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General Manual Triplus trailer version

1. Figure 3 6 Principle of operation To operate progressive distribution blocks need no other energy source than the grease pressure supplied by the pump of the greasing system 1 2 EG1603P01 The lubricant flows from the input port via piston 3 through all segments to the left hand side of piston 1 Piston 1 is pushed to the right by the grease pressure The grease at the right hand side of piston 1 is pressed to output port 1 Because piston 1 has now been pushed to the right the lubricant now flows via piston 1 from the central input channel to the left hand side of piston 2 Piston 2 is then moves and supplies grease to output 2 Because piston 2 has been pushed to the right the lubricant now flows via piston 2 to the left hand side of piston 3 Piston 3 is pushed to the right and supplies lubricant to output port 3 After piston 3 has been pushed to the right the lubricant is pressed to the right hand side of piston 1 Piston 1 will move to the left and supply lubricant to output port 4 Afterwards piston 2 will also be pressed to the right and will supply lubricant to output port 5 Afterwards piston 3 will also be pressed to the right and will supply lubricant to output port 6 The distributio
2. 65 7 8 1 General mmm 65 7 8 2 Fuseratings 65 7 8 3 Pin layout of the connector on the pump unit 66 7 8 4 Wiring diagram 67 7 9 De aerating of the greasing system 68 7 10 Commissioning of the greasing system 68 8 Maintenance 69 8 1 General aleme e e a a se 0 E 70 8 2 Regularly checks of the greasing system 70 8 3 Filling the grease reservoir 71 8 4 Fault finding 72 9 Technical data 75 9 1 TRIPLUS trailer pump unit 76 9 2 Distribution blocks 77 Table of contents EG1603P01 9007 4990390 anss Jo ajeq Automatic Greasing System TRIPLUS PREFACE A EN AN NK Q Ten GROENEVELD your efficiency is our challenge 9007 1 q0 P0 onss jo med Preface EG1603P01 S Automatic Greasing System TRIPLUS Preface This general manual gives a description of the TRIPLUS automatic greasing system It aims at giving insight in the system s operation and possibilities Furthermore in this manual you will find the technical data on several components of the TRIPLUS automatic greas
3. 8 2 2 Groeneveld Transport Efficiency B V 8 2 3 TRIPLUS automatic greasing system 9 General information 11 3 1 Introduction 12 3 2 The TRIPLUS automatic greasing system 12 Description components 15 4 1 Properties 16 4 2 Composition of the TRIPLUS trailer pump 17 4 3 The integrated control and monitoring unit 18 4 4 The plunger pump 18 4 5 Safety and control features 19 4 5 1 Maximum grease pressure 19 4 5 2 Minimum grease level in the reservoir 19 4 5 3 Defective wiring and short circuits 19 4 6 The test pushbutton 19 4 6 1 Performing atest cycle 20 4 6 2 Retrieving fault messages 20 4 7 The signal light 20 4 8 The distribution blocks 22 4 8 1 o Properties 22 4 8 2 Composition 22 4 8 3 Principle of operation 23 4 8 4 Non
4. The type of secondary grease line most commonly used in the transport industry is the polyamide line with an outside diameter of 3 16 or 6 mm These grease lines are supplied as composite lines In a composite line 2 or 3 polyamide lines are held together by a single plastic jacket Each grease line in such a composite line has its own colour red blue or black so that they can be easily distinguished at the ends of the composite line necessary for easy installation and maintenance If a composite line is connected to doser segments with different grease outputs the individual grease lines should be connected as follows e Doser segment with the lowest output Red line e Doser segment with the highest output Black line e Doser segment with intermediate output Blue line EG1603P01 Installation 64 Automatic Greasing System TRIPLUS 6 7 2 Mounting the secondary lines Take attention at the following points during mounting the secondary grease lines and couplings e Always make sure the screw threads of the coupling s and the grease point are identical e To identify them elbow couplings with metric screw thread are marked with a M Straight couplings with metric screw thread have a groove on their hexagons e Always apply brake booster rubbers when routing grease lines along the vehicle s booster lines this to prevent the booster lines from becoming pinched off over time by the tie wraps that are usually used to
5. PARAMETERS TIMER Pump startup delay XXXXX msec del rdiv cbp psdt EG1603P01 The screen shows the grease output in cc of output port 1 The grease output set must match the grease demand per greasing cycle of the branch of the greasing system connected to this output port Range 0 0 999 9 cc The location of the cursor the flashing square indicates the digit will be changed after you entered a digit the cursor will automatically move forward to the next digit Press lt ENTER gt when you are satisfied with the setting The cursor will then disappear from the screen The screen shows the output in cc of the plunger pump per revolution of its drive shaft determined by the stroke length and diameter of the plunger With this para meter the program will be able to calculate the number of revolutions needed to achieve a certain grease output during each greasing cycle The default value is 0 10 cc r and may not be changed The screen shows the duration of the greasing interval expressed in brake commands Range 0 65535 brake commands If necessary change this value and confirm with lt ENTER gt The screen shows the delay in milliseconds between the activation of the brake lights of the vehicle and the start of the pump of the greasing system This delay prevents the fuse from blowing which would be likely to happen if both were switched on simult neously The default is 300 ms and th
6. pending poc error loc bits 1 pol pending error bits 2 NEXT T 48 The Gina EG1603P01 9007 4940390 anss 10 aeg Automatic Greasing System TRIPLUS DESIGNING A SYSTEM A 900Z 43gopo onss jo med GROENEVELD your efficiency is our challenge 49 Designing a system EG1603P01 Automatic Greasing System TRIPLUS 5 1 Introduction The following aspects influence the design of a TRIPLUS greasing system The number of grease points to be connected and e The position of the grease points on the vehicle or machine e The grease demand of the grease points e The greasing interval required by the grease points 2 The space available on the vehicle or machine for the pump unit and the dis tribution blocks 3 The NLGI class of the grease to be used and the lowest ambient temperature under which the greasing system is expected to function 5 2 Points of departure Maximum working pressure 275 bar Number of grease output ports 1 Maximum number of distribution blocks in series 2 Available segment types table 1 Minimum number of doser segments in a distribution block 3 Maximum number of doser segments in a distribution block 12 Pressure drops in a distribution block related to table 2 s The number of segments in the distribution block s The NLGI class of the grease used s The ambient operating temperatures Pressure drops in the grease
7. 1 330 2255213 Mobile 1 800 5867283 Groeneveld Pacific West L L C 1089 Valentine Avenue SE Pacific WA 98047 U S A Tel 1 253 8633700 Fax 1 253 8633131 Mobile 1 253 6061838 Groeneveld Atlantic South Inc 7820 Professional Place suite 6 Tampa FL 333637 U S A Tel 1 883 983 1883 Fax 1 813 983 1873 Toll free 1 877 977 7772 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
8. AN AK 900Z 43gopo onss jo med GROENEVELD your efficiency is our challenge 27 The Gina EG1603P01 28 Automatic Greasing System TRIPLUS 4 1 Introduction The GINA Groeneveld tester for Installation and Analysis is a programming and read out device for the digital control unit of the TRIPLUS automatic greasing sys tem 9 OOO OOS 000G SOR S Bl Figure 4 1 The GINA In the description that follows all screens of the GINA are dealt with in the order in which they have been placed in its menu system To get acguainted with the menu system and the features the GINA offers we advise you to follow the seguence as presented if only once In practise there is of course no reason whatsever for such arigid and time consuming approach The read outs and setting have been grouped in three menus main menu para meters timer and diagnosis menu You can access each of these menus by pressing lt MAIN gt lt PARAMETERS gt or lt DIAGNOSIS gt on the keypad of the GINA You can do so at any time regardless of the screen currently shown on the display Some screens just show information You cannot change anything in those screens Other screens allow you to change parameters or the status of a particular input or output You can recognise those screens by the blinking cursor that appears on them with the exception of the system configuration and error logging reset screens A number of screens sho
9. Groeneveld L Efficienza nel Trasporto S r l GENT Via Chiari 100 23868 Valmadrera Lecco ITALIA Tel 39 3 41200536 Fax 39 3 41201539 Groeneveld Italia GRIT Via Chiari 100 23868 Valmadrera Lecco ITALIA Tel 39 3 41201133 Fax 39 3 41201158 Groeneveld Transport Efficiency B V Postbus 777 4200 AT Gorinchem THE NETHERLANDS Tel 31 183 641400 Fax 31 183 624993 Groeneveld Information Technology B V Stephensonweg 12 4207 HB Gorinchem THE NETHERLANDS Tel 31 183 641400 Fax 31 183 641690 Groeneveld New Zealand Ltd 58 Newton Road P O Box 4509 Mt Maunganui NEW ZEALAND Tel 64 7 5720684 Fax 64 7 5724587 Groeneveld Polska Sp 2 0 0 Ul Ostrowska 476 61 342 Poznan POLAND Tel 48 61 8726207 08 09 Fax 48 61 8798166 Groeneveld South Africa Unit 65 Sunny Rock Park Sun Rock Close Germiston 1401 SOUTH AFRICA Tel 27 11 4503977 Fax 27 11 4503980 Groeneveld Ib rica S A Pol Ind Mercederias C Font de Sant Lloren 36 08720 Vilafranca del Pened s Barcelona SPAIN Tel 34 93 8171822 Fax 34 93 8172061 Groeneveld Transport Efficiency U K Ltd The Greentec Centre Gelders Hall Road Shepshed Loughborough Leicestershire LE12 9NH UNITED KINGDOM Tel 44 1509 600033 Fax 44 1509 602000 Groeneveld Transport Efficiency Inc 1130 Industrial Parkway North Brunswick Ohio 44212 U S A Tel 1 330 2254949 Toll free 1 800 5867283 Fax
10. status of various output signals pol open load in circuit of electric pump motor lowl minimum grease level reached in the reservoir test test pushbutton actuated rviv relief valve activated maximum grease pressure exceeded EG1603P01 9007 4940390 anss Jo aeg Date of issue October 2006 Automatic Greasing System TRIPLUS INP OUTP hh mm ss 1 0 3 0 0 0 0 end1 lol spr revol Press lt DIAGNOSIS gt DIAGNOSIS MENU err I O var tinfo Press lt F3 gt Var VARIABLES hh mm ss Remainder brakes XXXXX rbrk rrev rerr rcem Press lt F2 gt rrev VARIABLES hh mm ss Remainder revolution XXXXX rbrk rrev rerr rcem Press lt F3 gt rerr VARIABLES Release errors XXX rbrk rrev rerr rcem hh mm ss Press lt F4 gt rcem EG1603P01 Dit is het derde I O scherm Getoond wordt de status van diverse ingangssignalen end1 sensor signal at each distribution block cycle in output port 1 lol open load in signal light circuit spr spare revol sensor impulse sent at every revolution of the drive shaft of the pump The screen shows the remaining part expressed in brake commands of the current greasing interval The screen shows the remaining part of the number of revolutions of the drive shaft of the pump that consitute the pump phase that is currently being executed The screen shows the moment the mre filter gets active From start of the pumping phase this counter
