Professional Documents
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TABLE OF CONTENTS
Section/Para Page Section/Para Page
1 Component 4.2 Component Installation 4-4
1.1 System Pump 1-1 4.2.1 Introduction 4-4
1.1.1 Description 1-1 4.2.2 General Installation Guidelines 4-5
1.1.2 Features/Benefits 1-1 4.2.3 Mounting the Pump 4-6
1.1.3 Operation 1-2 4.2.4 Mounting Divider Valves 4-7
1.1.4 Specifications 1-2 4.2.5 Installing Tubing, Pipes and Hoses 4-9
1.1.5 Dimensions 1-3 4.3 Line Cleaning 4-13
1.1.6 Mounting 1-3 5 System Operation
1.1.7 Wiring 1-3 5.1 System Function 5-2
1.2 System Strainer 1-4 5.1.1 Operation of System 5-2
1.3 Divider Valve Assemblies 1-6 5.1.2 Tri-Lube Operation Instructions 5-2
1.3.1 Master Divider Valve Assembly 1-7 5.2 Divider Valve Assemblies 5-2
1.3.2 Bell Crank Divider Valve Assembly 1-8 5.3 System Pump 5-2
1.3.3 Left Side Divider Valve Assembly 1-9 5.4 System Timer 5-2
1.3.4 Right Side Divider Valve Assembly 1-10 6 Troubleshooting and Maintenance
1.3.5 Rear Divider Valve Assembly 1-11 6.1 How to Remove Air from System 6-2
1.3.6 How to Order 1-12 6.1.1 Purging Air from the System 6-2
1.4 On-Board Timer 1-13 6.2 How to Locate Blockage 6-6
2 Original System Design 6.2.1 Description 6-6
2.1 System Schematic 2-2 6.2.2 Locating Blockage 6-7
2.2 Kit Components 2-3 6.2.3 Contamination Blockage 6-9
2.3 Lubricating Points 2-4 6.2.4 Separation Blockage 6-9
2.4 General Notes 2-5 6.3 How to Replace a Pump Cartridge 6-10
3 Definitions 6.3.1 Replacing Pump Cartridges 6-10
3.1 Glossary of Lubrication Terms 3-1 6.3.2 Cartridge Removal 6-10
4 Installation Details 6.3.3 Cartridge Insertion 6-11
4.1 Pre-Filling of System 4-2 6.4 How to Replace Strainer Element 6-12
4.1.1 Filling Secondary-to-Lube Point Lines 4-2 7 Spare Parts
4.1.2 Filling Master-to-Secondary Lubelines 4-3 7.1 System Parts 7-1
4.1.3 Filling the Master Divider Valve 4-3 7.1.1 Pumps 7-1
7.1.2 High Pressure Strainer 7-1
7.1.3 Divider Valve Accessories 7-1
Caterpillar 980G Installation & Maintenance L44878
Section/Para Page
7.2 System Pump 7-2
7.3 Divider Valve Component Details 7-3
7.4 Spare Parts Kit 7-4
8 Optional Equipment
8.1 Auto Relief for Secondary Divider Valve Ass’y 8-1
8.2 Reservoir Fill Strainer 8-1
8.3 Cycle Switch w/12 ft Cable 8-2
8.4 Troubleshooting Grease Gun w/Gauge 8-3
8.4.1 Description 8-3
8.4.2 Features 8-3
8.4.3 Specifications 8-3
8.4.4 Dimensions 8-3
8.4.5 Manual Pump Part List 8-3
8.5 Portable Filler-Pak 8-4
8.5.1 Description 8-4
8.5.2 Features 8-4
8.5.3 Specifications 8-4
8.5.4 Dimensions 8-4
Caterpillar 980G Installation & Maintenance L44878
OPERATION AND
SERVICE INSTRUCTIONS
SECTION 1
Components
1-1
Caterpillar 980G Installation & Maintenance L44878
1-2
Caterpillar 980G Installation & Maintenance L44878
MANUAL
RUN
BUTTON
11.50
REF
11.25
REF
.406” WIDE
SLOT 4 PLACES
2.25 REF
LL-
-FULL-
Tri-Lube i-Lub
20.90 Pump ump
REF LUBRIQUIP
Centralized Lubrication Systems
Package ackag
LUBRIQUIP, INC. A Unit of IDEX Corpo ration C. A Unit of IDEX Corporation
18901 Cranwood Pkwy, Cleveland, Ohio 44128 od Pkwy, Cleveland, Ohio 44128
216 581-2000 (OHIO) FAX 216 581-8945 1-800-USA-LUBE (OHIO) FAX 216 581-8945 1-800-
SYSTEM
25.10 PRESSURE
REF GAUGE
NOTE:
1/4 NPT
CLEANING INSTRUCTIONS:
CAUTION :
LUBE
OUTLET
.406”
HOLE
FILL 5.00
STUD
PUMP
AUTO-RELIEF
7.156 THIS IS UNIT EQUIPPED WITH
O -BOARD TIMING APPARATUS
VALVE
REF
REMOVE THIS COVER TO ACCESS
TIMER PROGRAMMING SWITCHES
5.75 11.25
REF REF
SUPPLY
12’ CABLE
LOCATION
1-3
Caterpillar 980G Installation & Maintenance L44878
Drain
60 Mesh Screen
(Stainless Steel)
Spring
(Stainless Steel)
Out Housing
(Aluminum)
1-4
Caterpillar 980G Installation & Maintenance L44878
1-5
Caterpillar 980G Installation & Maintenance L44878
A wide variety of safeguards monitor and verify Designed with over 90 years experience
lube cycles. in centralized lubrication.
Cycle indicators: These mechanical and electrical • Install and maintain without disturbing lube lines
units sense the divider valve piston’s action for
accurate control and monitoring of lube cycles.
