Central lubrication system, description

The central lubrication system, TWIN, consists of a pump unit, main line channel A and channel
B, distribution blocks with dosage valves, secondary line and lubrication pressure sensor.
A control unit, integrated in the pump unit, affects the pump according to a pre-selected
lubrication cycle. In order to obtain correct lubrication in relation to existing operating and load
conditions, three different pre-programmed lubrication cycles can be selected. Choose which
lubrication cycle that is to be used with the switch for central lubrication (see [Invalid linktarget]).
The switch for selecting lubrication cycle is located on the instrument panel. The frequency with
which the pump lubricates depends on which cycle has been chosen.
Lubricant is pumped out via the two separate channels (A and B), that run to the distribution
blocks with dosage valve. The channels are pressurized alternately. In a lubrication cycle, one
channel is pressurized and the other is drained. During each lubrication cycle, each lubrication
point receives a specific amount of grease regardless if it is channel A or B that has been
pressurized.
The supplied amount of lubricant is determined by the size of the dosage valves, and is not
affected by back-pressure, temperature or the distance between lubrication point and pump
unit.
A control light is integrated in the switch and has the following functions:
o shows selected lubrication cycle
o test light during troubleshooting
o error indicator
Figure 1 Earlier version (C-series)
1. Pump unit 8. Main line channel B
2. Battery 9. Ignition
3. Distribution block 10. Switch
4. Dosage valve 11. Control light
5. Gear selector, forward-reverse 12. Test button
6. Lubrication pressure sensor, PS 13. Filling
7. Main line channel A
Figure 2 Later version (D-series and later)
1. Pump unit 8. Main line channel B
2. Battery 9. Ignition
3. Distribution block 10. Switch
4. Dosage valve 11. Control light
5. V-ECU 12. Test button
6. Lubrication pressure sensor, PS 13. Filling
7. Main line channel A
Lubrication cycles
The programmable control unit integrated in the pump unit determines the progress of each
lubrication cycle that takes place during four different phases, pump phase, lubrication
phase, pressure reduction phase and pause. It also decides how often a lubrication cycle
should be performed. In addition, there are safety functions that ensure lubrication even if there
are problems in the system.
A complete lubrication cycle consists of a cycle where all lubrication points are supplied with
lubricant through one of the channels in the main line.
A lubrication cycle is initiated by the control unit (CU802/CU19) that activates the pump. The
pump delivers pressure to line A. The pressure builds up to the pressure monitor
(SE802/SE113) which triggers a pressure signal. The pressure signal stops the pump and after
some time, channel A is depressurized. At the next lubrication cycle, the pump is activated via
the control unit (CU802/CU19). At the same time, the shift valve is activated and channel B is
pressurized.
Cycle A
During the pump phase, lubricant is pumped into the main line's channel A and then on to the
distribution block and dosage valves, which deliver a pre-determined amount of grease to each
lubrication point. During this time, channel B is connected to tank. When full pressure has been
reached, the lubrication pressure sensor (6) is affected so that the pump motor turns off, and
the pump phase ends.
During the lubrication phase, the pump motor is off. Pressure is maintained in the line to
ensure greasing of all lubrication points.
During the pressure reduction phase, channel A is depressurized and lubricant is thus
drained back to the reservoir.
The lubrication cycle ends with pause.
Cycle B
During the next lubrication cycle, lubricant is pumped into channel B. Otherwise, the lubrication
cycle is the same as for channel A.
The pressure builds up in one of the channels, at the same time as the other channel is
depressurized. A shift valve in the pump unit opens and closes the connection with both
channels.
Through channel A, alternatively B, the dosage valve is supplied with lubricant which at that
point is supplied in doses to the lubrication point.
Then, the dosage valve's piston returns and the dosage valve is filled with new lubricant for the
next lubrication cycle.
Since the return movement of the dosage valve's piston take place due to the pressure in the
channel, A or B, the dosage valves function independent of, for example, temperature and type
of lubricant.
This means that the pressure lines A and B, respectively, are never in direct contact with the
secondary line out to each respective lubrication point.
Different function parameters can be set in the control unit with one of the diagnostic tools, the
diagnostic unit or a software installed on a laptop PC. With the diagnostic tools, it is also
possible to read function data, for example, error indications that are registered in the control
unit's memory.
Figure 3
Lubrication cycles
1. Pump unit
2. Main line, Channel A and Channel B
3. Distribution block
4. Dosage valve
5. Secondary line
6. Lubrication pressure sensor, PS
Connections on circuit board (earlier version)

