Installation Manual

Automatic TWIN-3 Greasing System

Wheel Loader
Caterpillar 972K
F210510R00

your efficiency is our challenge

All rights reserved. No part of this manual may be copied and/or published by means of printing, photocopying,
microfilm or by any other means without prior written permission from Groeneveld. This applies also to the
drawings and diagrams appended.

Groeneveld reserves the right to change parts at any time, without prior or direct notice to the customer. The
contents of this manual may also be changed without prior notice.

This manual applies to the standard version of the product. Groeneveld cannot accept liability for any damage
arising from the use of specifications other than that supplied.

You are requested to contact Groeneveld technical service for information concerning adjustment, maintenance
work or repairs that is not described in this manual.

Whilst this manual has been prepared with the greatest possible care Groeneveld cannot accept responsibility for
any errors of the concequences of such errors.
 Wheel Loader Caterpillar 972K

1.
TABLE OF CONTENTS
1. Preface - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
1.1. General information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
1.2. Use of symbols - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
1.3. Safety precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
1.4. General fitting instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7

2. System lay-out - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
2.1. F207483 Twin 14-port block, complete - - - - - - - - - - - - - - - - - - - - - - - - 12
2.2. F211153 Twin 4+4-port block, complete - - - - - - - - - - - - - - - - - - - - - - - 14

3. Grease point location- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17

4. Drilling and welding activities - - - - - - - - - - - - - - - - - - - - - - - - - - - 21

4.1. Safety instructions for installation of attachment points - - - - - - - - - - - 22

5. Grease pump installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29

5.1. F210337 Twin pumpkit Caterpillar 972K (without pump) - - - - - - - - - - 30

6. Electrical components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33
6.1. F210338 Electronics installation kit Caterpillar 950K-972K- - - - - - - - - - 34

7. Distribution blocks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 37
7.1. F210506 Installation kit Twin 14-port block / F207483 B1 - - - - - - - - - - 38
7.2. F210507 Installation kit Twin 4+4-port block / F211153 B2 - - - - - - - - - 44
7.3. F210508 Installation kit tubes- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45

8. Installation main line - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49

8.1. F210509 Twin Main line kit Caterpillar 972K - - - - - - - - - - - - - - - - - - - - 50

9. Parameter settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55

10. Vehicle CMPD display & codes - - - - - - - - - - - - - - - - - - - - - - - - - - - 57

10.1. Verifying Parameter Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58
10.2. Changing Parameter Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58
10.3. Checking errors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58

11. Testing of the system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 65

Date of issue: February 2012

F210510R00 Table of contents 3

 Wheel Loader Caterpillar 972K

Date of issue: February 2012

4 Table of contents F210510R00

 Wheel Loader Caterpillar 972K

1.

2.
PREFACE
Date of issue: February 2012

your efficiency is our challenge

F210510R00 Preface 5
 Wheel Loader Caterpillar 972K

1.1 General information

This installation manual describes the mounting of the Twin-3 system on the
Caterpillar Wheel Loader type 972K.

Automatic Twin-3 Greasing System

Machine type Number of Groeneveld Manual

grease points order number
number

Caterpillar 972K no pump 21 x F210505/1 F210510R00

Caterpillar 972K 4L pump 21 x F210505 F210510R00

Caterpillar 972K 8L pump 21 x F211137 F210510R00

1.2 Use of symbols

Symbol Explanation
H High pressure hose 1/4” I/D or 3/8” I/D
1/4” S6-0200-E6 1/4” = internal diameter
S6 = connector straight ø6mm
0200 = length (mm)
E6 = connector elbow ø6mm
P Grease pump
PS Main line pressure switch

Distribution block

4.25 Position number on the parts list

Grease point position number

BK Black
BN Brown
BU Blue
Date of issue: February 2012

RD Red
GY Grey
YE Yellow
BR Brass
PA Polyamide
SST Stainless steel
ST-YG Yellow passivated steel
ST-G Galvanised steel

6 Preface F210510R00
 Wheel Loader Caterpillar 972K

1.3 Safety precautions

For starting installation, carry out the following tasks:
• Remove ignition key to prevent engine from starting while you are working.
• Block all moving parts, like lifting frames, breaking points and mast parts.
• Block the wheels.
• Follow machine manufacturer’s guidelines for general safety and precautions.

During activities that require a lifting jack:

• The machine should not rest on the lifting jack solely. Use additional support.

General:
• Always keep your work area clean.

1.4 General fitting instructions

Before
• Check if all the parts of the Twin-system are present by using the parts list.
• Check if all the grease points are open and provided with grease. Lubricate
the grease points if there is not sufficient grease. This way damage due to
insufficient grease is prevented.