11. the sum of all rated grease outputs of all doser segments in the block System featuring a main distribution block Determine the composition of the main distribution block by e Determining the ratios of the grease demands of the distribution blocks to be connected to the main distribution block e Selecting segment types for the main distribution block with which those ratios are most precisely matched e Determining the required grease output of the pump unit This is the sum of the grease demands of all distribution blocks connected with that output port excluding the main distribution block This value can be used in a later stage to determine the grease output of that out put port of the pump unit System without a main distribution block e The determined values may be used to calculate the required grease output port of the pump unit Determine the lengths of the primary grease lines between the pump unit and the distribution blocks between the distribution blocks and the lengths of the second ary grease lines between the distribution blocks and the grease points Note those lengths on the greasing plan Determine the number of non return valves that must be incorporated into the greasing system EG1603P01 Designing a system 53 54 Automatic Greasing System TRIPLUS 5 3 6 Check the design Before the components of the system are assembled and installed the projected system should be checked by calculation ag
12. 6 2 Safety precautions 1 2 10 11 12 13 56 Installation Take the necessary precautions to prevent potentially dangerous situations from occuring during installation checking and maintenance Always apply or use adequate safety measures to prevent bodily harm and damage before you start working on the vehicle Ensure the vehicle is immobilised before you start work Remove the ignition key and store it in a safe place Block parts that may move on their own accord Engage the parking brake Pay special attention to tailbords loading flaps drop flaps etc Take care that you can work safely unter these parts without these parts can drop down Never work underneath a vehicle which is raised by a jack only Always use a trestle and check that the ground is firm and flat enough Keep in mind that a vehicle with air suspension may drop of its own accord Only work underneath the cabin if it is fully tilted and latched Otherwise a support must be placed underneath the cabin to ensure the cabin cannot drop back Disconnect the earth clamp from the vehicle s battery This prevents electrical equipment from being inadvertently activated Avoid working on the cooling system without allowing it to cool down first The system is pressurised and may cause burns Direct contact with the poi sonous cooling fluid must be avoided Adhere to all regulations specifications and limitations as specified by the manufacturer of the
13. available in the workshop With such a system the greasing system can be de aereted quickly by connecting the primary grease line of the TRIPLUS system at the pump unit with that system After the system has been de aereted the primary line must be recon nected to the output port of the pump unit Method 2 This method may be used when only a hand operated grease gun is available The procedure is the same as described for method 1 Method 3 This method will have to be used when neither a pneumatic system or a hand op erated grease gun is available The pump unit must then be started and be allowed to run until the branch of the system connected to the selected output port is prop erly de aereted The system has been de aereted properly when a closed collar of fresh grease is present at all grease points Commissioning of the greasing system During commissioning the system parameters greasing interval grease supply per phase etc must be set or checked using the GINA Detailed information about the system parameters and the operation of the GINA can be found in the chapter GINA of this manual After you have set or checked the system parameters with the GINA you should ini tiate a test cycle with the GINA or the test pushbutton on the pump unit A test cy cle should be performed for every grease output port of the pump unit After conclusion of the test cycle you can check with the GINA whether the system func tioned pr
14. bench vice b Turn the line into the sleeve to end of the sleeve counter clockwise c Turn the line backward 1 4 to 1 2 turn d Apply oil or grease to the pillar the sleeve and the inside of the line e Turn clockwise the grease line pillar in the sleeve untill it is in position without tension f Mount the coupling at the other end of the grease line in a similar way Press couplings applied with a simple hand operated press for high pressure line DN4 05716 a Slide the press sleeve completely over the end of the grease line so that the line fills the sleeve completely b Slide use some oil if necessary the pillar or the required coupling pin into the end of the grease line untill the pillar is completely in the grease line c Place the assembly in the press in such a manner that a little piece of the sleeve remains visible at both sides Apply pressure until the lever of the hand operated press reaches its end stop d Mount the coupling at the other end of the grease line in a similar way ATTENTION A simple hand operated press that can be placed in a bench vice is used with DN4 high pressure lines The thin walled sleeve of the couplings for this type of grease line must be pressed exactly in the middle so that small piec es of unpressed sleeve remain on both sides This note of attention does not apply to sleeves meant for use with a hydraulic press Those types of sleeves must be pressed over their whole lengt
15. contact is installed in the grease channel between the plunger pump and the output port This relief valve will start to lead the grease back to the reservoir if the maximum grease pressure is exceeded during the pump phase of a greasing cycle The grease pressure may become too high for example when one of the grease lines to the grease points has become blocked or when the viscosity of the grease has become too high at low temperature Minimum grease level in the reservoir A minimum level switch is installed in the grease reservoir If the grease reaches its minimum level the control unit will process store and report the occurrence of that condition Defective wiring and short circuits Open loads interruptions in the wiring to the sensors minimum level switch relief valve electric motor and external signalling devices e g buzzer or signal light will be detected and processed by the control unit Short circuits in the wiring or components will also be noticed by the control unit The test pushbutton The test pushbutton on the pump unit has two functions e Performing a test cycle via the grease output port of the pump unit e Retrieving error messages stored in the memory of the control unit GA ENEL Figure 3 3 The test pushbutton EG1603P01 Description components 19 20 Automatic Greasing System TRIPLUS 3 6 1 3 6 2 3 7 Performing a test cycle A test cycle can be performed using the test pushbutt
16. machine vehicle or engine Only use tools that fit and are designed for the specific task you want to per form with them A vehicle or machine may only be operated by those who are competent to do so and aware of all possible dangers If necessary an expert should be con sulted Keep the environment in which you work clean and tidy This enhances safety EG1603P01 9007 4940390 anss Jo aeg Date of issue October 2006 Automatic Greasing System TRIPLUS 6 3 General installation directives EG1603P01 Check the contents of the parts kit using the parts list including in the kit Before you start installing the greasing system Check that all grease points are open and furnished with a sufficient amount of grease If that is not the case grease the grease points by hand This prevents insufficient greasing of the grease points during the period following the first few greasing cycles of the greasing system Apply Teflon tape or another type of sealant e g Loctite to the couplings and plugs on the distribution blocks and pump unit if not already fitted with O rings gaskets or sealing rings While mounting the couplings and plugs make sure that the tape does not cause internal contamination of the system Prevent contamination of the system during the installation Work with clean tools and clean the areas on the vehicle or machine where the distribution blocks and pump unit are to be mounted before you star
17. rcel remaining end switch pulses to prevent end line errors resi remaining number of revolutions until the reserve of grease is been used rdgr relief valve activated during pump phase rdiv grease output per revolution of the pump drive shaft rerr relief valve errors rrev remaining number of revolutions for the current pump phase rto revolution time out skrv total number of revolutions of the drive shaft that were skipped spr spare srno serial number tbrk total number of brake commands total numbers EEPROM writes tcy total cycles test test pushbutton text vers text version software GINA time time tinfo timer information tive timer version tpt total pumping time u ac user id last access u ch user id last change var variables year year 46 The Gina EG1603P01 9007 4990390 anss Jo aeg Date of issue October 2006 Automatic Greasing System TRIPLUS 4 8 2 Main menu 1 info time contr u ac hrs d ac min u ch d ch p s day p ui mnth acces year 1 NEXT 4 8 3 Parametersmenu PARAMETERS del rdiv cbp psdt mre poct loct end 4 NEXT EG1603P01 The Gina 47 Automatic Greasing System TRIPLUS 4 8 4 Diagnosismenu err UO var tinfo poc pump rbrk rdgr spr rrev lowl lamp rerr pdiff hist spr rcem endi pol reel prno tcy eres lowl srno tork pol test tive tpt lol rviv skrv loc end 1 lol spr revol
18. reading or programming the control unit you can switch off the GINA Press lt POWER ON OFF gt and disconnect the interconnection cable and remove the GINA The Gina EG1603P01 9007 4940390 anss Jo med Date of issue October 2006 Automatic Greasing System TRIPLUS 4 8 Layout of the menu system 4 8 1 Used abbreviations Abbrevia EG1603P01 tion access ald 8 auto cbp contr d ac d ch day del end1 err hist hrs 1 0 info lol Iwl man mode month mre p s p ui pdif poc poct pol Meaning minus decreasing contrast plus increasing contrast authorisation level authorisation level device 8 Triplus trailer version automatic greasing interval expressed in brake commands screen contrast time amp date last access time amp date last change day delivery output 1 end switch in the system connected to output port 1 errors history hours inputs outputs information GINA lamp open load low level switch manual minutes mode month filter period in which a possible opening of the over pressure relieve valve will be ignored by the program software version GINA user id GINA production info pump over current pump over current time pump open load The Gina 45 Automatic Greasing System TRIPLUS Abbrevia Meaning tion prno part number psdt pump startup delay time pump pump rork relief valve activated before start of pump phase
