集中润滑系统使用说明

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Operation and maintenance manual

KFU2-40
Centralized lubrication system of chassis

Contents

Operation explanation…………………………………………..3
Fault elimination…………………………………………………9
System repair……………………………………………………11
Service parts…………………………………………………….19

Operation explanation
I、 Centralized lubrication system is controlled by DKQ model controller. The operation method will be explained in the following sections taking the DQZ-10 controller as an example.
System is in normal situation
■        turn on ignition switch (key) and the power lamp (green lamp) is on. From then the time counting will begin.









Notes：
1、This time counting is an accumulative result on the basis of last time due to the memory function of the controller.
2、 If a vehicle has been run over 24 hours and the controller doesn’t have time display. Mandatory lubrication of 30 seconds should be carried out by pressing tuning button after vehicle start up.

■ If counted time reaches the set interval time（10 hours or 20hours）, the operation lamp (green lamp) will be on and controller will order the oil pump to run.










■ The pressure sensor inspects that the system pressure has reached a normal value 105 seconds before oil pump operation and input a switch signal to the controller. Then the normal lamp (yellow lamp) of the controller will be on.










■ The oil pump will continue to operate for 25 seconds before stop. The operation lamp (green lamp) and normal lamp (yellow lamp) of the controller will be out. Then another interval time counting begins.











Faults occur
■ If the pressure sensor doesn’t inspect that the system pressure has reached the normal value 105 seconds before oil pump operation, the controller will stop time counting. Then the fault lamp (red lamp) will be on and issue an alarm signal (buzzer rings)



Fault types
There are two possibilities when the controller issues an alarm：
I、occasional interference：High voltage impulse or strong magnetic interference will result in controller faults.
II、fault of the system itself: Reasons such as oil shortage in oil tank, motor fault, oil leakage of main pipe or pressure sensor damage etc. will all result in alarm of the controller.
Failure predication
First method:
step one： Press “failure elimination” key, then the failure lamp of the controller will be out and the buzzer will stop ringing.

Step two：Press “tuning button” without release. If the normal lamp of the controller is always on during next 105 seconds, last fault was because of occasional interference. If the failure lamp of the controller is on again and the buzzer rings again, the failure comes from the failure of the system itself.



warning：

If the system itself has fault, inspection must be carried out immediately and the failure must be eliminated.



Second method：
Step one：turn off the ignition switch and turn on it again after the fault lamp of the controller has been out and the buzzer has stopped ringing.
Step two：same as the step two of the first method
Operation method of tuning button
If you want to fill extra oil to the chassis, press “tuning button” key without release by your finger until dozens of seconds after the normal lamp of the controller being on.
  warning：
1、Don’t lubricate manually by using tuning button several times within a short period, otherwise there will be excessive grease in friction pairs, which results in grease waste.
2、Don’t use too much force to press “tuning button” key, otherwise you will damage the key.



Fault elimination
Elimination method of familiar system fault
Fault phenomena        Fault cause        Elimination method
Oil pump motor doesn’t work        1、Wrong wire connection of the controller        Connect correctly according to the wiring diagram of the controller
        2、Controller damager        Change another controller
        3、Wire disconnection of the oil pump        Connect wire again
        4、Motor or carbon brush damage        Change another motor or carbon brush
        5、Oil pump lock        Disassemble oil pump for cleaning
The pressure in system main fuel pipe can’t reach 3.8Mpa at motor operation        1、There is air at the oil sucking end of the oil pump        Expel air by shaking the oil tank etc. Then start up the motor by tuning button
        2、oil sucking end of the oil pump is blocked        Clean oil sucking end of the oil pump
        3、The air vent of the oil pump is blocked due to excessive oil in the tank or external dunghill        Open the oil pump cover and blow compressed air into the oil tank through filler to get through air vent.
        4、Main fuel pipe breaks off or the joint becomes flexible        Inspect main fuel pipe and its joint, then repair.
        5、Add grease of wrong brand        Clear up original wrong grease and then add correct grease. Loose pump outlet joint and start up the oil pump by manual button
        6、Overflow valve of oil pump damages        Repair overflow valve or change the entire pump

Elimination method of familiar system fault
Fault phenomena        Fault cause        Elimination method
There is no grease out from dispensers after the motor stops rotating        1、The unloading valve of the oil pump locks and the system can’t unload        Disassemble the unloading valve core and wash it in the coal oil
Controller issues an alarm although the pressure in the system main pipes is normal        1、Pressure sensor is damaged        Change another pressure sensor
There is no grease in a few friction pairs.        1、The dispenser connected to this lubrication point is damaged        Disassemble the plunger of dispenser connected to this point and wash it in coal oil or change it
        2、The sub fuel pipe connected to this lubrication point breaks off        Change this sub fuel pipe
        3、The oil way of the friction pair is blocked        Inject grease used in the lubrication system by a grease gun into the oil way to get through it
  tips：
The fault cause must be correctly found and this fault must be eliminated as soon as the fault cause is found. Otherwise, friction pairs of the chassis will be lubricated abnormally, which accelerates abrasion of components of friction pairs.

