Automatisch vetsmeersysteem Central grease lubrication system Automatisch Fettschmieranlage

Automatisch vetsmeersysteem Central grease lubrication system Automatisch Fettschmieranlage General instructions for the central grease lubrication system in transportation and industry, equipped with EPG-10 timer, EPG-15 timer and EBCP brake counter. Edition 3/07 Dec. 12

NOTES All rights reserved. Nothing from this edition may be reproduced and/or published by means of print, photocopy, microfilm or any other means, without prior written permission from Sterk Technisch Adviesbureau B.V. This also applies to the enclosed drawings and diagrams. Sterk Technisch Adviesbureau B.V. reserves the right to modify parts at any moment, without giving prior or direct notice to the client. The content of this manual may also be changed without advance warning. This manual is valid for the standard model of the product. Therefore, Sterk Technisch Adviesbureau B.V. cannot be held responsible for possible damage resulting from different specifications of the delivered product. For information on adjustments, maintenance tasks or repairs not described in this manual, we ask you to contact the Technical Service Department of Sterk Technisch Adviesbureau B.V. Although this manual has been put together with all possible care, Sterk Technisch Adviesbureau B.V. cannot accept responsibility for possible errors in this document or their consequences. 1

General instructions for use of the central grease lubrication system for applications in transportation and industry, equipped with EPG-10 timer, EPG-15 and EBCP brake counter. The ECOSTAR central lubrication system has been constructed from materials of high quality, guaranteeing a long service life and disruption-free operation under the most severe conditions. The result: - reduction of maintenance costs. This manual provides a straightforward description of the operating principle, the system overview, installation and trouble shooting. It is important to read this manual first, in order to obtain maximum efficiency from the system. Table of contents: Page: Notes 1 General introduction / Table of contents 2 System overview tractor / truck with electronic pulse generator EPG-10 3 System overview tractor / truck with electronic pulse generator EPG-15 4 System overview trailer / semi-trailer 5 Operating principle of tractor / truck system Operating principle of trailer / semi-trailer system 6 Technical data of components Information on grease pump 7 Operating principle of components: grease pump, meters 8 Operating principle of electronic pulse generator EPG-10 9 Operating principle of electronic pulse generator EPG-15 10 Operating principle of brake counter EBCP, solenoid valve, pressure switch, pressure reducing valve, manifolds and truck + trailer / semi-trailer, connection diagrams 11 Where are the various Ecostar components mounted? 12-13 - 14 Parts list for grease pump 15-16 Installation procedure Filling the grease container 17-18 - 19 Activating the systems Routine check 19 20-21 Routine check Recommended lubricants 22 Troubleshooting 23 2

System overview tractor / truck with EPG-10 pulse generator 1. Accessory tank 7. Ignition switch 2. Pressure reducing valve 8. Fuse min. 3 Amp 3. Electronic pulse generator / Solenoid valve EPG-10 9. Pressure switch 4. Grease pump 10. (Bronze) manifold with meters 5. Control light on dashboard 11. Grease points 6. Battery 3

System overview tractor / truck with EPG-15 pulse generator 1. Accessory tank 7. Ignition switch 2. Pressure reducing valve 8. Fuse min. 3 Amp 3. Solenoid valve 9. Battery 4. Grease pump 10. Pressure switch 5. Electronic pulse generator EPG-15 11. (Bronze) manifold with meters 6. Control light on dashboard 12. Grease points 4

System overview trailer / semi-trailer with EBCP brake counter 1. Air tank 5. Pressure gauge 2. Overflow valve 6. Brake light (brake command) 3. Electronic brake counter EBCP 7. Manifold with meters 4. Grease pump 8. Grease points 5