Cycle indicator pin: Valve sections are available with
a factory-installed indicator pin which moves in and
out as lubricant passes through the valve.
Top View
Side View
Front View
1-6
3.00
(76.2) 1.50
(38.1)
3.00
.78 (76.2) 1.50
CYCLE
Caterpillar 980G Installation & Maintenance L44878
(19.7) (38.1)
.78 INDICATOR
(19.7) 3.00 CYCLE
1.50 INDICATOR
(76.2)
(38.1)
.78
(19.7) CYCLE
INDICATOR
1/4-18 1/4-18
NPSF NPSF
ITEM 1.3.2
QTY DESCRIPTION Bell Crank, Right and Left Side
PART Divider Valve Assembly 562762 (106-109-866) LUBE INLET
NUMBER
LUBE INLET
** 5
(38.1) 2
5 .92
.78 3.58 .72 (23.4) .92
LUBRIQUIP MSP-25S
(19.7) (90.9)
LUBRIQUIP
3.58 LUBRIQUIP
MSP-35T MSP-25S3 (18.3) (23.4)
(90.9)
4.55 3
*5 3.58
4.55
(115.6)
(115.6)
LUBRIQUIP
LUBRIQUIP
MSP-25S
LUBRIQUIP
MSP-15S
MSP-15S 4
.92
(23.4) 1/8-27 NPSF
(90.9) 4 LUBE OUTLET
1/8-27 NPSF
3
4.55 LUBE OUTLET
(115.6) LUBRIQUIP MSP-15S
1/4-18 NPSF 4 1/8-27 NPSF
LUBE INLET LUBE OUTLET
.63
Ø.28 (7.1) THRU 1.75 (15.9)
MOUNTING HOLES (44.5)
.63
Ø.28 (7.1) THRU
4 PLACES 1.75 (15.9)
2.18 MOUNTING HOLES (44.5)
(55.4) 4 PLACES .63
1.13 Ø.28 (7.1) THRU 1.75 (15.9)
(28.7)MOUNTING HOLES (44.5)
4 PLACES
.49 .42
(12.4)
Item Qty. Description ITEM (10.6)
QTY DESCRIPTION Part No. PARTOld Part No.
NUMBER
2
2
ITEM 1QTYVALVE BLOCK 35T
DESCRIPTION 106-100-235
PART NUMBER
2 1 Valve Block - 35T .72
3 2(18.3)1 1 VALVE BLOCK
562726 106-100-235
LUBRIQUIP MSP-35T VALVE BLOCK25S35T 106-100-055
106-100-235
ITEM QTY DESCRIPTION PART NUMBER
3 1 Valve Block - 25S 4 3 1.921 VALVE BLOCK
VALVE BLOCK15S25S 562715 106-100-035
106-100-055
106-100-055
3.58 2 1 5VALVE(23.4)
2BLOCK 35TPIPE
PLUG 1/8 106-100-235
503-485-000
(90.9)
LUBRIQUIP MSP-25S
4 1 Valve 4
Block3- 15S1 VALVE 1 VALVE BLOCK 15S 562713 106-100-035
106-100-035
3 BLOCK 25S 106-100-055
4.55 5 2 PLUG 1/8 PIPE 503-485-000
4 1 VALVE BLOCK 15S 106-100-035
(115.6) LUBRIQUIP
5
MSP-15S
4
2 1/8 in. Pipe Plug* 1/8-27 NPSF 557349 503-485-000
5 2 PLUG 1/8
LUBEPIPE
OUTLET 503-485-000
*1/8 in. pipe plugs may be on opposite sides of right vs left side divider assembly based on lube line
accessibility. See system schematic on page 2-6.
.63
Ø.28 (7.1) THRU 1.75 (15.9)
MOUNTING HOLES
4 PLACES
(44.5) 1-7
3.00
1.50
(76.2)
3.00 (38.1)
1.50
.78 (76.2)
(38.1)
(19.7)
Caterpillar 980G Installation & Maintenance 3.00.78
(76.2)
(19.7)
1.50
(38.1)
L44878
.78
(19.7)
1/4-18 NPSF
1.3.3 Left Side Divider Valve Assembly 562765 (106-109-869) LUBE INLET
1/4-18 NPSF
LUBE INLET 2.18
(55.4)
1/4-18 NPSF 1.13
2.18
LUBE INLET (28.7)
(55.4)
1.13 .42
.49 (28.7) (10.6)
2.18
(12.4) .42
.49 (55.4)
2 1.13 (10.6)
(12.4)
(28.7)
.42 .72
.49 2
LUBRIQUIP MSP-40T (10.6) (18.3)
(12.4) .72
3.00 LUBRIQUIP MSP-40T .92
(18.3)
1.50 2
(76.2) LUBRIQUIP MSP-35T
(23.4)
(38.1) .72 .92
3 (23.4)
.78 LUBRIQUIP MSP-40T
LUBRIQUIP MSP-35T
(18.3)
4.50
(19.7) 3
(114.3) LUBRIQUIP MSP-10T .92
4.50 4 (23.4)
*
LUBRIQUIP MSP-35T
(114.3) LUBRIQUIP MSP-10T
6 5.48 3 4
LUBRIQUIP MSP-10S
* 6
4.50 (139.2)
(114.3) 5.48
LUBRIQUIP
(139.2)
MSP-10T
LUBRIQUIP
4
MSP-10S
5 1/8-27 NPSF
LUBE OUTLET
1/8-27 NPSF
5
*
1/4-18 NPSF
6
LUBE INLET
5.48
(139.2) LUBRIQUIP MSP-10S
1/8-27 NPSF
LUBE OUTLET
5
2.18 LUBE OUTLET
(55.4) .63
1.13 (15.9)
1.75
(28.7) .63
.42 Ø.28 (7.1) THRU (44.5)
(15.9)
.49 (10.6)MOUNTING HOLES 1.75
(12.4) Ø.28 (7.1) THRU
4 PLACES (44.5)
MOUNTING HOLES .63
2 4 PLACES 1.75 (15.9)
Ø.28 (7.1)
.72 THRU (44.5)
LUBRIQUIP
Item
MSP-40T
Qty. Description MOUNTING
(18.3) HOLES
Part No. Old Part No.
