AA – 05 Engl.

CENTRAL LUBRICATION SYSTEM

DESCRIPTION

AA-05_3.1

9th Edition, engl.

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Copyright © Plasser & Theurer

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well to translate the work. Without written consent of Plasser & Theurer no part of this work
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CONTENTS

GENERAL 2

DEFINITION 2

OPERATING ELEMENTS 3

CONTROL PANEL FOR CENTRAL LUBRICATION SYSTEM 4

FUNCTION 5

THE PRINCIPLE OF AN "SSV" (LUBRICANT DISTRIBUTRO) 6

PRINCIPLE OF THE MAIN DISTRIBUTOR 7

OPERATION 8

EMERGENCY OPERATION 8

ERRORS IN THE SYSTEM 9

FAULT DETECTION AFTER INDICATION OF MALFUNCTION 10

EXCHANGE OF PUMP ELEMENT 11

TIME CONTROL UNIT 12

9th Edition, engl.

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GENERAL

A central lubricating system achieves the ideal situation of an automatic acting lubrication,
with small dosed quantities and short lubrication intervals. This produces a lasting,
economic and reliable lubrication and also achieves a reduction of wear.

Central lubrication means that several lubrication points are fed from a centrally positioned
lubricant pump.

lubrication points lubrication points

individual lubrication central lubrication

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DEFINITION

pump main distributor

sub distributor

main pipe

sub pipe

lubrication pipe

bearing
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OPERATING ELEMENTS

1= Lid with integrated time control unit

2= Main distributor
3= Piston detector
4= Nipple for emergency operation
5= Filter (see spare parts catalogue)
6= Pressure gauge
7= Feed pipe
8= Return pipe
9= Filling nipple
10 = Drive motor
11 = Safety valve (250 bar)
12 = Grease storage container (2 l)
13 = "MAX"-filling level
14 = "MIN"-filling level
15 = Stop valve for warning system and buzzer test
16 = Quick release coupling for re-filling
17 = Pump element

9th Edition, engl.

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AA-05 B10

CONTROL PANEL FOR CENTRAL LUBRICATION SYSTEM

1 = Switch and lamp for grease container

Switch = fill container
Lamp flashing = fill container
2 = Switch and indication - lubrication pump active (additional lubrication)
3 = Functional indication for the main lubricant distributor
In standard operational mode the LED is either “OFF” of “ON” for approx. 70.
4 = Indication - malfunction (blockage) and buzzer reset
Permanent light = failure
Pulsating = grease container empty
5 = Warning buzzer in case of malfunction
Permanent sound = failure
Pulsating = grease container empty
6 = Operation hour counter - central lubrication system (option)

Remark:
The arrangement of the control elements (see above figure) can vary depending on the
machine type.
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FUNCTION

An electro-motor drives an eccentric shaft and this activates a lubricant pump. The grease
is under pressure and is fed through a filter into the main distributor. A safety valve and a
pressure gauge are fitted to the main pipe for safety and supervision of the system. The
pump can move grease up to penetration class NLGI 2.

The time control unit, on which the required operating and rest times are set, is housed in
the lower part of the grease storage container. The times are already set ex works (see
drawing "Central Lubrication System UD 320 …").

The quantity of lubricant is controlled and dosed in the progressive lubricant distributors
"SSV".
The "SSV" contains pistons which are pushed by a system of notches and borings so that
lubricant is deposited in sequence (continuously, progressively) at all exits. If a piston
stops (lack of grease, blockage of a bearing, pollution or due to a fault of the drive motor),
the next piston cannot be moved. This means that all pistons in the system are stuck.

In the main distributor one piston is provided with a control pin. This control pin actuates a
piston detector which sends impulses to a switch-gear as long as the system is working
correctly. If the impulses stop or if the spacing from impulse to impulse is too long, the
alarm "error in the system" start up.
These impulses are shown by the LED (orange).

CAUTION:
Later addition or reduction of lubrication piping changes the lubricant feed to
the bearings. An express approval on our part is absolutely necessary
before any proposed alterations!

9th Edition, engl.

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THE PRINCIPLE OF AN "SSV" (lubricant distributor)

By closing one discharge, the lubricant is fed additionally to the next discharge. This
results in a wide range of dosage options.

The feeding sequence of an "SSV 8" is … 7, 5, 3, 1, 8, 6, 4, 2. Start of feeding sequence

depends on positioning of feeder pistons. The "SSV" works in each case until the full
quantity of lubricant has been distributed. If the supply of lubricant is interrupted by a
lubrication break, when the supply is resumed the feeding sequence continues there
where it was interrupted. The feed volume is 0.2 cm3 per discharge and stoke of feeder
piston.