Operating principle of tractor / truck system The air-controlled grease pump is largely made from stainless steel and equipped with a support piston in the grease container. This provides a clear indication of the grease level. Activation of the grease pump is controlled by a combination of electronic pulse generator (timer) and solenoid valve, type EPG-10, which is fitted under the grease pump or is controlled by an electronic pulse generator (timer) type EPG-15, which is mounted in the central fuse box, in combination with a solenoid valve which is fitted under the grease pump. The EPG-10 and EPG-15 measures the time as long as the ignition is on. Once the (previously) set time has been reached, the EPG-10 and EPG-15 sends a signal to the solenoid valve. The solenoid gives an air command to the grease pump, which will press the grease into the main tubing, manifolds and meters (in the right quantity) and through the secondary tubing to the grease points. After ± 3 minutes the signal shuts off, the air is released and the grease pump pressure falls away. A visual check of the correct functioning of the grease lubrication system is possible with the help of the control light (EPG-10 + EPG-15), fitted on the dashboard. This will light up during the ± 3 minute grease cycle and then go out again. If the control light remains lit continuously, this indicates a fault in the system. If the air pressure is higher than ± 12 bar, a pressure reducing valve must be employed. The EPG-15 is equipped with a test mode. In this mode, the grease pump alternates between 1 minute of continuous pressure and 1 minute of release, as long as the ignition is on. The control light comes on during the pressure stage, as verification that there is sufficient system pressure. It remains lit continuously if there is a fault. Position Aux on the EPG-15 is for special applications. It is also possible to override the solenoid valve and grease pump manually (for testing or additional lubrication). Operating principle of trailer / semi-trailer system The air-controlled grease pump is largely made from stainless steel and equipped with a support piston in the grease container. This provides a clear indication of the grease level. Activation of the grease pump is controlled by a combination of electronic brake counter / solenoid valve, type EBCP, which is fitted under the grease pump. A signal is given to the brake counter each time the brakes are used. After a preset number of braking operations, an air command is given to the grease pump, which will press the grease into the main tubing, manifolds and meters (in the right quantity) and through the secondary tubing to the grease points. Each time a brake signal is received, the LED lights up green. When the preset brake count is reached, the LED lights up red and an air command is given to the grease pump. After a number of braking operations (the LED now lights up red each time), the air will be released from the grease pump and the counting will restart. The LED will now light up green again. A visual check of pressure build-up and pressure release is possible with the help of the pressure gauge mounted on the front of the grease pump. If the air pressure is higher than ± 12 bar, a pressure reducing valve must be employed. It is also possible to override the solenoid valve and grease pump manually (for testing or additional lubrication). 6

Technical data of components 1. Grease pump with support Air pressure: 6-12 bar Grease pressure : Air pressure = 9 :1 piston: Grease output: max. 40cc Capacity grease container: 4 l / 6,5 l 2. Meters: P max. ± 200 bar Reset pressure 9 bar 3. Pulse generator EPG-10: P max. 12 bar Power supply 12 VDC or 24 VDC 4. Pulse generator EPG-15: Power supply between 10 VDC and 32 VDC 5. Solenoid valve: P max. 12 bar Power supply 24 VDC (optional 12 VDC) 6. Brake counter EBCP: P max. 12 bar Power supply 12 VDC or 24 VDC 7. Pressure switch: P max. 125 bar Switch pressure ± 40 bar 8. Pressure reducing valve: Primary. max. 18 bar Secondary max. 10 bar Grease pump with support piston: This grease pump is equipped with a support piston in the grease container. The support piston provides the following advantages: Self-cleaning of the inner surface of the grease container, which makes level checking easier. This eliminates the problem of dried grease remaining on the inner surface. Ensures optimum filling of the pump chamber, even at low temperatures when the grease would be viscous. Prevents coning in the grease container. Ageing of the grease is considerably reduced due to the separation of the grease from the atmosphere. The pump has an output capacity of 40 cm³ at a pressure ratio of 1:9, making it suitable even for the lubrication of very large applications with more than 100 meters (dependent on output of meters used). Air pressure above the support piston ensures that the pump chamber is fully filled in the suction phase. All existing advantages of an entirely closed system are retained. 7

