General Manual

Automatic Greasing System

EcoPlus

F214317R02
 General information

Type of manual General Manual

System EcoPlus Automatic Greasing System
Document number F214317R02
Release date May 2018
Revision 02

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 Manual

TABLE OF CONTENTS
1. PREFACE .........................�������������������������������������������������������5
2. GENERAL INFORMATION ���������������������������������������������������7
2.1 Introduction .....................................................................................................................�� 8
2.2 The EcoPlus automatic greasing system ...............................................................�� 9
3. COMPONENT DESCRIPTION ���������������������������������������� 11
3.1 Composition of the EcoPlus Pump unit .................................................................12
3.2 The control unit ..............................................................................................................13
3.3 Behaviour during power off / on ..............................................................................13
3.4 The piston pump ............................................................................................................13
3.5 Safety and control features ........................................................................................14
3.5.1 Relief valve..............................................................................................................14
3.5.2 Low level switch (optional)...............................................................................14
3.5.3 Manometer ............................................................................................................14
3.5.4 Revolutions of pump drive shaft....................................................................14
3.5.5 Defective wiring and short-circuits...............................................................15
3.5.6 Block switch (optional).......................................................................................15
3.5.8 Signal light..............................................................................................................16
3.6 Divider blocks ..................................................................................................................16
3.6.1 Properties................................................................................................................16
3.6.2 Composition..........................................................................................................16
3.6.3 Principle of operation.........................................................................................17
3.6.4 Non-return valves................................................................................................18
3.6.5 Failure of one of the divider segments.........................................................18
3.6.6 Closing outputs....................................................................................................18
3.6.7 Combining outputs.............................................................................................18
4. DESIGNING A SYSTEM...�����������������������������������������������������19
4.1 Introduction .....................................................................................................................20
4.2 Points of departure .......................................................................................................20
4.3 Method ..............................................................................................................................22
4.3.1 Determine the operating conditions ...........................................................22
4.3.2 Produce a greasing plan....................................................................................22
4.3.3 Determine the grease demand of the grease points..............................22
4.3.4 Group the grease points....................................................................................23
4.3.5 Determine the layout of the system..............................................................23
5. INSTALLATION ................�����������������������������������������������������25
5.1 Overview ...........................................................................................................................26
5.2 Safety precautions .........................................................................................................26
5.3 General installation directives ...................................................................................26
5.4 Mounting the pump unit ............................................................................................27
5.5 Divider blocks ..................................................................................................................27
Release date: May 2018

5.5.1 General.....................................................................................................................27
5.5.2 Assembly.................................................................................................................27
5.5.3 Mounting................................................................................................................28
5.6 Primary grease lines .....................................................................................................28
5.6.1 Line types ...............................................................................................................29
5.6.2 High pressure hose assembly..........................................................................29
5.6.3 Crimp diameter.....................................................................................................29
5.7 Secondary grease lines and couplings ..................................................................30
5.7.1 Grease line types..................................................................................................30
5.7.2 Installing the secondary lines..........................................................................30

 F214317R02 3
 EcoPlus Automatic Greasing System

5.8 Electrical wiring ..............................................................................................................31

5.8.1 Fuse ratings............................................................................................................31
5.8.2 Pin layout of the connector on the pump unit..........................................32
5.9 Bleeding the system .....................................................................................................36
5.9.1 Bleeding the pump (when required)............................................................36
5.9.2 Bleeding the primary grease line(s)...............................................................36
5.10 Commissioning of the greasing system ................................................................37
5.11 Performing a test cycle ................................................................................................37
6. MAINTENANCE................�����������������������������������������������������39
6.1 General ..............................................................................................................................40
6.2 Regularly checks of the greasing system ..............................................................40
6.3 Replacing the grease cartridge. ................................................................................41
6.3.1 Wiring diagram standard .................................................................................42
6.3.2 Wiring diagram command input....................................................................43
6.3.3 Wiring diagram Trailer .......................................................................................44
7. USER INTERFACE...........�����������������������������������������������������45
7.1 Introduction .....................................................................................................................46
7.1.1 Function keys.........................................................................................................46
7.1.2 Commands.............................................................................................................46
7.1.3 Access levels .........................................................................................................47
7.1.4 Accessing Supervisor mode.............................................................................47
7.2 Main menu .......................................................................................................................47
7.3 Information menu .........................................................................................................48
7.4 Parameter menu ............................................................................................................49
7.4.1 Cmd input sub-menu.........................................................................................51
7.4.2 Trailer sub-menu..................................................................................................52
7.4.3 Example of changing a parameter................................................................53
7.5 Diagnostics menu ..........................................................................................................54
7.5.1 Errors.........................................................................................................................54
7.5.2 Inputs sub-menu..................................................................................................56
7.6 Trouble shooting ............................................................................................................57
7.6.1 Recognizing malfunctions................................................................................57
7.6.2 General malfunction reports...........................................................................57
7.6.3 Error codes by signal light................................................................................58
7.6.4 Error codes by user interface...........................................................................58
8. TECHNICAL DATA............�����������������������������������������������������61
8.1 Technical data pump unit ...........................................................................................62
8.2 Distribution blocks ........................................................................................................63
Release date: May 2018

4 F214317R02 
 General Manual

1. PREFACE
Release date: May 2018

Preface F214317R02 5
 EcoPlus Automatic Greasing System

This general manual gives a description of the EcoPlus 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 of several components of the EcoPlus 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

problems.

Warning

Warns the user for physical injuries or serious damage to the equipment caused by im-
proper actions.

Release date: May 2018

6 F214317R02 Preface
 General Manual

2. GENERAL INFORMATION
Release date: May 2018

General information F214317R02 7

 EcoPlus Automatic Greasing System

2.1 Introduction

With a Groeneveld automatic greasing system, all the connected grease points of the vehicle
or machine are automatically lubricated with exactly the right amount of grease at just the
right moment. In addition, optimum grease distribution is attained over the whole surface to
be lubricated, All actions are automatically performed by the system. The operator needs only
to ensure the periodic change of the grease cartridge.

Groeneveld’s automatic greasing system has been thoroughly tested to guarantee a long and
trouble-free service life, even under severe operating conditions.

Besides correct installation and the use of the prescribed type of grease, a periodic check
of the operation is a condition for the continued good functioning of the system. This peri-
odic check is easy to carry out and can be done together with the usual maintenance of the
machine. Partly through a careful choice of materials, the automatic greasing system proper is
practically maintenance-free.

Attention

The use of an automatic greasing system eliminates a large proportion of the time-con-
suming work of manual lubricating. Do not forget, however, that there could still be
lubrication points that have to be lubricated by hand.

Release date: May 2018

8 F214317R02 General information

 General Manual

2.2 The EcoPlus automatic greasing system

The EcoPlus is designed for use on vehicles and machines with there own power supply for
powering the greasing system when in operation.
A version of the EcoPlus is available for use on trailers where power is supplied by the brake
lights.
The amount of grease that will be supplied to each connected grease point is governed by
ratios that result from a choice of divider segment types and the manner in which these seg-
ments are combined in the assembled divider blocks.
The pump unit can be extended with a second grease outlet. In this way the greasing system
can be separated in two systems parts on more complex vehicles or machines

A Groeneveld EcoPlus Automatic greasing system comprises of the following parts :

• An electric grease pump with cartridge, and integrated digital control unit.
• One or more divider blocks (composed of multiple divider segments).
• Primary grease lines between the pump and the divider blocks and interconnecting the
divider blocks themselves.
• Secondary grease lines between the divider blocks and the individual grease points.

1 2 3 4

1
1
3
2
1
1
3
1
1
4
1

1. EcoPlus pump
2. Primary grease lines
1
3
1
2
1

3. Distribution blocks
4.Seconday grease lines

Options available, or depending on EcoPlus model

• Pistons available in sizes;
Release date: May 2018

• No. 3 = 0.15cc, No. 4 = 0.20cc or No.5 = 0.25cc

• Block switch for monitoring grease flow on divider blocks.
• Low level switch
• Signal lamp
• Manometer for pressure indication

General information F214317R02 9

 EcoPlus Automatic Greasing System

Notes

Release date: May 2018

10 F214317R02 General information

 General Manual

3. COMPONENT DESCRIPTION
Release date: May 2018

Component description F214317R02 11

 EcoPlus Automatic Greasing System

3.1 Composition of the EcoPlus Pump unit

12 4

10
8 3

14

13
7

5
11
1. Cartridge cover / O-ring
Release date: May 2018

2. Low level magnet ring

3. Grease cartridge NLGI-2
4. Wiring harness.
5. Motor cover.
6. Control unit 12/24 Vdc
7. Motor 12 or 24 Vdc
8. Pump body
9. Pump Flange 6
10. Pump element (no.3,4 or 5)
11. Relief valve with manometer
12. Low level switch
13. Plug M12x1.5
14. Plug M20x1.5

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 General Manual

3.2 The control unit

The control and monitoring unit initiates and controls the greasing cycles of the greasing sys-
tem. All required system and program parameters (e.g. interval time, grease delivery) can be
set. The control unit monitors the performance of various components of the greasing system
and processes, stores and reports the malfunctions it detects.

The control unit can be programmed or read out using the user interface on the display

P3 Motor rotation -

P2 Motor rotation signal P1 Low level sensor contact 1

P1 Display light ground
P1 Motor rotation + P2 Low level sensor contact 2 Display information P2 Display light power

J7
J4 J5
J10
P5 Lamp output
J3 P4 Input B contact 2

P1 Power supply P3 Input B contact 1

Keypad
P2 Ground P2 Input A contact 2

P1 Input A contact 1
J1 J6
J2

P1 Motor +

P2 Motor -

3.3 Behaviour during power off / on

When power to the system is switched off (power down), the software saves several variables
in the control unit memory bank. These are retrieved at power on, so the software can resume
operation at the point when the power was switched off. This means that when, for example,
the system is switched off during a pump cycle, the remaining revolutions needed to finish
the pump cycle are stored in the memory bank. When the system is powered again, the previ-
ously aborted pump cycle is resumed and the remaining cam shaft revolutions finished.

