Groeneveld Automatic TWIN Greasing System

IT 38 G
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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 also 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 or the concequences of
such errors.

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Groeneveld

Automatic Twin Greasing System

Installation Manual

January 2000

Wheel Loader
Caterpillar IT 38 G

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Contents
1. Introduction 5
2. System lay-out 7
3. Grease point location 8
4. Welding and drilling activities 10
5. Grease pump installation 30
6. Electrical installation 31
7. Electric diagram 32
8. Distribution block installation 33
9. Main line installation 45
10. Micro controller settings 49
11. Testing of the system 49
12. Total kit information 50

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1. Introduction Explanation of colour codes

(used in wiring diagrams)
This installation is based on the standard version of the Caterpillar
IT 38 G wheel loader. Colour Colour code
Black BK
Brown BN
Red RD
Automatic Twin Greasing System Yellow YE
Green GN
System Greasing points Groeneveld no. Caterpillar no. White WH
Caterpillar IT 38 G 33 x 7300568 7300568F Blue BU
Caterpillar IT 38 G SS 33 x - - Grey GY

Explanation of symbols etc.

Symbol Explanation
H High pressure hose ¼ I/D
R Protection ring
TP Tube protection hose ø 7mm ID (36608)
S tie Small cable tie (186mm) (00208) General installation instructions
L tie Large cable tie (338mm) (11107)
P Grease pump • Check the content of the kit using the parts list provided.
PS Pressure switch • Before connecting the grease system, check all grease points
with a hand gun and fill them if appropriate. This way damage
Distribution block due to insufficient grease is prevented.
• When plain threaded stud couplings are used a teflon tape or
sealant (i.e. Lock-tite) to prevent leakage. We advise the use of
Position number on article list couplings with counter-lock nut and O-ring.
• Prevent at all times that debris or dirt can enter the system.
Work in a clean manner.
Grease point position number • Remember: small pollution’s in lines and metering units can
cause the system to fall!

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2. System lay-out

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3. Grease point location

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4. Welding and drilling activities

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5. Grease pump installation

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6. Electrical installation

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7. Electric diagram
1. Cabin
2. + 15 Fuse
3. – 31 Central earth connection
4. Pressure switch
5. Grease pump motor
6. 5/2 way valve
7. Low level switch
8. Test switch
9. Micro controller unit
10. Grease pump body
11. Cycle mode switch
12. Control lamp

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8. Distribution block installation

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9. Main line installation

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10. Micro controller settings 11. Testing of the system

Code Description Setting • Start a continuously test by means of the test button on the
grease pump or with the GINA.
HDCY Heavy duty cycle 20 minutes
• Remove the end-plugs out of the distribution blocks.
NDCY Normal duty cycle 40 minutes
• If grease without any inclusion of air leaves a distribution block
LDCY Low duty cycle 60 minutes
this means that venting has been completed. Reinstall the end-
CMS Cycle mode select 1 or 2 or 3
plugs in all distribution blocks.
MPT Maximum pumping time 6 minutes
• Having venting the system, execute a continuous cycle test in
VMF Venting multiply factor 10 (/10) x
order to check that the system functions correct.
NOA Number of attempts 10 x
• Check if all the grease points are delivered with new grease.
BCDC Blink code duty cycle 4x
• Stop the continuous test (turn of the ignition).
Consumption of grease each cycle:10,3 cc. • Operate the machine in all positions and check if all the points
are well situated and are not damaged.
• Check the timer settings by means of the GINA (if available).