19. return valves 24 4 8 5 Failure of one of the doser segments 24 4 8 6 Closing outputs 24 4 8 7 Combining outputs 25 The Gina 27 5 1 Introduction 28 5 2 Connecting the GINA 29 5 3 Control pad 29 5 4 Switching on the GINA 29 5 5 The Main menu 31 5 6 Parameters timer 35 5 7 Diagnosis menu 37 5 8 Layout of the menu system 45 5 8 1 Used abbreviations 45 5 8 2 Main menu 47 5 8 3 Parameters menu 47 5 8 4 Diagnosis menu 48 EG1603P01 Table of contents SINILNO9 40 q414V1 Automatic Greasing System TRIPLUS 6 Designing a system 49 6 1 Introduction m m m mm 50 6 2 Points of departure 50 6 3 Method ere mumun 52 6 3 1 Determine the operating conditions 52 6
20. return valves and plugs into the output ports of the distribution blocks as indicated on the drawing 8 Mount the secondary grease lines 9 Connect a grease pump or manual grease gun to the port of the primary grease line to test the operation of the distribution block and to check for leakage EG1603P01 Installation 60 Automatic Greasing System TRIPLUS 6 5 3 Mounting the distribution blocks Determine the location of the distribution block on the vehicle or machine Consult the specific installation instruction card and or take account of e No stresses may be present in the mounted distribution block It is best to use mounting brackets to install the distribution blocks The distribution blocks should not be installed too near moving parts The distribution blocks should not be installed near parts that become hot e g turbo charger exhaust e Existing mounting holes in the chassis should be utilised whenever possible The distribution blocks can be mounted with the mounting brackets in two ways 1 First mount the brackets Then mount the distribution block onto the brackets this method is compulsory if the brackets are welded onto the vehicle or machine 2 First mount the distribution block onto the bracket Then mount this assembly on the vehicle Which method is to be preferred depends on the manoevring space you have avail able ATTENTION Always apply toothed spring washers to the M5 mounting nuts a
21. such as at which in tervals number of brake commands or pulses grease should be applied and with what guanties are laid down in the control unit The control unit monitors the per formance of various components of the greasing system and stores and reports the malfunction it detects The control unit can be programmed or read out with a GINA Groeneveld tester for INstallation and Analysis see Figure 3 2 Figure 3 2 Connecting the GINA to the trailer pump The plunger pump The electric motor drives the plunger pump through a reduction gear The plunger pump comprises a drive shaft with excentric a cylinder with piston and a non return valve The excentric moves the piston back and forth once every revolution of the drive shaft During the return stroke of the piston grease is sucked from the reservoir into the cylinder through an opening in the cylinder wall During the forward stroke of the piston the grease is pressed via the non return valve towards the output port s of the pump unit The amount of grease supplied during each stroke revolutions of the drive shaft depends on the fixed diameter of the cylinder and the stroke length of the piston Description components EG1603P01 9007 4990390 anss Jo med Date of issue October 2006 Automatic Greasing System TRIPLUS 3 5 3 5 1 3 5 2 3 5 3 3 6 Safety and control features Maximum grease pressure A relief valve fitted with an electrical
22. the close off to exit through the output that remains open it doubles the output of the one that remains open The distribution block will become inoperable if the little plug is not removed Description components EG1603P01 900Z 4940390 anss 10 aeg Date of issue October 2006 Automatic Greasing System TRIPLUS 3 8 7 Combining outputs The outputs of a distribution block can be combined by installing an external interconnection line The total grease output in that case is the sum of all outputs thus interconnected The two outputs of a doser segment can be combined by removing the little inter nal plug that seperates the two outputs and closing off one of the ports This dou bles the output of the port that remains open A u HH OH O O O UMUM Figure3 7 Combining outputs The values in the illustration represent the outputs of the ports in mm 0 001 cc per complete cycle of the distribution block The amount supplied is determined by the diameter of the piston EG1603P01 Description components 25 26 Automatic Greasing System TRIPLUS Notes Description components EG1603P01 9007 4940390 anss Jo aeg Automatic Greasing System TRIPLUS THE GINA ASW
23. the normal maintenance of the vehicle or machine during oil replacement for instance Careful selection of construction materials makes the greasing system itself vitually maintenance free ATTENTION The automatic greasing system reduces the time and effort spent on manual greasing significantly However do not forget that there may be grease points that are not served by the greasing system and must still be greased by hand The TRIPLUS automatic greasing system A Groeneveld TRIPLUS automatic greasing system serves each grease point of the vehicle machine or installation in sequence i e grease is supplied to the connected grease points one at a time and one after the other it is a progressive greasing system TRIPLUS systems are mainly applied on machines with a fixed number of grease points that require fixed amounts of grease at fixed intervals This because the amount of grease that will be supplied to the individual grease points is governed by the distribution ratios that results from the choice of doser segment types and the manner in which those segments are combined in distribution blocks A Groeneveld TRIPLUS automatic greasing system comprises the following parts see Figure 2 1 1 An electric grease pump plunger pump with integrated grease reservoir and a digital control unit with data storage facility 2 One or more distribution blocks assembled from multiple doser segments 3 Primary grease lines betwee
24. trailer pump unit are The grease interval is determined by the number of brake commands received by the braking system The grease output of the pump is monitored The maximum acceptable grease pressure is monitored The grease level in the reservoir is monitored The electrical wiring and components are monitored Description components EG1603P01 9007 4990390 anss Jo aeg Date of issue October 2006 Automatic Greasing System TRIPLUS 3 2 Composition of the TRIPLUS trailer pump The TRIPLUS trailer pump comprised the following components A a Grease reservoir with follower piston Stirring gear Plunger pump Electronic control and monitoring unit with permanent memory Relief valve with return line to the grease reservoir and electric contact for monitoring purposes by the control unit Grease output port 1 Impulse sender used to count the number of revolutions of the drive shaft of the pump Electric motor with reduction gear Test pushbutton Filler grease nipple with filter De aerating and grease overflow opening Electrical connector Minimum grease level switch Figure 3 1 Oo TRIPLUS trailer pump EG1603P01 Description components 17 18 Automatic Greasing System TRIPLUS 3 3 3 4 The integrated control and monitoring unit The control and monitoring unit iniates and controls the greasing cycles of the greasing system All reguired system and program parameters
25. 3 2 Produce a greasing plan 52 6 3 3 Determine the grease demand of the grease points 52 6 3 4 Group the grease points 53 6 3 5 Determine the layout of the system 53 6 3 6 Check the design 54 7 Installation mmm 55 7 1 OVENVIEW sss E ele a si e e amme ia e a T 56 7 2 Safety precautions 56 7 3 General installation directives 57 7 4 TRIPLUS pump unit 58 7 4 1 Pump types 2 rere ree ee eee eee eee 58 7 42 Mounting the pump 58 7 5 TRIPLUS distribution blocks 59 7 5 1 General 2 22 eee ee ee ee ee ee eee eee eee 59 7 5 2 Assembling distribution blocks 59 7 5 3 Mounting the distribution blocks 60 7 6 Primary grease lines and couplings 61 7 6 1 Grease line types eee eee eee 61 7 6 2 Mounting the primary grease lines 61 7 7 Secondary grease lines and couplings 63 7 7 1 Grease line types eee ee eee rene 63 7 7 2 o Mounting the secondary lines 64 7 8 Electrical wiring
26. General Manual Automatic Greasing System TRIPLUS Trailer version EG1603P01 your efficiency is our challenge General information Type of manual System Document number Date of issue Revisie 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 General Manual Automatic Greasing System TRIPLUS EG1603P01 October 2006 01 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 conceguences of such errors Date of issue October 2006 Automatic Greasing System TRIPLUS Preface 5 Introduction 7 2 1 Introduction
27. Gina 39 Automatic Greasing System TRIPLUS INP OUTP Mode O auto 1 man X 2 test Mode Press lt NEXT gt INP OUTP 1 0 1 0 0 0 0 pump spr lamp spr hh mm ss Press lt NEXT gt INP OUTP 1 0 2 0 0 0 0 pol lowl test rviv hh mm ss Press lt NEXT gt The Gina The screen shows the current operating mode of the greasing system 0 auto the system operates on automa tic and is executing the program stored in the control unit 1 man the functions of the greasing system are operated by hand by means of the GINA 2 test thesystemisperformingatest cycle amount dependent on parameter setting You can change the current operating mode by pressing one of the numeric keys lt 0 gt to lt 2 gt and confirm that with lt ENTER gt If the current greasing cycle in auto mode is interrupted that greasing cycle will not be completed when the system is put back on auto The auto mode will automatically be restored when the contact is switched on This is the first O screen It shows the status of various output signals pump electric pump motor is running lamp signal light lits spr spare To test the system these outputs may toggled manually by pressing function key lt F1 gt and lt F3 gt to de activate the signal light or the pump motor You can only do this after the system s operating mode has been set to 1 manual This is the second W O screen It shows the
28. ainst the operating conditions it was designed for Will it work under the giving operating conditions The loss of pressure in the system may not exceed Pp Pp equals 90 of the maxi mum operating pressure supplied by the pump unit 1 2 5 Calculate the pressure loss Py over the distribution blocks under the set oper ating conditions using table 2 Determine using the greasing plan which grease point is furthest from the pump unit Calculate using table 3 the total pressure loss P over that grease line Determine which type of grease point is connected to this grease line Deter mine the resistance Ps induced by that type of grease point see 5 2 Points of departure Calculate the largest total loss of pressure Pt for each output port of the pump unit by adding together the values of the pressure losses in the grease lines distribution blocks and at the grease point Pt Pv P Ps Check that Pt lt Pp If the loss of pressure in the system exceeds Pp investigate the following Is it possible to use a grease of a lower NLGI class Is it possible to raise the minimum operating temperature requirement It might be necessary to redesign the system and reconsider whether e Its not better to omit the main distribution block e The layout of the system can be modified to shorten the grease lines or to reconfigure the distribution blocks e Using a grease line of larger diameter to reduce pressure loss will
