CPL SYSTEMS / GROENEVELD AUTOMATIC GREASING SYSTEM COMPLETE SYSTEM CHECK PNEUMATIC PUMP

Transcription

1 CPL SYSTEMS / GROENEVELD AUTOMATIC GREASING SYSTEM COMPLETE SYSTEM CHECK PNEUMATIC PUMP Feb 5,

2 CPL SYSTEMS / GROENEVELD AUTOMATIC GREASING COMPLETE SYSTEM CHECK - PNEUMATIC PUMP THE SYSTEM DOES NOT WORK 1 Remove the plug from the front of the pump and install a pressure gauge capable of hydraulic pressure of 100 bar (1500 psi). 2 Turn on the ignition and activate a test cycle on the timer (see timer test procedures found on page 8. 3 If the system does not activate, perform a Quick Electrical Check, at the timer plug in the cab. They are found on pages 3 & 4. This should tell you if the problem is electrical in nature, and where it is likely to be. 4 If the power check does not indicate 12 volts being provided to the timer with the ignition on, then trace that wiring back to the fuse and/or power source. 5 If the ground check does not indicate a good ground then it must be restored. 6 If the solenoid circuit indicates a problem, the procedure to check it out is found on page 6. 7 If the pressure switch circuit indicates a problem, the procedure to check it out is on page 7. 8 If the timer check indicates a problem with the timer, the procedure to check it out is on page 8. 9 If the system did actuate but the alarm goes off, then it is not building enough pressure to close the pressure switch. Go to the pump check on page 9. Feb 5,

3 QUICK ELECTRICAL CHECK AT THE TIMER PLUG TIMER & SOLENOID USED STARTING IN 1990 SOLENOID CHECK #4 pin GROUND CHECK Checks the wires, connections and the solenoid coil - ignition off resistance R = 19 or 20 ohms Checks the wires and connections for a good ground - ignition off resistance R = 0 ohms Vehicle ground POWER CHECK Checks for proper voltage supply to the timer at two locations - ignition on voltage V = 12 volts at both locations TIMER CHECK #4 pin PRESSURE SWITCH CHECK #2 pin Checks wires, connections and pressure switch - it is normally open - closes at 40 bar - ignition on, push red button for 5 seconds if system pressure < 40 bar resistance R = open circuit if system pressure > 40 bar resistance R = 0 ohms Checks to see if the timer is supplying power to the solenoid to activate the system - ignition on, push the red button for 5 seconds voltage V = 12 volts #1 and then #12 pin Feb 5,

4 QUICK ELECTRICAL CHECK AT THE TIMER PLUG AAT 3 TIMER & SOLENOID USED BEFORE 1990 SOLENOID CHECK #4 pin #5 pin GROUND CHECK Checks the wires, connections and the solenoid coil - ignition off resistance R = 10 to 12 ohms Checks the wires and connections for a good ground - ignition off resistance R = 0 ohms Vehicle ground POWER CHECK Checks for proper voltage supply to the timer at two locations - ignition on voltage V = 12 volts at both locations TIMER CHECK #5 pin PRESSURE SWITCH CHECK #2 pin Checks wires, connections and pressure switch - it is normally open - closes at 40 bar - ignition on, turn stepswitch to test position if system pressure < 40 bar resistance R = open circuit if system pressure > 40 bar resistance R = 0 ohms Checks to see if the timer is supplying power to the solenoid to activate the system - ignition on, should be constant power to the solenoid voltage V = 12 volts #1 or #7 and then #6 or #12 pin Feb 5,

5 SYSTEM SCHEMATICS AAT 3 timer plug pins old style Vehicle ground 1 - ignition switch (+15) 2 - pressure switch 3 - ground 4 - solenoid 5 - solenoid 6 - battery (constant) Schematic with AAT 3 Timer timer plug pins or 1 - ignition switch (+15) 2 - pressure switch 3 - ground 4 - solenoid 7 - minimum level 9 - ground 12 - ignition or battery Schematic with Timer Feb 5,