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0000546 Pump kit Caterpillar
12. Total kit information
Pos. Q’ty GTE number Description
High pressure hose specifications 2.1 1 08312 Pump bracket
2.2 3 Kg. 38922 Greenlube EP-2 grease / 1 Kg.
Pos. Q’ty GTE number Description 2.3 2 39008 Clamp 14 mm, M10 bolt
H1 2 830480 HPH ¼” E10 – 1500 – S8 2.4 1 83101 Twin reservoir sticker
H2 2 830005 HPH ¼” S8 – 3000 – S8 2.5 1 83401 Twin pump 12cc/24V/3L/250 bar
H3 1 830062 HPH ¼” S6 – 1150 – S6 2.6 3 108020 Bolt M8 x 20
H4 1 830557 HPH ¼” S6 – 300 – S10 2.7 4 108050 Bolt M8 x 50
H5 1 830033 HPH ¼” S6 – 600 – S6 2.8 4 220008 Self-locking nut M8
H6 1 830498 HPH ¼” S6 –2250 – S6 2.9 12 300008 Washer M8
H7 1 830276 HPH ¼” S6 –2200 – S6 2.10 3 330008 Spring washer M8
H8 1 830128 HPH ¼” S6 –1500 – S6
H9 1 830434 HPH ¼” S6 – 1300 – S6 0000700 Installation kit 21-port block / 731322
H10 1 830062 HPH ¼” S6 – 1150 – S6 Pos. Q’ty GTE number Description
H11 1 830557 HPH ¼” S6 – 300 – S10 3.1 3 07908 Male stud coupling ø6 x 1/8G
H12 1 830033 HPH ¼” S6 – 600 – S6 3.2 14 08008 Male stud elbow ø6 x 1/8G
H13 1 830498 HPH ¼” S6 –2250 – S6 3.3 2 08508 Reducing adaptor 1/8G
H14 1 830276 HPH ¼” S6 –2200 – S6 3.4 8 11608 Reducing adaptor 1/8G 80mm
H15 1 830128 HPH ¼” S6 –1500 – S6 3.5 2 13617 Male stud coupling ø6 x M8
H16 1 830434 HPH ¼” S6 – 1300 – S6 3.6 1 15001 Elbow 1/8G
3.7 4 16012 Cover plate single tube clamp
0000699 Welding plate Caterpillar IT 38 G 3.8 2 21301 Elbow M6 x M8
3.9 2 36208 Bracket for tube clamp
Pos. Q’ty GTE number Description 3.10 10 36608 Tube protection hose ø7
1.1 2 10312 Tube G1/8xø10x1750mm 3.11 4 81502 Single tube clamp ø6
1.2 2 35808 Spacer , 20-20-10 3.12 2 97701 Reducing adaptor 1/8G 70mm
1.3 8 39702 Protection ring ø 60 x 40 3.13 2 101020 Bolt M10 x 20
1.4 0,4 45922 Steel protection bar 30 x 3 3.14 4 126030 Allen bolt M6 x 30
1.5 1 78022 Welding plate for pump bracket 3.15 4 126035 Allen bolt M6 x 35
1.6 14 78801 Welding plate double tube clamp 3.16 2 300010 Washer M10
1.7 2 81401 Welding plate 8-port block 3.17 2 330010 Spring washer M10
1.8 8 82002 Welding plate single tube clamp 3.18 1 731322 Twin 21 Port block, complete

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0000701 Installation kit 2 x 8-port block / 731323 + 731324
0000702 Main line kit Caterpillar IT 38 G
Pos. Q’ty GTE number Description
4.1 4 08508 Reducing adaptor 1/8G Pos. Q’ty GTE number Description
4.2 4 09202 Spring washer M6 5.1 7 13312 Cover plate double tube clamp
4.3 8 13312 Cover plate double tube clamp 5.2 1 27133 Bracket for tube clamp
4.4 2 14901 Elbow M10x1 5.3 7 78701 Double tube clamp 2 xø12
4.5 4 15001 Elbow 1/8G 5.4 1 108030 Bolt M8 x 30
4.6 4 16012 Cover plate single tube clamp 5.5 6 126035 Allen bolt M6 x 35
4.7 2 16301 Allen plug 1/8G 5.6 1 126050 Allen bolt M6 x 50
4.8 1 32002 Steel pipe ø8 5.7 1 220008 Self-locking nut M8
4.9 2 39008 Clamp ø14, M10 bolt 5.8 1 230006 Self-locking nut M6 SS
4.10 4 43402 Male stud coupling ø6 x 1/8G 5.9 1 300006 Washer M6
4.11 8 43802 Male stud elbow ø6 x 1/8G 5.10 1 300008 Washer M8
4.12 2 47702 Equal connecting elbow coupling ø10 5.11 2 830480 H1 : HPH ¼” E10 – 1300 – S8
4.13 16 78701 Double tube clamp 2 x ø12 5.12 2 830005 H2 : HPH ¼” S8 – 3000 – S8
4.14 4 81802 Single tube clamp ø12
4.15 8 97701 Reducing adaptor 1/8G 70mm 0000504 After market installation kit Caterpillar
4.16 1 108016 Bolt M8 x 16
4.17 12 126030 Allen bolt M6 x 30 Pos. Q’ty GTE number Description
4.18 8 126065 Allen bolt M6 x 35 6.1 100 00208 Small cable tie 186mm
4.19 1 300008 Washer M8 6.2 3 02808 Elec. wire1,5mm² RD+GL+BL
4.20 1 731323 Twin 8-port block, complete 6.3 2 02908 Elec. wire 1,5mm² RD+BR
4.21 1 731324 Twin 8-port block, complete 6.4 5 03203 Crimp connector 1.5mm²
6.5 1 04812 Pressure switch cable 8 Mt.
6.6 25 11107 Large cable tie 338mm
6.7 1 12817 Cycle mode switch N/O 24V
6.8 1 13003 Connector 8-pole male
6.9 1 22603 Connector 8-pole female
6.10 1 61006 Connector 2-pole male
6.11 1 61106 Connector 2-pole female
6.12 7 61416 Crimp connector 1,5mm²
6.13 7 67806 Crimp connector 1,5mm²
6.14 1 82301 Pump cable harness
6.15 1 800003 Crimp connector 4-6 QMM M8

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