29. and a malfunction is indicated Automatic Greasing System TRIPLUS Defective pump unit or blockage in the system Retrieve the fault code If Maximum pressure exceeded relief valve opened during a pump phase 1 System contains grease that is not suit able for the current operating conditions Solution Replace the grease in the pump and flush the system 2 Distribution block grease line or grease point blocked Solution Remove the grease lines behind the main block one by one and each time perform a test cycle If the maxi mum pressure error does not occur during a test the problem is lo cated in the branch you disconnected If the line with the problem leads to a block you should repeat this procedure for the lines connected to that block until you find the blockage Removing the blockage If the maximum pres sure error persists even after disconnecting every grease line in turn the blockage resides in the block itself Disas semble the block and clean it internally Other fault codes Remedy the indicated malfuntion Remark A programming and read out unit GINA is used to program and read out the control unit The GINA can also be used to consult a list of faults that have occurred and were stored in the memory of the control unit If the sys tem features a signal light in the cabin the stored fault codes can also be viewed with the aid of this signal li
30. ation number of the person who most recently connected a GINA to this control unit ATTENTION This number is overwritten when the GINA is switched off with your own indification number The screen shows the date and time at which a GINA has most recently been connected with this control unit ATTENTION This date and time will be updated when you switched off the GINA The screen shows the identification number of the person who most recently changed any settings of this control unit ATTENTION This number will be over written with your own identification number when you switch off the GINA provided you have changed at least one setting The screen shows the date and time at which the settings of this control unit were most recently changed ATTENTION This time and date will be updated when you switch off the GINA provided you have changed at least one setting The Gina 31 Automatic Greasing System TRIPLUS INFO Software version Prog unit XXXX p s p ui acces Press lt F2 gt p uil INFO User ID Prog unit XXXX p s p ui acces Press lt F3 gt acces INFO Authorisation level xxx Device 7 ald7 ald8 Press lt F2 gt ald8 INFO Authorisation level xxx Device 8 ald7 ald8 Press lt NEXT gt INFO Software version Prog unit XXXX p s p ui acces Press lt NEXT gt text vers xxxx78002 September 1997 The Gina The screen shows the version number of the software i
31. be greased by hand Regularly checks of the greasing system Check the following points of the TRIPLUS greasing system 1 The grease level in the reservoir of the pump unit refill on time 2 The pump unit for damage and leakage 3 The operation of the whole greasing system Perform a test cycle for every grease output port of the pump unit Retrieve the fault codes stored in the control unit either by using the test pushbutton on the pump unit or by con necting a GINA to the control unit 4 The primary and secondary grease lines for damage and leakage 5 The grease points collar of fresh grease should be present at all grease points Maintenance EG1603P01 9007 4940390 anss Jo med Date of issue October 2006 Automatic Greasing System TRIPLUS 7 3 Filling the grease reservoir When the grease in the reservoir reaches its minimum level the reservoir needs to be refilled To facilitate this the pump unit is fitted with a grease nipple onto which a garage grease pump can be placed To be able to fill the reservoir using a special filling pump a special filler coupling can be installed Groeneve d can supply you with both mobile or stationary hand operated or pneumatic filling pumps Figure 7 1 Filling the reservoir with a garage grease pump Filling procedure The grease pump must be suitable for class 2 grease First fill the filling hose with grease if the filling pump or grease barrel is new This pre
32. bout the oper ation of the greasing system through a signal light which is installed on the dashboard in the cabin The physical form of the signal light may vary but it is always in stalled so that is easily visible Figure 3 4 The signal light Description components EG1603P01 9007 4990390 anss Jo med Date of issue October 2006 Automatic Greasing System TRIPLUS The signal light produces the following signals 1x3 seconds on 5 seconds after switch The supply voltage for ing on contact the control unit is avail able and the signal light is OK 1x2 minutes on After completion of a An error occurred during pump phase the pump phase Pre cisely which error occur red can be determined by using the test push button Repeatedly 1 x 0 3 sec After momentarily press A test cycle is being per onds on followed by a ing the test pushbutton formed via grease out pause of 2 seconds once put port 1 The signal light indicates the fault codes by blinking The decades of the fault code long pulses 0 5 seconds The units of the fault code short pulses 0 15 seconds There is a two second pause between successive fault codes For example if the fault codes 13 and 22 are displayed you will see the blink codes long short short short fault code 13 two second pause long long short short fault code 22 two second pause Each fault message has been assigned a two digit fault cod
33. counts down till 0 which is the moment the filter gets active and possible over pressure relieve valve openings will be ignored by the program The Gina 41 Automatic Greasing System TRIPLUS VARIABLES hh mm ss Remainder cycles empty XXX rbrk rev rerr rcem Press lt NEXT gt VARIABLES hh mm ss Remainder cycles end line XXX rcel Press lt NEXT gt DIAGNOSIS MENU err I O var tinfo Press lt F4 gt tinfo DIAGNOSIS MENU pdif hist Press lt F1 gt pdif PRODUCTION INFO Part number XXXXX prno srno tive Press lt F2 gt srno PRODUCTION INFO Serial number XXXXXXXXXX prno srno tive 42 The Gina The screen shows the remaining revolutions of the drive shaft after the first empty reservoir warning until the reserve of grease 400cc 4000 revolutions is been used The screen shows the remaining number of pulses of the end switch during a pump phase to avoid an error The screen shows the part number of the control unit PCB The screen shows the serial number of the control unit PCB EG1603P01 9007 1 q0V0 anss Jo med Date of issue October 2006 Automatic Greasing System TRIPLUS Press lt F3 gt tive PRODUCTION INFO The screen shows a version number which denotes both the software version and the Timer version type of hardware present XXX prno srno tive Press lt NEXT gt DIAGNOSIS MENU pdif hist Press lt F2 gt hist The screen shows the tota
34. creen shows the number of greasing cycles in which the grease level switch in the reservoir reported a low grease level The screen shows the number of greasing cycles during which the pump was discon nected by the control unit because its drive shaft rotated too slowly or not at all The Gina 37 Automatic Greasing System TRIPLUS ERRORS End line switch XXXXX end1 eres pol Press lt F2 gt eres ERRORS Empty reservoir XXXXX end1 eres pol Press lt F3 gt pol ERRORS Pump open load XXXXX end1 eres pol Press lt F4 gt lol ERRORS Lamp open load XXXXX end1 eres pol Press lt NEXT gt ERRORS Lamp over current XXXXX loc Press lt NEXT gt 38 The Gina lol lol lol lol The screen shows the end switch in the greasing system connected to the output port did not send any or not enough pulses to the control unit The screen shows the number of cycles which are not progressed because of the empty reservoir After the first empty reservoir warning the control unit calculates how many cycles can be progressed with the available grease in the reservoir After those number of cycles without filling the reservoir the pump stops with greasing only the errors are counted The screen shows how many times the short circuit in circuit of the electric pump motor has been occured The pump phase has been cut short The screen shows how many times open load in the signal light cir
35. cuit has been occured The screen shows how many times over current in the signal light circuit has been occured EG1603P01 9007 4990390 anss Jo med Date of issue October 2006 Automatic Greasing System TRIPLUS DIAGNOSIS Pending errors 1 0 0 0 0 poc loc pol lol Press lt NEXT gt DIAGNOSIS Pending errors 2 0 0 0 0 rdgr rto end1 eres Press lt NEXT gt DIAGNOSIS MENU err 1 0 var tinfo Press lt F2 gt I O EG1603P01 The screen shows four pending errors 0 did not occur 1 occurred poc short circuit in circuit of the electric pump motor during the last pump phase The pump phase has been cut short loc short circuit in the signal light circuit during the last pump phase pol open load in circuit of electric pump motor during the last pump phase lol open load in the signal light circuit during the last pump phase The screen shows four pending errors 0 did not occur 1 occurred rdgr relief valve activated during the last pump phase rto the drive shaft of pump turns too slowly or not at all during the last pump phase The pump phase has been cut short end1 the end switch in the greasing system did not send any or not enough pulses to the control unit during the last pump phase eres reservoir is empty the reserve of grease 400cc 4000 revolutions after the first low level warning is expired The pump is discon nected and the signal lamp lits The
36. e 10 No error on this moment 11 Distribution block monitoring switch has not switched 12 Relief valve activated during a pumpphase in output port 1 maximum grease pressure exceeded 15 Grease reservoir is empty The pump did not complete the programmed number of 21 c S revolutions within the set time 22 Pump motor open load 23 Pump motor eliminated during pump phase concerning a too high flow usage 33 Signal light open load 34 Signal light short circuit in wiring or lampfitting 35 Short circuit components or wiring called in of above EG1603P01 Description components 21 22 Automatic Greasing System TRIPLUS 3 8 3 8 1 3 8 2 The distribution blocks Properties TRIPLUS distribution blocks distribute the grease to the various grease points and meter out the amount of grease that goes to each individual grease point They do so in a progressive sequential way The progressive distribution blocks in the greasing system distribute the grease to the grease points one grease point at a time and one grease point after another Progressive distribution blocks can be placed in series in which case an output of a block is used to feed the next block in line through a primary grease line Composition A progressive distribution block comprises the following components 1 astart segment 2 an end segment 3 atleastthree doser segments The doser segment