Operating principle of the components 1. Grease pump with support piston (truck) The air pressure in cylinder area 1 forces piston 10 upwards. At the same time the lubricant in chamber 2 is compressed, valve 11 closes the passageway 3 to reservoir area 4 and pressure is built up. Simultaneously, this pressure is applied to press grease into the main tubing 5. After the lubrication cycle, the air pressure falls away in chamber 1 and piston 10 is forced downwards by the spring 6. The pressure also falls away in chamber 2 and main tubing 5. The resulting overpressure in the main tubing enables the excess grease to return to chamber 2 and reservoir 4. Valve 11 opens passageway 3 and the lubricant is sucked from the reservoir 4 into chamber 2. After this, the lubrication cycle can start again. While piston 10 is moving upwards, the air above the piston in chamber 7 is partially moved into area 9 (above the support piston) via de-aeration tubing 8; to avoid overpressure above the grease, the air can flow into the free space through insert T- coupling 12 (or insert Y-coupling 16) and de-aeration tubing 15. When piston 10 moves downwards, the compressed air in cylinder area 1 is partially moved into area 9 (above the support piston) via solenoid valve 13 and de-aeration tubing 14 as well as de-aeration tubing 8; to avoid overpressure above the grease, the air can flow into the free space through insert T-coupling 12 (or insert Y-coupling 16) and de-aeration tubing 15. This construction makes it impossible for dirty or moist air from outside to come into direct contact with the grease. 2. Meters Figure A Grease is pumped into area 1 via the main tubing against the spring. The grease in area 2 is then pumped to the lubrication points. Figure B When the grease pressure falls away, the grease in area 1 will disperse to area 2 by means of the spring. 8

3. Electronic pulse generator EPG-10 The electronic pulse generator emits a direct pulse to the solenoid valve, assembled on the pump, after a preset interval time of between 10 and a maximum of 480 minutes (ignition on!). The preset pulse duration is adjustable between 1 and a maximum of 10 minutes. Enables visual monitoring of the system s functioning by means of the control light on the dashboard. The manual override can be used to check that the system is working properly. Functional description of single pulse generator, type EPG-10: The pulses emitted by the electronic pulse generator control the solenoid valve, which in turn activates the grease pump. These pulses are stored internally and can be read out afterwards with the help of a portable programmer box. With the programmer box, the time interval can be set between 10 and a maximum of 480 minutes. The pulse duration is also adjustable between 1 and a maximum of 10 minutes. The pulse generator also stores the unsuccessful grease pulses and is equipped with an internal switch, in case a pressure switch is installed in the lubrication system. Reading out and activating the switch is performed via the programmer box. The pulse generator measures the time as long as the engine ignition is on. This time will be stored when the ignition is switched off. The pulse generator then goes into sleep mode. The control light on the dashboard lights up in the following situations: a. output pulse indication while the solenoid valve is being energized. b. low-pressure alarm indication if the pressure in the lubrication circuit has not risen to a sufficient level during the output pulse. The low-pressure alarm indication is equipped with a hold function. This means that, when an alarm is detected, the LED remains lit (the presence of an alarm does not affect the operation of the pulse generator). If the pressure in the lubrication circuit successfully reaches the required level again during a subsequent output pulse, the LED will go out after this pulse. An internal fuse has not been fitted; use an external fuse (max. 3 Amp). Summary of technical specifications: Supply voltage (pulse generator) : 12 and 24 VDC Current (solenoid) : max. 300 ma Output current (lamp) : LED 20 ma with series resistor Output pulse duration : 60 600 seconds Interval time range : 10 480 minutes Output in test mode : 60 seconds on / 60 seconds off Operating temperature range : -10 C - +50 C Electrical connections : screw connector, 4-conductor cable 9

