Groeneveld OnePlus General Manual
  1. Manuals
  2. Brands
  3. Groeneveld Manuals
  4. Lubrication systems
  5. OnePlus
  6. General manual

Groeneveld OnePlus General Manual

Automatic greasing system
Hide thumbs
Table of Contents

Advertisement

Quick Links

General Manual
P l u s
O n e
Automatic Greasing System
OnePlus
EG1605R01
your efficiency is our challenge

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the OnePlus and is the answer not in the manual?

Questions and answers

Related Manuals for Groeneveld OnePlus

Summary of Contents for Groeneveld OnePlus

  • Page 1 General Manual P l u s O n e Automatic Greasing System OnePlus EG1605R01 your efficiency is our challenge...
  • Page 2 Groeneveld. This applies also to the drawings and diagrams appended. Groeneveld reserves the right to change parts at any time, without prior or direct notice to the customer. The contents of this manual may also be changed without prior notice.

  • Page 3: Table Of Contents

    Properties - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 2.2. Composition of the OnePlus pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 2.3.
  • Page 4 OnePlus pump unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...

  • Page 5: Preface

    This general manual gives a description of the OnePlus 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 OnePlus automatic greasing system.

  • Page 6: General Information

    (it is a progressive greasing system). OnePlus 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...
  • Page 7 Automatic Greasing System OnePlus Groeneveld OnePlus automatic greasing system could comprise the following parts (see Figure 1.1): An electric grease pump (plunger pump) with integrated grease reservoir and a digital control unit with data storage facility. Manometer. Primary grease lines between the pump unit and the distribution blocks and interconnecting the distribution blocks themselves.

  • Page 8: Description Components

    Automatic Greasing System OnePlus Description components Properties The pump unit is the heart of the OnePlus automatic greasing system. The Groeneveld OnePlus pump is a Low Cost solution for compact off-road machines, industrial machines and trucks that specifically require NLGI-2 grease and do not have a compressed air system.
  • Page 9 Automatic Greasing System OnePlus Figure 2.1 OnePlus pump EG1605R01 Description components...

  • Page 10: The Integrated Control And Monitoring Unit

    Advanced functionality can be programmed with an UniGINA ( versal roeneveld tester for stallation and nalysis) (see Figure 2.2) OnePlus CNTR PAGE SHIFT LGHT CAPS PAGE LOCK LOCK & > < ENTER Figure 2.2 Connecting the UniGINA to the OnePlus pump. Description components EG1605R01...

  • Page 11: Selector Switches

    Automatic Greasing System OnePlus Selector switches The integrated control and monitoring unit features two selector switches for controlling (see Figure 2.3): • the interval in between the cycle starts and • the amount of grease per greasing cycle TIME AMOUNT...

  • Page 12: The Plunger Pump

    Automatic Greasing System OnePlus 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.

  • Page 13: Performing A Test Cycle

    Automatic Greasing System OnePlus 2.7.1 Performing a test cycle A test cycle can be performed using the test push button, as follow: The supply voltage for the pump unit must be available (ignition on). Depress the test push button for 2 to 5 seconds.

  • Page 14: The Optional Indicator Lamp

    Automatic Greasing System OnePlus The optional indicator lamp The driver or operator will be informed about the operation of the greasing system through a indicator lamp which is installed on the dashboard in the cabin. The physical form of the indictor lamp may vary, but it is always installed so that is easily visible.

  • Page 15: The Distribution Blocks

    2.9.1 Properties OnePlus 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.

  • Page 16: Principle Of Operation

    Automatic Greasing System OnePlus 2.9.3 Principle of operation Figure 2.7 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: The lubricant flows from the input port, via piston 3, through all segments to the left-hand side of piston 1.

  • Page 17: Non-Return Valves

    Automatic Greasing System OnePlus 2.9.4 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.

  • Page 18: Combining Outputs

    Automatic Greasing System OnePlus 2.9.7 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 internal plug that seperates the two outputs and closing-off one of the ports.

  • Page 19: The Optional Distribution Block Monitoring Switch

    2.10 The optional distribution block monitoring switch The OnePlus automatic greasing system can be equipped with a switch for monitoring one of the distribution blocks. When this switch does not change state during a number of successive greasing cycles, it will warn the operator by switching on the indicator lamp on the dashboard continuously.

  • Page 20: Designing A System

    Automatic Greasing System OnePlus Designing a system Introduction The following aspects influence the design of a OnePlus greasing system: The number of grease points to be connected and: • The position of the grease points on the vehicle or machine.
  • Page 21 Automatic Greasing System OnePlus Table 1: Outputs of doser segments Segment type Output per segment Output with combined (2 outputs) [cc] outputs [cc] 2 x 0,045cc 0,090cc 2 x 0,125cc 0,250cc 2 x 0,200cc 0,400cc Table 2: Internal resistance in a distribution block (bar) Grease T [°C]...

  • Page 22: Method

    Automatic Greasing System OnePlus Method Determine the conditions under which the system must be able to operate. Make a so-called greasing plan. Indicate, in the greasing plan, the grease demand and greasing interval required by each grease point. Compile the greasing points in groups.