37. educed wear of the greased components due to accurate and constant greasing e ess repair and replacement costs e less unnecessary down time less loss of production EG1603P01 Introduction 10 Automatic Greasing System TRIPLUS Notes Introduction EG1603P01 9007 4940390 anss Jo aeg Automatic Greasing System TRIPLUS GENERAL INFORMATION 900Z 43gopo onss jo med GROENEVELD your efficiency is our challenge 11 General information EG1603P01 12 Automatic Greasing System TRIPLUS 2 1 2 2 Introduction With an automatic greasing system of Groeneve d all grease points of a vehicle or machine are lubricated automatically at the correct moment and with the correct amount of grease Because greasing takes places while the vehicle or machine is in operation the applied grease is spread optimally over the whole surface to be greased The greasing system requires no user intervention to operate apart from periodically replacing the grease in its reservoir Groeneveld s automatic greasing systems are designed with the utmost care and tested rigorously This guarantees an extended operational life and error free operation even under the most extreme operating conditions Proper installation using the correct type of grease and periodic checks are prerequisites for the continual hassle free operation of the system The periodic checks which take little time and effort can be performed during
38. er with the grease lines e Connect the trailer pump to the braking lights supply wire and ground potential do not exchange these connections Make the connection in a waterproof junction box on the trailer and ensure the cable is fed into the junction box properly watertight If required mount an extra swivel onto the junction box Fuse ratings 12 Vdc 15A 5A 24 Vdc 7 5 A 5A EG1603P01 Installation 65 66 Automatic Greasing System TRIPLUS 6 8 3 Pin layout of the connector on the pump unit Stoplight Ground 31 n a Signal light n a K line communication with the GINA n a ooi dl Ol ul BI WwW N End switch for output port 1 Installation EG1603P01 9007 4940390 anss Jo med Automatic Greasing System TRIPLUS 6 8 4 Wiring diagram Pump unit Revolution sensor Relief valve Test pushbutton Minimum grease level switch Control unit Pump motor End distribution switch Signal light Stoplight 8 Pole connector Battery CONAUM PWNS dh _ dh T End pressure switch we Figure 6 1 Wiring diagram Date of issue October 2006 EG1603P01 Installation 68 Automatic Greasing System TRIPLUS 6 9 6 10 De aerating of the greasing system The greasing system can be de aereted in three different ways Method 1 This method can be used when a pneumatic greasing system is
39. fix grease lines e Never add extra grease points on your own accord The integrity of certain structures may be adversely affected by drilling holes Always adhere to the relevant directives issued by the vehicle s manufacturer If a vehicle specific greasing plan is available the types or combination of cou plings to be used at grease point will have been noted on that plan First remove the existing grease nipple at the grease point and replace it by the required coupling s If the grease point to be connected is a so called added grease point a hole must be drilled and the right thread tapped Do not forget to clean the new hole of any debris Mount the required coupling s onto the grease point see the greasing plan Make sure that elbow couplings point in the direction of the grease line avoid unnecessary sharp corners in the grease line ATTENTION Always check that the newly drilled grease point is open by applying a hand operated grease gun to it 1 Determine the most suitable route for the composite grease line to the grease line s Cut the grease line at roughly the required length 3 Determine approximately the required length of the individual grease lines in a composite polyamide line Make absolutely sure that you do not dam age the individual grease lines 4 Strip and remove the outer jacket 5 Fix the line in place with tie wraps or clamps up to the coupling at the grease point 6 C
40. for instance whether the vehicle or machine is capable of supplying the greasing system with an uninterrupted power supply voltage 15 or 30 e The number of greasing points to be served and the layout of the greasing system e The specific wishes the user may have concerning the greasing system The following pump unit types are available e The TRIPLUS pump units with 1 2 or 3 independent grease output ports e The TRIPLUS trailer pump unit with 1 grease output port The TRIPLUS pump units are usually applied on pulling vehicles trucks TheTRIPLUS trailer pump units are primarily meant for use on pulled vehicles trailers Mounting the pump 1 If the projected location for the pump unit is not indicated on a vehicle specific greasing plan determine in consultation with the client the most suitable location of the pump unit on the vehicle Take account of s The pump unit must be easily accessible for filling its grease reservoir e The grease level in the reservoir must be easy to inspect visually e The pump unit must be protected against possible damage 2 First investigate whether existing mounting holes in the chassis of the vehicle can be used to mount the mounting plate of the pump unit Always follow the directions of the vehicle s manufacturer when you need to drill new holes Do not let the mounting plate rest on the profile flange of the chassis and do not drill additional mounting holes in the flange in an effo
41. ght and the test pushbutton on the pump unit EG1603P01 Maintenance 73 74 Automatic Greasing System TRIPLUS Notes Maintenance EG1603P01 9007 4940390 anss Jo aeg Automatic Greasing System TRIPLUS TECHNICAL DATA Ymm ve Mi A AK cer 9007 43gopo onss jo med GROENEVELD your efficiency is our challenge 75 Technical data EG1603P01 Automatic Greasing System TRIPLUS 8 1 TRIPLUS trailer pump unit Maximum operating pressure 250bar Operating temperature 1 20 85 C Supply voltage either 12 or 24 Vdc Rating pump motor nominal at 20 C 36 W Rest current 10 mA Capacity grease reservoir standard 3 litres Minimum level switch standard l hard anodised aluminium nylon Pump material reinforced Delivery pump output 0 1 cc per stroke Protection class IP67 for lower part of pump unit Grease types NLGI 2 Other grease reservoirs are available on request Depending on the ambient temperature consult your grease supplier Figure 8 1 Dimensions of the TRIPLUS trailer pump with 3 litre reservoir 76 Technical data EG1603P01 900Z 4940390 anss 10 aeg Date of issue October 2006 Figure 8 2 Automatic Greasing System TRIPLUS Distribution blocks Maximum operating pressure Operating temperature Minimum number of doser segments Maximum number of doser segments Material Material O rings Grease inlet port th
42. gnal light defec tive Check the fuse and if reguired replace the fuse Check the ground con nection and if required repair it Replace the bulb Check the wiring and if required repair it Signal light lights during 2 minutes after a pump phase has been con cluded 1 Minimum level in grease reservoir reached 2 System is malfunction ing Fill the reservoir Retrieve the fault codes with the test pushbut ton or the GINA and repair the system All grease points con nected to one of the grease output ports of the pump unit are too dry but no malfunction is indicated The interval pause phase or pump phase for this grease output port is not set correctly for the current applica tion Set a shorter interval or lengthen the pump phase for this output port of the pump unit Too much grease has been applied to all grease points The interval pause phase or pump phase for this grease output port is not set correctly for the current applica tion Lengthen the interval or set a shorter pump phase for this output port of the pump unit One or more grease points are to dry while others received the cor rect amount of grease Maintenance Improper composition of the distribution blocks Change the composi tion of the distribution blocks EG1603P01 9007 4990390 anss Jo med Date of issue October 2006 All grease points are too dry
43. h EG1603P01 Installation 61 62 Automatic Greasing System TRIPLUS Press couplings applied with a hydraulic press for high pressure mik line DN6 00817 wip g Check that the press is fitted with the correct type of press blocks and the set press diameter The correct press diameter for this type of grease line is 14 6 mm Slide the sleeve over the end of the grease line until it covers the line com pletely Slide use some oil if necessary the pillar or the required coupling pin into the end of the grease line until the pillar is completely in the grease line Pull the sleeve back slightly until it touches the outside edge of the cou pling pin While doing this ensure that the pillar remains in place and is not pressed out of the grease line Place the assembly into the press and press the sleeve to the required diameter 14 6 mm Check the resulting diameter by measuring it between ridges that may have formed Mount the coupling at the other end of the grease line in a similar way Remove any burrs and other remnants produced by cutting the line and clean the grease line by blowing it through Check that the line is free of obstructions and check it for internal damage behind the couplings the inner lining may have been upset Fill the line with grease Either use a pneumatic or hand operated grease gun Install the grease line and fix it in place with tie wraps or clamps Do not yet connec
44. ing system In this manual the following icons are used to inform or warn the user ATTENTION Draws the user s attention to important information meant to avoid prob lems WARNING Warns the user for physical injuries or serious damage to the equipment caused by improper actions EG1603P01 9007 4940390 anss Jo med Automatic Greasing System TRIPLUS INTRODUCTION G 9007 43gopo onss jo med GROENEVELD your efficiency is our challenge Introduction EG1603P01 Automatic Greasing System TRIPLUS 1 1 1 2 Introduction This chapter offers a short presentation of Groeneveld Transport Efficiency and the products supplied by us Furthermore a description of the TRIPLUS automatic greasing system is provided GROENEVELD Transport Efficiency B V Investing in operational safety Based on this idea Groeneve d was founded in 1971 The already international network is managed from the head office in Gorinchem The Netherlands Groeneveld aims at further expansion of this leading position which was realized thanks to the solid image and a customer oriented working method Groeneveld employees form a dedicated team that works with daily enthusiasm to satisfy the customer s needs Far reaching automation enables a high working rate The ISO 9001 standard forms the basis for guaranteed quality of Groeneveld products Frequent contact with the relations and an extensive dealer network guarantee Groeneveld s go