3.4 The piston pump

The electric motor drives the a cam shaft through a reduction gear. The cam drives a piston in
a cylinder with a non-return valve. The eccentric cam moves the piston back and forth, once
every revolution of the cam shaft. During the return stroke of the piston, grease is sucked
from the cartridge into the cylinder
Release date: May 2018

During the forward stroke of the piston, the grease is pressed, via the non-return valve, to-
wards the outlet(s) of the pump unit.
The amount of grease supplied during each stroke (revolutions of the cam shaft) depends on
the diameter of the cylinder and the stroke length of the piston.

Component description F214317R02 13

 EcoPlus Automatic Greasing System

3.5 Safety and control features

3.5.1 Relief valve

A relief valve is installed directly after the pump outlet. This relief valve leads the grease back
to the reservoir if the maximum grease pressure (275 bar) is exceeded during the pump phase
of a grease cycle.
The grease pressure may become too high for example, when one of the divider blocks or
grease lines becomes blocked or when the viscosity of the grease has become too high (at
low temperature).

3.5.2 Low level switch

The EcoPlus pumps can be equipped with a low level switch.

After reaching this low level the cartridge will still contain approximately 150cc of grease.
The pump will disable itself after the pre-set number of greasing cycles with an activated low
level switch (Default on 50 cycles, parameter can be set in supervisor mode) is reached.

For example : 10 revolutions (10 x 0.25cc = 2.5cc per cycle) 150 cc : 2.5cc per cycle = 60 cycles.
The parameter should be set to 60 cycles. The pump will execute 60 pump cycles before the
pump stops (this parameter has to be set).

3.5.3 Manometer

The EcoPlus can be equipped with a manometer. (Depended on model)

This will represent the current pressure in the pump outlet, this can visually proof the system
is working correctly or whether the relief valve is active when the pressure is to high.
The background of the manometer is coloured with red and green sections so even with out
system knowledge, a read out of the system functionality can be made.

Release date: May 2018

Manometer with relief valve

3.5.4 Revolutions of pump drive shaft

An in the motor integrated sensor monitors the drive shaft revolutions. When it does not
sense a revolution every two seconds the control unit will show “Slow motor” on the display
and register this as a fault.

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 General Manual

3.5.5 Defective wiring and short-circuits

Open-loads (interruptions) in the wiring of the minimum level switch, the electric motor and
any signal lamp will be detected, processed and stored by the control unit. This is also applica-
ble to short-circuits in the wiring.

3.5.6 Block switch (optional)

The EcoPlus automatic greasing system can be equipped with a switch for monitoring piston
movement in one or two divider blocks (Not on trailer version). When this switch does not
change state during a number of successive greasing cycles (from open to closed or from
closed to open), this will /could result in a pump stop as indicated on the display and the
lamp.

Attention

Please be aware that at low temperatures it can take more successive cycles to cause a
single state change of the block switch. This is caused by the following system variables
and parameter.

• Operating temperature
The colder the operating temperature, the higher the required operating pressure due to
resistance of the pistons in the divider block and the connected secondary lines. So when
last cycle was executed in the ambient temperature of 20°C and the next cycle to be exe-
cuted is at a temperature of 0°C. This results in that the grease pressure in the primary-line
needs to be higher then before, so it will take longer for the pistons in the divider to start
moving.
• Expansion of the primary grease line
The more the line expands under pressure, the longer it will take to reach the pressure level
that makes the pistons in the divider block moves again.
• Length of the primary grease line
The longer the line, the longer it will take to reach the pressure level that makes the pistons
in the divider block move again.
• Grease quantity per cycle
The smaller the set grease quantity per greasing cycle the longer it takes to reach the pres-
sure level that makes the pistons in the divider block move again.

Another possibility is that occasionally a state change is missed by the controller, because
power was switched off the moment the divider block started operation(e.g. the sun heated
the divider block until all pressure in the primary line was gone) although the timer does
compare the power-on block switch state with the power -off state, it still occasionally miss a
state change when it changed state twice and became equal again.

So we advise to maintain a wide safety margin of minimal 10 cycles, when it comes to setting
Release date: May 2018

this parameter. Only in case of a very short main-line and / or a high grease output setting,
causing a number of state changes per greasing cycle is it allowed to be set below 10 cycles.

Component description F214317R02 15

 EcoPlus Automatic Greasing System

3.5.8 Signal light

The signal light has to be mounted in the field
of vision of the driver and out of direct sunlight,
because of the visibility of the signals.

When the control units detects two successive

cycles with an active low level switch the signal
lamp will start flashing until the cartridge is
replaced.

01
When the control unit detects an error the signal

6.
97
D lamp will be lit continuously
VEL
ENE
GRO
Refer to ”Error codes by signal light” on page 58
for more information.

3.6 Divider blocks

3.6.1 Properties

The divider blocks distribute and measure out the grease to the various grease points in a
progressive way. That means that all grease points will be greased successively one after
another. The divider blocks can be placed in sequence, in which case an output of a divider
block is used to feed the next block by a primary grease line.

3.6.2 Composition
A progressive divider block comprises the follow-
ing components:
2 3
1. A start-segment
2. Min. 3 and Max. 12 divider segments
3. An end-segment

The divider segments are available in several sizes:

Size 1 (2x 0.045cc or 1x 0.090cc)
Size 2 (2x 0.075cc or 1x 0.150cc)
Size 3 (2x 0.125cc or 1x 0.250cc)
Size 4 (2x 0.200cc or 1x 0.400cc)
1 Size 6 (2x 0.300cc or 1x 0.600cc)
Release date: May 2018

Each divider segment always has two grease outlets, with identical grease outputs per cycle.
The connections of the grease channels between the divider segments are sealed with O-rings.
The divider segments between the start- and end-segment are strung together by two bolts.
For each additional divider segment, longer bolts are required.

16 F214317R02 Component description

 General Manual

3.6.3 Principle of operation

1 2 3
1a
1 1 1

2b
2 2 2

3b
3 3 3

4 5 6
1b
1 1 1

2a
2 2 2

3a
3 3 3

To operate, progressive divider blocks need grease pressure supplied by the pump:
1. The lubricant flows from the entrance of the block, via piston 3, through all segments to
the left-hand side of piston 1.
When piston 1 is pushed to the right by the grease pressure. The grease at the right-hand
side of piston 1 will be pressed to outlet 1a.
2. 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.
Piston 2 is then moves and supplies grease to output 2b.
3. 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
outlet 3b.
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 outlet 1b.
5. Afterwards piston 2 will also be pressed to the left and will supply lubricant to outlet 2a.
6. Afterwards piston 3 will also be pressed to the left and will supply lubricant to outlet 3a.
7. The divider 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.
Release date: May 2018

Attention
The description and illustration above assume there is a fixed starting-off point for the
divider segments in the divider block. This is not so. The divider block always continues
from where it left-off during the previous pump phase of the grease cycle.

Warning
To be able to operate at all a divider block needs to have at least three divider segments.

Component description F214317R02 17

 EcoPlus Automatic Greasing System

3.6.4 Non-return valves

Non-return valves are installed in the outputs of the divider block to prevent lubricant from
flowing back into the divider block. All outlets which are used to interconnect divider blocks
must be fitted with non-return valves. Outlets which secondary grease lines are connected on,
must also be fitted with non-return valves if significantly high return pressures are expected.

3.6.5 Failure of one of the divider segments

If one of the divider segments fails to operate properly (due to internal or external damage)
the whole greasing system will fail to operate.

3.6.6 Closing outputs

An output may only be closed-off after removal of the internal plug(2) that separates the two
outputs of a divider 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 divider block will become inoperable if the internal plug is not removed.

3.6.7 Combining outputs

The outputs of two or more segments of a divider block can be combined by installing ex-
ternal interconnection lines (1). To make this possible the internal plug (2), that separates the
outputs of a divider segment needs to be removed. The total grease output in that case is the
sum of all outputs interconnected.

0.090cc 0.045
1
(2)

0.045cc 0.045cc
1

0.125cc 0.125cc
3

0.200 0.125
3
0.450cc (2)
(1)
Release date: May 2018

0.200 0.200cc
4

(3)
The values in the illustration represent the grease outputs of the ports in cc’s per complete
cycle of the divider block. The amount supplied (3) is determined by the pump.

18 F214317R02 Component description

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4. DESIGNING A SYSTEM
Release date: May 2018

Designing a system F214317R02 19

 EcoPlus Automatic Greasing System

4.1 Introduction

The following aspects influence the design of a EcoPlus greasing system:

• The number of grease points to be connected.

• 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.
• The space available on the vehicle or machine for the pump unit and the divider blocks.
• The NLGI class of the grease to be used and the lowest ambient temperature under which
the greasing system is expected to function.

