Groeneveld OnePlus Configuration guide

OnePlus
General Manual
Automatic Greasing System
OnePlus
EG1605R01
your efficiency isour challenge

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.
General information
Type of manual General Manual
System Automatic Greasing System OnePlus
Document number EG1605R01
Date of issue October 2011
Revisie 01

Automatic Greasing System OnePlus
Table of contents 3
Date of issue: October 2011
EG1605R01
Table of contents
Preface - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
1. General information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
1.1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
1.2. The OnePlus automatic greasing system - - - - - - - - - - - - - - - - - - - - - - - - 6
2. Description components- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
2.1. Properties - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
2.2. Composition of the OnePlus pump- - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
2.3. The integrated control and monitoring unit- - - - - - - - - - - - - - - - - - - - 10
2.4. Selector switches - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
2.4.1. Setting possibilities selector switches - - - - - - - - - - - - - - - - - - 11
2.5. The plunger pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12
2.6. Safety and control features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12
2.6.1. Maximum grease pressure - - - - - - - - - - - - - - - - - - - - - - - - - - 12
2.6.2. Defective wiring and short-circuits - - - - - - - - - - - - - - - - - - - - 12
2.7. The test push button - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12
2.7.1. Performing a test cycle- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13
2.7.2. Retrieving fault messages- - - - - - - - - - - - - - - - - - - - - - - - - - - 13
2.8. The optional indicator lamp- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14
2.9. The distribution blocks- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
2.9.1. Properties - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
2.9.2. Composition - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
2.9.3. Principle of operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16
2.9.4. Non-return valves - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
2.9.5. Failure of one of the doser segments - - - - - - - - - - - - - - - - - - 17
2.9.6. Closing outputs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
2.9.7. Combining outputs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18
2.10. The optional distribution block monitoring switch - - - - - - - - - - - - - - - 19
3. Designing a system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20
3.1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20
3.2. Points of departure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20
3.3. Method - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22
3.3.1. Determine the operating conditions- - - - - - - - - - - - - - - - - - - 22
3.3.2. Produce a greasing plan- - - - - - - - - - - - - - - - - - - - - - - - - - - - 22
3.3.3. Determine the grease demand of the grease points - - - - - - - 22
3.3.4. Group the grease points- - - - - - - - - - - - - - - - - - - - - - - - - - - - 23
3.3.5. Determine the layout of the system - - - - - - - - - - - - - - - - - - - 23
3.3.6. Check the design - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24

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EG1605R01
4. Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25
4.1. Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25
4.2. Safety precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25
4.3. General installation directives- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26
4.4. OnePlus pump unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27
4.4.1. Mounting the pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27
4.5. OnePlus distribution blocks- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27
4.5.1. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27
4.5.2. Assembling distribution blocks - - - - - - - - - - - - - - - - - - - - - - - 27
4.5.3. Mounting the distribution blocks - - - - - - - - - - - - - - - - - - - - - 28
4.6. Primary grease lines and couplings - - - - - - - - - - - - - - - - - - - - - - - - - - - 29
4.6.1. Grease line types - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29
4.6.2. Mounting the primary grease lines - - - - - - - - - - - - - - - - - - - - 29
4.7. Secondary grease lines and couplings - - - - - - - - - - - - - - - - - - - - - - - - - 31
4.7.1. Grease line types - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 31
4.7.2. Mounting the secondary lines - - - - - - - - - - - - - - - - - - - - - - - - 32
4.8. Electrical wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33
4.8.1. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33
4.8.2. Fuse ratings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33
4.8.3. Pin-layout of the connector on the pump unit- - - - - - - - - - - - 33
4.8.4. Wiring diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 34
4.9. De-aerating of the greasing system- - - - - - - - - - - - - - - - - - - - - - - - - - - 35
4.10. Commissioning of the greasing system - - - - - - - - - - - - - - - - - - - - - - - - 35
5. Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 36
5.1. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 36
5.2. Regularly checks of the greasing system - - - - - - - - - - - - - - - - - - - - - - - 36
5.3. Filling the grease reservoir - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 37
5.4. Fault finding- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 38
6. Technical data - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 41
6.1. OnePlus pump unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 41
6.2. Distribution blocks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 42
6.3. Regulations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 42

Automatic Greasing System OnePlus
Preface 5
Date of issue: October 2011
EG1605R01
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.
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.

General information6
Date of issue: October 2011
Automatic Greasing System OnePlus
EG1605R01
1 General information
1.1 Introduction
With an automatic greasing system of Groeneveld 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 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.
1.2 The OnePlusautomatic greasing system
A Groeneveld OnePlus 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).
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
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.