During installation
• Prevent dirt from entering the system during installation.
• Use clean tools.
• Clean the machine at points, where the pump and the distribution blocks
have to be installed. Even small pollution can cause failure of the system!
• Even if stud couplings or plugs are not provided with an O-ring sealing or
sealing ring, use teflon tape or a liquid sealing agent.
Date of issue: February 2012

F210510R00 Preface 7
 Wheel Loader Caterpillar 972K

Notes

Date of issue: February 2012

8 Preface F210510R00
 Wheel Loader Caterpillar 972K

2.

3.
SYSTEM LAY-OUT
Date of issue: February 2012

your efficiency is our challenge

F210510R00 System lay-out 9

 Wheel Loader Caterpillar 972K

Parts list

The Twin-3 system for the Caterpillar 972K comprises the following parts:

Kit number Groeneveld order Description

number

F210337 Twin pumpkit Caterpillar 972K

F210338 Electronics installation kit Caterpillar 972K

F207483 F210506 Installation kit Twin 14-port block B1

F211153 F210507 Installation kit Twin 4+4-port block B2

F210508 Installation kit tubes

F210509 Twin Main line kit Caterpillar 972K

F210510 Install manual Caterpillar 972K

F208912 High-pressure hose 1/4” S10-3060-S8 H1 2x

F208671 High-pressure hose 1/4” S10-3160-S8 H2 2x

Date of issue: February 2012

10 System lay-out F210510R00

 Wheel Loader Caterpillar 972K

P
F124669

H1
B1 F208912
F207483

H2
F208671

B2
F211153
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F210510R00 System lay-out 11

 Wheel Loader Caterpillar 972K

Parts list

2.1 F207483 Twin 14-port block, complete

Pos. Q’ty Groeneveld order Description

number

1 4 F115464 Body, male stud elbow 1/4” - ø8mm ST-YG

2 4 F110620 Metering unit No.3 - 0.150cc/M22/6mm/BR

3 4 F110789 Metering unit No.4 - 0.200cc/M22/6mm/BR

4 2 F110790 Metering unit No.6 - 0.300cc/M22/6mm/BR

5 3 F110791 Metering unit No.8 - 0.400cc/M22/6mm/BR

6 1 F124500 Pressure switch 150 bar, complete BR

7 1 F112005 Twin 14-port block without stud BR

8 0,95m F110661 Grease pipe 1 x ø6mm x 1.5 PA per m

9 1,05m F110661 Grease pipe 1 x ø6mm x 1.5 PA per m

10 1,2m F110661 Grease pipe 1 x ø6mm x 1.5 PA per m

11 0,5m F110661 Grease pipe 1 x ø6mm x 1.5 PA per m

12 2,25m F110661 Grease pipe 1 x ø6mm x 1.5 PA per m

13 1,5m F110661 Grease pipe 1 x ø6mm x 1.5 PA per m

14 0,5m F110661 Grease pipe 1 x ø6mm x 1.5 PA per m

15 0,5m F110661 Grease pipe 1 x ø6mm x 1.5 PA per m

16 1,95m F110661 Grease pipe 1 x ø6mm x 1.5 PA per m

17 1,7m F110662 Grease pipe 2 x ø6mm x 1.5 PA per m

18 1,7m F110662 Grease pipe 2 x ø6mm x 1.5 PA per m

19 13 F113155 Protective cap ø6mm

20 1 F111316 Tube marker no. 0

21 6 F104066 Tube marker no. 1

22 2 F104067 Tube marker no. 2

23 2 F104068 Tube marker no. 3

Date of issue: February 2012

24 1 F104069 Tube marker no. 4

25 1 F104070 Tube marker no. 5

26 1 F104071 Tube marker no. 6

27 1 F104072 Tube marker no. 7

28 1 F104073 Tube marker no. 8

29 1 F111317 Tube marker no. 9

12 System lay-out F210510R00

 Wheel Loader Caterpillar 972K

29

14 12 10 9 8
17 18

15 11 13 16

2 4

3
6

1
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F210510R00 System lay-out 13