4.2 Points of departure

Pump
Maximum working pressure 275 bar
Piston size see table 1
Number of outlets 1 or 2
Divider blocks
Maximum number of divider blocks in series 2
Available segment types see table 2
Minimum number of divider segments in a distribution block 3
Maximum number of divider segments in a distribution block 12
Internal resistance in a distribution block, related to see table 3
• The number of segments in the divider block
• The NLGI class of the grease used
• The ambient operating temperatures
Primary and secondary grease lines
Internal resistance in the grease lines see table 4
• 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
Release date: May 2018

Slide bearing 15 bar

20 F214317R02 Designing a system

 General Manual

Table 1: Grease delivery of the available piston types (cc)

No revolutions Piston No.3 Piston No.4 Piston No.5

(Delivery parameter) 0.15cc /stroke 0.20cc/stroke 0.25cc/stroke
1 0.15 0.20 0.25
5 0.75 1.00 1.25
10 1.50 2.00 2.50
50 7.50 10.00 12.50
99 14.85 19.80 24.75

Table 2: Outputs of divider segments

Segment type Output per segment(2 outputs / cc) Output with combined outputs (cc)
1 2 x 0.045 cc 0.090 cc
2 2 x 0.075 cc 0.150 cc
3 2 x 0.125 cc 0.250 cc
4 2 x 0.200 cc 0.400 cc
6 2 x 0.300 cc 0.600 cc

Table 3: Internal resistance in a divider block (bar)

Grease T [°C] 3 Divider segments 8 Divider segments 12 Divider segments

class
+20 14 bar 16 bar 22 bar
+10 28 bar 24 bar 26 bar
0 34 bar 44 bar 55 bar
NLGI 2
-10 52 bar 58 bar 72 bar
-15 73 bar 77 bar 100 bar
-20 80 bar 85 bar 170 bar
Table 4 : Internal resistance of the grease lines (bar per metre)

Grease T [°C] PA Ø 3/16 PA Ø 6 High-pressure hose High-pressure hose

class Ø 2.4mm i.d. Ø 3.0mm i.d. DN4 Ø4.0mm i.d. DN6 Ø6.0mm i.d.
+20 6 bar 6 bar 6 bar 3 bar
+10 14 bar 8 bar 6 bar 4 bar
0 17 bar 12 bar 10 bar 6 bar
NLGI 2
-10 25 bar 18 bar 16 bar 9 bar
-15 34 bar 25 bar 20 bar 14 bar
Release date: May 2018

-20 55 bar 36 bar 30 bar 22 bar

Attention

The values in these tables were collected during laboratory and field tests and will be supple-
mented as new data becomes available.

Designing a system F214317R02 21

 EcoPlus Automatic Greasing System

4.3 Method

1. Determine the conditions under which the system must be able to operate.
2. Make a greasing plan.
3. Indicate, in the greasing plan, the grease demand and greasing interval required by each
grease point.
4. Compile the greasing points in groups.
5. Determine the required layout of the greasing system.
6. Check by calculation, whether the system will be able to operate under the conditions
determined during step 1.

4.3.1 Determine the operating conditions

Determine what the lowest expected ambient temperature will be.

4.3.2 Produce a greasing plan

Make a simplified layout drawing of the vehicle or the machine. Indicate the positions of the
grease points on that drawing and number them.

4.3.3 Determine the grease demand of the grease points

The grease demand of a grease point over a period of time is determined by grease output
per greasing cycle and greasing frequency. This information can be extracted from :

• The maintenance instruction for the vehicle or machine.

• Existing greasing plans for grease systems.
• Information provided by the manufacturer, importer,dealer maintenance personal or user.
• See tables below.

Table on road

Description Grease Description Grease

demand demand
Upper king pin 0.125 cc King pin, single grease point 0.250 cc
Lower king pin 0.125 cc Automatic slack adjuster 0.045 cc
Suspension bearing, Suspension bearing
0.045 cc 0.045 cc
brake axle (drum side) (slack adjuster side)
Upper stabiliser 0.045 cc Lower stabiliser 0.045 cc
Spring shackle 0.125 cc Spring pin 0.125 cc
Release date: May 2018

Cabin bearing 0.045 cc 5th wheel locking pin 0.045 cc

5th wheel 0.600 cc Tail board hinge 0.045 cc
5th wheel, tilt bearing 0.075 cc Support bearing drive shaft
0.045 cc
Tail board cylinder 0.045 cc
These values are a indication and this can greatly vary dependant on type and use of the vehicle.

22 F214317R02 Designing a system

 General Manual

Table off road (based on a mini excavator with a operating weight till 7,5 tonnes )
Description Grease Description Grease
demand demand
Turntable 0.125 cc Stick pivot bearing 0.250 cc
Arm cylinder barrel end 0.250 cc Bucket cylinder barrel end 0.045 cc
Arm cylinder rod end 0.075 cc Bucket cylinder rod end 0.150 cc
Upper tail swing bearing 0.125 cc
Dog bone pin 0.200 cc
Lower tail swing bearing 0.125 cc
Boom pin 0.200 cc
Swing cylinder barrel end 0.045 cc
Bucket pin 0.600 cc
Swing cylinder rod end 0.045 cc
Stick cylinder barrel end 0.045 cc Bottom H link pin 0.400 cc
Stick cylinder rod end 0.045 cc Upper H link pin per side 0.150 cc
These values are a indication and this can greatly vary dependant on type and use of the vehicle.

4.3.4 Group the grease points

Compile groups of grease points, taking into account the following:

• A main divider block or multiple grease outlets on the EcoPlus pump may be utilised.
• The maximum and minimum number of divider segments that can be combined in a single
divider block.
• Determine the lengths of the primary and secondary lines in relation with the NLGI class of
grease that must be used and the projected operating temperatures.
• Any special demands that might be placed on the grease output and the greasing interval

4.3.5 Determine the layout of the system.

Note the positions of the pump unit and the divider blocks on the greasing plan.
Determine the required number of pump outlets, composition of the divider blocks, based on
the group of grease points to be connected with that block. Indicate the routing of the grease
lines on the greasing plan.

Take into account :

• The routing of the lines and the type of secondary grease lines that will be used (single or
composite lines with 2 to 3 separate lines)
• The possibility to combine the output of divider segments
• The minimum (3) and the maximum (12) number of divider segments that can be combined
in to a single divider block.

Calculate the grease demand of each divider block in the system per complete cycle.
This is required to determine the parameters in the pump.
Release date: May 2018

Designing a system F214317R02 23

 EcoPlus Automatic Greasing System

System featuring a main divider block

In a system with more then two divider blocks or when the grease ratio between the two
divider blocks cannot be met with the available pump piston sizes, a main divider block is
required.

Determine the composition of the main divider block by:

• Determining the ratios of the grease demands of the divider blocks to be connected to the
main divider block.
• Selecting divider segments types for the main divider block with which the ratios are most
precisely matched.
• Determining the required grease output (delivery dependent to the piston used in each
outlet) of the pump. This is the sum of the grease demands of all the divider blocks con-
nected to a pump outlet (excluding the main divider block).
This value can be used in a later stage to determine the grease output of the pump.

System without a main divider block

In case of a system with two divider blocks of which the ratio between the grease require-
ments of both blocks per cycle can be met with the available outlet sizes of the pump, an
extra outlet is preferred above the use of a main divider block.

Determine the lengths of the primary grease lines between the pump unit and the divider
blocks(and between divider blocks) and the length of the secondary grease lines between the
divider blocks and the grease points. Note those lengths on the greasing plan.
Determine the number of non-return valves that must be incorporated into the greasing
system.

Checking the system

Before the components of the system are assembled and installed, the projected system
should be checked, by calculation against the operating conditions it was designed for.
The loss of pressure in the system may not exceed Pp (pp equals 90% of the maximum oper-
ating pressure supplied by the pump unit.)

1. Calculate the pressure loss Pv over the divider blocks, under the set operating conditions
using table 2.
2. Determine using the greasing plan which grease point is furthest from the pump. Calcu-
late , using table 3 the total pressure loss “PI” over that grease line.
3. Determine which type of grease point is connected to this grease line. Determine the
resistance “Ps” induced by that type of grease point (see Points of departure)
4. Calculate the largest total loss of pressure “Pt” for each outlet by adding the values
Release date: May 2018

of the pressure losses in the grease lines, divider blocks and the at the grease point.
(Pt = Pv + PI + Ps)
5. Check that Pt < Pp

If the loss of pressure in the system exceeds Pp investigate the following:

1. Is it possible to use a grease of a lower NLGI class ?

2. Is it possible to raise the minimum operating temperature requirement ?
3. It might be necessary to redesign the system and reconsider whether :
• Is it not better to omit the main divider block by using a extra outlet on the pump.
• The layout of the system can be modified to shorten the grease lines or to reconfigure
the divider blocks.
• Using a grease line of a larger diameter to reduce the pressure loss.

After the redesign always recalculate the suitability of the system

24 F214317R02 Designing a system

 General Manual

5. INSTALLATION
Release date: May 2018

Installation F214317R02 25
 EcoPlus Automatic Greasing System

5.1 Overview

To install the Groeneveld greasing system the following tasks must be performed:

1. Mounting the pump with integrated control unit.

2. Mounting the progressive divider blocks.
3. Mounting the primary grease lines (between pump and divider blocks and between the
divider blocks themselves.
4. Mounting the secondary grease lines and couplings.
5. Mounting the electrical wiring.
6. Testing of the system.

5.2 Safety precautions

1. Take the necessary precautions to prevent potentially dangerous situations from occur-
ring during installation, checking and maintenance.
2. Always apply or use adequate safety measures to prevent bodily harm and damage
before you start working.
3. Ensure that the machine is immobilised before you start work. Therefore remove the
ignition key and store it in a safe place.
4. Pay special attention to blocking parts such as dipper arm. Make sure that it is safe to
work under these parts and that they cannot drop down.
5. Never work underneath a machine that is raised by a jack only. Always use a trestle and
check that the ground is firm and flat enough.
6. Beware when working on a vehicle with air-suspension, the air pressure can drop caus-
ing the vehicle to lower unexpectedly.
7. Only work underneath the cab when its fully tilted and secured, if its required to work in
the area with a unsecured cab, block it yourselves.
8. Disconnect the earth-clamp from the battery. This prevents electrical equipment being
inadvertently activated.
9. Adhere to all regulations, specifications and limitations as specified by the manufacturer
of the machine.
10. Use only clean tools that fit and are designed for the specific task you want to perform
with them.
11. A machine may only be operated by those who are competent to do so and aware of all
possible dangers. If necessary, an expert should be consulted.
12. Keep the working area clean and tidy. This enhances safety.