System repair
ⅠChange motor                                        step one：disassemble motor
Open the oil pump cover and loose four M5X30 bolts locating on the flange of the motor. Then disassemble the mot or upward.


Step two：install new motor（connection sleeve has been installed on the motor shaft）
Install a new motor after aiming the connection sleeve on the motor shaft at the connection rod and then tighten four M5X30 bolts.




Ⅱchange filter screen
If the filter screen is blocked by dirt, it must be cleared up. If the filter screen distorts seriously, it must be changed.



Ⅲrepair of overflow valve
The repair of overflow valve is mainly to wash it after being blocked by dirt. step one：open the oil pump cover and loose four M8X16 bolts on the front and rear protective plate. Then loose six M5X30 bolts on the cover plate of the oil pump   before taking out the pump assembly. Wash the oil stain by coal oil.















Notes：
A cover must be added onto the oil tank for dust proof after the pump assembly has been taken out.


Step two：Disassemble all internal components of overflow valve in order and wash them in coal oil. Then assemble again in order







Step three：Put the pump assembly in the oil tank again and tighten the bolts before installing the cover.
Notes：
If internal components of overflow valve have been damaged, corresponding components even the whole overflow valve must be changed.

Ⅳ repair of unloading valve
The repair of unloading valve is also mainly to wash it after being blocked by dirt.
Step one：same as that of the repair of overflow valve.
Step two：Loose unloading valve joint (unloading bulk head) and disassemble all internal components of unloading valve in order. Then wash them in coal oil and assemble them in order again.







-40B and new -40 pump


Notes：
Old products: When you disassemble the seal cylinder of the unloading valve, you should turn on the power to enable the oil pump to corotate for a few moments. After the seal cylinder is pushed out, turn off the power and take it out for wash.
-40B pump and new -40 pump：When you disassemble the base of the unloading valve and bowl-shaped seal ring, you should turn on the power to enable the oil pump to corotate for a few moments. After the valve base and seal ring are pushed out, turn off the power and take them out for wash.
Step three：same as step three of overflow valve repair
Notes：
A cover must be added onto the oil tank for dust proof after the pump assembly has been taken out.
notes：
If internal components of unloading valve have been damaged, corresponding components must be changed.


Ⅴrepair of dispenser
If there is no grease discharge at the dispenser outlet corresponding to a certain lubrication point, this dispenser is surely locked. Ration joint, spring and piston should be disassembled in order and washed in coal oil. Then assemble them again in order. If there is still no grease discharge, oil discharge valve should be disassembled in order and washed in coal oil. Then assemble them again in order.








notes：
If internal components of dispenser have been damaged, corresponding components even the whole dispenser must be changed.
tips：
Impurity should be avoided to enter dispenser shell at component disassembly.
Service parts

No.        PARTS        TYPE        PRICE
1        program controller        DKQ-10 24V/10h        ￥280.00
2        filter screen        KFU2-40-05-03        ￥3.20
3        12VDC direct current motor        YZD-40-24        ￥200.00
4        dispenser        ZXQ2        ￥80.00
5        dispenser        ZXQ4        ￥160.00
6        dispenser        ZXQ6        ￥240.00
7        pressure sensor        EY35-3        ￥88.00
8        corrugated pipe        BWG8        ￥2.30
9        corrugated pipe        BWG10        ￥2.50
10        corrugated pipe        BWG13        ￥2.80
11        nylon pipe        NL4-W        ￥3.00
12        nylon pipe        NL4-R        ￥3.00
13        nylon pipe        NL4-Y        ￥3.00
14        hollow screw        PA4        ￥1.00
15        hollow screw        PA10        ￥1.80
16        bipyramide cutting sleeve        PB4        ￥0.70
17        bipyramide cutting sleeve        PB10        ￥1.20
18        bush        PO4        ￥0.50
19        bush        PO10-1        ￥1.30
20        joint of taper thread with right angled end        PHF4        ￥4.00
21        direct through end taper thread joint        Pd4        ￥3.00
22        greaser        SJP80        ￥100.00

Any question,pls call SanLang Service Number:8008201781.

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不过是English