Groeneveld CompAlube Configuration guide

General Manual
CompAlube
Automatic greasing system
EG0105P02
your efficiency is our challenge

General information
Type of manual General Manual
System CompAlube Automatic greasing system
Manual number EG0105P02
Publication date September 2005
Revision 02
All rights reserved. No part of this manual may be copied and/or published by means of printing, photocopying,
microfilm or by any other means without prior written permission from Groeneveld. This applies also to the
drawings and diagrams appended.
Groeneveld reserves the right to change parts at any time, without prior or direct notice to the customer. The
contents of this manual may also be changed without prior notice.
This manual applies to the standard version of the product. Groeneveld cannot accept liability for any damage
arising from the use of specifications other than that supplied.
You are requested to contact Groeneveld technical service for information concerning adjustment, maintenance
work or repairs that is not described in this manual.
Whilst this manual has been prepared with the greatest possible care Groeneveld cannot accept responsibility for
any errors of the concequences of such errors.

CompAlube Automatic greasing system
Table of contents 3
Publication date: September 2005
EG0105P02
Foreword - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
1.1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
1.2. Groeneveld Transport Efficiency B.V. - - - - - - - - - - - - - - - - - - - - - - - - - - 8
1.3. Groeneveld greasing systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
1.4. Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
2. System description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
2.1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12
2.2. Main components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12
2.3. The CompAlube pump unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14
2.3.1. Pneumatic CompAlube with brake-counter - - - - - - - - - - - - - 14
2.3.2. Pneumatic CompAlube with integrated electronic timer - - - 15
2.3.3. Pneumatic CompAlube with integrated electronic timer - - - 16
3. Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
3.1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18
3.2. Control unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18
3.2.1. CompAlube with brake-counter - - - - - - - - - - - - - - - - - - - - - 18
3.2.2. CompAlube with electronic timer - - - - - - - - - - - - - - - - - - - - 18
3.3. Pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19
3.3.1. Plunger pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19
3.3.2. Gear pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20
3.4. Metering units - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21
3.4.1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21
3.4.2. Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21
3.5. Monitoring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 23
3.5.1. Grease-pressure indicator - - - - - - - - - - - - - - - - - - - - - - - - - - 23
3.5.2. Grease-pressure switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24
3.6. Test cycle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24
4. Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25
4.1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26
4.2. Performing a test cycle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26
4.2.1. Pneumatic CompAlube with brake-counter - - - - - - - - - - - - - 26
4.2.2. Pneumatic CompAlube with electronic timer - - - - - - - - - - - - 27
4.2.3. Electrical CompAlube with electronic timer - - - - - - - - - - - - - 27
4.3. Replacing the grease cartridge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28
4.4. Refilling through the filling connection - - - - - - - - - - - - - - - - - - - - - - - 31
4.5. Setting the greasing interval - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 32
4.5.1. CompAlube with brake-counter - - - - - - - - - - - - - - - - - - - - - 32
4.5.2. CompAlube with electronic timer - - - - - - - - - - - - - - - - - - - - 32
4.6. Venting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 32
1. q^_ib=lc=`lkqbkqp