5.3 General installation directives

1. Check the contents of the parts kit using the parts list included in the kit. Especially
check that the voltage of the pump matches the voltage of the vehicle.
Release date: May 2018

2. Before start installing the greasing system, check that all the grease points are open and
furnished with a sufficient amount of grease. If that is not the case, grease the grease
point by hand. This prevents insufficient greasing of the grease point during the period
following the first greasing cycles of the greasing system.
3. Apply Teflon tape, or another type of sealant (e.g. Loctite), to the coupling and plugs, if
not already fitted with O-rings,gaskets or sealing rings. While mounting the couplings
and plugs, make sure that the tape does not cause internal contamination of the system.
4. Prevent any contamination of the system during installation. Use clean tools and
clean the locations on the machine where the pump unit and other parts are to be
installed. Even small contamination can cause the greasing system to malfunction.
Flush the primary grease lines after installation or maintenance, if contaminations or
moisture could not be prevented from entering the system. The de-aerate procedure
may be used to flush the system.

26 F214317R02 Installation
 General Manual

5. During installation of grease hoses and electric wires, ensure that:

• The hoses and wires are not fastened to or near hot parts such as exhaust, turbo or air
conditioning unit.
• The hoses and wires taut and fixed in place with small or large straps or clamps.
• The hoses and wires are not installed alongside moving parts in such a way that they
may become damaged (in time).
• The hoses and wires have a sufficient length, particularly if they are laid to moving
parts. Check this by shifting the moving parts to its extreme positions.
• Ensure that grommets are used wherever there is a chance of a hose or wire being
damaged.

5.4 Mounting the pump unit

1. Determine together with the client where the pump unit should be mounted, if this is
not already indicated in machine-specific installation instructions. Make sure that:
• The pump unit is easily accessible for replacing the cartridge.
• The grease level is easy to inspect visually.
• The pump unit is protected against possible damage.
2. Investigate whether existing holes of the machine can be used to mount the mounting
plate of the pump unit.
Always follow the directions of the machine manufacturer when you need to drill holes.
Be sure not to damage anything (e.g. lines or wires) that may be present behind the part
in which you drill a hole. After drilling a hole, always remove the swarf (with compressed
air).
3. If the mounting plate is to be welded onto the machine, the directions of the machine
manufacturer should be strictly adhered to.
4. Mount the mounting plate with the pump unit onto the machine.
5. Remove the transport plugs from the grease outlet.
6. Mount the couplings for the primary grease lines onto the outlet of the pump unit.

5.5 Divider blocks

5.5.1 General

The composition of a progressive divider block is always machine/vehicle specific. If the

divider blocks are part of an installation kit the divider blocks will usually be pre-assembled
including the secondary lines.

5.5.2 Assembly

The Divider block must be assembled before it can be installed on the vehicle/machine.
To ensure the reliability of the greasing system, the divider blocks should be assembled in a
Release date: May 2018

clean, dust-free environment.

The criteria that governs the composition (number and type of divider segments) of a divider
block are discussed in the designing a system (4) section of this manual.

Installation F214317R02 27
 EcoPlus Automatic Greasing System

1. First study the drawing of the divider 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 lines are available.
3. Begin by placing the start-segment onto the work bench with the port for the primary
grease line facing downwards.
4. Place, in the order as indicated on the drawing the various divider segments on top of
the start segment. Place the end segment at the top of the stack. Ensure that all the
openings in the segments are lined-up and check that the required O-rings have been
correctly placed between all segments.
5. Place the compression bolts with serrated lock washers through their respective holes.
Tighten the two bolts alternately and in phases (Allen key : 5mm) Torque 12 Nm
6. If the two outlets of the divider segment need to be combined , remove the internal
plug that separates the two outlets (Allen key 2.5mm). The grease output of the port that
remains open will then be double its normal output.
7. Mount the couplings, non-return valves and plugs into the outlets of the divider blocks,
as indicated on the drawings.
8. Mount the secondary grease lines.
9. Connect the grease pump or manual grease gun to the port of the primary grease line to
test the operation of the divider block and check for leakage.

5.5.3 Mounting

Determine the location of the divider block on the vehicle/machine. Consult the specific
installation instruction manual (if present) and take account of :

• No stresses may be present in the mounted divider block. Its best to use mounting brackets
to install the divider blocks.
• The divider blocks should not be installed near to moving parts.
• The divider blocks should not be installed near parts that become hot (e.g. turbo charger,
exhaust.
• Existing mounting holes in the chassis should be used whenever possible.

The divider blocks can be mounted with a mounting bracket in two ways:

1. First mount the brackets. Then mount the distribution block onto the brackets. This
method is compulsory if the brackets are welded on the vehicle or machine.
2. First mount the divider block onto the bracket. Then mount this assembly on the vehicle/
machine.

Which method is preferred depends on the manoeuvring space available.

Attention
Release date: May 2018

Always apply serrated lock washers to the M5 mounting nuts and bolts of the divider
blocks. Tighten the bolts alternately and evenly. Maximum torque 5 Nm.

5.6 Primary grease lines

The primary grease lines are situated between the pump and the divider blocks and/or be-
tween the main divider block and divider blocks.
The most common line used in EcoPlus installation is DN4. This high quality hose combines
compactness with high strength and flexibility

28 F214317R02 Installation
 General Manual

5.6.1 Line types

• High pressure hose DN4 (5/32) : F123414, Diameters inside 4.0mm, outside 8.6mm
• High pressure hose DN6 (1/4) : F113422. Diameters inside 6.4mm, outside 12.2mm
• Metal tube with sizes Ø 6x1mm or Ø 8x1mm;

5.6.2 High pressure hose assembly

1. Cut the length of the hose to the required length;

2. Remove any burrs and other remnants produced by cutting the hose and clean the
grease hose by blowing it through.
3. Assemble the removable fitting or crimp fittings.
4. Fill the hose with grease. (if not pre-filled) with either a pneumatic or hand operated
grease gun;
5. Install the hose and fix it into place with cable ties or clamps. Don’t connect the primary
hose to the pump outlet yet, if you want to use a pneumatic or hand operated grease
gun to de-aearate the system.

Removable fittings

1. Clamp the ferrule in a vice;

2. Turn the hose counter clockwise into the ferrule till the end;
3. Turn the hose clockwise 1/4 up to 1/2 a turn;
4. Apply oil or grease to the insert, the ferrule and the inside of the hose;
5. Turn the hose insert clockwise in the ferrule until it’s in position without tension;
6. Mount the coupling at the other end of the hose in a similar way.

Crimp fittings

1. Check if the press holds the correct die set for the required ferrule diameter;
2. Slide the ferrule over the hose until the end.
3. If necessary use some oil and slide the insert into the end of the grease hose until the
insert is completely in the hose.
4. Pull the ferrule back slightly until it touches the outside edges of the coupling pin.
While doing this, ensure that the insert remains in place and is not pressed out of the
hose;
5. Place the assembly into the press and use the press to crimp to the required diameter;
6. Check the resulting outside diameter by measuring the insert with a calliper.(only possi-
ble for straight inserts)
7. Mount the crimp fitting at the other end of the grease hose in a similar way.

5.6.3 Crimp diameter

• Ferrule DN4 (5/32): F115311 crimp diameter 1.4 mm; +0/-0.2

Release date: May 2018

• Ferrule DN6 (1/4) : F113941 crimp diameter 13.9 mm; +0/-0.2

Installation F214317R02 29
 EcoPlus Automatic Greasing System

5.7 Secondary grease lines and couplings

5.7.1 Grease line types

The secondary grease lines are the ones between the divider blocks and the grease points.
These grease lines are connected to the grease points with the aid of a special couplings. A
wide variety of couplings are available.

Which types of couplings should be applied, depends among other things, on :

• The screw thread at the grease point.
• The position of the grease point.
• The direction in which the grease line approaches the grease point.
• The type of grease line used (poly-amide lines with brass or steel couplings;metal lines or
high-pressure lines with steel couplings).
• The operation conditions.

The secondary grease lines can be supplied in a number of different sizes and materials;
• Poly-amide lines with outside diameter of 6mm (standard),
• Stainless steel lines with the outside diameters of 6 mm (standard).
• Cunifer lines with a outside diameter of 6 mm (standard)
• High-pressure hoses with inside diameters of 4mm or 6mm (5/32” and 1/4”)

The type of secondary grease lines commonly used in transport and off-road applications is
the poly-amide lines with a outside diameter of 6mm. These grease lines are also supplied
as composite lines. In a composite line 2 or 3 poly-amide lines are held together by a single
plastic jacket. Each grease line in such a composite line has its own colour (red,blue,black), so
that they can easily be distinguished at the ends of the composite line,this is useful for during
installation and maintenance.

If a composite line is connected to a divider segments with different grease outputs, the indi-
vidual grease lines should be connected as follows.
• Divider segments with the lowest output Red line
• Divider segments with the highest output Black line
• Divider segments with intermediate output Blue line.

5.7.2 Installing the secondary lines

Pay attention to the following points during the installation of the secondary lines and cou-
plings:
• Always make sure the thread on the couplings and the grease points are identical.
• To identify them, elbow couplings with metric thread are marked with a “M”. Straight cou-
plings with metric thread have a groove on there hexagons.
Release date: May 2018

• Always apply a spacer between the airlines for the brake actuator and grease lines when
routing alongside them. This prevents the airlines for the brake actuator from damage due
to the use of cable ties and friction from the grease line.
• Never add extra grease points off you own accord. The integrity of certain structures may be
adversely affected by drilling holes. Always adhere to the relevant directive issued by the
vehicle manufacturer.

30 F214317R02 Installation
 General Manual

If a vehicle specific installation instruction is available, the types (or combination) of couplings
to be used at grease point will have been noted on that plan.

