A new Greasing System (RH90-340 Diesel and Electro) Supplied together

with the new PLC (Elrest)

Greasing sequence in the superstructure:
The control of the installation does no longer depend on time but on the actual position of the
control piston in the grease distributor. Despite lower pressure in the system, supply of grease
is guaranteed due to monitoring at the stick. The control pistons are monitored via a grease
distributor at the stick rear wall. It is to be assumed that it has the most unfavourable position
in this system because of the largest distance to the grease pump.

The most important advantage of the modified control is the lower level of pressure the system
is operated with. The long 360bar permanent pressure at the pump is avoided so that the
lifetime of the pump is prolonged considerably. Furthermore all system components are less
stressed as 170bar pressures are achieved at a maximum.

At the beginning of a grease cycle, voltage is applied to the hydraulic valve of the pump by
means of the PLC, and the hydraulic pump starts pumping in line 1 until the initiator 1 switches
over (lamp 1 Ini on, lamp 2 Ini off). After a follow time of 22 sec and 4 sec of switching over
(pump switches off during 4 s) the pump in line 2 starts pumping until initiator switch no. 2
switches over (lamp Ini 2 on, lamp Ini 1 off). The hydraulic valve and thus the pump are
switched off after pumping for 22sec. During a greasing cycle the lamps of the initiators must
switch on at least once (first initiator no.1!).

Normal greasing time or duration of a greasing cycle in the superstructure:

In the beginning the greasing time depends on the pump adjustments made by Lincoln; the
initiators switch over at approx. 40bar (duration approx. 7-10 sec). In order to guarantee supply
of all grease distributors a follow-up period of 22 sec per line has been set until greasing is
deviated or switched off. In this case pressure achieves approx. 170 bar in the end of each
greasing / line. During a switch over of 4 sec. the pump is switched off.

A complete grease cycle (time for greasing and a pause) is always started after the time set in
the PLC has expired. At the beginning of a greasing period the greasing cycle begins again.
Time can be changed by the BCS and should be pre-set to 20 and 30 min, i.e. 1200-1800 sec,
the minimum value being 5 min (300 sec), the maximum time 40 min (2400 sec). Settings are
made on the 2nd BCS level of access PLC options.

Time is counted only when the machine is in operation, i.e. when boom, stick or bucket are
operated (pressure switch load /DSL is enabled). The travel times of the excavator are not
counted, there is no greasing during breaks. Thus the supply of grease is adapted to demand
and any unnecessary greasing during production breaks is avoided. Moreover it is guaranteed
that grease breaks are made at regular intervals. The automatic change from summer to
winter operation is a further advantage. Upon higher lubricant viscosity in winter, grease is
automatically pumped for a longer time.
Upon any start of the engine, a new cycle is started.

X+22s X+22s X+22s X+22s

Grease time Line1 Line2

25s 15s 80s 60s 40s 80s 60s 15s

Operation time

Greasing system RH90-RH340 SPS Elrest.doc 1

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 may not be empty.
There may not be any fault message.

The functions of the reset button:

Greasing of the Superstructure:
Press button: Function:
1 sec resets PLC 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)

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
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 stick cylinder:

After a fault message persisting during 15 min in the superstructure the stick switches off.

BCS fault messages (without grease pump being switched off) superstructure:
When a cable of the pressure sensor is broken
When a cable of the grease level sensor is broken

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.)

The greasing of the undercarriage:

How to grease the undercarriage:

The greasing of the undercarriage is always started when the machines travels for at least 5 s,
i.e. the pressure switch Travel (DSF) is pushed. Then the pump is started and a grease cycle
is passed no matter if the machine travels or not after the start of the pump.
The pump switches off upon achieving a pressure of 180 bar
Thereafter the pressure must decline to below 50 bar for at least 5 sec before a new greasing
cycle is started (the pressure switch Travel being enabled during 5 sec).

Normal greasing time or duration of a greasing cycle undercarriage:

The very greasing takes approx. 10 sec.

Greasing system RH90-RH340 SPS Elrest.doc 2

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 running.
The grease drum may not be empty.
There may not be any error message.

The functions of the reset button:

Greasing of the undercarriage:
Press button: Function:
1 sec re-sets PLC values and deletes fault messages
(also done upon engine start!)
5 sec starts the test mode (15 min)
1 sec stops the test mode

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

When pressure exceeding 210bar is built up.
When pressure exceeding 180bar is built up and pressure which does not fall below 50 bar
within 1 min.
No 50bar pressure built up after valve was opened within 30sec
No 50-180bar pressure built up after valve was opened within 30sec
Fault messages can only be deleted by pressing the re-set button (1 sec).

BCS fault messages (without grease pump being switched off) undercarriage:
When cable of the pressure sensor is broken

Test mode undercarriage:

The test mode is initiated by pressing the re-set button for 5 sec. The pump operates 15 min
Continuously (DSF is bridged). The test mode can be stopped by pressing the re-set button for
1 sec.
(Greasing time can only be set in the PLC).

Greasing system RH90-RH340 SPS Elrest.doc 3

Greasing cycle: Greasing of the superstructure

Grease interval / break interval

t0 t1 t2 t3 t4 t5 t6

Pump status

Pressure at the pump 4s

End of line switch (line A)

22s

End of line switch (line B)

22s

Relief valve

- A new grease cycle starts as soon as pause time (t0) has elapsed.

- Pump is switched on and pumps grease to line A.

- At (t1) the End of Line initiators at the stick indicate that the movement of the control piston towards
direction A is finished.

- Now an additional greasing time of 22sec is passing in the system. This time guarantees that even
possibly slower pistons have enough time to reach final position A.

- The pump is switched off after further pumping during (t2) is over and the switch valve is operated.

- After a 4s break the pump is re-activated (t3) and pumps grease into line B.

- At (t1) the End of Line initiators at the stick indicate that the movement of the control piston towards
direction B is finished.

- Now an additional greasing time of 22sec is operating in the system. This time guarantees that even
possibly slower pistons have enough time to reach final position B

- The pump is switched off after trailing off time (t2) is over and the switch valve is operated and 5sec
later the relief valve is switched off.

- When (t6) is reached a new greasing cycle starts.

Greasing system RH90-RH340 SPS Elrest.doc 4

Pressure build-up for the greasing of the superstructure

Measurements in the system showed that the control pistons of the stick grease distributor
reach their final position at a pressure of approx. 40 bar (at the pump). After ca. 7sec this
pressure is attained.
Due to further pumping, however, pressure continues rising.

grease pressure

200
grease pressure at the

150
pump [bar]

100

50

0
0 5 10 15 20 25
follow time [s] Reihe1

The control is set to a 22sec follow time so that a pressure of c. 170bar is attained at the
pump.

Display and settings in the BCS

In the BCS, the sequence of a grease cycle is indicated by means of a red bar in the control
field of the greasing system. In case the pressure switch charge is activated, the bar turns
green from the left to the right. When the bar has completely changed to green time has
elapsed and greasing and a grease cycle start anew.
During greasing the background of the pictogram is displayed in yellow. In the BCS, the
grease pressure is indicated by means of an analogue signal.
Time can be changed via the BCS and should be pre-set to 20 to 30 min, i.e. 1200-1800 sec,
the minimum value being 5 min (300 sec), the maximum time 40 min (2400 sec). Settings are
made on the BCS level of access.
It must also be set if the machine is equipped with a grease drum and/or a greasing system for
the undercarriage.

Greasing system RH90-RH340 SPS Elrest.doc 5