6 SOLENOID CHECK These two connected to the timer plug Solenoid used until 1990 : A P This solenoid can be identified by the shape of the cap covering the electrical connection. It is grey or black in colour, square in shape, made of plastic and held in place with a single screw in the middle. It houses 3 female spade connectors that plug onto the male spades on the solenoid. The two terminals opposite each other are the two that are connected to the wiring going to the timer plug. Solenoid used starting in 1990 : A P This solenoid has a round twist-on M24 connector. The two, round, pin type terminals are connected to the wiring going to the timer. Solenoid test procedure : If the Quick Electrical Check on page 3 indicated a problem in the solenoid circuit, the solenoid can be checked quickly and then the wiring and connections between the timer and the solenoid have to be checked. To check the solenoid circuit internally, carefully remove the electrical plug from the solenoid and check the resistance between the two terminals. With an AAT 3 timer the resistance should be ohms. With an timer the resistance should be ohms. If the resistance is not to specifications, then the solenoid should be replaced. Recheck from the timer plug after any repairs are made Feb 5,

7 PRESSURE SWITCH CHECK Remove the brass plug from the front of the pump and install a pressure gauge capable of hydraulic pressure of 100 bar (1450 psi.). Activate the system from the timer and check for a system pressure of 60 bar (870 psi.) at the pump. If the Quick Electrical Check indicated a problem in the pressure switch circuit the pressure switch can be checked quickly while the system is on pressure. Both switches are normally open so when the system is on pressure you are looking for that switch to close (it s a 40 bar switch). If it s okay then the wiring and the connections between the switch and the timer have to be checked. Old style (single terminal), used until 1990 : With an ohmmeter and the system on pressure, check for continuity between the pressure switch terminal and the body of the switch. The should be no resistance. i.e. R should be 0. If it s open circuit then the switch is faulty or system pressure is below 40 bar. Check between the terminal and the vehicle chassis. Again there should no resistance. If there is a reading, then the metal to metal contact between the manifold and the chassis is not acceptable. Disassemble the manifold from the chassis, clean up the corrosion, provide bare metal contact and reassemble the components. If these two check out okay then the wiring and connections between the pressure switch and the timer have to be checked. New style (two pins), used starting in 1990 : With an ohmmeter and the system on pressure, check for continuity between the two pressure switch pins. There should be no resistance. i.e. R should be 0. If it s open circuit then the switch is faulty or system pressure is below 40 bar. If it checks out okay then the wiring and connections between the pressure switch and the timer have to be checked. Feb 5,

8 TIMER CHECK The AAT 3 timer used until 1990 : AAT 3 timer test procedure : Turn on the ignition and verify that there s 120 lbs. of air pressure in the air system. To test the system use a small Manual flat screwdriver to push the stepswitch in slightly and turn VDC 1,6 A Type AAT3 until the arrow is pointing to the test position. The timer will now, automatically, go on for two minutes and off for one minute. It will continue to do this until the arrow is turned back or the ignition is turned off. After 70% of each cycle is complete (approximately 80 seconds), a self check is performed and a buzzer will come on if there s a malfunction. In order to use the manual test button the stepswitch has to be set in the manual position. Pushing the red button activates the solenoid, but only as long as you keep it pushed in. The manual button has to stay pushed in for two full minutes to complete one lubrication cycle. NOTE - the low pressure alarm buzzer does not work when using the manual push button. The timer used starting in 1990 : timer test procedure : Turn on the ignition and verify that there s 120 lbs. of air pressure in the air system. The stepswitch arrow should be pointing at one of the time settings i.e to 5 hours - do type vdc not turn it to test A or B. To start a cycle, push the red button in and hold it there for 5 seconds. When the button is released, a three minute cycle will begin. After 70% of the cycle is complete (approximately 150 seconds), a self check will be performed and a buzzer will come on if there s a malfunction. The timer will finish the three minute cycle and shut off. To repeat a cycle, the red button has to be pushed again and held for 5 seconds. Position A is used to do a stepswitch test or an accelerated cycle function. The stepswitch test is performed when checking to see if a particular interval time setting is defective. The accelerated cycle is used to speed up the lubrication cycle to 20 times it s normal frequency. Position Test B is used with the Readout unit only. Contact your CPL Dealer for details should you feel that any of these checks need to be done. After any timer testing, set the stepswitch back to the 1.5 hours cycle interval. Feb 5,