45. ircuit in the signal light circuit before it disconnect the signal light The default is 10 ms and value should not be changed The screen shows the number of grease cycles within at least 1 pulse of the end block switch optional must been received to prevent an error The setting should be 0 when no end switch is installed If necessary change this setting and confirm with lt ENTER gt EG1603P01 9007 4990390 anss Jo med Date of issue October 2006 Automatic Greasing System TRIPLUS 4 7 Diagnosis menu Press lt diagnosis gt DIAGNOSIS MENU err 1 0 var tinfo Press lt F1 gt err ERRORS Pump over current XXXXX poc rdgr lowl rto Press lt F2 gt rdgr ERRORS Release during grease XXXXX poc rdgr lowl rto Press lt F3 gt lowl ERRORS Low level XXXXX poc rdgr lowl rto Press lt F4 gt rto ERRORS Revolution time out XXXXX poc rdgr lowl rto Press lt NEXT gt EG1603P01 The diagnosis menu shows various pieces of information concerning the current status of the greasing system such as error messages and the status of its input and output signals The screen shows the total number of times an overcurrent or short circuit has been detected in the circuit of the electric motor of the pump unit The screen shows the total number of time the relief valve in the pump unit activated itself because the maximum grease pressure was exceeded during a pump phase The s
46. is menu by pressing respectively lt MAIN gt lt PARAMETERS gt or lt DIAGNOSIS gt This message appears when the GINA is unable to communicate with the control unit Communication error This can be cause by s bad connection wire in cable broken or bad connector e GINA switched on too quickly Always try to alleviate the problem first by turning the GINA off and then on again or by pressing one of the softkeys lt F1 gt lt F2 gt lt F3 gt or lt F4 gt EG1603P01 The Gina 29 30 Automatic Greasing System TRIPLUS This message appears ifthe control unit is not supported by this GINA DEVICE NOT SUPPORTED You need another GINA to access this control unit The Gina EG1603P01 9007 4940390 anss Jo med Date of issue October 2006 Automatic Greasing System TRIPLUS 4 5 The Main menu Press lt main gt MAIN MENU info time contr Press lt F1 gt info INFO User ID last access XXXXXX u ac d ac u ch d ch Press lt F2 gt d ac INFO Time amp date last access XX XX XX XX XX u ac d ac u ch d ch Press lt F3 gt u ch INFO User ID last change xxxxxx u ac d ac u ch d ch Press lt F4 gt d ch INFO Time amp date last change XX XX XX XX XX u ac d ac u ch d ch Press lt NEXT gt EG1603P01 The main menu contains various data about the GINA and the control unit that is connected You can change only some of the data The screen shows the indific
47. is should not be changed The Gina 35 Automatic Greasing System TRIPLUS Press lt NEXT gt PARAMETERS TIMER Max release errors xxx mre poct loct endi Press lt F2 gt poct PARAMETERS TIMER Pump oc time xxx msec mre poct loct endi Press lt F3 gt loct PARAMETERS TIMER Lamp oc time xxx msec mre poct loct endi Press lt F4 gt end1 PARAMETERS TIMER End line switch xxx cycles mre poct loct endi The Gina The screen shows a filter period in of the total pumping phase in which a possible opening of the over pressure relieve valve will be ignored by the program The maximum setting is 50 calculated from the end of the pumping phase which means that during the second half of the pumping phase valve openings will be ignored The standard setting is 25 ignoring possible valve openings during the last 1 4 of the pumping phase Openings during the first 3 4 will cause a release during grease rdg error and trigger the lamp for the rest of the pumping phase If necessary change this setting and confirm with lt ENTER gt The screen shows the amount of time in milliseconds the control unit tolerates an overcurrent or short circuit in the electric motor of the pump before it disconnect the electric motor The default is 50 ms and value should not be changed The screen shows the amount of time in milliseconds the control unit tolerates an overcurrent or short c
48. l number of HISTORY correct executed greasing cycles The Total cycles number of in correct cycles can be found in XXXXXXXX the error menu tcy tbrk tpt skrv Press lt F2 gt tbrk The screen shows the total number of brake HISTORY commands received That number coincides Total brake pulses with the number of times that the EEPROM XXXXXXXX has been overwritten tcy tbrk tpt skrv Note When the interval between two stoplight pulses is shorter than 5 seconds the second pulse will be ignored by the program Press lt F3 gt tpt HISTORY The screen shows the total pumping time of E the pump unit Total pumping time XXXXX tcy tbrk tpt skrv Press lt F4 gt Skrv EG1603P01 The Gina 43 44 Automatic Greasing System TRIPLUS HISTORY Skipped revolutions XXXXX tcy tbrk tpt skrv The screen shows the total number of revolutions of the drive shaft of the pump that were skipped during all pump phases All programmed revolutions that were not completed during the previous pump phase are added to this counter when the next pump phase begins If the counter reaches a value higher than about 20 of the total programmed revolutions number of greasing cycles multiplied by the programmed number of revolutions per cycle the greasing interval has been set too short or the number of revolutions per cycle output of the pump in cc has been set too high All screens have now been visited If you have completed
49. lines connected with table 3 s The diameter of the lines e The length of the lines e The NLGI class of the grease used e The ambient operating temperatures 9007 4940390 anss Jo aeg Ball or roller bearing 5 bar Slide bearing 15 bar 50 Designing a system EG1603P01 Date of issue October 2006 Automatic Greasing System TRIPLUS Table 1 Outputs of doser segments 2 x 0 045cc 0 090cc 125 2 x 0 125cc 0 250cc 2 x 0 200cc 0 400cc Table 2 Internal resistance in a distribution block bar NLGI 2 20 14 bar 16 bar 22 bar 10 28 bar 24 bar 26 bar 0 34 bar 44 bar 55 bar 10 52 bar 58 bar 72 bar 15 73 bar 77 bar 100 bar 20 80 bar 85 bar 170 bar Table 3 Grease line resistance bar per metre Remark The values in these tables were collected during laboratory and field tests and will be supplemented as new data becomes avialable EG1603P01 Designing a system 51 Automatic Greasing System TRIPLUS 5 3 Method 1 Determine the conditions under which the system must be able to operate 2 Make a so called greasing plan 3 Indicate in the greasing plan the grease demand and greasing interval required by each grease point 4 Compile the greasing points in groups 5 Determine the required layout of the greasing system 6 Check by calculation whether the s
50. n block then arrives back at its starting off point and the cycle will repeat as long as there is pressure in the primary grease line Description components 23 24 Automatic Greasing System TRIPLUS 3 8 4 3 8 5 3 8 6 Remark The description and illustration above assume there is a fixed starting off point for the doser segments in the distribution block This is not so The dis tribution block always continues from where it left off during the previous pump phase of the grease cycle WARNING To be able to operate at all a distribution block needs to have at least three doser segments Non return valves Non return valves are installed in the outputs of the distribution block to prevent lubricant from flowing back into the distribution block All output ports to which primary lines are connected or which are used to interconnect distribution blocks must be fitted with non return valves Output ports which secondary grease lines are connected must be fitted with non return valves if significantly different return pressures are expected at different output ports Failure of one of the doser segments If one of the doser segments fails to operate properly due to internal or external damage the whole greasing system will fail to operate Closing outputs An output may only be closed off after removal of the little plug that seperates the two outputs of a doser segment Removing the plug allows the grease meant for
51. n the pump unit and the distribution blocks and interconnecting the distribution blocks themselves 4 Secondary grease lines between the distribution blocks doser segments and the individual grease points General information EG1603P01 900Z 4940390 anss 10 aeg Date of issue October 2006 Automatic Greasing System TRIPLUS Figure 2 1 System overview Two types of pump units are available e The TRIPLUS pump e The TRIPLUS trailer pump The TRIPLUS pump is applied when the supply voltage needed to power the greasing system is always available while the vehicle or machine is in operation The TRIPLUS trailer pump is used on pulled vehicles where the supply voltage will not always be available EG1603P01 General information 14 Automatic Greasing System TRIPLUS Notes General information EG1603P01 9007 4940390 anss Jo aeg Automatic Greasing System TRIPLUS DESCRIPTION COMPONENTS 9007 43gopo onss jo med GROENEVELD your efficiency is our challenge 15 Description components EG1603P01 16 Automatic Greasing System TRIPLUS 3 1 Properties The Groeneveld TRIPLUS trailer pump is designed specifically for use on machines and pulled vehicles on which a supply voltage for the greasing system is not al ways available while the vehicle trailers or machine is in operation The trailer pump unit features an integrated control unit The most significant properties of the TRIPLUS
52. n this GINA The screen shows the identification number of the registered user of this GINA The screen shows the access level of the control unit GINA in the TRIPLUS program truck version device 7 You cannot change this setting The screen shows the access level of the control unit GINA in the TRIPLUS program trailer version device 8 You cannot change this setting The screen shows the version number of the software in this GINA The screen shows the version number of the display texts in the software of the GINA EG1603P01 9007 1 q0V0 anss Jo med Date of issue October 2006 Automatic Greasing System TRIPLUS Press lt MAIN gt MAIN MENU info time contr Press lt F2 gt time TIME Enter hours XX hrs min Press lt F2 gt min TIME Enter minutes XX hrs min Press lt NEXT gt DATE Enter day XX day mnth year Press lt F2 gt mnth DATE Enter month XX day mnth year Press lt F3 gt year EG1603P01 The main menu contains various data about the GINA and the control unit that is connected You can change only some of the data The screen shows the hours of the current date and time You can change this setting with the numeric keys Confirm the new setting with lt ENTER gt The screen shows the minutes of the current date and time You can change this setting with the numeric keys Confirm the new setting with lt ENTER gt As soon as you pres