4. Electronic pulse generator EPG-15 The electronic pulse generator emits a direct pulse to the solenoid valve, assembled on the pump, after a preset interval time of between 30 and a maximum of 270 minutes (ignition on!). Enables visual monitoring of the system s functioning. The test mode or the manual override can be used to check that the system is working properly. Functional description of single pulse generator, type EPG-15: The pulses emitted by the electronic pulse generator control the solenoid valve, which in turn activates the grease pump. With the front switch, the time interval can be set between 0.5 and a maximum of 4.5 hours, in half-hour steps. This switch also has a test mode in which a sequence of output pulses (1 minute on / 1 minute off) is generated continuously for quick testing of the (grease) lubrication system. Position Aux is for special applications. Adjustments can only be checked and modified with a programmer box. The pulse generator measures the time as long as the engine ignition is on. If this time is to be stored when the ignition is switched off, there must be a continuous power supply to the battery + connection. In this event, the pulse generator goes into sleep mode. The front LED and control light on the dashboard lights up in the following situations: a. output pulse indication, while the solenoid valve is being energized. b. low pressure alarm indication, if the pressure in the lubrication circuit has not risen to a sufficient level during the output pulse. The low pressure alarm indication is equipped with a hold function. This means that, when an alarm is detected, the front LED and control light remains lit (the presence of an alarm does not affect the operation of the pulse generator). If the pressure in the lubrication circuit successfully reaches the required level again during a subsequent output pulse, an automatic reset will take place and the LED will go out. The front toggle switch has a double function: a. reset of the low pressure alarm, regardless of the position of the pulse generator. b. manual generating output pulse, this overrides the internal clock. An internal fuse has not been fitted; use external fuse (max. 3 Amp). The solenoid output is protected against inductive loads. The pulse generator is mounted using the 2 parker screws. Summary of technical specifications: Supply voltage range : between 10 and 32 VDC Current (sleep mode) : 7 ma at 24 VDC / 2 ma at 12 VDC Current (solenoid) : max. 300 ma Output current (lamp) : LED 20 ma with series resistor Output pulse duration : 180 seconds Interval time range : 30 270 minutes Output in test mode : 60 seconds on / 60 seconds off Operating temperature range : -10 C - +50 C Dimensions : 110 x 40 x 50mm (w x h x d) Electrical connections : plug-in screw connector, max. 4 mm² 10

5. Brake counter EBCP (trailers / semi-trailers) Each time the brakes are used a command is given to the brake counter as a result of the brake light coming on. The LED lights up green each time a brake signal is received. When the preset brake count is reached, the electronic brake counter will give a direct pulse to the solenoid valve (mounted on the pump), which gives an air command to the grease pump. The LED now lights up red. After a number of braking operations (the LED now lights up red each time), the air will be released from the grease pump and the counting will restart. The programmer box and manual override can be used to check that the system is working properly (see page 21). With this programmer box, the number of braking signals can be set between 10 and a maximum of 250. 6. Solenoid valve By energizing solenoid A, plunger B is lifted and connection 1 to 2 is effected. Connection 3 will be closed. After the grease cycle, the energizing shuts off, solenoid A is closing connection 1 and the air pressure relieves via connection 3. The manual override (see page 19) can be used to check that the system is working properly. 7. Pressure switch bipolar (truck) Gives a signal when the system pressure reaches approx 30 40 bar. Industrial application: 8. Pressure reducing valve To reduce a primary pressure (1) that is too high, i.e. > 12 bar, to a lower secondary pressure (2). 9. Manifolds Made of high-quality, corrosion-resistant bronze and can be supplied with 4, 7, 9, 12 or 14 outlets. Easy to fit thanks to threaded end: nut and locking ring provided. 10. Connection diagrams EPG-10 / EBCP 1. Yellow L. Control light on dashboard 2. Brown D. Pressure switch 3. White E. Brake lights 4. Green 5. Blue 6. Red Truck EPG-10 Trailer / Semi-trailer 11