 Wheel Loader Caterpillar 972K

Parts list

2.2 F211153 Twin 4+4-port block, complete

Pos. Q’ty Groeneveld order Description

number

1 1 F111640 Twin 4+4-port block, flat BR

2 1 F110789 Metering unit No.4 - 0.200cc/M22/6mm/BR

3 2 F110790 Metering unit No.6 - 0.300cc/M22/6mm/BR

4 2 F110791 Metering unit No.8 - 0.400cc/M22/6mm/BR

5 1 F111683 Metering unit No.9 - 1.000cc/M22/6mm/BR

6 2 F112657 Metering unit No.10 - 2.000cc/M22/6mm/BR

7 1 F117298 Adjustable elbow P8-ø8mm ST

8 1 F115464 Body, male stud elbow 1/4” - ø8mm ST-G

9 1 F115487 Body male stud coupling 1/4”- ø8mm ST-G

10 2 F000686 Threaded plug G1/4” BR

11 2 F104436 Sealing ring

12 2 F115622 H.P.H. 1/4” S6-0650-S6

13 2 F116717 H.P.H. 1/4” S6-0500-S10

14 1 F116780 H.P.H. 1/4” S6-1600-E6

15 1 F116788 H.P.H. 1/4” S6-1950-E6

16 1 F126583 H.P.H. 1/4” S10-2050-E6

17 1 F119634 H.P.H. 1/4” S10-2050-E6

18 2 F194573 H.P.H. 1/4” S8-0400-M16

19 2 F116775 Female stud coupling M10x1 - ø6mm ST-G

20 1 F108295 Bracket 4+4 port block

21 3 F113534 Tube clamp double ø12mm

22 3 F115932 Cover plate, tube clamp double 6-12mm

23 3 F104050 Allen bolt M6 x 40 ST-G

Date of issue: February 2012

24 2 F110297 Spring washer M6 ST-G

25 2 F101272 Allen bolt M6 x 30 ST-G

26 2 F001085 Sealing ring 10x13x1mm

27 2 F110239 Straight connecting coupling ø10mm ST-G

28-31 4 F173798 Protective spiral ø23 x 400mm

32-35 2 F173798 Protective spiral ø23 x 500mm

14 System lay-out F210510R00

 Wheel Loader Caterpillar 972K

21

22

13

12
18 34 35 14 15
18

8 2
6 10 8 4 1
9
10-11
7
27 17 16 32 28 24-25
8 9 6 10
5

19--26

33 12

30
13
31
20
29
23
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F210510R00 System lay-out 15

 Wheel Loader Caterpillar 972K

Notes

Date of issue: February 2012

16 System lay-out F210510R00

 Wheel Loader Caterpillar 972K

3.

4.
GREASE POINT LOCATION
Date of issue: February 2012

your efficiency is our challenge

F210510R00 Grease point location 17

 Wheel Loader Caterpillar 972K

6 10 14

3 4 2 5 9 8 17 20 16

Date of issue: February 2012

18 Grease point location F210510R00

 Wheel Loader Caterpillar 972K

21 11 12

18 15 19 7 13 1
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F210510R00 Grease point location 19

 Wheel Loader Caterpillar 972K

Notes

Date of issue: February 2012

20 Grease point location F210510R00

 Wheel Loader Caterpillar 972K

4.

5.
DRILLING AND WELDING ACTIVITIES
Date of issue: February 2012

your efficiency is our challenge

F210510R00 Drilling and welding activities 21

 Wheel Loader Caterpillar 972K

4.1 Safety instructions for installation of attachment points

When drilling:
• Wear safety goggles.
• Make sure there are no vital parts behind the hole to be drilled.

Drilling

Drilling depth

Full drilling

Tap

Fill the grease point with grease

Drilling location

In case of welding:
• Ask the workshop manager whether welding is allowed in this room.
• Disconnect the earthing cable from the battery or remove the earthing key.
• Disconnect any computers present. In case of doubt, always refer to the
supplier of the machine.
• Wear welding goggles and overalls.

Welding
Date of issue: February 2012

Grind

Welding location

22 Drilling and welding activities F210510R00

 Wheel Loader Caterpillar 972K

2 2

6 4

5
Date of issue: February 2012

F210510R00 Drilling and welding activities 23

 Wheel Loader Caterpillar 972K

3.17

100

20

130 70

3.22

Date of issue: February 2012

24 Drilling and welding activities F210510R00

 Wheel Loader Caterpillar 972K

Detail A (R) Detail B (L + R)

3.17

55 130 20
6.2

40

430

3.20
100

170
Date of issue: February 2012

40

F210510R00 Drilling and welding activities 25

 Wheel Loader Caterpillar 972K

350 350 350

90

6.2

4.12 4.12

Date of issue: February 2012

26 Drilling and welding activities F210510R00

 Wheel Loader Caterpillar 972K

4.15

195

280
4.6

220

120

4.6

180
Date of issue: February 2012

195

4.15

F210510R00 Drilling and welding activities 27

 Wheel Loader Caterpillar 972K

Notes

Date of issue: February 2012

28 Drilling and welding activities F210510R00

 Wheel Loader Caterpillar 972K

5.