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CompAlube Automatic greasing system
EG0105P02
5. Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -33
5.1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 34
5.2. General installation instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 34
5.3. Safety precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 35
5.4. Installation of the CompAlube pump unit - - - - - - - - - - - - - - - - - - - - - 36
5.4.1. The CompAlube pump unit - - - - - - - - - - - - - - - - - - - - - - - - - 36
5.4.2. Fitting the pump on the vehicle - - - - - - - - - - - - - - - - - - - - - - 36
5.5. Grease lines and couplings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 37
5.5.1. Fitting the grease lines and couplings - - - - - - - - - - - - - - - - - 38
5.5.2. Maximum grease line length - - - - - - - - - - - - - - - - - - - - - - - - 39
5.6. Pneumatic lines - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40
5.6.1. Pneumatic CompAlube with brake-counter - - - - - - - - - - - - - 40
5.6.2. Pneumatic CompAlube with electronic timer - - - - - - - - - - - - 41
5.7. Electrical cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 42
5.7.1. The pneumatic CompAlube with electronic timer - - - - - - - - - 42
5.7.2. The electrical CompAlube with electronic timer - - - - - - - - - - 42
5.8. CompAlube for lorries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 42
5.8.1. Pneumatic CompAlube with integrated brake-counter - - - - - 42
5.9. Venting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 43
5.9.1. The pneumatic CompAlube with brake-counter - - - - - - - - - - 43
5.9.2. The CompAlube with electronic timer - - - - - - - - - - - - - - - - - 44
5.9.3. Grease lines - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 44
5.10. Putting into service - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45
5.10.1. The pneumatic CompAlube with brake-counter - - - - - - - - - - 45
5.10.2. The pneumatic CompAlube with electronic timer - - - - - - - - - 47
5.10.3. The electrical CompAlube with electronic timer - - - - - - - - - - 48
6. Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -51
6.1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 52
6.2. Periodic check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 52
6.3. Trouble shooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53
6.3.1. Pneumatic CompAlube malfunctions - - - - - - - - - - - - - - - - - - 53
6.3.2. Electrical CompAlube malfunctions - - - - - - - - - - - - - - - - - - - 54
7. Technical specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -55
7.1. Pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 56
7.2. Metering units - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57
7.3. Maximum grease line length - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57
7.4. Brake-counter (pneumatic CompAlube) - - - - - - - - - - - - - - - - - - - - - - - 57
7.5. Electronic timer (pneumatic CompAlube) - - - - - - - - - - - - - - - - - - - - - - 57
7.6. Electronic timer (electrical CompAlube) - - - - - - - - - - - - - - - - - - - - - - - 57
7.7. Control lamp - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57
7.8. Pump dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58

CompAlube Automatic greasing system
Foreword 5
Publication date: September 2005
EG0105P02
1. FOREWORD
your efficiency is our challenge

Foreword6
Publication date: September 2005
CompAlube Automatic greasing system
EG0105P02
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. The system manual can also be used as user manual.
The manual comprises different sections, indicated with a chapter number. The
numbering of the illustrations starts anew at the beginning of each chapter.
Chapter 1, the introduction gives a description of Groeneveld and greasing systems
in general.
Chapter 2 describes the complete CompAlube greasing system.
Chapter 3 gives an insight into the operation of the system components.
In chapter 4, the operation of the greasing system is treated.
In chapter 5, the installation of the system is treated.
Maintenance is treated in chapter 6.
The manual concludes with chapter 7, which contains the technical specifications
of the CompAlube greasing system.
The folllowing pictograms are used in this manual to notify or warn the user:
Caution:
Notifies the user about important supplementary information, with the
purpose of avoiding problems.
WARNING
Warns the user if there is a danger of bodily injury or serious damage to the
equipment through incorrect actions/operation.

CompAlube Automatic greasing system
Introduction 7
Publication date: September 2005
EG0105P02
1.
1. INTRODUCTION
your efficiency is our challenge

Introduction8
Publication date: September 2005
CompAlube Automatic greasing system
EG0105P02
1.1 Introduction
This chapter contains a brief presentation of the Groeneveld Transport Efficiency
company and the products that we supply. In addition, a description of the
CompAlube Automatic greasing system is given.
1.2 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.
The people at Groeneveld form a team that works with great enthousiasm to
please its customers. A high level of automation allows rapid reactions. The ISO
9001 standard forms the basis for the guaranteed qualitiy of Groeneveld's
products. Frequent contact with all business relations and an elaborate dealer
network are the warranty for the good name of Groeneveld. We know what
today's entrepreneurs need: not an off-the-shelf product, but a customised
solution for the automation of the daily maintenance.
New technologies create new applications. This is why Groeneveld has an ample
budget for research and development to create new cost-effective products.
Groeneveld's Research and Development organisation co-operates closely with
leading R&D organisations and manufacturers of vehicles and machines.
Besides the CompAlube Automatic greasing system, Groeneveld supplies products
such as:
• temperature recording sytems
• on-board computer systems
• speed limiters
• automatic oil-level controllers
• reversing protection systems
Groeneveld supplies a complete range of cost-effective and comfort-enhancing
products.
Figure 1.1 The head office of Groeneveld