Where are the various ECOSTAR components mounted? 12

Continued: examples on trucks 13

Continued: examples on trailers and semi-trailers 14

PVP model with support piston 07-200 (4 l) / 07-385 (6.5 l) 15

Parts list for grease pump Item no. Code no. Description 1 07-010-558 Spring overfill valve 3 07-010-561S Overfill valve (kit) 5 07-010-5540 Column + foot valve holder 4 l 07-010-5730 Column + foot valve holder 6.5 l 7 07-010-4660 O-ring 11 07-010-548 Pump house 12 16-041-6 A2 Ring (2x) 13 16-013-6 10 A2 Bolt (2x) 14 07-010-435 O-ring 15 07-010-417 Gauze filter 17 07-010-5560 Filling-filter locking ring (kit) 21 07-010-093/01 Dust hood aluminium (kit) 07-010-0931 Dust hood rubber 23 07-010-543 O-ring 24 07-010-478 Pin (2x) 25 07-010-743 Type plate 26 07-010-576 Threated end 6,5 ltr.+ 16-021-10 A2 nut (2x) 27 07-010-5300 Piston tube (kit) 29 07-011-463 Plunger spring 31 07-011-4130 Piston (kit) 35 16-043-8 A2 Toothed washer (4x) 36 07-010-427 Bolt (4x) 37 07-549S Cylinder tube (kit) 47 07-010-571 Bolt 4ltr. 48 07-010-434 Dubo ring 49 07-0120-555 Top cover 50 07-010-546 Cover ring 51 07-010-420 O-ring 53 07-010-457 Support piston 55 07-010-5570 Piston guide (kit) 56 07-010-401 Grease holder 4 l 07-010-402 Grease holder 6,5 l 57 07-010-3400 Level sticker reservoir 58 07-010-340 Ecostar grease pump sticker 59 07-010-464 Recessed-head screw (4x) 60 07-010-572 Ring (4x) 61 07-010-552 Bottom cover 62 07-010-545 O-ring 64 07-010-5620 Overflow port 65 07-010-5630 Nut 67 07-010-159 Seal washer aluminium 68 07-060-9910 De-aeration coupling T 69 07-010-028 De-aeration tubing 25cm 4 l De-aeration tubing 36cm 6.5 l De-aeration tubing 10/15/25cm 70 07-011-566 De-aeration coupling T 71 07-010-664 Insert Y-coupling 73 07-010-1590 Seal washer copper (2x) 74 07-010-208 Banjo housing 5/16 / 8mm 07-060-151 Banjo housing 10mm 75 07-010-207 Banjo nipple 5/16 / 8mm 07-010-243 Banjo nipple 10mm 76 07-060-209 Collar plug 07-010-107 Pressure gauge 0-160 bar 16

Installation procedure Location of the grease pump: Mount the pump on the chassis where it is both easily visible and accessible. Preferably in the middle of the vehicle or behind the cabin. Ensure that the fill coupling can be easily reached. Electronic pulse generator EPG-10 / Solenoid valve (tractor / truck): Screw valve using port 2 into the bottom connection of the pump cylinder tube. Install the air tubing from air pressure tank or accessory tank to port 1 connection of the solenoid valve (see system overview on page 3). Fit the insert T-coupling into the exhaust (port 3) of the solenoid valve, the insert T-coupling onto the back of the pump and connect both with the de-aeration tubing (see page 8, no.12, 14 and 15). Connect current supply wires from electronic pulse generator to control light, cabin fuse box compartment and pressure switch. Insulate unused main cable wiring. Connect according to diagram (see page 9 + 11). Make use of an accessory fuse (max. 3 Amp). Solenoid valve for EPG-15 (tractor / truck): Screw valve with port 2 into the bottom connection of the pump cylinder tube. Install the air tubing from air pressure tank or accessory tank to port 1 connection of the solenoid valve (see system overview on page 4). Fit the insert T-coupling into the exhaust (port 3) of the solenoid valve, the insert T-coupling onto the back of the pump and connect both with the de-aeration tubing (see page 8, no.12, 14 and 15). Electronic pulse generator EPG-15 (tractor / truck): Preferably, this should be fitted in the cabin fuse box compartment. Connect current supply wires from electronic pulse generator to control light, cabin fuse box compartment, pressure switch and solenoid valve. Connect according to diagram (see page10). Make use of an accessory fuse (max. 3 Amp). Push the front toggle switch into manual with ignition on: the solenoid valve should operate now. Electronic brake counter EBCP / Solenoid valve (trailer / semi-trailer): Screw valve using port 2 into the bottom connection of the pump cylinder tube (see system overview on page 5). If no space is present under the pump: mount the brake counter using a mounting support (option) on the side of the grease pump. Install the air tubing from port 2 into the bottom connection of the pump cylinder tube. Install the air tubing from air pressure tank or accessory tank to port 1 connection of the solenoid valve (see system overview on page 5). Fit the insert coupling into the exhaust (port 3) of the brake counter, the insert Y-coupling onto the back of the pump and connect both with the de-aeration tubing (see page 8, no.14, 15 and 16). Connect current supply wires from electronic brake counter to the trailer / semi-trailer power box. Attention: use a present brake light and ground connection in this box. Connect according to diagram (see page 11). Manifolds with meters: The manifolds should preferably be mounted on the chassis girders or the transfer girders (see pages 12, 13 and 14). Remove all lubrication nipples and fit the correct male stud or elbow coupling. Attention! Before removing the lubrication nipples, check if the grease points are well lubricated. If not, then lubricate these first! Attach meter tubing to existing tubing by means of nylon Tie-raps or clamping brackets; always leave sufficient length for moving parts. 17