6.
GREASE PUMP INSTALLATION
Date of issue: February 2012

your efficiency is our challenge

F210510R00 Grease pump installation 29

 Wheel Loader Caterpillar 972K

Parts list

5.1 F210337 Twin pumpkit Caterpillar 972K (without pump)

Pos. Q’ty Groeneveld order Description

number

1.1 1 F204517 Bracket, pump

1.2 4 F113437 Hexagonal bolt M8 x 50 ST-G

1.3 4 F104586 Plain washer M8 ST-G

1.4 4 F113423 Selflocking nut M8 ST-G

1.5 3 F112335 Hexagonal bolt M10 x 30 ST-G

1.6 6 F113426 Plain washer M10 ST-G

1.7 3 F113424 Self-locking nut M10 ST-G

1.8 1 F176610 Bracket kit, Twin 8kg pump

1.9 1 F124671 Twin-3 pump 12cc/24V/8L/250 bar/Tyco/Canbus

1.9 1 F124669 Twin-3 pump 12cc/24V/4L/250 bar/Tyco/Canbus

Date of issue: February 2012

30 Grease pump installation F210510R00

 Wheel Loader Caterpillar 972K

FRO
NT

1.8

1.4 4x
1.3 4x

1.1
1.9 1.5 3x

1.6 6x

1.7 3x

1.9
1.2 4x
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F210510R00 Grease pump installation 31

 Wheel Loader Caterpillar 972K

Notes

Date of issue: February 2012

32 Grease pump installation F210510R00

 Wheel Loader Caterpillar 972K

6.

7.
ELECTRICAL COMPONENTS
Date of issue: February 2012

your efficiency is our challenge

F210510R00 Electrical components 33

 Wheel Loader Caterpillar 972K

Parts list

6.1 F210338 Electronics installation kit Caterpillar 950K-972K

Pos. Q’ty Groeneveld order Description

number

2.1 50 F111891 Cable tie, black 186mm

2.2 2 F116460 Clamp ø14mm for M10 bolt

2.3 2 F110878 Hexagonal bolt M8 x 25 ST-G

2.4 2 F133423 Self-locking nut M8 ST-G

2.5 4 F104586 Plain washer M8 ST-G

2.7 1 F210347 Cable harness pump 950K-972K

Date of issue: February 2012

34 Electrical components F210510R00

 Wheel Loader Caterpillar 972K

FRO
NT

2.2
Connector on machine
2.4
2.5

2.6
2.3
Date of issue: February 2012

F210510R00 Electrical components 35

 Wheel Loader Caterpillar 972K

CONN 4
+15 1 1 PRESSURE
2 2 SWITCH
CAN LOW 3 3
CAN HIGH 4 4
-31

1 2

1 2
TWIN-3 PUMP

WT
BR
1 RD
2 BK
3
4 GN
5 YE
6
7 BR
8 WT

Date of issue: February 2012

36 Electrical components F210510R00

 Wheel Loader Caterpillar 972K

7.