4 PLACES
2 1 Valve Block - 40T ITEM (23.4)
.92
QTY DESCRIPTION
562727 106-100-245
PART NUMBER
LUBRIQUIP MSP-35T
2 ITEM1 QTY VALVE BLOCK 40T 562726 106-100-245
3 3
1 Valve Block - 35T DESCRIPTION 106-100-235
PART NUMBER
4.50 3 2 1 1 VALVE BLOCK
VALVE BLOCK35T 40T 106-100-235
106-100-245
(114.3) LUBRIQUIP MSP-10T
4 4 1 Valve Block - ITEM
10T QTY4 DESCRIPTION
3 1 1 VALVE BLOCK
VALVE 562721
BLOCK10T 35T PART NUMBER 106-100-185
106-100-185
106-100-235
5.48 2 1 5 VALVE
4 1 BLOCK
1 VALVE 40TBLOCK10S 10T
BLOCK
VALVE 106-100-245
106-100-025
106-100-185
(139.2) LUBRIQUIP
5
MSP-10S
1 Valve Block - 10S
3 1/8-27
1 6 VALVE NPSF
1 BLOCK 35T
562712
106-100-235106-100-025
503-485-000
5 5LUBE 1 PLUG
OUTLET
1/8
VALVE PIPE
BLOCK 10S 106-100-025
4 1 VALVE BLOCK 10T 106-100-185 503-485-000
6 1 1/8 in. Pipe Plug 6 1 PLUG 1/8 PIPE 557349 503-485-000
5 1 VALVE BLOCK 10S 106-100-025
*1/8 in. pipe plugs may be located on6 opposite
1 side 1/8
PLUG of divider
PIPE valve assembly to503-485-000
aid in lube line
3.00
accessibility
.63 (76.2) 3.00 1.50
(38.1) 1.50
1.75 (15.9) (76.2)
.78 (38.1)
Ø.28 (7.1) THRU (44.5)
MOUNTING HOLES (19.7)
3.00.78
(76.2) 1.50
4 PLACES (19.7) (38.1)
.78
(19.7)
1/4-18 NPSF
1.3.4 Right
ITEM QTY Side Divider ValvePART
DESCRIPTION Assembly
NUMBER 562763 (106-109-867) LUBE 1/4-18
INLET NPSF
2 1 VALVE BLOCK 40T 106-100-245 LUBE INLET
*5
(90.9)
4.55 3
*5
1/4-18 NPSF
4.55
(115.6) LUBRIQUIP MSP- 5S
1/8-27 NPSF
LUBE OUTLET
4
LUBE INLET LUBE OUTLET
.63
1.75 (15.9) .63
Ø.28 (7.1) THRU (44.5) 1.75
(15.9)
2.18 MOUNTING HOLES
Ø.28 (7.1) THRU (44.5)
(55.4) 4 PLACES
MOUNTING HOLES .63
1.13 4 PLACES 1.75 (15.9)
(28.7) (44.5)
Ø.28 (7.1) THRU
.49 .42
MOUNTING HOLES
(12.4) 4 PLACES(10.6)
ITEM QTY DESCRIPTION PART NUMBER
Item 2 Qty. Description 2 ITEM QTY DESCRIPTION
VALVE BLOCK 40T
Part No. Old Part
PART No.
NUMBER
106-100-245
.721
21 VALVE
1VALVE BLOCKBLOCK 35T 40T562727 106-100-245
106-100-235
LUBRIQUIP MSP-40T
2 1 Valve Block ITEM
- 40T QTY3 DESCRIPTION
(18.3)
PART NUMBER
106-100-245
106-100-235
4 31 VALVE
1VALVE BLOCKBLOCK5S 35T 106-100-015
.92
3.58
3 1 Valve Block - 235T 1 5 VALVE 4(23.4)BLOCK
1PLUG 40T
VALVE BLOCK 106-100-245
5S 562726 106-100-235
106-100-015
503-485-000
(90.9) LUBRIQUIP MSP-35T 1 1/8 PIPE
3 3 1 VALVE
5 BLOCK
1 PLUG35T1/8 PIPE 106-100-235 503-485-000
4.55
(115.6) LUBRIQUIP MSP- 5S
4 1 Valve Block - 45S 1 VALVE BLOCK 5S 562711
106-100-015106-100-015
4 5 1 PLUG 1/8-27
1/8 NPSF
PIPE 503-485-000
5 1 1/8 in. Pipe Plug LUBE OUTLET 557349 503-485-000
*1/8 in. pipe plugs ma be located on opposite side of divider valve assembly to aid in lube line
accessibility
.63
1.75 (15.9)
Ø.28 (7.1) THRU (44.5)
MOUNTING HOLES
4 PLACES 1-8
1/4-18 NPSF
LUBE INLET
1/4-18 NPSF
1.3.5 Rear Divider Valve Assembly 562764 (106-109-868) LUBE INLET
1/4-18 NPSF
LUBE INLET
2.18
(55.4)
2.18 1.13
(55.4)
(28.7)
.49 1.13
(28.7) .42
(12.4) 2.18 (10.6)
.49 (55.4) .42
(12.4) 1.13 (10.6)
2
(28.7)
.49 2 .72
.42
3.00 (12.4) LUBRIQUIP MSP-40T (18.3)
(10.6) .72
(76.2) 1.50
(38.1) LUBRIQUIP MSP-40T (18.3).92
2 (23.4)
3.58 .92
LUBRIQUIP MSP-10T
.78 (90.9) .72
(19.7) 3.58 3 (23.4)
(18.3)
*5
LUBRIQUIP MSP-40T
LUBRIQUIP MSP-10T
4.55 (90.9) 3
(115.6) .92
*5
LUBRIQUIP MSP-30S
3.58 4.55 4 (23.4) 1/8-27 NPSF
(90.9) (115.6)
LUBRIQUIP MSP-10T
LUBRIQUIP MSP-30S
LUBE OUTLET
3 4 1/8-27 NPSF
* 5
1/4-18 NPSF
4.55
(115.6) LUBRIQUIP MSP-30S
LUBE OUTLET
4 1/8-27 NPSF
LUBE INLET LUBE OUTLET
.63
1.75 (15.9)
.63
Ø.28 (7.1) THRU (44.5) (15.9)
1.75
MOUNTING HOLES
2.18 Ø.28 (7.1) THRU (44.5)
4 PLACES
(55.4) MOUNTING HOLES .63
1.13 4 PLACES1.75 (15.9)
(28.7) Ø.28 (7.1) THRU (44.5)
.49 MOUNTING.42 HOLES
(12.4) Item Qty. Description (10.6)