Figure 4

1 Pump housing BL Blue

2 Test button GN Green
3 Level monitor OR Orange
4 Solenoid, shift valve R Red
5 Pump motor SB Black
6 Control unit VO Violet
7 Electrical connection (connector between pump and machine) Y Yellow
8 Connection, electric power supply
9 Connection, activation signal from V-ECU (forward/reverse control)
10 Pressure monitor in distribution block
11 Switch in cab
Connections on circuit board (later version)

Figure 5

1 Pump housing BL Blue

2 Test button GN Green
3 Level monitor OR Orange
4 Solenoid, shift valve R Red
5 Pump motor SB Black
6 Control unit VO Violet
7 Electrical connection (connector between pump and machine) Y Yellow
8 Connection, electric power supply
9 Connection, activation signal from V-ECU (forward/reverse control)
10 Pressure monitor in distribution block
11 Switch in cab
Control lamp, signal codes
Control light built into switch:
-shows which lubrication cycle is used
-test-light when troubleshooting
-malfunction indicator
Signal code Cause
1 The control light flashes 4 4 x 1 flash: Lubrication cycle pre-set in position for very tough conditions.
times (0.5 s on, 0.5 s off) when 4 x 2: Lubrication cycle pre-set in normal position.
the ignition is activated. 4 x 3: Lubrication cycle pre-set for easy conditions.
2 The control light flashes (0.5 s Low lubricant level in lubricant reservoir.
on, 0.5 s off) for 2 min. every
time a lubrication cycle is
started.
3 The control light is on The lubrication pressure sensor is not activated from low pressure to high
continuously for 2 min. after pressure during the pump phase, which results in max. pump time.
finished pump phase.
Possible causes:
Internal leakage
Shift valve does not drain.
Pressure sensor is clogged.
Electrical malfunction, contact or defective cable.
Low ambient temperature and wrong consistency of lubricant.
4 The control light is on The control unit has interrupted the signal to the pump and the shift valve.
continuously. Possible causes:
One of the error codes under item 3 has been generated during ten
consecutive cycles, or ten times after one another in the same main line.
Reset by pressing in the test button for min 1 second, at the same time as
the ignition is in position 1.
Combination of any of the error codes under item 3 and alarm for low
lubricant level. Reset by filling lubricant.
5 The control light flashes (2 Single test lubrication cycle in progress.
sec. on, 2 sec. off) at each
lubrication cycle.
6 The control light flashes (0.2 Continuous test lubrication cycle in progress.
sec. on, 0.2 sec. off) at each
lubrication cycle.

Dosage valves, description

The dosage valves are adapted so that each lubrication point receives the correct amount of lubricant.
The dosage valves are marked with stamped numbers, for identification of correct.
The dosage valves are gathered in distribution blocks, available with varying number of connections. Connections
not used are plugged.
The dosage valves should never be dismantled since impurities may penetrate, which causes malfunction. Dosage
valves cannot be repaired; instead they must be replaced if they're defective.
The dosage valve consists of two chambers, one for each channel.
During the lubrication cycle when lubricant is pressed in from one channel to the chamber, a piston in the dosage
valve is affected which presses in the lubricant in the other chamber out to the lubrication point.
During the lubrication cycle, the piston in the dosage valve is pressed alternately back and forth when the pressure
in channels A and B shifts.
The function of the dosage valve is described by a division into four subsequent phases.
Figure 1 Distribution block with dosage valves

Different phases of the dosage valves

Phase 1
The dosage valve is not yet filled with lubricant.

Figure 2 Phase 1
Phase 2
From the main line's channel A, lubricant is pumped into the dosage valve (pump phase in cycle A).
The piston 3, is pressed forward until it has passed channel 1.
The lubricant passes via the channel 1, fills the chamber 2, the piston 4 is pressed forward.
After a certain time, channel A is depressurized. This does not affect the dosage valve.
The stroke of the piston 4, determines the amount of lubricant.