CompAlube Automatic greasing system
Introduction 9
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EG0105P02
1.3 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.
The most important advantages:
• longer maintenance intervals; less unnecessary down-time.
• reduced wear of the greased parts, as a result of accurate and constant
greasing.
• lower repair and replacement costs.
• less unexpected down-time; less loss of production.
1.4 Operation
With CompAlube automatic greasing system from Groeneveld, all lubrication
points of a vehicle or machine are automatically lubricated at the right moment
and with the right amount of grease. Moreover, an optimum grease distribution is
obtained over the whole surface to be greased, because the machine or vehicle is
greased while it is operational. All actions are automatically performed by the
system. The user only needs to make sure that the reservoir is periodically refilled
and that the system is inspected.
Groeneveld's automatic greasing systems are carefully designed and thoroughly
tested to guarantee a long and trouble-free service life, even under the heaviest
operating conditions.
Besides correct installation and the use of the prescribed type of grease, a periodic
check of the operation is a condition for the continued good functioning of the
system. This periodic check is easy to carry out and can be done together with the
usual maintenance. Partly through a careful choice of materials, the greasing
system itself is almost maintenance-free.

Introduction10
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CompAlube Automatic greasing system
EG0105P02
Notes

CompAlube Automatic greasing system
System description 11
Publication date: September 2005
EG0105P02
2.
2
.SYSTEM DESCRIPTION
your efficiency is our challenge

System description12
Publication date: September 2005
CompAlube Automatic greasing system
EG0105P02
2.1 Introduction
The Groeneveld CompAlube greasing system is specially developed for use on
vehicles with a maximum of 19 lubrication points that must be greased. It is easy to
install, requires almost no maintenance and is extemely reliable.
2.2 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):
1. Pump unit with integrated:
• pneumatic grease pump (plunger pump)
• grease reservoir (grease cartridge)
• control unit (pneumatic brake-counter or electronic timer)
• metering units
• grease-pressure indicator
• filling connection (optional)
2. Grease lines from the metering units to the individual grease points.
3. Air lines to the pump.
4. Brake-counter, if installed.
5. Installation bracket for the pump (not shown).
Figure 2.1 Pneumatic CompAlube greasing system
GROENEVELD
GROENEVELD
A product of
Groeneveld Transport Efficiency Inc.
1130, Industrial Parkway North
Brunswick, Ohio 44212, USA
Tel. [phone] 586 7283
Fax [phone]
D C A B
2
3
P
4
S
1
Gro_G0105_200

CompAlube Automatic greasing system
System description 13
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EG0105P02
An electrical CompAlube greasing system has the following components (Figure
2.2):
1. Pump unit with integrated:
• electrical grease pump (gear pump)
• grease reservoir (grease cartridge)
• control unit (electronic timer)
• metering units
• grease-pressure sensor
• filling connection (optional)
2. Grease lines from the metering units to the individual grease points.
3. Electrical cable to the pump.
4. Installation bracket for the pump (not shown).
Figure 2.2 Electrical CompAlube greasing system
GROENEVELD
GROENEVELD
A product of
Groeneveld Transport Efficiency Inc.
1130, Industrial Parkway North
Brunswick, Ohio 44212, USA
Tel. [phone] 586 7283
Fax [phone]
D C A B
2
3
1
Gro_G0105_201

System description14
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CompAlube Automatic greasing system
EG0105P02
2.3 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.
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.
2.3.1 Pneumatic CompAlube with brake-counter
The pneumatic CompAlube pump unit with brake-counter has the following
components (Figure 2.3):
1. Transparent protection cover
2. Grease cartridge
3. Grease piston
4. Check valve
5. Metering units
6. Spring
7. Main air piston
8. Set screw
9. Control unit (pneumatic brake-counter)
10. Brake command air piston
11. Filling connection (optional)
12. Test screw (on brake-counter)
13. Compressed air connection (P)
14. Grease-pressure indicator
15. Brake command air connection (S)
Figure 2.3 Pneumatic CompAlube with brake-counter
PNEUMATIC PUMP
Type n c.c.
o
Groeneveld Transport Efficiency B.V.
Gorinchem, the Netherlands
Made by Groeneveld Italia s.r.l.(Lc)
P
A
S
Gro_G0105_202
2109
678
3
11
13
12
15
14
4
5
1