4 PLACES Part No. Old Part No.
2
2 1 Valve Block - 40T ITEM
.72 QTY DESCRIPTION
562727 106-100-245
PART NUMBER
LUBRIQUIP MSP-40T (18.3)
3 1 Valve Block - 10T ITEM
2
.92
QTY
1 VALVE BLOCK 562721
DESCRIPTION 40T 106-100-185
PART NUMBER
106-100-245
3.58 32
(23.4) 11 VALVEBLOCK
VALVE BLOCK 10T 40T 106-100-245
106-100-185
(90.9)
LUBRIQUIP
4
MSP-10T
3
1 Valve Block - 30SITEM QTY 4 3DESCRIPTION
11 BLOCK 562716
VALVEBLOCK
VALVE 10T
30S 106-100-065
PART NUMBER 106-100-185
106-100-065
4.55 2 1 5 4VALVE
1 1 BLOCK
VALVE
PLUG 40T
BLOCK
1/8 PIPE 30S 106-100-245 106-100-065
503-485-000
(115.6) LUBRIQUIP
5
MSP-30S
1 1/8 in. Pipe Plug* 557349 503-485-000
4 3 1 1/8-27
5VALVE
NPSF1 BLOCK
PLUG10T
1/8 PIPE 106-100-185 503-485-000
*1/8 in. pipe plugs may be located on opposite
4 1 side
LUBE of divider
OUTLET
VALVE BLOCKvalve
30Sassembly to aid 106-100-065
in lube line
accessibility 5 1 PLUG 1/8 PIPE 503-485-000
.63
1.75 (15.9)
Ø.28 (7.1) THRU (44.5)
MOUNTING HOLES
4 PLACES
1-9
Caterpillar 980G Installation & Maintenance L44878
T - Twin Valve
S - Single Valve - Right Hand Outlet
L - Single Valve - Left Hand Outlet
B - Twin Valve w/Cycle Pin Right (Located on Master Valve Assembly)
ORDERING EXAMPLE
4-section MSP Divider Valve Assembly, standard seals, NPT
ports and performance indicators in each working outlet.
Consisting of:
1 - .030 Twin Valve with Cycle Pin Right Side
1 - .040 Single Valve - Right Hand Outlet
1 - .040 Single Valve - Right Hand Outlet
1 - .020 Twin Valve
Ordering Code - MSP-NPT-MS-P-4-30B-40S-40S-20T
1-10
Caterpillar 980G Installation & Maintenance L44878
2+ 2 3- 3
SUPPLY CABLE
1A 2A
BLACK GND
WHITE WHITE
KEY
SWITCH
ORANGE WIRE + MOTOR
- BLACK WIRE
1-11
Caterpillar 980G Installation & Maintenance L44878
There are two banks of 4 miniature switches mounted on Note that one, two, three, or all four switches in either bank
the timer. These are known in industry as DIP (Dual In-line may be turned on at the same time. It is in this fashion that the
Package) Switches. One bank controls the amount of time the switches “add”, or combine to provide a range of programmable
pump motor runs (ON TIME); the other controls the amount of times to control the pump’s operational cycle. In addition,
time that the motor rests (OFF TIME). Pushing a switch UP turns note that the switches may be on in any combination, it is not
it on and programs the timer to stay ON (or OFF) for the number required that only adjacent switches be on. See timer switch
of minutes printed on the label above the switch. settings below. Each time the main power to the Tri-Lube pump
is turned off, the timer cycle will be interrupted; when the power
is reconnected, a timer “On” condition will begin a lube cycle.
When setting the timer, be sure to heed the max. 25% Motor
duty cycle note.
1-12
Caterpillar 980G Installation & Maintenance L44878
OPERATION AND
SERVICE INSTRUCTIONS
SECTION 2
Original System Design
1
-FULL-
Tri-Lube
2
Pump
0 - 5000 PSI
Package
GAUGE
CHASSIS (RED)
GROUND LOCATE MASTER DIVIDER
IGNITION SWITCH
2 AMP SLOW (KEY) 3 VALVE AT CENTER
BLOW FUSE & HOLDER BETWEEN BOOM ARMS
(SUPPLIED BY OTHERS) (WITHIN VIEW OF
OPERATOR)
20T
15S
4 30T
4
A 35T D
5
25S C
6 D 35T A
15S B
C 25S
BELLCRANK E 40T G
B 15S
LEFT
DIVIDER VALVE
F 35T H
7
J 10T L G 40T E BELLCRACK
ASSEMBLY RIGHT SIDE
10S K H 35T F
DIVIDER VALVE
N 40T N
5S L ASSEMBLY
LEFT SIDE M 10T M
DIVIDER VALVE
30S P RIGHT SIDE
ASSEMBLY
DIVIDER VALVE
REAR ASSEMBLY
DIVIDER VALVE
ASSEMBLY
2-1
Caterpillar 980G Installation & Maintenance L44878
2-2
Caterpillar 980G Installation & Maintenance L44878
2-3
Caterpillar 980G Installation & Maintenance L44878
OPERATION AND
SERVICE INSTRUCTIONS
SECTION 3
Definitions
Auto Relief Valves: A relief valve that mounts in the T: Located on top surface of divider valve next to
indicator port of the divider valve working section. divider valve displacement. The “T” represents a
This device relieves a downstream high pressure divider valve section that must use both outlet ports.