Automatic Greasing System OnePlus
General information 7
Date of issue: October 2011
EG1605R01
A Groeneveld OnePlus automatic greasing system could comprise the following
parts (see Figure 1.1):
1. An electric grease pump (plunger pump) with integrated grease reservoir and
a digital control unit with data storage facility.
2. Manometer.
3. Primary grease lines between the pump unit and the distribution blocks and
interconnecting the distribution blocks themselves.
4. Main distribution block.
5. One or more distribution blocks (assembled from multiple doser segments).
6. Secondary grease lines between the distribution blocks (doser segments) and
the individual grease points.
7. Distribution block monitoring switch.
Figure 1.1 System overview
OnePlus
BAR
0
100
250
350
400
1
2
3
3
4
35
7
6

Description components8
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Automatic Greasing System OnePlus
EG1605R01
2Description components
2.1 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.
The system will automatically lubricate all points connected to the lubrication
system on a timed cycle, with the correct quantity of grease.
The most significant properties of the OnePlus pump unit are:
• Single grease outlet port.
• Interval time and the grease output quantity can be adapted with two rotary
selection switches on the control unit behind the bottom cover of the pump.
• The control unit monitors the electrical wiring and components.
• The system can be extended with an optional block monitoring switch for
guarding the functionality of a distribution block in the system.
• The indicator lamp, supplied with the optional block switch warns the
operator for serious system errors.
ATTENTION
The minimum grease level and the opening of the maximum pressure re-
lieve valve are not monitored by the controller in the pump.
2.2 Composition of the OnePluspump
The OnePlus pump comprises the following components (see Figure 2.1):
1. Grease reservoir.
2. Follower piston.
3. Electrical connector.
4. Filler coupling with grease filter.
5. Test push button.
6. Electronic control and monitoring unit with a permanent memory.
7. Electric motor with reduction gear and sensor (counts the number of revolu-
tions of the drive shaft of the plunger pump).
8. Relief valve with return line to the grease reservoir and monitoring by the
control unit.
9. Plunger pump.
10. Grease output port.
11. Stirring device.

Automatic Greasing System OnePlus
Description components 9
Date of issue: October 2011
EG1605R01
Figure 2.1 OnePlus pump
1
2
3
4
5
6
78
9
10
11

Description components10
Date of issue: October 2011
Automatic Greasing System OnePlus
EG1605R01
2.3 The integrated control and monitoring unit
The control and monitoring unit initiates and controls the greasing cycles of the
greasing system. All required system and program parameters, such as the time
periods behind the interval selector switch setting possibilities and the grease
output quantities behind the amount selector switch possibilities are laid down in
the control unit. The control unit monitors the performance of various components
of the greasing system, and processes and stores the mal functions it detects.
The basic parameter settings, like interval period and grease amount, can be set by
means of two selector switches. You can find these switches on the controller-
board, behind the bottom cover of the pump.
Advanced functionality can be programmed with an UniGINA (UNIversal
Groeneveld tester for INstallation and Analysis) (see Figure 2.2)
Figure 2.2 Connecting the UniGINA to the OnePlus pump.
OnePlus
F5
F1
F6
F2 F7 F3 F8 F4
SHIFT
ENTER
OFF
ON
&
A
1
B
2
C
3
D
4
G
5
H
6
I
7
L
8
M
0
R
9
N
#
F
%
K
(
P
+
U
)
Q
-
V
/
W
*
Y
=
Z
?
T
CUR
S
:
O
<
J
>
E
.
Z
,
SPC
CAPS
LOCK
NUM
LOCK
BGNPAGE END
CNTR
LGHT
PAGEINS
DEL

Automatic Greasing System OnePlus
Description components 11
Date of issue: October 2011
EG1605R01
2.4 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
Figure 2.3 Selector switches
2.4.1 Setting possibilitiesselector switches
ATTENTION
In indivudal cases the times and amounts behind the selector switches
settings can be customized and differ from the above displayed factory
settings.
Time interval Grease amount
1 5 minutes 1 cc per cycle
2 10 minutes 2 cc per cycle
3 15 minutes 3 cc per cycle
4 30 minutes 4 cc per cycle
5 45 minutes 5 cc per cycle
6 60 minutes 6 cc per cycle
7 90 minutes 7 cc per cycle
8 120 minutes 8 cc per cycle
9 180 minutes 9 cc per cycle
0 240 minutes 10 cc per cycle
55
TIME AMOUNT
selectorswitch
time interval
selector switch
grease amount

Description components12
Date of issue: October 2011
Automatic Greasing System OnePlus
EG1605R01
2.5 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 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.
2.6 Safety and control features
2.6.1 Maximum grease pressure
A relief valve is installed in the grease channel between the plunger pump and the
grease 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).
2.6.2 Defective wiring and short-circuits
Open-loads (interruptions) and short circuits in the pump wiring will be detected
and processed by the control unit.
2.7 The test push button
The test push button on the pump unit has two functions:
• Performing a test cycle via the grease output port of the pump unit.
• Retrieving error messages stored in the memory of the control unit.
Figure 2.4 The test push button