Cutting open the multiple tubing: Avoid damaging and/or cutting the inner tubes. 1. Approximately measure the 2. Strip back. 3. Carefully cut off the stripped- 4. The freed end desired length of the tubing back part without touching looks like this. and cut open the outside the remaining piece. cover. Main tubings: Attach main tubing (5/16 outside diameter synthetic tubing) from pump to manifolds. Use a tubing cutter to make straight, neat cuts in the tubing and assemble as specified. First, place the sleeve nut over the tubing. Then fit the locking ring, with the conical side towards the end of the tubing. Do not forget to mount an insert in the main tubing! Use 3/16 and 5/16 outside diameter tubing for installation and repairs. Do not use flexible tubes due to expansion under pressure. Only use tubes prescribed by the manufacturer. Caution: keep tubing away from hot parts (exhaust etc.). Filling the grease container: The grease container must only be filled via the fill coupling mounted on the side of the grease pump. Remove the dust cap and clean the couplings before filling. Fill the container until the bottom of the support piston reaches the top of the blue triangular sticker. Major resistance can occur during filling if the filter behind the fill coupling is blocked (with dirt). Do not overfill the container. Replace dust cap after filling. Only use greases in NLGI-class EP-0 or EP-00. For lubricants see page 21. Refilling the Ecostar grease pump: On delivery of Ecostar grease pumps, both the grease container and the plunger chamber are filled with grease. This means that after only a few pump strokes, the pump delivers grease. If, however, the minimum grease level has been ignored and the pump has sucked in air, 18

Refilling the Ecostar grease pump (continue): many pump strokes may be required before grease is delivered again. After filling the grease container, you can shorten the interruption in the delivery of grease (after disconnecting the main tubing to the pump!) by blocking off the grease exhaust with your thumb during the air release of the pump. This creates a vacuum inside the pump and pressure will rise above the support piston. Grease will be pressed from the container into the plunger chamber. In this way, grease will be delivered after only a few pump strokes. Testing the electronic pulse generator EPG-10, EPG-15 and EBCP brake counter using the programmer box: To allow optimal testing of all three systems, the programmer box is equipped with an extensive program which recognise automatically if an EPG-10 timer, an EPG-15 timer or an EBCP brake counter is connected. The tester offers the possibility of: - Reading the current time and braking settings. - Changing the settings. - Retrieving the history. -Testing the lubrication system. Activating the EPG-10 system (check voltage first!) Manual control of the electronic pulse generator / solenoid valve: Turn ignition on, start the engine, check air tanks: P min. 6 bar. Activate pump cycle by means of the manual override. Put a screwdriver into the groove of the slotted valve and turn slowly clockwise (test / 1) until you feel resistance. Continue to turn slowly until the grease pump builds up pressure. Verify using a pressure gauge. If you turn the screwdriver anticlockwise (stand-by / 0) the air is released and the grease pump pressure falls away. Wait for a moment before operating the slotted valve again. Continue pumping until lubricant emerges from the manifold without air bubbles, insert plug and move on to the next manifold. Proceed until main tubing and manifolds are filled with grease. Verify using the pressure gauge that the pressure of the grease pump in the system is constant; if not, de-aerate again. If necessary, additional lubrication is possible with the manual override. It needs to be operated for long enough to enable the grease pump to build up sufficient pressure. Allow the grease pump to pump a few more times, and check that grease beads appear at all bearings. The system is now ready for operation! Setting time intervals and pulse duration of electronic pulse generator EPG-10: Settings can only be checked and modified using the EPG-10 / EPG-15 / EBCP programmer box. Time interval range: 10 minutes 8 hours, pulse duration range: 1 10 minutes, depending on vehicle use. The default settings are: time interval 2.5 hours, pulse duration 3 minutes. These cannot be changed by the user. If too much grease is delivered, extend the time interval. In the event of insufficient lubrication, shorten the time interval. 19