condition in excess of its rating and allows the Do not plug either outlet port. This will prevent
remainder of the system to receive lubricant. The lubrication to all or part of the system which can
grease relieved from the Auto relief also provides a damage pins and/or bearings. Example = 10T
visual diagnostic signal that blockage exists in the
system downstream of the connected lube outlet. Lube Cycle/Lube Interval/Lube Period: Terms used
interchangeably to describe the time period from one
Cycle Indicator: A pin fixed to and/or extended by lubrication event to the start of the next.
the measuring piston in a divider valve, dual-line
valve or injector that gives visual indication of piston Lube Pump Ratio: The area of the power piston
movement. (hydraulic or air) divided by the area of the lube
piston. This ratio establishes the maximum lubricant
Cycle Switch: A switch that is attached to and discharge pressure for any given input pressure
actuated by the cycle indicator and gives electrical (hydraulic or air.
indication of piston movement.
NLGI (National Lubricating Grease Institute): An
Divider Valve: A positive displacement lubricant organization of grease manufacturers that works with
(oil, or grease) measuring valve that both divides the ASTM (American Society for Testing Materials) to
and proportions input flow. The internal pistons (3 develop technical standards.
minimum) are actuated by flow and sequentially
dispense lubricant to the connected points. NLGI Grade Number: Numbers assigned by the NLGI
to classify greases according to their hardness as
Divider Valve Assembly: A specific assembly of measured by a cone penetration test. The numbers
various sizes and styles of divider valves selected for range from 000 (very fluid) to #6 (solid). Only the 000
specific bearing points as shown on system schematic thru #2 grade are considered usable in centralized
and lubrication points list. lubrication systems.
Feeder Size: A specific divider valve detailing its Service Factor: As shown in original divider work
displacement and choice of either as “S” or “T”. sheet. This factor is used in sizing a system and takes
Example = 10T into consideration both the loads and environmental
working conditions and location on equipment.
S: Located on top surface of divider valve next to
divider valve displacement. The “S” represents a
divider valve section that uses only 1 outlet port. It
can be the left or right one but can not be both. Never
plug both ports. This will prevent lubrication to all
or part of system which can damage pins and/or
bearings. Example = 10S
3-1
Caterpillar 980G Installation & Maintenance L44878
OPERATION AND
SERVICE INSTRUCTIONS
SECTION 4
Components
4-1
Caterpillar 980G Installation & Maintenance L44878
4.1.2 Filling Master-To-Secondary Lubelines 4.1.3 Filling The Master Divider Valve
Refer to image below when performing this procedure: Refer to image below when performing this procedure:
1. Remove the port plugs or auto relief valves from 1. Verify that all port plugs or auto relief valves
all of the indicator ports on the front of the have been removed from all indicator ports in the
master divider valve. master divider valve.
2. Connect a hand pump filled with clean, filtered 2. Verify that the system pump is properly
lubricant to the indicator port closest to the connected to the inlet port of the master divider
lube output port that is feeding the line to the valve.
secondary divider valve.
3. Cycle the system pump sufficiently to fill the main
3. Stroke the hand pump to fill the line between the feeder line between the pump and the master
master divider valve and secondary divider valve. divider valve, and lubricant is observed being
discharged from all of the indicator ports on the
4. Continue to stroke the pump until the lubricant front of the master divider valve with no evidence
purges all of the air out of the internal passages of included air.
of the secondary divider valve and lubricant flows
freely from all indicator ports with no evidence of 4. Reinstall the master divider valve port plugs or
included air. auto relief valves into their respective positions.
5. Reinstall the port plugs in their respective NOTE: If any maintenance procedures requiring
positions in the secondary divider valve. Do not loosening or disconnecting of any connectors or
replace the port plugs in the master divider valve fittings are performed subsequent to completion of
yet. the pre-filling procedures described above, but prior
to machine start-up, the pre-filling procedures should
6. Repeat Steps 1 through 5 for each of the other be repeated to assure that the lubrication system is
lube lines between the master divider valve and completely filled with lubricant and is air-free. Since
all other secondary divider valves. the most critical operating period for a newly installed
machine, in terms of potential for being damaged by
7. Do not replace any of the port plugs or auto relief unremoved/unfiltered lubricant contaminants and
valves removed in Step 1 from the master divider lack of adequate lubrication, is the initial start-up and
valve assembly until the air-purging procedure operation, compliance with the recommended pre-
described in Section 1.2 (Filling the Master filling procedures is crucial for attaining a problem-
Divider Valve) has also been completed. free start-up of the machine tool and continued
reliable long term operating capability.
