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Summary of Contents for Groeneveld CompAlube
- Page 1 General Manual CompAlube Automatic greasing system EG0105P02 your efficiency is our challenge...
- Page 2 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.
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Page 3: Table Of Contents
Main components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12 2.3. The CompAlube pump unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14 2.3.1. - Page 4 CompAlube for lorries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 42...
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Page 5: Foreword
CompAlube Automatic greasing system your efficiency is our challenge EG0105P02 Foreword... - Page 6 CompAlube Automatic greasing system This system manual contains a description of the CompAlube automatic greasing system. The intention is to give potential customers an insight into how the system works, what the possibilities are and, in brief, the maintenance aspects. In addition, this manual contains the technical data of the different parts of the greasing system.
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Page 7: Introduction
CompAlube Automatic greasing system your efficiency is our challenge EG0105P02 Introduction... -
Page 8: Introduction
CompAlube Automatic greasing system is given. GROENEVELD Transport Efficiency B.V. Investing in reliability. Groeneveld was established in 1971 with just that in mind. In the meantime, this has resulted in an international network of companies, governed from the head office in Gorinchem, The Netherlands. Groeneveld strives continuously to strengthen its already predominant position, which has been obtained through a solid image and customer-oriented approach. -
Page 9: Groeneveld Greasing Systems
CompAlube Automatic greasing system Groeneveld greasing systems Groeneveld's automatic greasing systems takes care of the daily maintenance of everything that has moving parts. They prevent unnecessary wear and down-time and thus costs and annoyance. Groeneveld greasing systems are applied, for example, in: manufacturing, machines for civil engineering, agriculture, ships, the off-shore industry and the transport industry. - Page 10 CompAlube Automatic greasing system Notes Introduction EG0105P02...
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Page 11: System Description
CompAlube Automatic greasing system your efficiency is our challenge EG0105P02 System description... -
Page 12: Introduction
19 lubrication points that must be greased. It is easy to install, requires almost no maintenance and is extemely reliable. Main components There are two versions of the CompAlube available: a pneumatic plunger pump and an electrical gear pump. A pneumatic CompAlube greasing system has the following components (Figure 2.1):... - Page 13 CompAlube Automatic greasing system An electrical CompAlube greasing system has the following components (Figure 2.2): Pump unit with integrated: • electrical grease pump (gear pump) • grease reservoir (grease cartridge) • control unit (electronic timer) • metering units • grease-pressure sensor •...
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Page 14: The Compalube Pump Unit
CompAlube Automatic greasing system The CompAlube pump unit The pump unit is the heart of the CompAlube greasing system. It is a very compact unit in which the most important components are integrated. The pump unit requires virtually no maintenance and is easy to install and put into service. -
Page 15: Pneumatic Compalube With Integrated Electronic Timer
CompAlube Automatic greasing system 2.3.2 Pneumatic CompAlube with integrated electronic timer The pneumatic CompAlube pump unit with integrated electronic timer has the following components (Figure 2.4): Transparent protection cover Grease cartridge Grease piston Check valve Metering units Spring Main air piston... -
Page 16: Pneumatic Compalube With Integrated Electronic Timer
CompAlube Automatic greasing system 2.3.3 Pneumatic CompAlube with integrated electronic timer The electrical CompAlube pump unit with integrated electronic timer has the following components (Figure 2.5): Transparent protection cover Grease cartridge Gear pump Pressure regulating valve Metering units Motor Printed circuit board... -
Page 17: Operation
CompAlube Automatic greasing system your efficiency is our challenge EG0105P02 Operation... -
Page 18: Introduction
3.2.2 CompAlube with electronic timer When the CompAlube has an integrated electronic timer, the timer controls the actions of the CompAlube greasing system. The timer is an electronically operated device that is suited for vehicles that do not have a permanent electrical power supply. -
Page 19: Pump
CompAlube Automatic greasing system Pump 3.3.1 Plunger pump When the brake-counter allows compressed air to flow from the air tank behind the air/grease piston (Figure 3.1) of the plunger pump, this piston is pushed sideways. The grease in chamber (2) is now placed under pressure, so that valve (3) is pressed against the seat and the path to the grease reservoir is closed off (the check valve). -
Page 20: Gear Pump
CompAlube Automatic greasing system 3.3.2 Gear pump The gear pump (1) is switched on by the electronic time switch (2) (Figure 3.2). The grease is now pumped from the reservoir (3) to the metering units. The pump continues to run during the total cycle time. This cycle or pulse time is 2 minutes. -
Page 21: Metering Units
3.4.1 Introduction Nine different metering units can be supplied for the CompAlube pump; each with a different grease output, varying from 0.025 cc to 1.0 cc per greasing cycle. By carefully selecting the type of metering unit, each grease point will receive the right amount of grease. - Page 22 CompAlube Automatic greasing system Phase C When the pump stops and the grease pressure disappears, spring (8) pushes plunger (4) back, to block channel (1) (Figure 3.5). O-ring (10) prevents the grease in chamber (7) from being sucked back into the chamber. Spring (11) pushes plunger (5) back, so that the grease in chamber (3) is transferred to chamber (9), through channel (2).