9 PNEUMATIC PUMP CHECK Remove the brass plug from the front of the pump and install a pressure gauge capable of hydraulic pressure of 100 bar (1450 psi.). Make sure you have 120 lbs. of air pressure in the vehicle. Remove the main grease line from the pump and then remove the fitting from the pump. Install a 1/4 npt pipe plug in that hole. Turn on the ignition and activate the system using the timer. Check the pressure gauge and watch what it does. The pressure has to be at 60 bar (870 psi.) or more and it should stay at the same level until the cycle ends (three minutes). If the pressure holds then the pump is okay. If it does not hold, then there are four possibilities and they are listed below. Refer to the exploded parts diagram, on page 9, for component numbers used below. Air seal is leaking : Can you hear or feel any air leaking from the air release hoses that are connected to the #21 banjo connectors? If yes, then remove both hoses and determine if the air is coming from the solenoid or from the banjo connectors. If it coming from the solenoid then it must be cleaned or replaced. If it s coming from the banjo then it s from the air side of the piston in the pump. The piston #29, seal #30 and sleeve #23 must be inspected and cleaned or replaced as necessary. Activate the system and check the pressure again Return valve leaking : If the pump pressure shot up towards the 60 bar, then dropped back almost immediately, then the return valve #14 is suspect. Remove the return valve end cap, pull the valve body out with needle nose pliers, pull out the spring and then the ball. Inspect the ball and replace if any pits or corrosion in it are found. Check to see that the spring is not broken. Put the ball back in the pump, place a 5/16 or 8mm round brass driver into the housing, holding it tightly against the ball. Strike the end of the driver firmly with a small hammer to seat the ball in the housing. Clean and re-install the other components, activate the system and check the pressure again. Grease seal leaking : If the pump pressure goes up and then slowly drops down, then the grease side of the piston in the pump is suspect. You may also see grease spraying out of the air release hose connected to the banjo fitting. The piston #29, seal #28 and cylinder #26 must be inspected and cleaned or replaced as necessary. Activate the system and check the pressure again. Flapper valve leaking : If you didn t get any pressure at all and the follower plate jumped about 3/16 (5mm) when you activated the system, the the flapper valve #24 is suspect. Remove the grease cylinder #26, check for damaged seating surfaces, clean or replace the flapper and reassemble the pump. Activate the system and check the pressure again. Feb 5,

10 PNEUMATIC PUMP EXPLODED PARTS DIAGRAM Feb 5,

11 Air, Electrical and Grease Schematic for Tractor AGS timer plug pins 1 - ignition switch (+15) 2 - pressure switch 3 - ground 4 - solenoid 7 - minimum level 9 - ground 12 - ignition or battery pump low level switch banjo fittings timer plug injectors fuse ignition solenoid A P secondary air tank pressure switch protection valve Primary air line AGS vent line Electrical (+) Main grease line (-) plug manifold F:\Engineering\Technical info\ep-0 Tractor Schematic.pdf Feb 5,

12 Air, Electrical and Grease Schematic - Tractor AGS with harness timer plug pins 1 - ignition switch (+15) 2 - pressure switch 3 - ground 4 - solenoid 7 - minimum level 9 - ground 12 - ignition or battery pump low level switch banjo fittings timer plug pressure switch injectors fuse ignition solenoid A P secondary air tank protection valve plug manifold Primary air line AGS vent line Electrical (+) Main grease line (-) (P.S.) F:\Engineering\Installation...\Schematics\EP-0 Tractor Schematic with harness.pdf Feb 5,

13 Air and Grease Schematic for Trailer AGS Brake application counter P pressure (constant) A apparatus or pump R return air pump P A R banjo fittings injectors grease pressure indicator primary air tank protection valve Brake treadle on tractor secondary air tank OR tee Secondary air line Primary air line AGS air line Main grease line brake relay plug manifold EP-0 Trailer Schematic.pdf Feb 5,

14 CPL SYSTEMS CANADA 7065 TWISS ROAD, R. R. 3 CAMPBELLVILLE, ONTARIO L0P 1B0 phone: (905) , fax: (905) , info: (800) internet: for help: [email protected] Feb 5,