to the machine in the following locations:
- The left side and the right side of the engine end frame
- The left side and the right side of the non-engine end frame
- The left side of both tilt levers
The injector banks contain automatic lubrication injectors (15). The injectors are mounted to valve manifold (14). Valve manifold (14) is connected to lubrication line (12). The lubrication line is connected to the pump assembly. Outlet port (13) is connected to a lubrication line for a bearing.
Automatic Lubrication Injectors
When the pump is activated, the automatic lubrication injectors will cycle one time and rest until the pump assembly is activated again. The injectors have four stages for a complete cycle.
Stage 1
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| Illustration 5 | g00465522 |
Stage 1 (16) Measuring chamber. (17) Piston for the injector. (18) Outlet port. (19) Valve port. (20) Slide valve. (21) Spring. (22) Discharge chamber. (23) Passage. (24) Supply port for the lubricant. | |
Piston (17) for the injector is in the normal position or the rest position. Discharge chamber (22) is filled with lubricant from the previous cycle. The pressure of the incoming lubricant is ready to open slide valve (20). This will allow passage (23) to open. Passage (23) leads to measuring chamber (16) .
Stage 2
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| Illustration 6 | g00465524 |
Stage 2 (16) Measuring chamber. (17) Piston for the injector. (18) Outlet port. (19) Valve port. (20) Slide valve. (21) Spring. (22) Discharge chamber. (23) Passage. (24) Supply port for the lubricant. | |
When slide valve (20) opens passage (23), the lubricant enters measuring chamber (16). This will force the lubricant from discharge chamber (22) through outlet port (18). The lubricant then flows to the bearing that is being lubricated.
Stage 3
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| Illustration 7 | g00465525 |
Stage 3 (16) Measuring chamber. (17) Piston for the injector. (18) Outlet port. (19) Valve port. (20) Slide valve. (21) Spring. (22) Discharge chamber. (23) Passage. (24) Supply port for the lubricant. | |
As piston (17) for the injector completes the stroke, the piston pushes slide valve (20) past passage (23). This stops the entry of lubricant into passage (23) and measuring chamber (16). Piston (17) and slide valve (20) remain in this position until the pressure at supply port (24) is vented to the pump assembly.
Stage 4
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| Illustration 8 | g00465526 |
Stage 4 (16) Measuring chamber. (17) Piston for the injector. (18) Outlet port. (19) Valve port. (20) Slide valve. (21) Spring. (22) Discharge chamber. (23) Passage. (24) Supply port for the lubricant. | |
After venting, spring (21) expands. This will move slide valve (20) so that passage (23) and discharge chamber (22) are connected by valve port (19). Further expansion of spring (21) causes piston (17) to move. This forces the lubricant in measuring chamber (16) through passage (23) and valve port (19). This will refill discharge chamber (22). The injector is now ready for the next cycle.