CAUTION!
The discharges 1 and 2 should never be closed!

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mounted at the tamping unit

--x closed discharge

Æ feeding discharge
(details of feed volume in cm3)

Exact setting – see drawing "Central lubrication system UD 320 …".

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PRINZIPLE OF THE MAIN DISTRIBUTOR

return pipe
container

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The feeding sequence of the main distributor is I, II, III, IV, V, VI, VII, VIII, IX, X, XI, XII in
running order.
The grease quantities can be added up to 12 x 0.2 cm3/stroke. If the connection 12 is
used, it completes the internal return line.
Dosage options: see diagram.
Otherwise the allocated quantities of grease form the last-used discharge to discharge 12
will be returned to the container.
In the case of damage only the upper part of the flange distributor needs to be taken off.
The 6 fastening bolts of the upper part are tightened with 6 Nm ± 10 %.
The piston detector (page 3, item 3) has a fastening torque of 10 Nm ± 10 %.

9th Edition, engl.

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OPERATION

Before putting into operation for the first time or following a general overhaul, it must be
ensured that all pipes (main, secondary and lubrication pipes) are filled with grease.

IMPORTANT!
If, during later operation, a pipe has to be replaced by a new one, this has to
be filled with grease before assembly.

the system starts operation when the vibration drive is switched on and automatically the
lubrication cycle alternates with breaks.
At the end of the break the pump is switched on and the green lamp "pump in operation"
lights up.
As long as the lubrication cycle works satisfactorily, the yellow LED "operating indicator
main distributor" will be switched on or off approx. every 70 seconds.

When the vibration is switched off, the already completed break is stored.
When the vibration is switched back on the system continues to work from the point of
interruption (the breaks are added up).

During breaks the green lamp does not light up!

IMPORTANT!
However this does NOT mean that all lubrication points are supplied with grease. For this
reason it is particularly important to check the lubrication pipes and their connecting clips
daily for good condition. Breaks, cracks or loose connections cause leaks and thus a
cessation of lubrication. Such faults should be remedied immediately.

EMERGENCY OPERATION

The system is designed for hand operation in the event of an electrical malfunction.
In this case place a grease gun on the nipple for "emergency operation" and press the
grease gun slowly.

Refer to the contents list of the servicing instructions (WS) appertaining to the
machine which amount of grease has to be pumped in.

When operating the grease gun, watch the LED display and continue adding grease until
the required quantity of grease is reached.

For example: For a required amount of grease of approx. 35 cm3 it is necessary for the
LED display to light up ten times in order to supply all the lubrication points with grease
(with intact connections from the main distributor to the supply points).
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ERRORS IN THE SYSTEM

As soon as a piston comes to a halt an error warning is made by the piston detector. The
red lamp "Error in the system" lights up and the buzzer sounds alarm (page 4, item 4).
Fault detection as described below.

NOTE:
During fault detection the main battery switch and the vibration switch are ON.

GREASE RESERVES
check first if the grease container is full. Re-fill if necessary – see "Filling the system".

FILTER
The filter (page 3, item 5) has to be checked and cleaned together with the 1st machine
service (50 - 100 h), afterwards clean the filter every half year (or after 500 hours).

MOTOR FAULT
Check to see if there is a motor fault. Press button (page 5, pos. 2) and observe motor
running. If the pump does not run, there is a malfunction in connection with the drive
motor. Exchange the drive motor, if necessary.
Emergency operation is possible with hand pump – see "Emergency operation".

If there is a blockage in the system and the pump is transporting properly, the pressure will
build up in the system up to 250 bar (set value for the safety valve) and will escape
through the safety valve.
The piston at the piston detector (page 3, item 3) remains in the last position and activates
"malfunction" via pilot lamp (red and buzzer, page 4, items 4 and 5).

VENTING THE PUMP

If the grease container is not filled in good time it is necessary to vent the system.

After filling the storage container, unscrew the main pipe form the pump discharge and set
the pumps in operations (activating extra lubrication). If lubricant comes out at the pump
discharge, attach the main pipe again. Wipe off any excess grease.

9th Edition, engl.

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FAULT DETECTION AFTER INDICATION OF MALFUNCTION

A) Check motor running.

B) Is sufficient grease in the container?

C) If there is sufficient grease in the grease container and if the safety valve has not
reacted, press button (page 4, item 2) to check if the pump is transporting. Release
the main pipe form the pump discharge and check if the pump is transporting. If the
pump is transporting nor grease – see "Exchange of pump element".