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Page 23: Monitoring
CompAlube Automatic greasing system Monitoring 3.5.1 Grease-pressure indicator The indicator warns the driver or maintenance personnel in the event of an empty grease cartridge and incorrect functioning of the greasing system. The moment that the brake-counter starts the plunger pump, compressed air also flows under the piston in the grease-pressure indicator. -
Page 24: Grease-Pressure Switch
CompAlube Automatic greasing system 3.5.2 Grease-pressure switch The pump has a grease-pressure switch to signal a too low pressure in the pump during the greasing cycle (Figure 3.8). This grease-pressure switch is depressed so far at 30 bar that an earth connection is obtained. -
Page 25: Operation
CompAlube Automatic greasing system your efficiency is our challenge EG0105P02 Operation... -
Page 26: Introduction
CompAlube Automatic greasing system Introduction This chapter contains a description of how several components of the CompAlube greasing system must be operated These are in turn performing a test cycle, replacing the grease cartridge, refilling through the filling connection, setting the greasing interval and venting. -
Page 27: Pneumatic Compalube With Electronic Timer
CompAlube Automatic greasing system 4.2.2 Pneumatic CompAlube with electronic timer Press the test button on the right-hand side of the pump unit (Figure 4.2) for a minimum of three seconds but not longer than five seconds, until you hear compressed air starting to flow to the pump. (If you press the test button for longer than 5 seconds, you will start a multiple test cycle of 25 successive cycles that can be used for greasing after repairs on the vehicle). -
Page 28: Replacing The Grease Cartridge
CompAlube Automatic greasing system Replacing the grease cartridge The CompAlube pump unit is fitted with a grease cartridge (Figure 4.3). The cartridge is placed under a transparent protection cover and is easily and quickly replaced: Gro_G0105_402 Figure 4.3 Grease cartridge Caution: When replacing the grease cartridge, prevent dirt from entering the pump. - Page 29 CompAlube Automatic greasing system Remove the empty cartridge. The cartridge is screwed onto the pump. To remove it, turn it anti-clockwise (Figure 4.5) and lift it straight up. Gro_G0105_404 Figure 4.5 Removing the empty cartridge Remove the rubber gasket (Figure 4.6.C) and the cardboard disc (Figure 4.6.B) and replace them with the new parts, supplied with the new cartridge.
- Page 30 CompAlube Automatic greasing system Remove the cap from the new grease cartridge, but leave the foil in place. Screw the cartridge clockwise onto the pump (Figure 4.7). The foil is removed automatically. Gro_G0105_406 Figure 4.7 Fitting a new grease cartridge Clean the protection cover, place it on the pump (Figure 4.8) and turn it...