First remove the existing grease nipple at the grease point, and replace it by the required cou-
plings. If the grease point to be connected is a so-called “added” or “relocated” grease point a
hole must be drilled and threaded with the same thread as the required coupling.
Do not forget to clean the new hole of any debris. Mount the required coupling in the grease
point(see installation instruction). Make sure that elbow couplings point in the direction of
the grease line. Avoid unnecessary (sharp) corners in the grease line.

Attention

Always check that the newly drilled grease point is open by applying a grease gun to it.

1. Determine the most suitable route for the grease line to the grease point.
2. Cut the grease line at roughly the required length.
3. Determine approximately , the required length of the individual grease lines in a com-
posite line.
4. Strip and remove the outer jacket over this length. Make absolutely sure that you do not
damage the individual grease lines.
5. Fix the lines in place with cable ties or clamps up to the coupling at the grease point.
6. Cut the individual grease lines to the required length and connect it with the coupling to
the grease point.
Release date: May 2018

Installation F214317R02 31
 EcoPlus Automatic Greasing System

5.8 Installing the piston assembly

To replace or place a extra piston, follow the following guidelines.

• Make sure the direct environment is clean and free of dirt.
• Remove the Allen plug from the pump housing.
• Pull out the piston so its still in the cylinder but long enough to be place behind the cam.
• Tilt the assembly slightly so the piston can be placed behind the cam.
• Level the assembly and press on the cartridge (1) unit grease with out bubbles is visible.(2)
• Tighten the assembly in the pump housing.
• Clean the excess grease,around the assembly.
• Preform a test cycle to assure the correct working and bleed the system.

Attention

When after placement of the piston assembly you get a slow motor warning on the dis-
play, the pump assembly is not placed correctly.

Pump housing

Piston

Stirring gear

Cam

1. Pull out the piston assembly. 2. Tilt the piston assembly a little while inserting to be sure
it will be positioned without resistance behind the cam.
(1)

(2)

3. Press cartridge (1) until grease without bubbles 4. Tighten the piston assembly into the pump housing.
(2) is visible.

Release date: May 2018

32 F214317R02 Installation
 General Manual

5.9 Electrical wiring

Detailed wiring diagrams are available as aids to install the electrical wiring. Where possible,
pre-assembled wiring harnesses are delivered.

Attention

In order to avoid damage to the electrical system of vehicle or machine, the correct fuses
must be installed in the power supply circuit. Consult the table below or the wiring dia-
grams for the correct fuse ratings.

• Connect the wires only when the main components (pump unit, signal lamp and optional )
have been installed.
• Lay the wiring as far as possible along the passage of the existing electrical wiring and fas-
ten them with small or large straps.
• Always make wire connections in the cabin or in a watertight terminal box.

5.9.1 Fuse ratings

Voltage Fuse (pin 1) Fuse (pin 3 Fuse type

trailer mode)
12 Vdc 15 A 15 A Slow acting automotive fuse
24 Vdc 10 A 10 A Slow acting automotive fuse

5.9.2 Pin layout of the connector on the pump unit

Truck version
Connector Description of connection Diameter {mm2} Wire colour in wiring
pin number harness
1 Supply voltage (+15) 2.50 Red
2 Ground (-31) 2.50 Black
3 Input A Signal 0.75 Green
4 Inputs combined ground 0.75 Orange
5 Input B Signal 0.75 Pink
6 K-line 0.75 Purple
7 Lamp output (-) 0.75 Light blue
8 Lamp output (+) 0.75 Grey
* Input A = Block switch
* Input B = Block switch or command input.
Release date: May 2018

Trailer version
Connector Description of connection Diameter {mm2} Wire colour in wiring
pin number harness
1 Brake light (+) 2.50 Red
2 Ground (-31) 2.50 Black
3 Tail light (+) 2.50 Green
4 Lamp output (-) 0.75 Yellow
6 K-line 0.75 Purple

Installation F214317R02 33
 EcoPlus Automatic Greasing System

Truck version

* =Optional

Block switch* Block switch* Led*

A B

22K

22K
-31

K-line
87a
85

87
86

30

Fuse
Pink (5)
Red (1)
Black (2)
Green (3)
Orange (4)

Purple (6)
Blue (7)
Grey (8)

12v : 15 Amp
A

24v : 10 Amp

+15 +30
Release date: May 2018

Red (1)
Black (2)
Green (3)
Orange (4)
Pink (5)
Purple (6)
Blue (7)
Grey (8)

34 F214317R02 Installation
 General Manual

Truck version with command input

** * =Optional
Commando input :
Only possible to connect Block switch* Cmd input** Led*
a ground to start/stop the timer.
-31

A -

22K
-31

K-line
87a
85

87
86

30

Fuse
Pink (5)
Red (1)
Black (2)
Green (3)
Orange (4)

Purple (6)
Blue (7)
Grey (8)

12v : 15 Amp
A

24v : 10 Amp

+15 +30

Red (1)
Release date: May 2018

Black (2)
Green (3)
Orange (4)
Pink (5)
Purple (6)
Blue (7)
Grey (8)

Installation F214317R02 35
 EcoPlus Automatic Greasing System

Trailer version

* =Optional
BL = Brake lights
Led*
TL = Tail lights

+
+

* BL
TL

Red (1)
Black (2)
Green (3)
Yellow (4)

Release date: May 2018

Green (1)
Black (2)
Orange (3)
Blue (4)

36 F214317R02 Installation
 General Manual

5.10 Bleeding the system

5.10.1 Bleeding the pump (when required)

Proceed as follows:

• Disconnect the grease hose from the pump.

• In order to avoid soiling of the workplace, place a beaker or plastic mug under the grease
outlet port of the pump.
• Switch on the power of the machine.
• Start a multiple test by selecting this in the diagnostic menu. (or set interval to 1 Min and
delivery to 20 rotations, this will cause the pump to continuously run)
• Allow it to run until a continuous stream of grease emerges from the pump outlet port.
• When air bubbles no longer appears, the pump motor can be switched off by switching off
the ignition (or setting the interval and delivery back to original settings)
• Connect the grease hose to the pump again.

5.10.2 Bleeding the primary grease line(s)

Between pump and main or end divider block.

• Disconnect the primary grease line at the (main) divider block side.
• Place a breaker or plastic mug under the hose end.
• Switch-on the power of the machine.
• Start the pump by activating a multiple test in the diagnostic menu
• Switch-off power when grease starts to come out of the hose.
• Connect the grease hose to the (main) divider block.

Between main divider block and end divider block.

• Disconnect the primary grease line at the end divider block side.
• Place a breaker or plastic mug under the hose end.
• Switch-on the power of the machine.
• Start the pump by activating a multiple test in the diagnostic menu.
• Switch-off power when grease starts to come out of the hose.
• Connect the grease hose to the end divider block.

Bleeding the divider block, secondary grease lines and connected grease points.
• Switch-on the power of the machine.
• Start the pump by activating a multiple test in the diagnostic menu.
• Repeat this action until grease starts to come out of all grease points.
• Switch-off power when done.

Notes
Release date: May 2018

• The standard 5/32 primary hose and the 6mm PA secondary are pre-filled with grease and
do not need to be bleed during installation.
• We strongly advise to:
• Pre-fill other lines used as primary or secondary lines in the progressive system before
installation.
• Check all bearings for sufficiently greasing before installation.
This prevents long fill up times during bleeding of the system, while other grease points get
over-greased and start leaking.

Installation F214317R02 37
 EcoPlus Automatic Greasing System

5.11 Commissioning of the greasing system

The switch on the ignition (+15) and check that the user interface becomes active (also check
the signal light if connected). In doing this you ensure that the voltage and ground connec-
tions are correctly connected, the fuse has not blown( and the signal lamp is OK).
Now check the desired system parameters.

• The status of the remaining interval time or pump revolutions is visible on the status
screen.
• Whether errors are stored in the error menu. It is possible, however, that a minimum level
in the grease reservoir (“low level”) of an interrupted lamp circuit (“OL lamp circuit”) error is
stored due to the fact the voltage to the pump was switched on at a time when, for exam-
ple the grease cartridge had not yet been fitted or that the signal lamp was not yet con-
nected. Always check whether such errors in the error counts or indication counts groups
disappear after a correctly performed cycle.
• Check the system one last time for leaks. If leaks are found, remedy these and thoroughly
clean the area of the leakage so that the client does not get the impression that the system
is still leaking.
• Explain and demonstrate the function of the system to the client or machine dealer, if pres-
ent.
• The system is now ready for operation.

5.12 Performing a test cycle

A test cycle can be performed by using the user interface, as follows:

1. The supply voltage for the pump unit must be available (ignition ON).
2. Enter the main menu by pushing any button twice, scroll down to Diagnostic menu
and press select, scroll to the single of multi test cycle and press select again to start the
chosen test option,
3. This start the chosen greasing cycle.

To end the test cycle immediately switch the ignition off.

Any errors that occur during the test cycle will not be indicated by the signal lamp and will
not be stored in the memory bank of the control unit.

Attention

When the pump unit is already performing a pump phase, a test cycle cannot be per-
formed in this way.
Release date: May 2018

38 F214317R02 Installation
 General Manual

6. MAINTENANCE
Release date: May 2018

Maintenance F214317R02 39
 EcoPlus Automatic Greasing System

6.1 General

The maintenance of the Groeneveld EcoPlus system can be combined with the normal main-
tenance of the machine.

Warning

If a high-pressure steam/water jet is used to clean the machine, the pump unit should
not be directly exposed to the jet. This to prevent water from entering the pump unit
through its de-aerating opening. During normal operation, however, water will never be
able to enter the pump unit.

Attention

The automatic greasing system reduces the time and effort spent on manual greasing
significantly. However, do not forget that there may be greasing points that are not
served by the greasing system and must still be greased by hand.