If the pump is transporting, fix the main pipe back onto the pump discharge and
separate the main pipe after the filter.
Check if grease is flowing through the filter. If this is not the case, the filter ahs to be
cleaned or exchanged.
NOTE: Re-install filter correctly.

If grease flows through the filter, fix the main pipe back on again. Release one
secondary pipe after the other form the main distributor until the pump transports.
The trouble lies in the lubrication circuit of the secondary pipe last removed. If all
secondary pipes are removed and the pump still does not transport, the trouble lies in
the main distributor – see "Blockage in the main distributor".
Re-connect all pipes.

Continue at that sub distributor in which the trouble was found. Release one
lubrication pipe after the other from the sub distributor until the system works
normally. The lubrication pipe or bearing last released is that which caused the
blockage. If all lubrication pipes are released and the pump still does not transport,
the trouble lies in the sub distributor (see "Blockage in the SSV") or in a secondary
pipe.
First check the secondary piping for damage (crushing). Exchange defect secondary
piping. Fill new piping with grease before installation!
Re-connect all released connections.

Release the entry screw coupling at the bearing. If the lubricant runs out suddenly
under pressure and the system begins to run again normally, the bearing is blocked
and the lubrication line is free. Find out the cause of the blockage and remedy. If no
grease comes out and the system is still not working, then the lubrication line is
blocked. Exchange defect lubrication piping. Fill new piping with grease before
installation!

CAUTION!
It is extremely important that all piping removed (secondary piping and
lubrication piping) is re-connected to its original position because changed-
over piping alters the feed of lubricant to the bearing.

BLOCKAGE IN THE "SSV" (lubricant distributor)

If the blockage occurs due to soiling or hardened grease in an "SSV", exchange the
"SSV". Dismantle the "SSV" only in an emergency as the pistons have very tight
tolerances. Changed-over pistons do not fit into the "SSV"!
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BLOCKAGE IN THE MAIN DISTRIBUTOR

If the trouble should occur due to soiling or hardened grease in the main distributor,
exchange the upper part (flange distributor) (page 3, item 3).

EXCHANGE OF PUMP ELEMENT

The pump element can only be exchanged when the system is at standstill. When
installing the pump element, care should be taken that the scraper of the stirring paddle is
positioned opposite the pump element. Renew the sealing.
The fastening torque is 30 to 35 Nm.

FILLING THE SYSTEM

Always fill the grease container up to "MAX" level but TAKE CARE never to exceed the
"MAX" level!
The grease must be free of pollution and should not change its consistency in the course
of time.

IMPORTANT!
Basically the grease container must be filled over the quick release
coupling and/or the filling nipple!

Unless otherwise previously arranged the system will be filled ex works with "SHELL
ALVANIA GREASE RL2". If a change-over to another type of grease is to be made, its
suitability must be guaranteed by the corresponding supplier of lubricant.

We can accept no liability for any damage or subsequent damage

resulting form the use of unsuitable or incompatible lubricants.

For easier filling of the system, it is recommended to leave it running during filling. Press
button for this (page 4, item 1).

If the grease level drops to a minimum, the blue lamp will start to blink (page 4, item 1).
The blinking speed depends on the speed of the stirring paddle in the grease container.
After establishing this reserve indicator the grease container has to be filled up.

9th Edition, engl.

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TIME CONTROL UNIT

A lubrication cycle is composed of break time and working time (see time sequence
diagram). The set times can be seen in drawing UD 320 …, and on the supplement to the
servicing instruction page 1 (contents).

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Time Sequence Diagram
tB – operating hours T – lubrication cycle
tP – individual break times T1 – break times
T2 – working rimes

NOTE:
As too much lubricant can be equally as damaging as too little, the set times
should not be changed without our express permission.
Work and break time can be set by unscrewing the lid (page 3, pos. 1).

selector switch; break time AA-05 B01SW

Setting break time
The breaks can be set in 15 steps using the blue selector switch.
Time increments: minutes

Switch setting 1 2 3 4 5 6 7 8 9 A B C D E F

Minutes 3,75 7,5 11,25 15 18,75 22,5 26,25 30 33,75 37,5 41,25 45 48,75 52,5 56,25
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Selector switch; working time AA-05 B02SW

Setting working time
The working time can be set in 15 steps using the red selector switch.

Time increments: minutes

Selector switch 1 2 3 4 5 6 7 8 9 A B C D E F
Minutes 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30

9th Edition, engl.