Activating the EPG-15 system (check voltage first!) Manual control of the solenoid valve: Turn ignition on, start the engine, check air tanks, P min. 6 bar. Put a screwdriver into the groove of the slotted valve and turn slowly clockwise (test / 1) until you feel resistance. Continue to turn slowly until the grease pump builds up pressure. Verify using a pressure gauge. If you turn the screwdriver anticlockwise (stand-by / 0) the air is released and the grease pump pressure falls away. Wait for a moment before operating the slotted valve again. With the aid of the electronic pulse generator EPG-15: Turn ignition on, start the engine, check air tanks, P min. 6 bar. Activate pump cycle by means of the test position (A) on the electronic pulse generator (60 seconds on / 60 seconds off). Continue pumping until lubricant emerges from the manifold without air-bubbles, insert plug and move on to the next manifold. Proceed until main tubing and manifolds are filled with grease. Verify using a pressure gauge that the pressure of the grease pump in the system is constant; if not, de-aerate again. Keep the electronic pulse generator in the test position for some time, and check that grease beads appear at all bearings. After this, set the electronic pulse generator to the desired position. Time interval range: 0.5 4.5 hours, depending on vehicle use. The default setting is 2.5 hours, and can be changed by user. If too much grease is delivered, extend the time interval. In the event of insufficient lubrication, shorten the time interval. If the control light stays on, use the front toggle switch (B) to reset. This switch can be used to reset the pressure alarm and also, if necessary, manual generating the output pulse for additional lubrication. The engine ignition must be on in both cases! By using the toggle switch for additional lubrication (manual), it needs to be held for a longer time to enable the grease pump build up sufficient pressure. By releasing the switch, the air is released and the grease pump pressure falls away. Wait for a moment before operating the toggle switch again. The system is now ready for operation! Position Aux (C) is for special applications. Position Aux cannot be changed by user. Adjustments can only be checked and modified with the EPG-10 / EPG-15 / EBCP programmer box. 20

Activating the EBCP system (check voltage first!) System check trailer / semi-trailer with EBCP brake counter: To test the system, the EBCP is equipped with a manual override (for testing and additional lubrication). Test procedure: Check air tanks, P min. 6 bar. Put a screwdriver into the groove of the slotted valve and turn slowly clockwise (test) until the grease pump builds up pressure. Verify using the pressure gauge mounted on the front of the grease pump. By turning the screwdriver anti-clockwise (stand-by) the air is released and the grease pump pressure falls away. Wait for a moment before operating the slotted valve again. Attention: the valve can be stick in position test after turning anticlockwise in position stand-by. In this case, close the valve by using a brake command (brake light coming on!). Setting brake count of electronic brake counter EBCP: Settings can only be checked and modified using the EPG-10 / EPG-15 / EBCP programmer box. The number of braking signals can be set between 10 and 250. The default setting is: 80 braking signals, depending on vehicle use. This cannot be changed by the user. If too much grease is delivered, increase the brake count. In the event of insufficient lubrication, decrease the brake count. The system is now ready for operation! Routine check When possible, combine the routine check with other maintenance checks! The following rules are intended as a guide for mechanics and maintenance personnel: Container. Check for: Damage: if cracked, replace with a new unit. Amount of lubricant (page 18): fill with the correct grease (page 22). Leakage in the complete pump. If the cap of the fill coupling has been dislodged, thoroughly clean the coupling before replacing the cap. Electrical connections. Check: Pressure switch, solenoid valve, electronic pulse generator EPG-10, electronic pulse generator EPG-15 or brake counter EBCP for damage / oxidation. Operation of electronic pulse generator by means of test procedure on page 20 (for tractors / trucks only!). General checks: Air tubing and air tank connections leaking or damaged? Blow-off openings blocked? Main tubing leaking or damaged? Operation of pump / electronic pulse generator on tractors /trucks: turn ignition on and follow the test procedure ; check whether grease is reaching the bearings. Verify using a pressure gauge that the pressure of the grease pump in the system is constant. Also test the pump using the manual override of the solenoid valve. On trailers / semi-trailers: check the functioning of the pump using the manual override of the solenoid valve. 21