Figure 3 Phase 2

Phase 3
From the main line's channel B, lubricant is pumped into the dosage valve's channel 6 (pump phase in cycle B).
The piston 3, is pressed backward past the channel 8. Lubricant fills the chamber 7, the piston 4, is pressed back.
The lubricant in the chamber 2, on the other side of the piston 4, is pressed on via channel 1 to channel 9, the non-
return valve 10 opens, the lubricant is pressed further on the secondary line 5, and out to the lubrication point.
After a certain time, channel B is depressurized. This does not affect the dosage valve.

Figure 4 Phase 3
Phase 4
In this phase, the function sequence is the same as in phase 2. Now the chamber 7, is filled with lubricant.
The piston 4, is pressed forward, the chamber 2, is filled with lubricant. The lubricant in the chamber 7, is pressed
on via channel 8, to channel 9, the non-return valve 10 opens, the lubricant is pressed further on to the secondary
line 5, and out into the lubrication point.
As long as the lubrication system is functional, phases 3 and 4 will alternate with each other.

Figure 5 Phase 4
Lubrication cycle, description
A complete lubrication cycle consists of cycle A or cycle B.
The cycles consist of four phases each; the following describes the phases in cycle A.
1. Pump phase
2. Lubrication phase
3. Pressure reduction phase
4. Pause
The pump phase and lubrication phase are equal in duration. The duration of the pause depends on which
lubrication interval was selected. The total duration of the lubrication cycle is determined by which lubrication cycle
was selected.
If the lubrication cycle is interrupted because i.e. the operator turns off the machine, the lubrication cycle continues
at the same point where it was interrupted when the machine is started again. Thus, the lubrication cycle does not
start over from the beginning after an interruption.
Cycle A
Pump phase (1)
The pump motor starts, the shift valve is in resting position. Lubricant is pumped from the reservoir to the main
line's channel A, at the same time as the lubricant in channel B is drained back to the reservoir. When full pressure
is reached, the lubrication pressure sensor is affected so that the pump motor is turned off, the pump phase ends.
The duration of this phase may vary depending on i.e. temperature, type of lubricant.
Maximum pumping time is determined by the parameter "maximum pump time".
Lubrication phase (2)
The main line's channel is pressurized for as long as the duration of the pump phase, the shift valve is still in
resting position, and lubricant is thus forced out into the main line's channel A and then onto the dosage valves.
Pressure reduction phase (3)
The shift valve moves over to affected position, channel A is depressurized, lubricant from channel A is thus
drained back to the reservoir.
The time for this phase is dependent on the time for the pump phase. It is possible to adapt the multiplication factor
in the control unit's program to special conditions with the separate diagnostic unit.
Pause (4)
The pump motor is stationary; the shift valve is in resting position. The time for the phase is dependent on the pre-
set time for cycle A, and the time that was required for the three previous phases. In most cases, the pause is
longer than the other three phases together.
Under conditions when it takes a long time to build the pressure to the required value, the time for the first three
phases may become as long as or longer than all of cycle A. Under such conditions, the pause is omitted, and then
cycle B will be initiated immediately following the pressure reduction phase. The first three phases are always
performed.

Figure 1
Pressure during the different phases
A Lubrication cycle channel A P Pressure from pump
B Lubrication cycle channel B V Pressure to shift valve
1 Pump phase PA Pressure in channel A
2 Lubrication phase PB Pressure in channel B
3 Pressure reduction phase
4 Pause
Cycle B
The pause after cycle A is followed by cycle B with the same build-up as cycle A. The shift valve is affected,
lubricant is pumped out to channel B, at the same time as lubricant in channel A is drained back to the reservoir.
During the pressure reduction phase in cycle B, the shit valve returns to resting position, channel B is
depressurized, thus the lubricant from channel B is drained back to the reservoir.

Pressure monitor, description

The pressure monitor, which is located in one of the distribution blocks, ensures that connection is made with the
channel that has the highest pressure, the main line's channel A or channel B. The pressure monitor is not
adjustable, therefore the pressure monitor may have two different part numbers, since different placement in the
system results in the pressure having to be different. The pressure monitor is available in two versions.
Earlier version
Cycle A
The pressure in channel A is higher than in channel B. The balls (2) will be pressed against the seat (1). Channel B
closes at the same time as the connection between channel A and channel 4 opens up. The pressure against the
piston (5) then becomes the same as the pressure in channel A.
The pressure on the piston (5) overcomes the force of the spring (6), the piston will be pressed against the contact
plate (7), the contact plate is pressed up and connects between the electrical connections (8 and 9), the pump
motor turns off, the pump phase in cycle A ends.
During the pressure reduction phase channel A is depressurized, the spring presses back the contact plate and
piston, the connection between the electrical connections (8 and 9) is opened.