8.
DISTRIBUTION BLOCKS
Date of issue: February 2012

your efficiency is our challenge

F210510R00 Distribution blocks 37

 Wheel Loader Caterpillar 972K

Parts list

7.1 F210506 Installation kit Twin 14-port block / F207483 B1

Pos. Q’ty Groeneveld order Description

number

3.1 3 F000543 Stud elbow 1/4”UNF - G1/8” ST-G

3.2 6 F000542 Stud elbow G1/8” ST-G

3.3 25 F104556 Cable tie, black 338mm

3.4 50 F111891 Cable tie, black 186mm

3.5 9 F113779 Male stud coupling 1/8” - ø6mm BR

3.6 4 F101065 Male stud elbow 1/8” - ø6mm BR

3.7 1 F113781 Straight connecting coupling ø6mm BR

3.8 2 F100725 Adapter G1/8” - R1/8” - 80mm BR

3.9 2m F113446 Protective mantle ø7mm ID

3.10 3 F116460 Clamp ø14mm for M10 bolt

3.11 0.8m F113447 Tube ø6 x 1mm cunifer

3.12 1 F113428 Hexagonal bolt M10 x 16 ST-G

3.13 4 F112232 Hexagonal bolt M10 x 20 ST-G

3.14 6 F101272 Allen bolt M6 x 30 ST-G

3.15 4 F113426 Plain washer M10 ST-G

3.16 4 F113427 Spring washer M10 ST-G

3.17 2 F170566 Welding nut M10 x 30

3.18 6 F170756 Clamp ø6mm for M10 bolt

3.19 6 F179120 Tube clamp single ø6mm

3.20 6 F179124 Welding plate, tube clamp single 6-12mm

3.21 6 F179125 Cover plate, tube clamp single 6-12mm

3.22 1 F200896 Bracket 140 x 30 x 6mm

3.23 1 F207483 Twin 14-port block, complete

Date of issue: February 2012

38 Distribution blocks F210510R00

 Wheel Loader Caterpillar 972K

FRO
NT
3.21
3.14
3.13

3.2 6 3.17 8

1
2
3
3.5
4
10
11 3.1
12
3.23
3.22
3.15
3.10

3.16 3.7

3.12 3.18
3.20
3.19 3.6
13 3.11
3.8
5
7

BK BK BK BK BK BK
10 8 11 9 12 13
Date of issue: February 2012

2 1 3 4 6 5 7
RD RD BK BK BK BK BK

F210510R00 Distribution blocks 39

 Wheel Loader Caterpillar 972K

7 8

10
11
12

13 9

6
5 1
2
3
4
Date of issue: February 2012

40 Distribution blocks F210510R00

 Wheel Loader Caterpillar 972K

B1

3 2 1
4

6
Date of issue: February 2012

F210510R00 Distribution blocks 41

 Wheel Loader Caterpillar 972K

8 7 9
5

10
11

Date of issue: February 2012

42 Distribution blocks F210510R00

 Wheel Loader Caterpillar 972K

12 13
Date of issue: February 2012

F210510R00 Distribution blocks 43

 Wheel Loader Caterpillar 972K

Parts list

7.2 F210507 Installation kit Twin 4+4-port block / F211153 B2

Pos. Q’ty Groeneveld order Description

number

4.1 1 F211153 Twin 4+4-port block, complete

4.2 2 F108916 Bracket, tube clamps

4.3 1 F104521 Stud elbow 1/8” - 45º BR

4.4 4 F115930 Allen bolt M6 x 35 ST-G

4.5 8 F113534 Tube clamp double ø12mm

4.6 4 F113451 Welding plate, tube clamp double 6-12mm

4.7 1 F104513 Male stud coupling 1/8” - ø6mm ST-G

4.8 2 F111941 Male stud elbow 1/8” - ø6mm ST-G

4.9 2 F173797 Elbow connecting coupling ø10mm ST-G

4.10 4 F000541 Adapter G1/8” - R1/8” BR

4.11 1 F116460 Clamp ø14mm for M10 bolt

4.12 2 F108294 Threaded bush ø25 - 15mm - M10x1,5

4.13 1 F108420 Distance plate 35 x 30 x 10mm

4.14 8 F115932 Cover plate, tube clamp double 6-12mm

4.15 2 F108914 Threaded bush ø20 - 25mm - M10x1,5

4.16 2 F106744 Banjo bush ST-G

4.17 5 F112232 Hexagonal bolt M10 x 20 ST-G

4.18 3 F104050 Allen bolt M6 x 40 ST-G

4.19 1 F117845 Allen bolt M6 x 50 ST-G

4.20 5 F113426 Plain washer M10 ST-G

4.21 5 F113427 Spring washer M10 ST-G

4.22 2 F175814 Male stud elbow 1/8” - ø10mm - 45º ST-G

4.23 1 F179030 Male stud elbow G1/8”- ø6mm - 130º ST-YG

Date of issue: February 2012

4.24 1 F177323 Clamp ø90mm

4.25 1 F101375 Adapter G1/8” - R1/8” SST

4.26 1 F000542 Stud elbow G1/8” ST-G

4.27 1 F200894 Bracket 140 x 50 x 6mm + M10 nut

4.28 2 F119055 Banjo bolt G1/8” x 35 ST-G

44 Distribution blocks F210510R00

 Wheel Loader Caterpillar 972K

7.3 F210508 Installation kit tubes

Pos. Q’ty Groeneveld order Description

number

5.1 2 F109356 Thick-walled pipe ø10x3mm - R1/8" L = 1900mm

5.2 2 F106743 Thick-walled pipe ø10x3mm - R1/8" L = 800mm

FRO
NT

14 4.25
4.26
4.23

4.11

4.27

19
15
4.7 4.10
4.3
5.1
4.2
4.13 18
4.9

4.1
4.18
4.19
4.12 4.15
5.1 4.20
4.17 4.5
4.21
4.4
4.17

17 4.8
4.14
4.6
16
Date of issue: February 2012

4.22 20 4.28
17 16 15 14
4.24

4.16

6 10 8 4
5.2 21

8 9 6 10
5.2

20 21 19 18

F210510R00 Distribution blocks 45

 Wheel Loader Caterpillar 972K

19 14

17 15

20

21

18
Date of issue: February 2012

16

46 Distribution blocks F210510R00

 Wheel Loader Caterpillar 972K

14

15

B2

17

16
Date of issue: February 2012

19

F210510R00 Distribution blocks 47

 Wheel Loader Caterpillar 972K

18

21

20

Date of issue: February 2012

48 Distribution blocks F210510R00

 Wheel Loader Caterpillar 972K

8.