53. nd bolts of the distribution blocks Tighten the bolts alternately and evently Maximum tightening moment 5 Nm Installation EG1603P01 900Z 4940390 anss 10 aeg Date of issue October 2006 Automatic Greasing System TRIPLUS 6 6 6 6 1 6 6 2 Primary grease lines and couplings Grease line types The primary grease lines are those between the pump unit and the distribution blocks and between the distribution blocks themselves The primary grease lines are available in a number of different sizes and materials e Flexible high pressure line DN4 inside diameter 4 0 mm outside diameter 9 7 mm e Flexible high pressure line DN6 with steel wire armour inside diameter 6 0 mm outside diameter 12 0 mm e Metal lines with sizes 6 x 1mm or 8 x 1 mm The type of primary grease line most commonly used in the transport industry is the flexible high pressure line DN4 This high quality line combines compactness with high strength and flexibility Mounting the primary grease lines To limit the loss of pressure in the system particularly at low temperatures the length of the system of grease lines should be as short as possible Please take ac count of this especially when you decide to re route a grease line 1 Determine the required length of the grease line to be installed and cut it to that length 2 Mount the couplings onto the line with high pressure lines Removable couplings a Clamp the sleeve in a
54. od reputation We know what today s entrepreneur needs not a ready made product but a custom built solution for automating daily maintance New techniques offer new applications Therefore Groeneveld has a large budget for developing new cost reducing products Our own Research and Development department cooperates with prominent external organizations but also with leading manufacturers of vehicles and machines Besides the TRIPLUS automatic greasing system Groeneveld also supplies products like temperature registration systems board computer systems speed limiters automatic oil level regulator reversing security systems Groeneveld supplies a complete program of cost reducing and comfort enhancing products gI Figure 1 1 Head office Groeneveld Introduction EG1603P01 9007 4990390 anss Jo ajeq Date of issue October 2006 Automatic Greasing System TRIPLUS 1 3 TRIPLUS automatic greasing system Groeneveld s automatic greasing systems take care of the daily maintenance of anything that has moving parts These systems prevent unnecessary wear and down time and thus reduce exploitation costs and guard against annoying costly unexpected problems Groeneveld s automatic greasing systems are applied in among other fields manufacturing off the road vehicles agriculture and the off shore and transport industries The most important advantages e longer maintenance intervals less unnecessary down time e r
55. on as follow 1 The supply voltage for the pump unit must be available brakes on 2 Press the test pushbutton momentarily not longer than 1 second one time 3 The test cycle starts two seconds after you pressed the test pushbutton During the test cycle the signal light will blink at a particular frequency Any errors that occur during the test cycle will not be indicated by the signal light and will not be stored in the memory of the control unit Retrieving fault messages In the memory of the control unit information is stored about the operation of the greasing system Two categories of fault messages can be distinguished 1 Pending errors errors that were detected since the control unit was switched on last from the moment the supply voltage became available 2 Stored errors all errors that were detected by the control unit in the past All new errors that occur will be stored as pending errors If the control unit is switched off all pending errors will be added to list of stored errors and the list with the pending errors will be erased Retrieving fault messages The fault messages stored in the control unit s memory can be retrieved by keeping the test pushbutton on the pump unit depressed for at least five seconds Seven seconds after you released the test pushbutton the signal light will start producing the blink codes to indicate the stored errors The signal light The driver or operator will be informed a
56. operly Check again with the GINA whether the various input signals of the control system e g the extra control voltages S1 and S2 sensors and switches are received prop erly To do this check the read outs in the DIAGNOSIS IO screens 4 and 5 while switching the relevant input signals ATTENTION If the system has a TRIPLUS trailer pump it is required that the brake lights of the vehicle are lit during the test cycle s otherwise the pump unit would be without a power supply Installation EG1603P01 9007 4940390 anss Jo med Automatic Greasing System TRIPLUS MAINTENANCE 900Z 43gopo onss jo med GROENEVELD your efficiency is our challenge 69 Maintenance EG1603P01 70 Automatic Greasing System TRIPLUS 7 1 7 2 General The maintenance of Groeneveld s TRIPLUS systems can be combined with the nor mal maintenance of the vehicle or machine WARNING If a high pressure steam water jet is used to clean the vehicle or machine the pump unit of the greasing system should not be directly exposed to the jet This to prevent water from entering the pump unit through its de aer ating opening During normal operation however water will never be able to enter the pump unit ATTENTION The automatic greasing system reduces the time and effort spent on manual greasing significantly However do not forget that there may be grease points that are not served by the greasing system and must still
57. read Delivery per output type 45 two per segment Delivery per output type 125 two per segment Delivery per output type 200 two per segment EG1603P01 250bar 1 20 85 C 3 excluding start and end segments 12 excl start and end segments galvanised steel NBR M10 x 1mm 0 045 cc 10 125 cc 10 200 cc Dimensions of the distribution block Technical data 77 78 Automatic Greasing System TRIPLUS Notes Technical data EG1603P01 9007 4940390 anss Jo aeg Groeneveld Australia Pty Ltd 18 20 Mc Dougall Road P O Box 787 Sunbury Vic 3429 AUSTRALIA Tel 61 397 4099943 Fax 61 397 4099665 Groeneveld Belgium NV SA Industriezone Hogenakkerhoek Heirbaan 3 B 9150 Kruibeke BELGIUM Tel 32 3 8979860 Fax 32 3 8979861 Groeneveld CPL Systems Canada Inc 7065 Twiss Road R R 3 LOP 1BO Campbellville Ontario CANADA Tel 1905 875 1017 Fax 1905 875 2125 Groeneveld Deutschland GMBH Bullermanshof 2B 47441 Moers H lsdonk DEUTSCHLAND Tel 49 2841 793520 Fax 49 2841 7935222 Groeneveld France 53 rue Antoine Condorcet 38090 Vaulx Milieu FRANCE Tel 33 4 74999333 Fax 33 4 74999350 Groeneveld France IT 53 rue Antoine Condorcet 38090 Vaulx Milieu FRANCE Tel 33 4 74999333 Fax 33 4 74999350 GINTEC Active Safety Ltd 49 Hasharoshet 1st Karmiel 20101 ISRAEL Tel 972 4 9882220 Fax 972 4 9883179
58. rt to fix the mount ing plate even more securely Be sure not to damage anything e g lines or air tanks that may be present behind the part in which you drill a hole After drilling a hole always remove the chips with compressed air or brush 3 If the mounting plate is to be welded onto the vehicle the directions of the vehicle s manufacturer should be strictly adhered to Mount the mounting plate with the pump unit onto the chassis Remove the yellow red transport plugs from the grease output port and the de aerating opening of the pump unit 6 Mount the couplings for the primary grease line onto the output port of the pump unit wie Installation EG1603P01 9007 4990390 anss Jo aeg Date of issue October 2006 Automatic Greasing System TRIPLUS 6 5 TRIPLUS distribution blocks 6 5 1 General The composition of a progressive distribution block is always vehicle machine specific If the distribution blocks are part of an installation kit the secondary grease lines and the couplings for the primary grease lines to the pump unit or main distribu tion block will usually have already been mounted onto the distribution blocks If the blocks are not part of an installation kit and have not been pre assembled you should mount the grease lines and couplings before you mount the distribu tion block onto the vehicle or machine 6 5 2 Assembling distribution blocks The distribution block must be assembled before i
59. s lt ENTER gt the seconds will start running at zero The screen shows the day of the month of the current date and time You cannot change this setting The screen shows the month of the current date and time You cannot change this setting The Gina 33 34 Automatic Greasing System TRIPLUS DATE Enter year XX day mnth year Press lt MAIN gt MAIN MENU info time contr Press lt F3 gt contr MAIN MENU Adjust contrast The Gina The screen shows the year of the current date and time You cannot change this setting The main menu contains various data about the GINA and the control unit that is connected You can change only some of the data The contrast of the display may be increased or decreased in this screen Press lt F1 gt to lower the contrast or lt F4 gt to raise it EG1603P01 9007 4940390 anss Jo med Date of issue October 2006 Automatic Greasing System TRIPLUS 4 6 Parameters timer The parameters timer menu contains the parameter settings for the grease cycle You can view and or change these parameters provided you have the correct ac cess level Press lt parameters gt PARAMETERS TIMER Delivery xxx X cc del rdiv cbp psdt Press lt F2 gt rdlv PARAMETERS TIMER Rotation delivery x XX cc r del rdiv cbp psdt Press lt F3 gt cbp PARAMETERS TIMER Cycle brake pulses XXXXX del rdiv cbp psdt Press lt F4 gt psdt
60. s to be deliverable in several versions with several amounts quantity of grease which by cycle it is supplied By several doser segments in a distribution block combine can a certain partitioning of the grease be obtained Figure 3 5 o Distribution block Each doser segment always has two grease output ports with identical grease out puts per cycle The grease channels between the segments are sealed by O rings and the segments are pressed together with two compression bolts Description components EG1603P01 9007 4940390 anss Jo med Date of issue October 2006 Automatic Greasing System TRIPLUS 3 8 3 Principle of operation
61. solve the problem After you have redesigned the system you should always recalculate its suitability Designing a system EG1603P01 9007 4990390 anss Jo aeg Automatic Greasing System TRIPLUS INSTALLATION cer 9007 43gopo onss jo med GROENEVELD your efficiency is our challenge 55 Installation EG1603P01 Automatic Greasing System TRIPLUS 6 1 Overview To install a Groeneve d TRIPLUS greasing system the following tasks must be per formed 1 2 3 4 5 6 Mounting the pump including the control unit Mounting the progressive distribution blocks Mounting the primary grease lines between the pump and the distribution blocks and between the distribution blocks themselves Mounting the secondary grease lines and couplings Mounting the electrical wiring Testing the system There are a few different types of pump unit available all with integrated control unit The type of pump unit most suitable for a particular greasing system can be determined on the basis of The type and model of the vehicle or machine on which the TRIPLUS system is to be installed An important discriminator is for instance whether the vehicle or machine is capable of supplying the greasing system with an uninterrupted power supply voltage 15 or 30 The number of greasing points to be served and the layout of the greasing system The specific wishes the user may have concerning the greasing system
