Automatic Greasing System OnePlus
Installation
27
Date of issue: October 2011
EG1605R01
4.4 OnePlus pump unit
4.4.1 Mounting the pump
1. 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:
• The pump unit must be easily accessible (for filling its grease reservoir).
• The grease level in the reservoir must be easy to inspect visually.
• The pump unit must be protected against possible damage.
2. First investigate whether existing mounting holes in the chassis of the vehicle
can be used to mount the mounting plate of the pump unit. Always follow
the directions of the vehicle’s manufacturer when you need to drill new holes.
Do not let the mounting plate rest on the profile flange of the chassis and do
not drill additional mounting holes in the flange in an effort to fix the mount-
ing plate even more securely. Be sure not to damage anything (e.g. lines or
air- tanks) that may be present behind the part in which you drill a hole. After
drilling a hole, always remove the chips (with compressed air or brush).
3. If the mounting plate is to be welded onto the vehicle, the directions of the
vehicle’s manufacturer should be strictly adhered to.
4. Mount the mounting plate with the pump unit onto the chassis.
5. Remove the yellow/red transport plugs from the grease output port and the
de-aerating opening of the pump unit.
6. Mount the nut and sleeve on the output coupling of the pump unit.
4.5 OnePlus distribution blocks
4.5.1 General
The composition of a progressive distribution block is always vehicle/machine-
specific.
If the distribution blocks are part of an installation kit, the secondary grease lines
and the couplings for the primary grease lines (to the pump unit or main distribu-
tion block) will, usually, have already been mounted onto the distribution blocks.
If the blocks are not part of an installation kit and have not been pre-assembled,
you should mount the grease lines and couplings before you mount the distribu-
tion block onto the vehicle or machine.
4.5.2 Assembling distribution blocks
The distribution block must be assembled before it can be installed on the vehicle.
To ensure the reliability of the greasing system, the distribution blocks should be
assembled in a clean, dust-free environment.
The criteria that govern the composition (number and type of doser segments) of
a distribution block are discussed in the Designing a system section of this manual.
1. First study the drawing of the distribution block to be assembled.
2. Check whether all required components are at hand and whether the right
couplings for the right kinds of secondary grease line are available.
3. Begin by placing the start-segment (to which the primary grease line will be
connected) onto the work bench with the port for the primary grease line fac-
ing downward.
4. Place, in the order as indicated on the drawing, the various doser segments
on top of the start-segment. Place the end-segment on top of the stack.
Ensure that all the openings in the segments are line-up and check that the
required O-rings have been correctly placed between all the segments.
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