9.
INSTALLATION MAIN LINE
Date of issue: February 2012

your efficiency is our challenge

F210510R00 Installation main line 49

 Wheel Loader Caterpillar 972K

Parts list

8.1 F210509 Twin Main line kit Caterpillar 972K

Pos. Q’ty Groeneveld order Description

number

6.1 5 F113534 Tube clamp double ø12mm

6.2 5 F113451 Welding plate, tube clamp double 6-12mm

6.3 10 F104556 Cable tie, black 338mm

6.4 20 F111891 Cable tie, black 186mm

6.5 2 F116460 Clamp ø14mm for M10 bolt

6.6 5 F115932 Cover plate, tube clamp double 6-12mm

6.7 1 F115475 Hexagonal bolt M10 x 25 ST-G

6.8 1 F113426 Plain washer M10 ST-G

6.9 5 F115930 Allen bolt M6 x 25 ST-G

6.10 2 F208912 H.P.H 1/4” S10-3060-S8 H1

6.11 2 F208671 H.P.H. 1/4” S10-3160-S8 H2

Date of issue: February 2012

50 Installation main line F210510R00

 Wheel Loader Caterpillar 972K

6.10
3.23

6.11

4.1
Date of issue: February 2012

F210510R00 Installation main line 51

 Wheel Loader Caterpillar 972K

FRO
NT

6.8

6.7

6.5

6.10

6.9

6.1

3.23
6.6

6.2 4.1
6.11
Date of issue: February 2012

52 Installation main line F210510R00

 Wheel Loader Caterpillar 972K

B1
Date of issue: February 2012

F210510R00 Installation main line 53

 Wheel Loader Caterpillar 972K

Notes

Date of issue: February 2012

54 Installation main line F210510R00

 Wheel Loader Caterpillar 972K

9.

10.
PARAMETER SETTINGS
Date of issue: February 2012

your efficiency is our challenge

F210510R00 Parameter settings 55

 Wheel Loader Caterpillar 972K

Parameter settings

Consumption metering units each cycle : 9,80 cc

Date of issue: February 2012

56 Parameter settings F210510R00

 Wheel Loader Caterpillar 972K

10.

11.
VEHICLE CMPD DISPLAY & CODES
Date of issue: February 2012

your efficiency is our challenge

F210510R00 Vehicle CMPD display & codes 57
 Wheel Loader Caterpillar 972K

Vehicle CMPD display

Figuur 10.1 CMPD Display

10.1 Verifying Parameter Settings

Perform the following procedure in order to verify CAN-Bus connection

and Parameter Settings on CMPD display.

• Turn ignition switch ON.

• After 10sec. press button “i” on CMPD Display.
• With 4-arrow-pad button select “Machine Status” and press “OK”.
• With 4-arrow-pad button select “Autolube” and press “OK”.
• Parameter Settings will appear on screen. Check the settings.

10.2 Changing Parameter Settings

Perform the following procedure for changing parameter settings
on CMPD display.

• Turn ignition switch ON.

• After 10sec. press button “i” on in-cab monitor.
• With 4-arrow-pad button select “Settings” and press “OK”.
• With 4-arrow-pad button select “Machine” and press “OK”.
• With 4-arrow-pad button select “Autolube mode” and press “OK”.
Date of issue: February 2012

• A screen with “Light - Medium - Heavy”duty appears.

• With 4-arrow-pad button select desired setting and press “OK”.

10.3 Checking errors

Perform the following procedure for checking errors on CMPD display.

• Turn ignition switch ON.

• After 10sec. press button “i” on in-cab monitor.
• With 4-arrow-pad button select “Service” and press “OK”.
• With 4-arrow-pad button select “Diagnostic” and press “OK”.
• Screen will display error only when actual system error(s) is present.
• The CMPD display Error code/malfunction overview is listed on next page.

58 Vehicle CMPD display & codes F210510R00

 Wheel Loader Caterpillar 972K

CMPD display CAN error codes of Twin-3 pump.

Error code / Cause Solution

malfunction
1. SPN 5521 Error code currently not used Error code currently not used
FMI 11

2. SPN 5522 The pressure switch did not close

FMI 7 during a greasing cycle in
primary line-A.
Possibly caused by:

a. Broken/damaged primary a. Check condition of primary

line-A. lines and its connectors.
Replace or repair when
necessary.

b. Metering unit causes internal b. Proceed with “Procedure

by-pass. when an internal system leak
is suspected” on page 43 in
general manual EG1703.

c. Air trapped into pump and c1. Refill reservoir until reservoir
or primary line-A. is bled. See paragraph 4.5.2
“Filling the reservoir” in
general manual EG1703.

c2. Bleed the pump and primary

lines. Proceed with para-
graph 4.3 & 4.4 “Bleeding
pump & system” in general
manual EG1703.