6.2 Regularly checks of the greasing system

Check the following points of the EcoPlus greasing system:

1. The grease level in the cartridge of the pump unit (replace in time).
2. The pump unit for damage and leakage.
3. The operation of the whole greasing system. Perform a test cycle.
4. Retrieve the error codes stored in the memory bank of the control unit, by using the user
interface
5. The primary and secondary grease lines for damage and leaking.
6. A collar of fresh grease should be present alongside the outside of all grease points.

Release date: May 2018

40 F214317R02 Maintenance
 General Manual

6.3 Replacing the grease cartridge.

The EcoPlus pump is fitted with a grease cartridge. The cartridge is placed under a cover and
is easily and quickly replaced.

Attention

When replacing the grease cartridge, prevent dirt from entering the pump. Before
removing the cover and the cartridge, first clean the pump and its immediate surround-
ings. When removing a cartridge that is not completely empty be aware that grease can
drip out of the cartridge. Protect the environment and prevent grease spills. Empty car-
tridges and grease residues must be disposed off in accordance with local regulations.

1. Turn the cover with bayonet catch counter-clockwise and lift it off the pump;
2. Turn the empty cartridge with rubber gasket counter-clockwise and lift it straight up;
3. Check to make sure the sealing ring is removed with the old cartridge;
4. Remove the cap from the new cartridge
5. Put a film of grease onto the ring of the cartridge.
6. Screw the cartridge clockwise onto the pump;
7. Reuse the magnet ring if the pump is equipped with a low level indicator, slide the mag-
net ring over the first ridge of the cartridge,make sure the ring is positioned correctly;
8. Clean the cover and place it on the pump then turn it clockwise until locked.

1 2 3 4 5 6

A
A

B
C
Release date: May 2018

Maintenance F214317R02 41
 EcoPlus Automatic Greasing System

6.3.1 Wiring diagram standard

1. Pump unit.
2. Control unit.
3. Pump motor.
4. Revolution sensor.
5. Minimum level switch.
6. Battery of the machine.
7. Ignition switch.
8. Signal light.
9. Input B (block switch)
10. Input A (block switch)

Ground 1
4
Output Signal

Vdc Low 5

- + 6

7
lgn

2 GND

J4 J5 1 +15
8 8
J3 7
6 B
9
J1 5
22K
4
J2 A
Release date: May 2018

2 3 10

22K

- +
PUMP
3

42 F214317R02 Maintenance
 General Manual

6.3.2 Wiring diagram command input

1. Pump unit.
2. Control unit.
3. Pump motor.
4. Revolution sensor.
5. Minimum level switch.
6. Battery of the machine.
7. Ignition switch.
8. Signal light.
9. Input command
10. Input A (block switch)

Attention

When using the command: the switch needs to be to a ground signal on pin 5

(see page 34)

Ground 1
4
Output Signal

Vdc Low 5

- + 6

7
lgn

2 GND

J4 J5 1 +15
8 8
J3 7
6 B
9
J1 5
4
J2 A
2 3 10
Release date: May 2018

22K

- +
PUMP
3

Maintenance F214317R02 43
 EcoPlus Automatic Greasing System

6.3.3 Wiring diagram Trailer

1. Pump unit.
2. Control unit.
3. Pump motor.
4. Revolution sensor.
5. Minimum level switch.
6. Ground of the machine.
7. Brake lights.
8. Tail lights.
9. Lamp output

Ground 1
Output Signal

Vdc Low 5

- 6
BL

2 GND
1 7
J4 J5

3 TL
J3
+
6
J1
8
4
J2

9
2

- +
PUMP
Release date: May 2018

44 F214317R02 Maintenance
 General Manual

7. USER INTERFACE
Release date: May 2018

User interface F214317R02 45

 EcoPlus Automatic Greasing System

7.1 Introduction

The EcoPlus has a display with a user interface on the pump unit, this removes the need for
expensive diagnostic tools to change parameters and read out information and fault codes.

Attention

Representation of the screens is dependent on the software version, pump version and
settings made.

7.1.1 Function keys

The EcoPlus has a keypad with three function keys to navigate the user interface, the com-
mands per key can change per menu. Most common commands are Up,Down and Select.

By pressing the left and middle key simultaneously the program will go back one level.

7.1.2 Commands

Abbreviation Meaning
Up Increases the value selected
Down Decreases the value selected
Release date: May 2018

Select To confirm the selection

Save Store a setting
Cancel Stop the planned action
Clear Resets a counter
Prev Go to previous screen
Next Go to next screen
List Go to the current menu list

46 F214317R02 User interface

 General Manual

7.1.3 Access levels

In the user interface you have access to parameters and diagnostic information.
There are two access levels in the user interface.
• Basic, this is the normal operating mode of the EcoPlus and will give access to all the basic
functionalities.
• Supervisor mode, this is for the mechanic to set specific parameters and diagnostic informa-
tion.
When a ‘S’ is shown in the upper right corner of the screen,this means that the ‘Supervisor’
mode is active.

7.1.4 Accessing Supervisor mode

Attention

Only access supervisor mode when you are familiar with the EcoPlus system and have
had the required technical training.
Changes made in the parameters are stored in the memory

Take the following steps to get access to the supervisor mode.

• Make sure you are in the Main menu
• Press the outer two buttons on the keypad simultaneously <Up> and <Select>
• Hold these down for a period of two seconds.
• Hold the middle key <Down> with in two seconds of releasing the outer keys, hold the key
down until “S” appears in the top right corner (flashing)

7.2 Main menu

On power on the display becomes active.
The start up screen is shown shortly.

EcoPlus • When programmed to trailer version this screen is not

shown

The screen shows the running program phase and the

EcoPlus remaining period of this phase.

Most likely “Interval” with the remaining period in minutes

9 • Light: press one of the three buttons for lighting the
Interval min screen temporary (approx 60 sec).
When the light is switched on the screen now shows
Release date: May 2018

.--- Light ---. the menu indication instead, pressing on of the three
buttons will enter the menu.

Main Menu The main menu:

• Information: informs about the pump data
i Information • Parameters: to set and check the parameters
Parameters • Diagnostics: to preform tests and read out errors.

Diagnostics
Up Down Select

User interface F214317R02 47

 EcoPlus Automatic Greasing System

7.3 Information menu

Main Menu Select the information menu, by moving the cursor this is
done by pressing <Up> or <Down> until the Information
i Information tab is highlighted.
Then press <Select>
Parameters
Diagnostics
Up Down Select

Information • On-time hrs: Total hours the ignition (truck mode) or tail
light (trailer mode)has been active.
i On-Time hrs • Pump cycles: The total successful pump cycles.
• Total rev: The total cam shaft revolutions made.
i Pump cycles
i Total rev
Up Down Select

Information • Total test: Total test cycles preformed.

• No Pwr-on: The total times the pump was powered.
i Total test • SW version: The software version in the control unit.

i No Pwr-on
i SW version
Up Down Select

Information • Serial No: Shows the serial number of the control unit.
The serial number of the pump is show on the identifica-
i Serial Nº tion plate on the side of the motor cover.
• Back: Goes back to the main menu.
i BrakePulses
i Back Only visible when Trailer mode is active.
Up Down Select
• No BrakePulses: Show the number of counted brake
pulses of the vehicle in total, only visible in the Trailer
mode
Release date: May 2018

Only visible when Supervisor mode is active.

• On-Time sec: Total seconds the ignition (truck mode) or

tail light (trailer mode)has been active.

48 F214317R02 User interface

 General Manual

7.4 Parameter menu

Main Menu Select the parameters menu, by moving the cursor, this is
done by pressing <Up> or <Down> until the parameter tab
i Information is highlighted.
Then press <Select>
Parameters
Diagnostics
Up Down Select

Parameters • Interval: Sets the time between grease cycles in minutes

Default : 180 minutes; Range : 1-300 minutes
i Interval • Delivery: Sets the number of cam shaft revolutions per
grease cycle.
Delivery Default : 10 revolutions, Range: 1 - 99 revolutions
Display
Up Down Select Delivery is depended on the pump element used.
Standard element used is No.5 = 0.25cc per revolution.
With a delivery setting of 10 revolutions the pump pro-
Parameters duces 10 x 0.25cc = 2.5cc per cycle

i Interval • Display: Enters the display sub-menu.

i BrakePulses • BrakePulses: Set the number of brake pulses required to

Delivery start a grease cycle.
Up Down Select Only visible when Trailer mode is active

Display The Display sub menu contains the following parameters;

i Light on • Light on: The percentage of light when the display is

Light dim active. Default: 90%; Range 0 - 100%
• Light dim: The percentage of light when the display is
Contrast in-active. Default: 25%; Range 0 - 100%
Up Down Select • Contrast: Sets the contrast of the display.
Default: 15 units; Range; 0 - 40 units.

Attention

In the trailer version of the EcoPlus the “light on” and “light dim” percentage is set to 0%
Release date: May 2018

to prevent that the screen lights up on each brake pulse.

(This could confuse other traffic)

Parameters • Restore Par : The Restore Par option restores all parame-
ters to the same values as to when it was saved.
i Display
i Restore Par • If no parameters were saved after the installation (by
using the Store Par function in the supervisor menu).
Back It will restore the default factory settings, these might
Up Down Select not be correct for your application

User interface F214317R02 49

 EcoPlus Automatic Greasing System

Attention

The following parameters can only be set in supervisor mode, Only access these if you
are familiar with the EcoPlus system and have had the required technical training.

Changes made in the parameters are stored in the memory

Parameters • Block sw A: The number of greasing cycles in which min-

imal 1 state change of the optional block switch needs
i Block sw A to be detected in order to prevent the error from being
activated.
Block sw B Default: 0 (=off ); Range: 0 - 29 cycles)
Low Lvl
Up Down Select An optional block switch monitors the piston movement
of a divider block during a single or number of greasing
cycles. A piston movement indicates that grease from
the pump is still passing through. (see page 15)

Parameters • Block sw B: see Block switch A for explanation.