Automatic Greasing System OnePlus
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EG1605R01
2.7.1 Performing a test cycle
A test cycle can be performed using the test push button, as follow:
1. The supply voltage for the pump unit must be available (ignition on).
2. Depress the test push button for 2 to 5 seconds.
3. The test cycle starts the moment you release the test push button.
During the test cycle the optional indicator lamp will flash (1 second on / 1 second
off).
Any errors that occurs during a test cycle will not be indicated by the indicator lamp
and will not be stored in the memory of the control unit.
2.7.2 Retrieving fault messages
When the system is equipped with the optional indicator lamp, fault messages
stored during the last automatic greasing cycle (pending errors) can be retrieved by
keeping the test push button (see Figure 2.4) depressed for at least five seconds.
Seven seconds after you released the test push button the indicator lamp will start
producing the blink codes to indicate these pending errors.
The indicator lamp indicates the fault codes by blinking:
The decimals 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 11 and 22 are displayed, you will see the blink codes:
long, short fault code 11
two second pause
long, long, short, short fault code 22
two second pause
Each fault message has been assigned a two-digit fault code:
Fault
code
Meaning
10 No errors detected during last executed automatic cycle
11 No state change of the block switch during a number of cycles
21 Drive shaft does not rotate or rotates too slow
22 Open load pump motor circuit
23 Over current pump motor circuit
35 Short circuit pump motor
41 Parameter checksum error
42 Power dip during pump start
43 Open load block switch circuit

Description components14
Date of issue: October 2011
Automatic Greasing System OnePlus
EG1605R01
2.8 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.
Figure 2.5 The indicator lamp
The indicator lamp producesthe following signals:
*) When wanted the flashing during an automatic cycle can be switched off with
an UniGINA device.
Signal Moment Significance
1 x 3 seconds on. 1 second after switching
on ignition.
The supply voltage for
the control unit is avail-
able and the indicator
lamp is OK.
Short flashing period
(1 sec. on / 1 sec. off).
During a pump cycle. A test or automatic*
cycle is performed.
Continuously on. A serious error is
detected.
System does not func-
tion properly anymore.
Immediate action is
required!
GROENEVELD
976.01

Automatic Greasing System OnePlus
Description components 15
Date of issue: October 2011
EG1605R01
2.9 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. 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).
2.9.2 Composition
A progressive distribution block
comprises the following components:
1. a start-segment
2. an end-segment
3. at least three doser segments
The doser segments 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 2.6 Distribution block.
Each doser segment always has two grease output ports, with identical grease
outputs per cycle. The grease channels between the segments are sealed by O-rings
and the segments are pressed together with two compression bolts.
WARNING:
To be able to operate at all, a distribution block needs to have at least three
doser segments.

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Automatic Greasing System OnePlus
EG1605R01
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:
1. The lubricant flows from the input port, via piston 3, through all segments to
the left-hand side of piston 1.
2. 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.
3. 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.
4. 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.
5. Afterwards piston 2 will also be pressed to the right and will supply lubricant
to output port 5.
6. Afterwards piston 3 will also be pressed to the right and will supply lubricant
to output port 6.
1. The distribution 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.
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.

Automatic Greasing System OnePlus
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EG1605R01
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
mustbe 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.
2.9.5 Failure of one of the doser segments
If a piston in one of the doser segments gets stuck due to contamination, the whole
greasing system will fail to operate properly.
2.9.6 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
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.

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Automatic Greasing System OnePlus
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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. This
doubles the output of the port that remains open.
Figure 2.8 Combining outputs.
The values in the illustration represent the outputs of the ports in mm³ (0,001 cc)
per complete cycle of the distribution block. The amount supplied is determined by
the diameter of the piston.
1
1
3
3
4

Automatic Greasing System OnePlus
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Date of issue: October 2011
EG1605R01
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. This indicator
lamp is delivered in the optional block switch kit.
Figure 2.9 Optional distribution block monitoring switch.
ATTENTION
Please be aware that at low temperatures it will take more successive cycles
to cause a state change of the block switch. We therefore advise to choose
a multiply factor from the table below in order to multiply the number of
cycles in between 2 state changes of the block switch, found in the system
you want to program at ambient temperature (±15 to 20°C).
* Mentioned factors are based on a system with the block switch mounted to a secondary
distribution block and the use of Greenlube EP-2 grease.
Minimum
temperature sytem
needs to be
operational
Advised
multiply
factor*
Advised parameter
setting when state
change each cycle at
+20°C
Advised parameter
setting when state
change every 3
cycles at +20°C
0°C 3 x 3 (3 x 1) 9 (3 x 1)
-5°C 4 x 4 (4 x 1) 12 (3 x 4)
-10°C 5 x 5 (5 x 1) 15 (3 x 5)
-15°C 6 x 6 (6 x 1) 18 (3 x 6)
-20°C 8 x 8 (8 x 1) 24 (3 x 8)

Designing a system20
Date of issue: October 2011
Automatic Greasing System OnePlus
EG1605R01
3Designing a system
3.1 Introduction
The following aspects influence the design of a OnePlus greasing system:
1. The number of grease points to be connected and:
• The position of the grease points on the vehicle or machine.
• The grease demand of the grease points.
• 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.
3.2 Pointsof departure
Pump
Maximum working pressure 275 bar
Distribution blocks
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
• The number of segments in the distribution block
• The NLGI class of the grease used
• The ambient operating temperatures
Primary and secondary grease lines
Pressure drops in the grease lines, connected with: table 3
• The diameter of the lines
• The length of the lines
• The NLGI class of the grease used
• The ambient operating temperatures
Resistance at the grease point
Ball or roller bearing 5 bar
Slide bearing 15 bar