3. SPN 5523 The pressure switch did not close

FMI 7 during a greasing cycle in
primary line-B.
Possibly caused by:

a. Broken/damaged primary a. Check condition of primary

line-B. lines and its connectors.
Replace or repair when
necessary.

b. Metering unit causes internal b. Proceed with “Procedure

by pass. when an internal system leak
is suspected” on page 43 in
general manual EG1703.

c. Air trapped into pump and c1. Refill reservoir until reservoir
or primary line-B. is bled. See paragraph 4.5.2
Date of issue: February 2012

“Filling the reservoir” in gen-

eral manual EG1703.

c2. Bleed the pump and primary

lines. Proceed with para-
graph 4.3 & 4.4 “Bleeding
pump & system” in general
manual EG1703.

F210510R00 Vehicle CMPD display & codes 59

 Wheel Loader Caterpillar 972K

Error code / Cause Solution

malfunction
4. SPN 5524 The pressure switch was still
FMI 7 closed at the outset of a cycle in
primary line-A.
Possibly caused by:

a. Damaged PS wiring harness a. Check wiring and connectors.

to where wires are joined. Replace or repair when
necessary.

b. 5/2-way valve did not b. Check 5/2-way valve and

operate correctly. operate manually with the
use of an Uni- or PC-GINA.
Replace or repair when
necessary.

c. Pressure switch failed/bro- c. Check and or replace pres-

ken. sure switch (valve).

5. SPN 5525 The pressure switch was still

FMI 7 closed at the outset of a cycle in
primary line-B.
Possibly caused by:

a. Interrupted PS wiring har- a. Check wiring and connectors.

ness to where wires are Replace or repair when
joined. necessary.

b. 5/2-way valve did not b. Check 5/2-way valve and

operate correctly. operate manually with the
use of an Uni- or PC-GINA.
Replace or repair when
necessary.

c. Pressure switch failed/bro- c. Check and or replace pres-

ken. sure switch (valve).

6. SPN 5519 Cycles that have not been per-

FMI 18 formed, due to grease reservoir
ran empty and disabled the
pump, caused by:

a. Max. number of cycles with a. Refill the reservoir. Proceed

an activated low level switch with paragraph 4.5.2 “Filling
exceeded (with pump low the reservoir” procedure in
level stop activation). general manual EG1703.

b. A combination of an b. Refill the reservoir. Proceed

activated low-level switch with paragraph 4.5.2 “Filling
and initial “no pressure line- the reservoir” procedure.
Date of issue: February 2012

A or -B” error, indicating the Thereafter, proceed with

pump ran out of grease. paragraph 4.3 “Bleeding the
pump” procedure in general
manual EG1703.

60 Vehicle CMPD display & codes F210510R00

 Wheel Loader Caterpillar 972K

Error code / Cause Solution

malfunction
7. SPN 3597 Aborted cycles, due control unit
FMI 4 encountered successive power
dips in attempt to initiate pump
motor, caused by:

a. Faulty battery (vehicle) a. Charge or replace battery

b. Faulty wiring (ground wire) b. Check wiring. Replace or

repair when necessary.

c. Corroded pin-contact in con- c. Check connections at pump

nector and in cabin. Replace or
repair when necessary.

8. SPN 5526 The pressure switch did not close

FMI 11 during a greasing cycle in
primary line-A or -B while
control unit noticed a deviant
resistance over the pressure
switch circuit, caused by:

a. Faulty wiring or connectors a. Check wiring/connectors.

Replace or repair when
necessary, proceed with
paragraph 4.6.5
“Malfunction finding
procedures” in general
manual EG1703.

b. Defective pressure switch b. Replace pressure switch.