• (Parameter not available is Cmd input is activated)
i Block sw A • Low lvl: this option activates the low level switch.
Block sw B The control unit will ignore info from the low level sen-
sor if this is not activated.
Low Lvl Default: depended on model EcoPlus
Up Down Select

Attention

In the trailer version of the EcoPlus block switches are not supported.

Parameters • Pump stop: The allowed number of pump cycles to be

preformed after reaching low level,before the pump is
i Pump stop stopped due to calculated empty.
(Parameter not available if Low lvl is set to “off”)
Lamp outp.
Trailer Default: 50 cycles; Range: 0 - 200 cycles.
Release date: May 2018

Up Down Select
Low level warning will become active when approx-
imately 150 cc grease is left in the cartridge, use the
pump delivery to calculate the correct number of cycles.

Example : 10 revolutions (10 x 0.25cc = 2.5cc per cycle

150 cc : 2.5cc per cycle = 60 cycles.

• Lamp output: Set this option to “On” when a lamp is

connected to the output.
Default: On, Range: On or Off

50 F214317R02 User interface

 General Manual

Parameters • Save Par: This saves all the parameters currently made
in the pump, so it can be restored all at once in on a later
i Cmd input date.
• Restore Par : The Restore Par option restores all parame-
Save Par ters to the same values as to when it was saved.
Restore Par
Up Down Select

Parameters Selecting either Cmd or Trailer mode will change the pa-
rameter en information shown accordingly.
i Cmd input
Trailer For example when Block switch B is activated Cmd will not
no visible for selection and vice versa.

Up Down Select

7.4.1 Cmd input sub-menu

Attention

Cmd mode can only be active on truck pump, its not possible to use the Cmd option in
trailer versions of the pump, and will not be shown in the menu if trailer is active.

Cmd input • Ci by pin-5: This sets the timer so it starts counting down
the interval time when a signal (ground) is put on pin 5.
i Ci by pin-5 (block switch B will no longer be available)
Default: Off, Range: On or Off
off
On Off Select

Cmd input • Ci invert: This inverts the function of the of the com-
mand input, when invert is on the timer now stops when
i Ci invert a signal(ground) is put on pin 5
Default: Off, Range: On or Off
Release date: May 2018

off
On Off Select

EcoPlus Cmd • When the pump is set to command input mode, this is
visible on the status screen during normal operation by
the addition of Cmd after the EcoPlus name.
9
stopped min
• If the interval time is not counting down, this is shown
on the stats display. This will return to interval when the
.--- Menu ---.
timer is running.

User interface F214317R02 51

 EcoPlus Automatic Greasing System

7.4.2 Trailer sub-menu

Attention

Trailer mode will only be active on trailer pump, its not possible to use the trailer option
in truck versions of the pump.

Trailer • Trailer: This sets the trailer mode to active in the soft-
ware, this changes the behaviour of several inputs and
i Trailer adds and removes certain menu options in the interface.

Off
On Off Select

Trailer • Dual input: This sets the timer to accept power on pin 1
and pin 3 of the harness.
i Trailer Default: Off, Range: On or Off

Dual input Pin 1 = Brake light / Pin 3 = Tail light

Intv & brake • Intv & brake: Set this to “On” is you want to use both the
Up Down Select
brake counter and a interval timer to start a grease cycle,
both counters reset if a cycle is started.
Default: Off, Range: On or Off

Trailer • Brake delay: This sets the amount of time the brake
i Brake delay pulse needs to be active on pin 1 for it to count for the
timer. This to avoid rapid brake pulses from starting a
Back cycle to early.
Default: 0.5 sec, Range 0.5 - 25.0 sec
• Back: goes back to the Parameter menu.
Up Down Select

EcoPlus Tr • When the pump is set to trailer mode, this is visible on

the status screen during normal operation by the addi-
tion of Tr after the EcoPlus name.
9
Interval
Release date: May 2018

Brks
• Also the interval will be show in Brakes left before cycle
(or switching between brakes and minutes when “Intv &
.--- Menu ---.
brake” is set to “On”

Parameters • After activation of the trailer mode, a new parameter will

appear in the Parameter menu, this option No Braking al-
i Interval lows you to set the number of brake pulses are required
to start a cycle.
BrakePulses
Delivery • BrakePulses: The number of brake pulses required to
start a cycle.
Up Down Select
• Default: 50 Brake pulses, Range 1 - 999 Brake pulses

52 F214317R02 User interface

 General Manual

7.4.3 Example of changing a parameter

How to set the interval time.

EcoPlus • In the “status” screen press <any key> twice to get to the
main menu
9
Interval min

.--- Menu ---.

Main Menu • In the main menu, Press <down> once until “Parameters”
is highlighted, then press <Select>
i Information
Parameters
Diagnostics
Up Down Select

Parameters • Press <Up> or <Down> until the desired parameter is

highlighted and press select. For this example we use
i Interval Interval.
Delivery
Display
Up Down Select

i Interval • In the interval parameter there are three digits visible

that make up the units to be set in minutes.
• Press <Up> or <Down> to change the value of the first
180 Min Max: 300 highlighted digit then press <select> to confirm and go
Min: 1
to the next digit.

Up Down Select
Release date: May 2018

i Interval • After the last digit is selected, the user gets a confirma-
tion screen, with the entered value.
• Press <Save> to accept this as the new value.
180 Min Confrim? • Press <Cancel> to decline the new setting and the cur-
rent (old) parameter will be used.
• Both action will result in going to back to the Parameter
Save Cancel
menu

User interface F214317R02 53

 EcoPlus Automatic Greasing System

7.5 Diagnostics menu

Main Menu Select the diagnostics menu, by moving the cursor this is
done by pressing <up> or <down> until the parameter tab
i Information is highlighted.
Then press <Select>
Parameters
Diagnostics
Up Down Select

Diagnostics • Single test: Starts a single test cycle, one time the pump
revolutions set in the delivery parameter.
i Single test • Multi test: Starts a multiple test cycle, 10x the set revolu-
tions per cycle set in the delivery parameter.
Multi test
X Errors
Up Down Select

EcoPlus • When in a Multi test the display will show this, and count
down the remaining revolutions,the delivery cannot be
i Multi test changed, it will say “busy” on the screen.
108 • Cancel any test cycle, by switching the power off.
Pumping Revs
.--- Light ---.

7.5.1 Errors

In the Errors sub menu, the errors are subdivided into three categories; pending, total and
successive errors. In this paragraph the screens of the total errors are shown and explained.

Attention :
• Pending errors are also shown on the status screen of the display
• Total errors can be cleared in supervisor mode.
• When error counters are still empty (no errors) the pending en successive group will
Release date: May 2018

only show low level, Empty and Timing.

• When options like Block switch A or B are not activated in the parameters they will
also not show up in the errors.

Errors • Pending: The current errors of the system (also visible as

a warning on the status screen)
Xi Pending • Total: The number of times an error has occurred since
X Total the installation of the pump.
• Successive: The maximum number of times an error
X Successive has occurred in consecutive cycles. The value is only
Up Down Select overwritten if a new sequence of errors is larger then the
preceding sequence.

54 F214317R02 User interface

 General Manual

Total • Low level: The low level switch indicates the grease level
in the cartridge is low and would need to be changed
Xi Low level soon
• Empty: Pump stopped because the set amount of al-
X Empty lowed cycles has been exceeded.
X No flow A
Up Down Select

Total • No flow A: Block switch A did not change state at least

once during the set number of cycles in succession
Xi No flow A making it uncertain whether grease is still flowing from
X No flow B the divider block(s)
• No flow B: same as A only for the second input
X Timing • Timing: The set number of rotations per cycle exceed
Up Down Select the set interval time. Hence the pump is constantly
pumping, please check settings.

Total • System OV: The maximum voltage was detected, the

system will shut down to protect itself.
Xi System OV • Low Power: The voltage was to low for the system to
X Low Power function and the system has shut down.
• Motor short circuit: A short circuit was detected and the
X Motor SC attempted cycle was aborted.
Up Down Select

Total • Motor over current: A current above the maximum

Xi Motor OC allowed has been detected and the attempted cycle was
aborted.
X Motor OL • Motor open load: Open circuit detected to the pump
X Lamp OC motor.
• Lamp over current: a high current on the lamp circuit
Up Down Select
was detected

Total • Parameter Err: The control unit encountered corrupt

parameter data and restored to its default values, these
Xi Param Err do not guarantee a correct function of the system. An
error will be generated
X System Err • System Err: The control unit detected a corruption in the
Release date: May 2018

X Slow Motor software of the system, Changing the control unit will
most like be necessary
Up Down Select
• Slow motor: The control unit detected no rotation of the
pump motor when the motor was powered.

• Error time: When pressing next while reading out a

X Time low level error, it will go to the error time screen, showing you the
i time the fault has been active.
0.00Hrs
Prev Next

User interface F214317R02 55

 EcoPlus Automatic Greasing System

7.5.2 Inputs sub-menu

In the inputs sub-menu, the user can test the functioning and state of the inputs.

Diagnostics Select the inputs sub-menu, by moving the cursor this is

done by pressing <up> or <down> until the Inputs tab is
i Inputs highlighted.
Then press <Select>
Back
Up Down Select

Inputs • Low level: Allows you to test and see the current state of
i Low level the low level switch
• Input A: Allows you to test and see the current state of
i Input A Input A.
• Truck pump A = Block switch
i Input B • Trailer pump A = Brake input
Up Down Select • Input B: Allows you to test and see the current state of
Input B.
• Truck pump B = Block switch B or Cmd input
• Trailer pump B = not used.