4-2
Caterpillar 980G Installation & Maintenance L44878
4-3
Caterpillar 980G Installation & Maintenance L44878
4.2.2 General Installation Guidelines: The positioning and 3. If lubrication points are located on a portion of
orientation of components relative to each other is the equipment that is moving, the divider valves
essential to ensure the correct function and operation should be located to minimize the number of con-
of any centralized lubrication system. Even if the necting hoses that are required to be moving and
proper components have been selected, improper flexing. See Figure 1, page 4-6.
positioning may make it more difficult to purge air
out of the total system when air-bleeding procedures 4. Keep the lengths of installed tubing, pipes, and
are performed. Any trapped air left in the lines or hoses as short as possible in order to minimize
components of the lubrication system will impede and the total line volume/capacitance. Large line
degrade performance and response time capabilities. volumes increase the time necessary to build up
The basic rules to be followed for proper component to system operating pressure when the pump is
placement are: activated, resulting in a slower system response
time. The system response time delay may cause
1. The pump and reservoir should be mounted in a lube system fault indications when the allotted
convenient and protected area. time to achieve lubrication of all lube points
(Monitor Time) is exceeded. Therefore, designing
2. Reservoir fill line should be accessible and a and installing the system overall configuration to
strainer mounted before the fill stud. If required, minimize the total line lengths and size is very
a pressure gauge can be mounted in the cab important in optimizing the system performance
for system monitoring. A Timer should be used capabilities and minimizing response time.
whenever practical to accurately control lubricant
usage. All lubricant lines must be adequately See Figure 1 for example and diagram of this general
supported with clamps and anchored to the ma- system configuration guideline.
chine. Any line or component which is vulnerable
to damage should be guarded.
Figure 1
4-4
Caterpillar 980G Installation & Maintenance L44878
Figure 3
4-5
Caterpillar 980G Installation & Maintenance L44878
Figure 6
4-6
Caterpillar 980G Installation & Maintenance L44878
Figure 7 Figure 10
Figure 8 Figure 11
Figure 9
4-7
Caterpillar 980G Installation & Maintenance L44878
Figure 13
4-8
Caterpillar 980G Installation & Maintenance L44878
OPERATION AND
SERVICE INSTRUCTIONS
SECTION 5
System Operation
5-1
Caterpillar 980G Installation & Maintenance L44878
Installation: The Tri-Lube components are corrosion A. Setting the Timer Module (On Board DIP Switch
protected and gasketed where necessary and can Controlled Style)
withstand exposure to the elements and to periodic
equipment wash-down procedures. Do not, however, Part Number 563549 (529-860-161) 24 Volt
mount the Tri-Lube HD in a location where it faces the
possibility of being submerged in water. The Tri-Lube There are two banks of 4 miniature switches mounted
must be mounted in a vertical orientation against a on the timer. These are known in industry as DIP
bulkhead or framework supporting structure. Use (Dual In-line Package) Switches. One bank controls
(6) 3/8 in. diameter bolts or studs and appropriate the amount of time the pump motor runs (ON TIME);
washers, nuts, etc. to mount the pump. Assure the other controls the amount of time that the motor
that the reservoir is supported properly without rests (OFF TIME). Pushing a switch UP turns it on and
misalignment or strain to the tie rods. Shims may be programs the timer to stay ON (or OFF) for the number
required for use on the upper two mounting bolts to of minutes printed on the label above the switch.
achieve this requirement.
Note that one, two, three, or all four switches in either
Fusing Information: Regardless of the control bank may be turned on at the same time. It is in this
circuitry employed, the power supplied to the Tri-Lube fashion that the switches “add”, or combine to provide
HD from the main battery supply of the machine being a range of programmable times to control the pump’s
lubricated must come in through a fused circuit. User operational cycle. In addition, note that the switches
to supply 2 Ampere AGC style fusing hardware for 24 may be on in any combination, it is not required that
VDC applications. only adjacent switches be on. See page 1-13 for
available timer settings. Each time the main power
Wiring: The Red (+) and Black ( -, or ground) wires to the Tri-Lube HD pump is turned off, the timer cycle
must be connected to the main battery supply of the will be interrupted; when the power is reconnected,
machine through a fused circuit as described above. a timer “On” condition will begin a lube cycle. WHEN
The white wire supplies a signal generated by the Low SETTING THE TIMER, BE SURE TO HEED THE MAX.
Level Sensing Circuit. The green wire is unused. Refer 25% MOTOR DUTY CYCLE NOTE.
to page 1-12 for schematic.
*For the caterpillar 980G, the settings are 15
Plumbing: To satisfy large grease supply minutes “Off” and 2 minutes “On”.
requirements, two pump cartridge outputs are
manifolded together and then routed to the rest of Manual Run Switch: For convenience, a manual run
the lubrication system. This approach will shorten switch is provided on units with on-board timers to
pump-running time during each cycle and contribute assist in system testing and/or purging operations.
to extended system life. The addition of a gage to The pump motor will run whenever the switch is held
monitor system pressure and system circuit protection in either the up or down position. The switch has a
for each master assembly output leg in the form of spring return to the center off position. Use of this
relief valves is standard on this system. switch allows “jogging” of the pump without removal
of the gasketed timer cover.
Low Reservoir Level Sensing: A sensor will supply
a pulsed low level warning signal through the red Filling the Reservoir: Fill reservoir with contaminant
wire when the grease level in the reservoir tube drops free grease through the supplied fitting at the base
below the minimum level. This pulsed signal may of the reservoir. Do not attempt to fill from the top.
be connected to an optional external lamp, buzzer, To avoid plugging the vent tube that runs down the
or other signaling device supplied by the end user. back of the reservoir parallel to the tie rods, do not
Normal pump operation will continue after the low overfill. Maintain at least an inch or more of air space
level signal begins. However, if the warning is ignored at the top of the reservoir. Upon initial fill, and during
for too long, the pump will eventually run out of grease subsequent fills if the reservoir is allowed to run totally
entirely and begin pumping air into the system. The dry, the entrapment of a slug of air around the pump
low level circuit will automatically reset when the cartridge(s) can adversely affect the time it takes
reservoir is filled above the trip point. The signal to prime the pump(s). To avoid this, during these
present at the red wire is a pulsed sourcing type situations, if an air operated “barrel pump” is used
signal equal to the system voltage (24 VDC). Connect to supply grease for refills, slow the delivery rate by
the red wire to one side of the signaling device (lamp), backing air pressure to 35 psi max. (turned down from
and ground the other side of the signaling device. the normal 80 - 85 psi found in most situations).