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Page 31: Refilling Through The Filling Connection
CompAlube Automatic greasing system Refilling through the filling connection The grease in the reservoir must be refilled as soon as the minimum level is reached. A filling pump must be used for this. The filling procedure (Figure 4.9) is as follows: With a new filling pump, the filling hose must first be filled with grease. -
Page 32: Setting The Greasing Interval
4.5.1 CompAlube with brake-counter The greasing interval is set on the brake-counter integrated in the CompAlube pump unit. The number of times that the vehicle brakes is used as the basis for the greasing interval. A gauge is supplied for setting the greasing interval. This gauge is located on the inside of the brake-counter cover. -
Page 33: Installation
CompAlube Automatic greasing system your efficiency is our challenge EG0105P02 Installation... -
Page 34: Introduction
CompAlube Automatic greasing system Introduction To install a Groeneveld CompAlube greasing system, the following materials/ components must be fitted and the following tasks carried out: The CompAlube pump, including grease reservoir, control unit, metering units and grease-pressure indicator. The grease lines from the metering units to the individual grease points. -
Page 35: Safety Precautions
CompAlube Automatic greasing system Safety precautions Ensure that dangerous situations are avoided when carrying out work (installation or repair). Always apply or use adequate safety precautions to prevent bodily harm and damage before you start working. Ensure that a machine or vehicle is immobilised before you start work. -
Page 36: Installation Of The Compalube Pump Unit
Installation of the CompAlube pump unit 5.4.1 The CompAlube pump unit The CompAlube pump unit is always made specifically for the vehicle for which it is intended. Before the CompAlube pump unit can be installed on the vehicle, the following must be checked:... -
Page 37: Grease Lines And Couplings
Usually, polyamide grease lines with an outside diameter of 3/16" (4.8 mm) are used on the CompAlube pump unit. To be able to connect these grease lines easily and quickly, the metering units on the pump unit are fitted with push-in couplings as standard. -
Page 38: Fitting The Grease Lines And Couplings
CompAlube Automatic greasing system 5.5.1 Fitting the grease lines and couplings Caution! Do not add or modify existing grease points on your own initiative. Certain constructions can be weakened by drilling holes. Always follow the relevant vehicle manufacturer's instructions. First remove the original grease nipple from the grease point and replace it with the correct coupling or combination of couplings (see the grease plan). -
Page 39: Maximum Grease Line Length
CompAlube Automatic greasing system Fasten the grease line with clamps or brackets to just before the coupling on the grease point. Warning! If grease lines are laid along booster hoses, brake booster rubbers must always be used. These rubbers prevent the booster hose from being damaged or from being pinched by clamps Cut the grease line to the correct length and connect it to the coupling. -
Page 40: Pneumatic Lines
5.6.1 Pneumatic CompAlube with brake-counter Two air lines must be connected to the pneumatic CompAlube with brake-counter (Figure 5.3): • The air supply line - the line between vehicle's the air tank and port 'P' on the brake-counter. -
Page 41: Pneumatic Compalube With Electronic Timer
CompAlube Automatic greasing system 5.6.2 Pneumatic CompAlube with electronic timer One air line must be connected to the pneumatic CompAlube with electronic timer (Figure 5.4): • The air supply line - the line between vehicle's the air tank and port 'P' on the brake-counter. -
Page 42: Electrical Cables
5.8.1 Pneumatic CompAlube with integrated brake-counter A magnetic valve set is required if you want to install the pneumatic CompAlube with integrated brake-counter on a lorry. On lorries, it is not allowed to connect the integrated brake-counter directly to the pneumatic braking system and this is avoided by the use of the magnetic valve set. -
Page 43: Venting
CompAlube Automatic greasing system Venting 5.9.1 The pneumatic CompAlube with brake-counter Normally, the pump never needs to be vented because it is vented and tested before delivery. However, if the grease cartridge has been completely empty, the pump may need... -
Page 44: The Compalube With Electronic Timer
CompAlube Automatic greasing system 5.9.2 The CompAlube with electronic timer Normally, the pump never needs to be vented because the pump is vented and tested before delivery. However, if the grease cartridge has been completely empty, the pump may need to be vented again: Open the venting screw (Figure 5.6). -
Page 45: Putting Into Service
CompAlube Automatic greasing system 5.10 Putting into service After the installation, the CompAlube greasing system must be put into service. 5.10.1 The pneumatic CompAlube with brake-counter The main task is to set the brake-counter. The number of brake demands (the greasing interval) that must be set depends on several factors: •... - Page 46 CompAlube Automatic greasing system Make sure that the setting screw attached to the piston in the brake-counter does not rest on the end stop by activating the vehicle's brakes (Figure 5.11). Gro_G0105_510 Figure 5.11 Setting screw Use the gauge and two open-ended spanners (10 mm) to set the desired number of brake commands (Figure 5.12).