• Low level: Allows you to test and see the current state of
i Low level the low level switch.
• 0 : sufficient: the magnetic ring of the cartridge is
high so it doesn’t make contact with the switch.
0= sufficent
0 1= low
• 1: low: the magnetic ring of the cartridge is low so
it makes contact with the switch.
Prev Next List

• Input A: Allows you to test and see the current state of

i Input A Input A
• 0: input not active.
0= Input low (-) • 1: input active.
0 1= Input high (+)
• Screen for input B is the same.
Release date: May 2018

Prev Next List

Attention

The input A and B represent different functions depending on the model and connection
of the pump. Knowledge of the system is required to fully utilise the input screen. Below
are the functions possible.
Truck version
• A= Block switch A.
• B= Block switch B or Cmd input.

Trailer version
• A= Brake input
• B= not connected on trailer pump.

56 F214317R02 User interface

 General Manual

7.6 Trouble shooting

The greasing system is equipped with an electronic control unit with a memory bank. All rele-
vant data concerning the functioning of the greasing system are stored in that memory bank.
This data can be read out.

7.6.1 Recognizing malfunctions

Malfunctioning are recognizable or discovered as follows:

• The signal light no longer lights up when the ignition is switched on.
• The signal light shows a malfunction.
• The status screen give a error warning
• Reading the errors stored in the memory of the control unit.
• The grease cartridge hasn’t lowered in some time.
• When visually checking the grease point, it appears that no fresh grease collar is present.

7.6.2 General malfunction reports

Problem Cause Solution
Signal light does not light-up No supply voltage (+15) on pin Check the fuse and, if required,
after ignition was switched on. Nº 1 or at signal lamp. replace the fuse.
(Only applicable in Truck mode)
No ground (-31) potential on Check the ground connection
pin Nº 2. and if required repair it.

Signal light defective. Replace the bulb or LED.

Wiring to the pump unit or to Check the wiring and, if re-

the signal light defective. quired, repair it.
Signal light flashes Low grease level in the car- Be ready to replace the car-
tridge tridge in some time
Signal light ON continuously. Empty grease reservoir, pump Replace cartridge.
stopped
Retrieve fault by using the user
Persistent system error. interface and repair the system.
The greasing points connected The grease delivery and/or the Increase the number of rev-
are too dry, but no malfunction interval time is not set correctly olution and/or set a shorter
is indicated. for the current application. interval time.
Too much grease has been The grease output (cc) and/ Decrease the number of rev-
applied to all grease points or the interval time is not set olutions and/or set a longer
correctly for the current appli- interval time.
cation.
Release date: May 2018

One or more grease points are Improper composition of the Change the composition of the
too dry while others received divider blocks divider blocks (recalculate the
the correct amount of grease. system).

Attention

For setting and reading out the parameters of the control unit the user interface is used.
The user interface can also be used to consult a list of faults that have occurred and were
stored in the memory of the control unit.

User interface F214317R02 57

 EcoPlus Automatic Greasing System

7.6.3 Error codes by signal light

The signal lamp blinks when the cartridge has a low level, and is continuously on when car-
tridge is empty or any other error.

For locating the cause of errors always use the user interface on the pump.

Attention

The signal light and terror message in the user interface resets when the problem has
been resolved.

7.6.4 Error codes by user interface

Low level
EcoPlus • Cause:
• Grease in the cartridge reached the level where it
Low level activates the low level switch (approximately 150 cc
7 grease is left in the system).
Pumping Rev • Solution:
• Replace the cartridge in due time (see page 41)
.--- Light ---. Warning and lamp reset automatically when car-
tridge is replaced.

Empty
EcoPlus • Cause:
• Pump is disabled because the maximum allowed
Cartridge cycles with a active low level was reached, and the
pump is disabled
Pump stop • Solution:
• Replace the cartridge (see page 41) Warning and
.--- Light ---. lamp reset automatically when cartridge is re-
placed.

Timing fault
EcoPlus • Cause:
• The set interval time has passed before the end of
Timing fault the current pump cycle, causing the pump to be
9 continuously pumping
Pumping Revs • Solution:
• Check the parameter interval and delivery.
.--- Menu ---.
Release date: May 2018

No flow A - B
EcoPlus • Cause:
• Block switch A or B did not change state at least
Xi No flow A once during the set number of pump cycles, mak-
9 ing it uncertain whether grease is still reaching the
Pumping Revs divider block (not applicable on Trailer pump) .
• Solution:
.--- Menu ---. • Check the primary grease lines for leakage.
• Check grease delivery pump
• Check block switch functionality

58 F214317R02 User interface

 General Manual

Slow motor
EcoPlus • Cause:
• The motor does not run or runs more slowly then
normal.
• The motor revolution sensor is broken or discon-
Slow motor nected from the circuit board.
• Solution:
.--- Light ---. • Grease has become to hard due to low temperature
and the pump has difficulties greasing. Grease is
not suited for the low temperatures
• Piston for the pump outlet is mounted wrong and is
blocking the rotation of the motor, check outlet and
reinstall correctly
• Check the revolution sensor wiring and its function-
ality

System error 1 = Over voltage

EcoPlus • Cause:
• Power supply voltage exceeded 32 Volt, outputs will
X SYS ERR: 1 be disabled to protect the system.
• Solution:
Interval • Check power supply

.--- Menu ---.

System error 2 = Low power

EcoPlus • Cause:
X SYS ERR: 2 • Faulty battery (vehicle) below 9 volts
• Faulty wiring (ground)
Interval • Corroded pin-contacts in connector(s).
• Solution:
• Charge or replace battery.
.--- Menu ---.
• Check wiring. Replace or repair when necessary.
• Check connections at pump and in cabin. Replace
or repair when necessary.
System error 4 = Pump over current
EcoPlus • Cause:
• Control unit detected a too high current draw to
X SYS ERR: 4 pump motor and aborted the attempted cycle,
caused by:
Interval • Drive shaft blocked
• Extreme low working temperatures in combination
Release date: May 2018

.--- Menu ---. with a grease not suitable for these conditions.
• Solution:
• Check pump cam shaft or pistons on damage or
blockage and repair or renew pump section.
• Contact grease supplier, replace the grease in the
cartridge with grease suited for the conditions and
de-aerate the system

User interface F214317R02 59

 EcoPlus Automatic Greasing System

System error 8 = Pump open load

EcoPlus • Cause:
• Control unit detected an unusual resistance in the
X SYS ERR: 8 pump motor circuit and aborted the attempted
pump cycle, possibly caused by:
Interval • Interrupted wiring
• Defective motor
.--- Menu ---. • Corroded contacts
• Defective control unit
• Solution:
• Check wiring harness between pump motor and
circuit board and restore when necessary.
• Check the resistance of the motor. Replace when
necessary.
• Check wiring harness contacts on corrosion. Re-
place when necessary.
• Replace control unit when error persists.

System error 16 = Lamp over load

EcoPlus • Cause:
• Lamp output detected a to high current and will be
X SYS ERR: 16 disabled to protect the system.
• Solution:
Interval • Check power supply.
• Check wiring.
.--- Menu ---.

System error 32 = Parameter checksum error

EcoPlus • Cause:
• Control unit encountered corrupted parameters
X SYS ERR: 32 during power up and restored the default pro-
duction settings which can be unsuitable for the
Interval current application.
• Solution:
.--- Menu ---. • Replace control unit.
Release date: May 2018

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8. TECHNICAL DATA
Release date: May 2018

Technical data F214317R02 61

 EcoPlus Automatic Greasing System

8.1 Technical data pump unit

Maximum operating pressure: 275 bar

Operating temperature: -20 ... +70 °C

Power supply voltage: 12 or 24 Vdc

Rating pump motor (nominal at 20°C): 36 W

Rest current: 10 mA

Lamp output: 10 W

Advised fusing: 15A (12 Vdc) / 10A (24Vdc)

Capacity grease reservoir: 1.7 litres

Minimum level switch: optional

Pump material: hard anodised aluminium - nylon reinforced

Delivery: Piston stroke per outlet;

No.3 = 0.15cc No.4 = 0.20cc No.5 = 0.25cc

Protection class: IP67

EMC regulations (Truck version): ECE-R10, rev.5, ISO 13766 (2006), ISO 14982 (2009)
EN 12895 (2000), EN 13309 (2010),EN 50498 (2010)
EMC regulations (Trailer version: ECE-R10, rev.5, EN 50498 (2010)

Grease type: NLGI-2

Release date: May 2018

290

262 164

62 F214317R02 Technical data

 General Manual

8.2 Distribution blocks

Maximum operating pressure : 275bar

Operating temperature : -25 ... +70 °C

Minimum number of divider segments : 3 (excluding start and end segments)

Maximum number of divider segments : 12 (excluding start and end segments)

Material : Steel Zinc-Nickel alloy plated

Material O-rings : NBR

Grease inlet port thread : M10 x 1 mm

Delivery per segment type 1 : 2x 0.045cc or 1x 0.090cc

Delivery per segment type 2 : 2x 0.075cc or 1x 0.150cc

Delivery per segment type 3 : 2x 0.125cc or 1x 0.250cc

Delivery per segment type 4 : 2x 0.200cc or 1x 0.400cc

Delivery per segment type 6 : 2x 0.300cc or 1x 0.600cc

24 16 16 16 16 16 24
16,5
25

17
25

16,5
Release date: May 2018

8 4
16 16 16 16 16 16 16 16
36

Technical data F214317R02 63

Notes
 www.groeneveld-group.com

Groeneveld Transport Efficiency B.V. • Stephensonweg 12 • 4207 HB Gorinchem • P.O. Box 777 • 4200 AT Gorinchem
The Netherlands • T. +31 (0)183 641 400 • F. +31 (0)183 624 474 • www.groeneveld-group.com