  • Page 23: Group The Grease Points

    Automatic Greasing System OnePlus 3.3.4 Group the grease points Compile groups of grease points, taking account of the following: • The maximum and minimum number of doser segments that can be combined in a single distribution block. • 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.

  • Page 24: Check The Design

    Automatic Greasing System OnePlus 3.3.6 Check the design Before the components of the system are assembled and installed, the projected system should be checked, by calculation, against the operating conditions it was designed for. Will it work under the giving operating conditions?

  • Page 25: Installation

    Installation Overview Groeneveld To install a OnePlus greasing system the following tasks must be per- formed: Mounting the pump (including the control unit). Mounting the progressive distribution blocks. Mounting the primary grease line in between the pump and the (main) distri- bution block and when applied in between the main distribution block and the secondary distribution blocks.

  • Page 26: General Installation Directives

    Automatic Greasing System OnePlus General installation directives Check the contents of the parts kit (using the parts list including in the kit). Check whether the electrical parts in the system meet the vehicle voltage. Before you start installing the greasing system: Check that all grease points are open and furnished with a sufficient amount of grease.

  • Page 27: Oneplus Pump Unit

    Automatic Greasing System OnePlus OnePlus pump unit 4.4.1 Mounting the pump 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: •...

  • Page 28: Mounting The Distribution Blocks

    Automatic Greasing System OnePlus 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. 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.

  • Page 29: Primary Grease Lines And Couplings

    Automatic Greasing System OnePlus Primary grease lines and couplings 4.6.1 Grease line types The primary grease lines are those between the pump unit and the main distribu- tion block and between the main distribution block and the secondary distribution blocks. The primary grease lines are available in a number of different sizes and ma- terials.
  • Page 30 Automatic Greasing System OnePlus Press couplings (applied with a hydraulic press) for high-pressure grease line DN6 (00817): a. 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.

  • Page 31: Secondary Grease Lines And Couplings

    Automatic Greasing System OnePlus Secondary grease lines and couplings 4.7.1 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.

  • Page 32: Mounting The Secondary Lines

    Automatic Greasing System OnePlus 4.7.2 Mounting the secondary lines Take attention at the following points during mounting the secondary grease lines and couplings: • Always make sure the screw threads of the coupling(s) and the grease point are identical. •...

  • Page 33: Electrical Wiring

    Automatic Greasing System OnePlus Electrical wiring 4.8.1 General Detailed wiring diagrams are available in the installation manual of the specific ve- hicles or machines. ATTENTION: To prevent damage to the electrical system of the vehicle or machine, the correct fuse(s) must be installed in power supply and control circuit.

  • Page 34: Wiring Diagram

    Automatic Greasing System OnePlus 4.8.4 Wiring diagram Pump unit Pump motor Revolution sensor Test push button Control unit Ignition Battery Control input switch Indicator lamp 10. Distribution block monitoring switch + or - 1 2 3 4 5 6 Figure 4.1...

  • Page 35: De-Aerating Of The Greasing System

    With such a pump the greasing system can be de-aereted quickly by connect- ing the primary grease line of the OnePlus system (at the pump unit) with that pneumatic pump. After the system has been de-aereted, the primary line must be reconnected to the output port of the pump unit.

  • Page 36: Maintenance

    Regularly checks of the greasing system Check the following points of the OnePlus greasing system: The grease level in the reservoir of the pump unit (refill on time). The pump unit for damage and leakage.

  • Page 37: Filling The Grease Reservoir

    Automatic Greasing System OnePlus Filling the grease reservoir When the grease in the reservoir reaches the minimum level indicated on the res- ervoir, 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.

  • Page 38: Fault Finding

    Automatic Greasing System OnePlus Fault finding Problem Cause Solution Indicator lamp does not 1. No supply voltage Check the fuse and, if light-up for 3 seconds (+15) on pin 1 or at required, replace the after ignition was indicator lamp.
  • Page 39 Automatic Greasing System OnePlus Problem Cause Solution All grease points con- Defective pump unit or Retrieve the fault code. nected are too dry, and a blockage in the system. When the code indicates malfunction is indicated that there has been no...
  • Page 40 Automatic Greasing System OnePlus Problem Cause Solution 6. Distribution block, grease line or grease point blocked and pump pressure is raised to the maximum. Solution: Carefully remove the pressurized main line from the pump and mount a T- coupling with a mano- meter 0-400 bar.

  • Page 41: Technical Data

    : 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 6.1 Dimensions of the OnePlus pump unit with a 2 litre reservoir. EG1605R01 Technical data...

  • Page 42: Distribution Blocks

    Automatic Greasing System OnePlus Distribution blocks Maximum operating pressure : 275bar Operating temperature : -20 ... +85 °C Minimum number of doser segments : 3 (excluding start and end segments) Maximum number of doser segments : 12 (excl. start and end segments)
  • Page 44 Groeneveld Transport Efficiency B.V., Stephensonweg 12, 4207 HB Gorinchem, P.O. Box 777, 4200 AT Gorinchem, The Netherlands, Ph : +31 183 641 400, F : +31 183 624 474, http://www.groeneveld-group.com...

Table of Contents

Save PDF