9. SPN 5527 Control unit detected a too low

FMI 5 current draw to pump motor, in
combination with initial “no
pressure line-A or B” error,
caused by:

a. Interrupted wiring a. Check wiring. Replace or

repair when necessary.

b. Defective motor b. Check motor on wiring

faulty, check the resistance of
the motor. Replace when
necessary.

c. Defective control unit. c. Check control unit. Replace

or repair when necessary.
Date of issue: February 2012

F210510R00 Vehicle CMPD display & codes 61

 Wheel Loader Caterpillar 972K

Error code / Cause Solution

malfunction
10. SPN 5527 Control unit detected a too high
FMI 6 current draw to pump motor
and aborted the attempted
cycle, caused by:

a. Short circuit in wiring of a. Check the wiring of motor.

motor Replace or repair when nec-
essary.

b. Short circuit in motor. b. Check motor on wiring

faulty, check the resistance of
the motor. Replace when
necessary.

c. Drive shaft blocked c. Check the drive shaft on

blocking. Replace or repair
when necessary.

d. Extreme low working d. Replace the grease in the

temperature in combination reservoir and bleed the
with a grease not suitable for system with a suitable grease
these conditions. for the obtained working
conditions.

e. The "pump motor current e. Increase the "pump motor

limit" setting not suitable for current limit" parameter
the extreme low working setting but only after
temperature. checking whether the vehicle
wiring and fuse can handle a
higher setting.

11. SPN 5528 Control unit detected a too low

FMI 5 current draw to first coil of the
5/2-way valve in combination
with initial “system on pressure
before cycle” error, caused by:

a. Interrupted wiring of the coil a. Check wiring. Replace or

repair when necessary.

b. Defective coil b. Check coil on wiring faulty,

check the resistance of the
coil. Replace or repair when
necessary.

12. SPN 5528 Control unit detected a too high

FMI 6 current draw to 5/2-way valve in
combination with initial “system
on pressure before cycle” error,
Date of issue: February 2012

caused by:

a. Short circuit in wiring of the a. Check wiring. Replace or

coil repair when necessary.

b. Defective coil b. Check coil on wiring faulty,

check the resistance of the
coil. Replace or repair when
necessary.

62 Vehicle CMPD display & codes F210510R00

 Wheel Loader Caterpillar 972K

Error code / Cause Solution

malfunction
13. SPN 5529 Control unit detected a too low
FMI 5 current draw to first coil of the
5/2-way valve in combination
with initial “system on pressure
before cycle” error, caused by:

a. Interrupted wiring of the coil a. Check wiring. Replace or

repair when necessary.

b. Defective coil b. Check coil on wiring faulty,

check the resistance of the
coil. Replace or repair when
necessary.

14. SPN 5529 Control unit detected a too high

FMI 6 current draw to 5/2-way valve in
combination with initial “system
on pressure before cycle” error,
caused by:

a. Short circuit in wiring of the a. Check wiring. Replace or

coil repair when necessary.

b. Defective coil b. Check coil on wiring faulty,

check resistance of the coil.
Replace or repair when
necessary.

15. SPN 5530 Error code currently not used Error code currently not used
FMI 11

16. SPN 628 Control unit encountered cor- Replace control unit.
FMI 12 rupted parameters during
power up and restored the pro-
duction default settings.

17. SPN 5531 Real time clock battery low Replace control unit.
FMI 4 (2,2 V) at the control unit.

18. SPN 629 Control unit encountered a

FMI 12 corrupted real time clock
causing the events and errors to
be stored with in accurate time
& dates caused by:

a. RTC battery empty a. Replace control unit.

Date of issue: February 2012

F210510R00 Vehicle CMPD display & codes 63

 Wheel Loader Caterpillar 972K

Notes

Date of issue: February 2012

64 Vehicle CMPD display & codes F210510R00

 Wheel Loader Caterpillar 972K

11.

12.
TESTING OF THE SYSTEM
Date of issue: February 2012

your efficiency is our challenge

F210510R00 Testing of the system 65

 Wheel Loader Caterpillar 972K

Testing of the system

Warning

Only operate machine when fully familiar with the controls and permission
of the person in charge at the working place.

• Remove the end-plugs out of the distributions blocks.

De-aerate pipe A
• Start the pump manually with the Gina; leave the 5/2 magnet valve non-
excited (exit A).
• Close the distribution blocks with an end-plug as soon as main pipe (A) is
completely clear of air and dirt.
• Stop the pump.
• Remove main pipe A.

De-aerate pipe B
• Mount main pipe (B) on exit A of the pump.
• Start the pump manually with the Gina; leave the 5/2 magnet valve non-
excited (exit A).
• Close the distribution blocks with an end-plug as soon as main pipe (B) is
completely clear of air and dirt.
• Stop the pump.
• Connect main pipe (B) to exit B and main pipe (A) to exit A.

Accelerated test
• Start an accelerated test by means of the test button on the pump or with the
GINA.
• Check the main pipe for leakage.
• Check if all the grease points are provided with grease.
• Terminate the accelerated test by switching off the ignition.

• Switch the machine back on.

• Operate the machine in all positions and check if all the parts of the Twin-
lubrication have enough tolerance and do not jam or scrape.
• Check the timer settings by means of the GINA (if available).
• Shut the machine down. Date of issue: February 2012

66 Testing of the system F210510R00

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