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Page 47: 5.10.2 The Pneumatic Compalube With Electronic Timer
CompAlube Automatic greasing system 5.10.2 The pneumatic CompAlube with electronic timer The main task is to set the electronic timer. The duration of the greasing interval depends on: • the grease demand of the grease points. • the operating conditions (highway, city traffic, building site, etc.). -
Page 48: 5.10.3 The Electrical Compalube With Electronic Timer
CompAlube Automatic greasing system 5.10.3 The electrical CompAlube with electronic timer The main task is to set the electronic timer. The duration of the greasing interval depends on: • the grease demand of the grease points. • the operating conditions (highway, city traffic, building site, etc.). - Page 49 CompAlube Automatic greasing system DIP switch settings Interval switch 1 switch 2 switch 3 switch 4 30 minutes not relevant 45 minutes not relevant 60 minutes not relevant 90 minutes not relevant 120 minutes not relevant 150 minutes not relevant...
- Page 50 CompAlube Automatic greasing system Notes Installation EG0105P02...
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Page 51: Maintenance
CompAlube Automatic greasing system your efficiency is our challenge EG0105P02 Maintenance... -
Page 52: Introduction
CompAlube Automatic greasing system Introduction The maintenance of the Groeneveld CompAlube greasing system can be combined with the normal maintenance on the vehicle or the machine. Caution! The automatic greasing system significantly reduces the time and effort spent on manual greasing. However, do not forget that universal joints, for instance, must still be greased by hand. -
Page 53: Trouble Shooting
CompAlube Automatic greasing system Trouble shooting 6.3.1 Pneumatic CompAlube malfunctions Problem Cause Solution Grease-pressure indicator 1. Cartridge or reservoir is Replace cartridge with full shows 'red'. empty. cartridge or refill the reservoir through the filling connection 2. Internal leakage in a Check if a grease point is metering unit. -
Page 54: Electrical Compalube Malfunctions
CompAlube Automatic greasing system 6.3.2 Electrical CompAlube malfunctions Problem Cause Solution The control lamp is lit 1. Cartridge or reservoir is Replace cartridge with full continuously. empty. cartridge or refill the reservoir through the filling connection 2. Internal leakage in a Check if a grease point is metering unit. -
Page 55: Technical Specifications
CompAlube Automatic greasing system your efficiency is our challenge EG0105P02 Technical specifications... -
Page 56: Pump
CompAlube Automatic greasing system Pump Description Pneumatic pump Pneumatic pump Electrical pump with brake-counter with electronic with electronic timer timer Power supply n.a. 12 VDC or 24 VDC 12 VDC or 24 VDC voltage Current 1A (12 VDC) 9A (12 VDC) consumption n.a. -
Page 57: Metering Units
CompAlube Automatic greasing system Metering units Maximum 19 metering units on the CompAlube pump. Available metering units Output Type 0 0.025 cm³/greasing cycle Type 1 0.050 cm³/greasing cycle Type 2 0.100 cm³/greasing cycle Type 3 0.150 cm³/greasing cycle Type 4 0.200 cm³/greasing cycle... -
Page 58: Pump Dimensions
CompAlube Automatic greasing system Pump dimensions Gro_G0105_700 Figure 7.1 Dimensions of the CompAlube pump unit Technical specifications EG0105P02... - Page 59 Tel.: +64 7 5720684 Tel.: +32 3 8979860 Fax: +64 7 5724587 Fax: +32 3 8979861 Groeneveld Polska Sp. Z.o.o. Groeneveld CPL Systems Canada Inc. Ul. Ostrowska 476 7065 Twiss Road R.R.#3. 61 - 342 Poznan, POLAND LOP 1BO Campbellville, Ontario, CANADA Tel.: +48 61 8726207/08/09...
- Page 60 Groeneveld Transport Efficiency B.V., Stephensonweg 12, 4207 HB Gorinchem, Postbus 777, 4200 AT Gorinchem, the Netherlands. Tel. +31 183 64 14 00, Fax +31 183 62 34 05, http:// www.groeneveld-groep.com...
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