Figure 1
Pressure monitor, earlier version
A. Connection, channel A
B. Connection, channel B
1. Seat 6. Spring
2. Balls, 2 pcs. 7. Contact plate
3. Seat 8. Electrical connection
4. Channel 9. Electrical connection
5. Piston
Cycle B
The pressure in channel B is higher than in channel A. The balls (2) will be pressed against the seat (3). Channel B
opens at the same time as channel A closes, at the same time as the connection between channel B and channel
4 opens up. The pressure against the piston (5) then becomes the same as the pressure in channel B.
The pressure on the piston (5) overcomes the force of the spring (6), the piston will be pressed against the contact
plate (7), the contact plate is pressed up and connects between the electrical connections (8 and 9), the pump
motor turns off, the pump phase in cycle B ends.
During the pressure reduction phase channel B is depressurized, the spring presses back the contact plate and
piston, the connection between the electrical connections (8 and 9) is opened.
Later version
Cycle A
The pressure in channel A is higher than in channel B. The slide (2) moves up until it stops, channel B closes at
the same time as the connection between channel A and channel 4 opens up. The pressure against the piston (5)
then becomes the same as the pressure in channel A.
The pressure on the piston (5) overcomes the force of the spring (6), the piston will be pressed against the contact
plate (7), the contact plate is pressed up and connects between the electrical connections (8 and 9), the pump
motor turns off, the pump phase in cycle A ends.
During the pressure reduction phase channel A is depressurized, the spring presses back the contact plate and
piston, the connection between the electrical connections (8 and 9) is opened.
Figure 2
Pressure monitor, later version
A. Connection, channel A
B. Connection, channel B
1. 6. Spring
2. Slide 7. Contact plate
3. Channel 8. Electrical connection
4. Channel 9. Electrical connection
5. Piston
Cycle B
The pressure in channel B is higher than in channel A. The slide (2) moves down until it stops, channel B opens at
the same time as channel A closes, at the same time as the connection between channel B and channel 3 opens
up. The pressure against the piston (5) then becomes the same as the pressure in channel B.
The pressure on the piston (5) overcomes the force of the spring (6), the piston will be pressed against the contact
plate (7), the contact plate is pressed up and connects between the electrical connections (8 and 9), the pump
motor turns off, the pump phase in cycle B ends.
During the pressure reduction phase channel B is depressurized, the spring presses back the contact plate and
piston, the connection between the electrical connections (8 and 9) is opened.

Pump unit, description

The pump motor (11) drives a radial piston pump. Drive is via a gear (9) that drives a shaft with an off-center
washer (4), the same shaft drives a stir paddle in the bottom of the reservoir. The off-center washer affects three
pistons (5) in the radial piston pump. The pistons pump lubricant from the reservoir through the shift valve (6) to the
connection (7 or 8) out to the main line's channel (A or B) further on to the dosage valves, and from there to the
lubrication points. The shift valve's position is determined by in which of the channels (A or B) that pressure is to be
built up. After each cycle (A or B), there's a change of channel. The pressure is built up alternately in both
channels.
While the pressure builds up in one channel, the shift valve opens the passage to the reservoir for the other
channel, and thus depressurization of that channel takes place.
The pump pressure is limited to 250 bar by the overflow valve (14).
The pump phase is interrupted when the desired pressure is reached at the lubrication pressure sensor.
On the left side of the pump housing, there is an opening for an air breather and run-off of excess lubricant from
the reservoir (15). When the reservoir is filled with lubricant, the air above the follower plate will be pressed away.
This air is led down through a channel in the follower plate's guide pin and leaves the pump unit via the breather
opening.
The lubricant reservoir has markings (lines) for max. and min. lubricant levels. The markings show the highest and
lowest levels for the follower plate, which follows the lubricant.
If the reservoir is overfilled with lubricant, the drain channel in the follower plate's guide opens and excess lubricant
drains through the pump unit's breather opening.
When the lubricant reaches a pre-determined min. level, this is indicated by a level switch (17).
For start of one or several test cycles, the pump is provided with a test button (12) on the outside of the housing.
The test button is also used to reset the control unit (10) in case of error codes.