62. t can be installed on the vehicle To ensure the reliability of the greasing system the distribution blocks should be assembled in a clean dust free environment The criteria that govern the composition number and type of doser segments of a distribution block are discussed in the Designing a system section of this manual 1 First study the drawing of the distribution block to be assembled 2 Check whether all required components are at hand and whether the right couplings for the right kinds of secondary grease line are available 3 Begin by placing the start segment to which the primary grease line will be connected onto the work bench with the port for the primary grease line fac ing downward 4 Place in the order as indicated on the drawing the various doser segments on top of the start segment Place the end segment on top of the stack Ensure that all the openings in the segments are line up and check that the required O rings have been correctly placed between all the segments 5 Place using two toothed spring washers the compression bolts through their respective holes Tighten the two bolts alternately and in phases allen key 5mm Tightening moment 12 Nm 6 If two output ports of a doser segment need to be combined remove allen key 2 5mm the little internal plug that seperates the two output ports The grease output of the port that remains open will then be double its normal output 7 Mount the couplings non
63. t installing them Even small contaminations can cause the greasing system to malfunction Flush the primary grease lines after installation or maintenance if contamina tions or moisture could not be prevented from entering the system The de aerating procedure may be used to flush the system During installation of the grease lines and electrical wiring ensure that e the lines are not mounted onto parts that may become hot such as the exhaust retarder compressor turbo charger and air conditioning e the lines are routed straight and neatly and are properly fixed in place with small or large tie wraps or clamps e the lines that are mounted along moving parts have enough slack and are mounted in such a manner that even in the long run they will not be damaged through abrasion or otherwise e the lines to moving parts are sufficiently long to follow the movements Check this by moving the parts to all positions possible e feed through rubbers are applied at all locations where the lines may otherwise get damaged Installation Automatic Greasing System TRIPLUS 6 4 6 4 1 6 4 2 TRIPLUS pump unit Pump types There are a few different types of pump unit available all with integrated control unit The type of pump unit most suitable for a particular greasing system is determined by e The type and model of the vehicle or machine on which the TRIPLUS system is to be installed An important discriminator is
64. t the primary grease line s to the output port s of the pump unit if you want to use the pneumatic or hand operated grease gun to de aerate the system ATTENTION Always use steel cutting rings when using metal grease lines and couplings Installation EG1603P01 9007 4940390 anss Jo med Date of issue October 2006 Automatic Greasing System TRIPLUS 6 7 6 7 1 Secondary grease lines and couplings Grease line types The secondary grease lines are the ones between the distribution blocks and the grease points These grease lines are connected to the grease points with the aid of special couplings A wide variety of couplings is available Which types of couplings should be applied depends among more things on The screw thread at the greasing point The position of the greasing point The direction from which the grease line approaches the grease point The type of grease line employed polyamide lines with brass or steel couplings metal lines or high pressure lines with steel couplings e The operation conditions The secondary grease lines can be supplied in a number of different sizes and materials e Polyamide lines with outside diameters of 3 16 or 6 mm standard e o Stainless steel lines with the outside diameters of 3 16 or 6 mm standard e Kunifer copper nickel lines with outside diameters of 3 16 or 6 mm standard e Flexible high pressure lines with inside diameters of 4 mm or 6 mm 1 4
65. ut the individual grease line to its required length and connect it with the coupling to the grease point a Installation EG1603P01 9007 4940390 anss Jo aeg Date of issue October 2006 Automatic Greasing System TRIPLUS 6 8 6 8 1 6 8 2 Electrical wiring General Detailed wiring diagrams are available as aids to install the electrical wiring Where possible pre assembled wire harnesses are employed ATTENTION To prevent damage to the electrical system of the vehicle or machine the correct fuses must be installed in power supply circuit 15 and 30 This does not apply to systems with a TRIPLUS trailer pump because those sys tems make use of the already adequately fused brake light circuit of the ve hicle Consult the wiring diagrams or the tables below for the correct fuse values On VLG vehicles special demands are placed on the components e g pump wiring and switches the location of the components on the vehicle the manner in which the greasing system is to be connected to the vehicle s electrical system Always verify whether the system you are installing and the methods you plan to use meet those demands s Install the wiring only after the main components of the greasing system have been mounted e g pump unit signal light monitoring switches on the distribution blocks e Try as far as possible to route the electrical wiring along the grease lines and fix the wiring in place togeth
66. vents air being introduced in the grease reservoir 1 Remove the dust cap of the filler coupling 2 Clean the filler coupling and the coupling on the hose thoroughly 3 Lock the hose onto the filler coupling or position the grease gun onto the filler coupling 4 Fill the reservoir up to its maximum level as indicated on the reservoir Never fill the reservoir any higher than the maximum level indicated otherwise the follower piston may become damaged 5 Remove the filling hose or grease gun 6 Clean the dust cap and the grease nipple or filling coupling with a clean rag Place the dust cap back onto the filler coupling Notes If the pumping action seems to go heavy check the filter behind the grease nipple or filling coupling on the pump unit Clean the filter and the grease nipple or filler coupling Also check the filling hose for obstructions and clean it Any air that may be introduced beneath the follower piston will escape through an opening at the top of the guide rod of the follower piston These air inclusions together with any excess grease will exit via the de aerating opening at the side on the pump unit EG1603P01 Maintenance 71 Automatic Greasing System TRIPLUS 7 4 Fault finding Signal light does not light up after contact was switched on 1 No supply voltage 15 on pin 1 or at signal light 2 No ground potential on pin 2 3 Signal light defective 4 Wiring to pump unit or to si
67. w the current time in their top right corner In the screens as reproduced in this manual this is indicated by hh mm ss Values are usually denoted to by a number of X signs with one x for every possi ble digit in the number The Gina EG1603P01 900Z 4940390 anss 10 aeg Date of issue October 2006 Automatic Greasing System TRIPLUS 4 2 4 3 4 4 Connecting the GINA The supply voltage of the control unit to be read or programmed must be available from the vehicle or an external power supply if need be Connect the GINA with the control unit using the supplied interconnection cable Control pad Key Function lt POWER ON OFF gt to turn the GINA on or off toggle lt F1 gt lt F4 gt soft keys to make a particular choice ina menu lt 0 gt lt 9 gt to enter numerical data lt MAIN gt to call the main menu to view miscellaneous information lt PARAMETERS gt to call the parameter menu to view and enter parameter data lt DIAGNOSIS gt to call the diagnosis menu to view various system data lt NEXT gt to go to the next screen in the menu system lt ENTER gt to confirm a setting you have changed or entered Switching on the GINA The GINA can be switched on after e the GINA has been connected with the control unit and e the power supply has been available to the control unit for at least 8 seconds Press lt POWER ON OFF gt You can access the main menu parameters timer and diagnos
68. yclinder 1 52 Designing a system EG1603P01 9007 4990390 anss Jo med Date of issue October 2006 Automatic Greasing System TRIPLUS 5 3 4 5 3 5 Group the grease points Compile groups of grease points taking account of the following e A main distribution block or multiple grease output ports on the TRIPLUS pump may be utilised e The maximum and minimum number of doser segments that can be combined in a single distribution block e The lengths of the primary and secondary lines in relation with the NLGI class of grease that must be used and the projected operating temperatures e Any special demands that might be placed on the grease output and the greasing interval Determine the layout of the system Note the positions of the pump unit and the distribution blocks on the greasing plan Determine the required composition of the distribution blocks based on the group of grease points to be connected with that block Indicate the routing of the grease lines on the greasing plan Take account of e The routing of the lines and the type of secondary grease lines that will be used single or composite lines with 2 to 3 seperate lines e The possibility to combine outputs of doser segments e The minimum 3 and maximum 12 number of doser segments that can be combined in a single distribution block Calculate the grease demand of the whole distribution block per whole cycle of the distribution block
69. ystem will be able to operate under the conditions determined during step 1 5 3 1 Determine the operating conditions Determine with which type and NLGI class of grease the system must be able to operate at the lowest ambient temperature expected 5 3 2 Produce a greasing plan Make a simplified layout drawing of the vehicle and or the machine Indicate the positions of the grease points on that drawing and number them 5 3 3 Determine the grease demand of the grease points Note the grease demand per particular period of each grease point in a particular period on the greasing plan The grease demand can be determined by combining the recommended amount and the recommended greasing frequency This infor mation can be extracted from e The maintenance instructions concerning the vehicle or machine e Existing greasing plans for class 0 or 2 grease systems e Information provided by the manufacturer importer dealer owner or maintenance personnel e The information in the table below Upper stub axle Stub axle single grease 2x3 point Lower stub axle 3 Automate piake 1 adjuster Suspension bearing 1 Suspension bearing 1 brake axle drum side brake adjuster side Upper stabiliser Lower stabiliser 1 Spring shackle 3 Rotation point of spring 3 Cabin bearing 1 Coupling disc pin 1 Coupling disc 2x4 Tail board hinge 1 Coupling disc rotation Suspension bearing l 1 z 1 point drive shaft Tail board c

General Manual Triplus trailer version

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