CompAlube Automatic greasing system
System description 15
Publication date: September 2005
EG0105P02
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):
1. Transparent protection cover
2. Grease cartridge
3. Grease piston
4. Check valve
5. Metering units
6. Spring
7. Main air piston
8. Magnetic valve
9. Printed circuit board
10. Electrical connection
11. Filling connection (optional)
12. Test button
13. Compressed air connection (P)
14. Grease-pressure indicator
Figure 2.4 Pneumatic CompAlube with integrated electronic timer
Gro_G0105_203
2
6798
3
11
13
12
14
10
4
5
1

System description16
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CompAlube Automatic greasing system
EG0105P02
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):
1. Transparent protection cover
2. Grease cartridge
3. Gear pump
4. Pressure regulating valve
5. Metering units
6. Motor
7. Printed circuit board
8. Electrical connection
9. Filling connection (optional)
10. Test button
11. Grease-pressure switch
Figure 2.5 Electrical CompAlube with integrated electronic timer
Gro_G0105_204
2
67
3
9
8
11
10
4
5
1

CompAlube Automatic greasing system
Operation 17
Publication date: September 2005
EG0105P02
3.
3. OPERATION
your efficiency is our challenge

Operation18
Publication date: September 2005
CompAlube Automatic greasing system
EG0105P02
3.1 Introduction
This chapter contains a description of the operation of various components of the
Groeneveld CompAlube automatic greasing system. These are the control unit,
grease pump, metering units, grease-pressure indicator, grease-pressure switch and
the test screw or test button.
3.2 Control unit
3.2.1 CompAlube with brake-counter
The Groeneveld CompAlube greasing system is controlled by a pneumatic brake-
counter. This makes it particularly suited for vehicles that do not have a permanent
electrical power supply, such as (semi-)trailers.
The brake-counter draws the compressed air it needs from a protected air tank. The
counter is connected to the brake command air connection of the vehicle's braking
system through the fast-braking valve. This connection has a restriction, so that the
vehicle can always stop in the event of a fractured or broken line.
Each time that the brake-counter has registered a certain number of brake
applications (this number can be set), it starts the plunger pump and the greasing
system starts its greasing cycle.
The brake-counter contains a cam that rotates a few degrees if the brake command
air operates a piston in the brake-counter when the vehicle brakes. After the set
number of brake applications has been 'counted', the cam opens the integrated 3/
2 valve and the plunger pump is activated. (The pump phase starts.)
After a second series of brake applications (depending on the counter setting), the
cam closes the 3/2 valve again and the plunger pump stops. This is the end of the
pump phase and the greasing cycle.
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. With the electronic timer, you can set the duration (in minutes) of the
greasing interval.

CompAlube Automatic greasing system
Operation 19
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EG0105P02
3.3 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). The grease now goes from chamber (2) through duct (4) to the grease
chamber (5) above the metering units. The metering units now apply the grease at
full pump pressure through the grease lines to the grease points. At the end of the
pump phase, the air pressure behind the air/grease piston (1) drops away and
spring (6) returns the piston to its starting position. At the same time, valve (3)
comes away from the seat and, as a result of the underpressure in chamber (2),
grease is sucked out of the grease cartridge.
Figure 3.1 Plunger pump
Gro_G0105_300
2
16753
4

Operation20
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CompAlube Automatic greasing system
EG0105P02
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.
During the cycle, the pump builds the grease pressure up further all the time. At a
pressure of 55 bar, the pressure regulating valve (4) opens, and the grease returns
to the reservoir. The grease pressure is therefore limited to 55 bar.
After the greasing cycle of 2 minutes, the pump's direction of rotation is reversed
for 90 seconds, to release the pressure in the pump and metering units.
Figure 3.2 Gear pump
Gro_G0105_301
3
251
4