Verify using the pressure gauge that the pressure of the grease pump in the system is constant. Inspect all lubrication points. If a lubrication point is dry (or too greasy) and the tube is not broken, first disconnect the tubing at the lubrication point (or meter). In case of no grease : remove meter and fit a new one of the correct type. In case of too greasy : remove meter and fit a new one of the correct type. Recommended lubricants Other types of grease are permitted, as long as they comply with the specifications printed on the blue and white sticker on the pump s grease container! Use NLGI EPG-0 or NLGI EPG-00 lithium-based greases. Supplier / Specifications (Bio = Biodegradable) Avia Kendall Tedcastle (T.O.P.) AVIALITH 000 EP-0 / 00 L-406 NLGI-0 G-39 AVIALITH 000 EP-00 Bio L-999 NLGI-0/00 AVIA AYNTOGREASE EP-0 Bio Texaco Maxol Multifak 6833 EP-00 BP H12-555 Multifak EP-0 Energrease ZS EP-0 / 00 Starfak EP-00 Bio Mobil Castrol Chassis Grease LBZ 00 Total DK-00 grease Mobilit SHC 007 EP-00 Bio Multis EP-0 CLS-00 grease Multis 200-00 Pennzoil Elf Pennlith EP 700 Grease EP-00 Valvoline Epexa 0 / 00 Semi-fluid Grease EP-00 Q8 Esso Rembrandt EP-0/EP-00 Beacon EP-0 / 00 Rubens EP-00 Fina Shell Ceran AD-0 Retinax CS 0/CS 00 Ceran EP-0 Alvania EP-0 (industrial) Lical Grease EP-0 Bio Chassis Bio Grease 0 Marson EPL-00 22

Troubleshooting Always use a pressure gauge, mounted on the front of the grease pump, to verify the system grease pressure! Fault: Cause: Remedy: 1. LED on dashboard System not reaching pressure. Check grease pump pressure using stays on. pressure gauge. Grease container empty and Fill container and de-aerate the air bubbles in main system. system. Pressure switch giving no signal. Check for wire ruptures or replace pressure switch. Main tubing broken. Repair (see 5). Temporary electrical fault. Check electronic pulse generator and fuse (see 3.). Reset pulse generator. Defective grease pump. Check grease pump (see 2). Defective solenoid valve. Check or replace valve (see 4). No air pressure. Air pressure 6 12 bar. 2. Pump does not work, No air pressure. Air pressure 6 12 bar. fails to reach pressure. Defective solenoid valve. Check or replace valve (see 4). Defective pulse generator. Replace pulse generator (see 3). Grease container empty and air in Fill container and de-aerate the pump pump. and, if necessary, the system. Piston does not go upwards. Disassemble tube and check piston. 3. Electronic pulse genera- Poor or interrupted connection. Check connections. tor does not work. Short-circuit. Check contacts. Defective fuse. Replace fuse, check contacts. Defective pulse generator. Replace pulse generator. 4. Solenoid valve does not Poor or interrupted electrical circuit. Check circuit, test manual override work, or does not work Blocked / dirty. Bad connection. without the electronic pulse generator properly. and check connections. 5. All bearings dry. Grease container empty. Fill container: see filling procedure + de-aerate system (see pages 18-21). Defective fuse or wire rupture. Check contacts / wire; repair or renew as necessary. Defective solenoid valve or Check, clean or replace valve and air tubing fractured. repair tubing. Defective pulse generator. Replace pulse generator (see 3). Main tubing fractured. Repair tubing and de-aerate when new piece of tubing is used. Wrong grease (too thick). Clean the container and pump the old grease out of the system (remove end stops from meter manifolds). Refill with the correct grease (see pages 18, 19 and 22). 6. One or more bearings Rupture in tubing to meter. Repair / fit new tubing. are dry. Lubrication frequency too low. Adjust pulse generator. Defective meter. Replace meter. Wrong output from meter. Replace meter with one of right size. 7. One or more bearings Meter leaking internally. Replace meter. have an excess of grease. Lubrication frequency too high. Adjust pulse generator. Wrong output from meter. Replace meter with one of right size. 23

NOTES / DRAWINGS 24

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