5-2
Caterpillar 980G Installation & Maintenance L44878
OPERATION AND
SERVICE INSTRUCTIONS
SECTION 6
Troubleshooting and Maintenance
6.1 How To Remove Air From System 6-1 6.2.4 Separation Blockage 6-7
6.1.1 Purging Air From The System 6-1 6.3 How To Replace A Pump Cartridge 6-8
6.2 How To Locate Blockage 6-4 6.3.1 Replacing Pump Cartridges 6-8
6.2.1 Description 6-4 6.3.2 Cartridge Removal 6-8
6.2.2 Locating Blockage 6-5 6.3.3 Cartridge Insertion 6-9
6.2.3 Contamination Blockage 6-7 6.4 How To Replace Strainer Element 6-10
6-1
Caterpillar 980G Installation & Maintenance L44878
Section 1 Section 2
PURGING AIR FROM SECONDARY DIVIDER PURGING AIR FROM MASTER-TOSECONDARY
VALVE-TO-LUBE POINT LINES DIVIDER VALVE LUBE LINES
Refer to Figure 1 when performing this procedure: Refer to Figure 2 when performing this procedure:
Step 1 - Install the line from the secondary divider Step 1 -Install the line from the master divider valve
valve to the lube point, but do not completely to the secondary divider valve, but do not
tighten the connection at the lube point. completely tighten the connection at the
secondary divider valve’s inlet.
Step 2 - Remove the port plug or the piston
enclosure plug in the working valve section Step 2 - Remove the auto relief valves, port plug or the
on the secondary divider valve assembly piston enclosure plug from the working valve
corresponding to the outlet port and line section on the master divider valve assembly
connected to the lube point. corresponding to the outlet port and line
connected to the secondary valve.
Step 3 - Attach a hand pump filled with clean, filtered
lubricant to the port on the secondary divider Step 3 - Attach a hand pump to the port on the master
valve that was opened in Step 2. divider valve that was opened in Step 2.
Step 4 - Operate the hand pump until air-free lubricant Step 4 - Operate the hand pump until air-free lubricant
is observed flowing from the line at the is observed flowing freely from the secondary
lubrication point. valve’s lube inlet connector.
Step 5 - Tighten the fitting at the lubrication point Step 5 - Tighten the fitting at the secondary valve’s
while lubricant is still flowing. inlet while lubricant is still flowing
Step 6 - Remove the hand pump and reinstall the port Step 6 - Remove all of the indicator port plugs
plug or piston enclosure plug removed in Step from the secondary divider valve’s working
2 into the secondary divider valve’s open port. sections.
The system is now ready for operation. Step 7 - Operate the hand pump again until air-free
lubricant is observed flowing out all of the
secondary divider valve’s indicator ports.
Step 8 - Reinstall all of the port plugs in the secondary
divider valve while lubricant is still flowing
from the ports.
Step 9 -Remove the hand pump and reinstall the auto
relief valve or piston enclosure plug removed
in Step 2 into the master divider working
valve’s open port.
The system is now ready for operation.
PISTON
ENCLOSURE
PISTON PLUG
ENCLOSURE
PLUG
REMOVE AUTO RELIEF
VALVE OR PORT PLUG
REMOVE
PORT
PLUG
AFTER BLEEDING
INLET REMOVE ALL
PORT PLUGS AND
BLEED ALL PORTS
Figure 1 Figure 2
6-2
Caterpillar 980G Installation & Maintenance L44878
Section 3 Section 4
PURGING AIR FROM PUMP-TO-MASTER DIVIDER PURGING AIR AFTER ADDING OR REPLACING A
VALVE LINES MASTER DIVIDER VALVE MODULE
Refer to Figure 3 when performing this procedure: This procedure should be followed whenever any
of the individual modules in a master divider valve
Step 1 - Install the line from the system pump to the assembly are added or replaced or when any of
master divider valve, but do not completely its auto relief valves or port enclosure plugs have
tighten the connection at the master valve’s been loosened or removed. Refer to Figure 4 when
lube inlet. performing this procedure:
Step 2 - Cycle the system pump until air-free lubricant Step 1 - Install the new or replacement module into
is observed flowing from the line at the the master divider valve assembly; also
master divider valve’s lube inlet. connect the tubing or hoses to the appropriate
secondary divider valve(s) or lubrication
Step 3 - Tighten the fitting at the lube inlet port while point(s) if the new/replacement module is
lubricant is still flowing. a base section. However, do not completely
tighten the connection(s) at the secondary
The system is now ready for operation.
divider valve’s inlet or at the lubrication
point(s).
Step 2 - Disconnect and remove the line from the
pump at the inlet of the master divider valve.
Step 3 - Attach a hand pump filled with clean, filtered
lubricant to the pump inlet port on the master
divider valve.
Step 4 - Operate the hand pump until air-free lubricant
is observed flowing from each secondary
valve’s lube inlet connector and/or each
lubrication point’s connector.
Step 5 - Tighten the fitting at the secondary valve inlet
or at the lubrication point while lubricant is
still flowing.
Step 6 - Remove the hand pump and reconnect the
system pump to the inlet of the master divider
valve.
The system is now ready for operation.
Figure 3 Figure 4
6-3
Caterpillar 980G Installation & Maintenance L44878
6-4
Caterpillar 980G Installation & Maintenance L44878
Piston
All servicing and disassembling should be carried
Enclosure out under the cleanness conditions possible. A
Plug blockage will be centrally signalled by a pressure
Valve Section gauge, optional pressure switch, or by the pump relief
Mounting Screws to atmosphere valve, exhausting lubricant. Before
Tie Rod proceeding as outlined, make a visual inspection of
Auto Relief the system and check for crushed lines or improper
Valve Port
divider valve installation. Verify that each divider valve
By-Pass
outlet required to discharge lubricant can do so and
Section that no pipe plugs have been installed in an outlet
designed to serve a bearing or another divider valve.