Figure 1
Pump unit
1. Follower plate 8. Connection main line, channel B
2. Reservoir 9. Gear
3. Stir paddle 10. Control unit,CU19 (C-series)/CU802 (D- and E-series)
4. Off-center washer 11. Pump motor, MO13
5. Pump piston (3 pcs.) 12. Test button (/reset button)
6. Shift valve 13. Filler connection
7. Connection main line, channel A 14. Overflow valve, (pressure limit 250 bar)
15. Breather opening 17. Level switch
16. Electrical connection

Shift valve, description

The shift valve opens and closes the pump's connection with the main line's channels during the lubrication cycle.
The shift valve's valve slide is affected by a spring and a solenoid.
In resting position, the valve slide is affected by the spring. In affected position, the solenoid is activated, which
overcomes the spring force and thus displaces the valve slide.
In resting position, channel P is connected with the main line's channel A. At the same time, the lubricant is drained
back from the main line's channel B to the reservoir via channel R B.
In affected position, channel P is connected to the main line's channel B. At the same time, the lubricant is drained
back from the main line's channel A to the reservoir via channel R A.

Figure 1
Shift valve in resting position
A Main line channel A
B Main line channel B
P Channel from pump
RA Return channel to reservoir
RB Return channel to reservoir

Troubleshooting

Error Cause Action

1 Control light does not Voltage drop from ignition. Ground Check fuse, replace if needed.
flash when ignition is in connection or control light defective. Check ground connection, if needed.
position 1. Control light defective. Change light bulb. Check cabling and
Cabling damaged between cab and pump repair or replace, if needed.
unit, or between pump unit and control
light.
2 Control light flashes Low lubricant level in reservoir. Fill lubricant in reservoir.
(0.5 sec. on, 0.5 sec. off)
for 2 min. every time a
lubrication cycle is
started.
3 The control light is on Leakage in main line, pump cannot build Repair the line and bleed air from the
for 2 min. after every up lubrication pressure. system.
pump phase. Air in system, causes insufficient pressure Bleed air from the system and test-run
during pump phase. with single test lubrication cycle.
Lubrication pressure sensor is defective. Check sensor, replace if needed.
O-ring in a dosage valve is defective or Check dosage valves and fit new O-
missing, pressure leak between main lines. rings, if needed.
Shift valve is defective, pump cannot build Check valve, replace if needed.
up lubrication pressure. Check with diagnostic unit.
Other causes.
4 The control light is on Ten consecutive identical error codes. Press and hold in test button on the
continuously. Interrupted check of the pump and shift pump for min. 1 second to reset the
valve (to protect control unit). error indication.
Low lubricant level in lubricant reservoir at Troubleshoot according to point 3.
same time as lubrication pressure has not Fill lubricant and reset by pressing
been achieved during pump cycle. and holding in the test button for min.
1 second.
Test-run with system test, if needed.
5 All lubrication points Interval too long between lubrication Select another lubrication cycle.
are dry but no error cycles. Check cabling and repair or replace, if
indication. Cabling damaged between machine and needed.
pump unit.
6 Too much lubricant at Time interval too short between lubrication Select another lubrication cycle.
all lubrication points. cycles.
7 One or several Squeezed or damaged line between Check and repair line, if needed.
lubrication points are dosage valve and lubrication point. Fit a dosage valve with greater
dry while others are Dosage valve has too low dosage volume. lubrication volume.
lubricated correctly. Dosage valve is defective. Remove and clean dosage valve, or
replace.
8 One or several Dosage valve has too high dosage volume. Fit a dosage valve with lower
lubrication points lubrication volume.
lubricate too much. Replace dosage valve.
9 The control light flashes Single test lubrication cycle in progress. Control light turns off automatically
(2 sec. on, 2 sec. off) after finished test lubrication cycle, or
during a complete when ignition is turned to position 0.
lubrication cycle.
10 The control light flashes Continuous test lubrication cycle in Control light turns off after finished
continuously (0.2 sec. progress. test lubrication cycle. To finish test
on, 0.2 sec. off) during lubrication cycle, the ignition must be
every complete turned to position 0.
lubrication cycle.
Wiring diagram 26

Figure 1
Wiring diagram, central lubrication system
L50B and L50C

Figure 1
L50B and L50C, with alternative front/reverse (dual command)

Figure 2
L70B and L70C

Figure 3
L90C, L120C, L150C, L180C and L180C HL

Figure 4
L330C

Figure 5