End Section
6-5
Caterpillar 980G Installation & Maintenance L44878
6-6
Caterpillar 980G Installation & Maintenance L44878
Figure E
6-7
Caterpillar 980G Installation & Maintenance L44878
6-8
Caterpillar 980G Installation & Maintenance L44878
position described below. If possible, look into 5. Remove the screen support (3) pushing in on it’s
the hole with the aid of a flashlight to check for a locating stud.
reasonably clear path.
6. Clean all parts with a compatible solvent.
3. Partially or completely remove the piston from the
cartridge and coat it with grease. This coating 7. Insert screen support (3) into 60 mesh screen
will provide some friction and prevent the piston (4) so the locating stud fits through the small
from slipping out of the position set in the next opening in screen.
step.
8. Carefully install the screen (4) and support (3) into
4. Re-insert the piston and let the end extend housing bowl (1).
approximately 1-5/8 in. from the end of the
cartridge. 9. Lubricate o-ring (2) with contaminant free grease.
Squeeze on 2 sides of the o-ring as it is pushed
5. Insert the cartridge assembly into the pump body into o-ring groove.
at a slight upward angel (approx. 15 degrees)
until the threads on the cartridge meet up with 10. Lubricate housing (6) threads and screw it into
the threads on the main body casting. Depending housing.
on the position of the cam, you should feel
11. Clean, then apply PTFE tape to drain plug (7)
some very slight resistance when (if) the tip of
threads. Screw drain plug into housing (6).
the piston mushroom touches the cam. As you
continue to push the cartridge in, the piston will CAUTION: Never use 1,1,1-trichloroethane, methylene
slide further back into the bore of the cartridge. chloride, other halogenated hydrocarbon solvents
The distance through which this sliding action or materials containing such solvents. Such use
occurs will vary with the position of cam. could result in a serious chemical reaction, with the
possibility of explosion, which could cause death,
6. Tip the piston end of the cartridge assembly down
serious bodily injury and/or substantial property
(rock the hex end up with your fingers) until it is
damage.
level. The centerline axis of the cartridge should
now be aligned with the axis of the threads in the Consult your material suppliers to ensure that the
main casting body. The mushroom button end of materials being used are compatible with aluminum
the piston should now be up over (captured by) and zinc parts.
the lip of the pullback ring.
7. To verify proper positioning, (the “capture”), pull
the cartridge straight back out from the casting
body slowly about 1/4 in. to 3/8 in. You should 1
feel some slight resistance as the mushroom
head catches on the lip and begins to pull the
piston out of the cartridge bore. Do no tip the 2
cartridge during this step. If you are not sure that
you feel this resistance, remove the cartridge and
go back to step 4.
3
8. Push the cartridge back in and engage the
threads; screw the cartridge in all the way and
tighten snugly with wrench. (approx 5-10 ft.lb)
4
6.4 HIGH PRESSURE STRAINER
REPLACEMENT
Strainer Change-Out Procedure 5
1. Turn keyswitch to off position
2. Remove the drain plug (7) from housing (6) to
relieve any trapped pressure. 6
6-9
Caterpillar 980G Installation & Maintenance L44878
OPERATION AND
SERVICE INSTRUCTIONS
SECTION 7
Spare Parts
11.25
3,000 psi
5.75
REF REF
Tubing, 1/4 in. OD x
13 2 556272 400-125-000
0.035 W SS 304
7-1
Caterpillar 980G Installation & Maintenance L44878
7.2.3 Divider Valve Accessories 30S .030 Single Outlet 562716 106-100-065
Description Part No. Old Part No. 35T .035 Twin Outlet 562726 106-100-235
35S .035 Single Outlet 562717 106-100-075
Relief-to-Atmosphere Valve 563175 508-310-465
40T .040 Twin Outlet 562727 106-100-245
1/8 in. NPT Pipe Plugs 557349 503-485-000
40S .040 Single Outlet 562718 106-100-085
7-2
Caterpillar 980G Installation & Maintenance L44878
7-3
Caterpillar 980G Installation & Maintenance L44878
OPERATION AND
SERVICE INSTRUCTIONS
SECTION 8
“Optional” Equipment
Description Part No. Old Part No. Description Part No. Old Part No.
Relief Pressure, 2,500 psi (172 bar) 563175 508-310-465 Grease Strainer w/100 Mesh Screen 563102 473-020-468
Replacement Screen 557153 473-020-465
8-1
Caterpillar 980G Installation & Maintenance L44878
4 8
3
.969
SJTO16-4 WIRE 2
CABLE 12 FT LG 5 6
9 6 7
PLACE #6 LOCKWASHER
UNDER ACORN HEX NUT
2.000 1.156
.502 DIA
REF
1
3.031
ELECTRICAL RATING:
28 VDC, Res., 3A, Make/Break
28 VDC, Ind., 3A, Make/Break
SPDT NEMA 6P Rating Meets IEC IP 67 Rating
Switch Completely Enclosed with
Boot-Sealed Plunger.
8-2
Caterpillar 980G Installation & Maintenance L44878
List
Key Description Part No. Old Part No.
Gasket (not shown) – 543-149-000
1 Pressure Gauge, 0-3,000 psi – 542-870-000
2 45º Street Elbow 560532 509-114-000
3 Bushing 556416 412-330-200
4 Service Tee 556419 412-380-010
5 Extension Nipple 557393 509-028-000
Hose Assembly Dis 511-291-000
8-3
Caterpillar 980G Installation & Maintenance L44878
8-4
All written and visual data contained in this document are based on the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice.
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