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Operation and Maintenance Manual
CONTENTS
IDENTIFICATION DATA OF MANUFACTURER ......................................................................................... 2
CUSTOMER SERVICE .................................................................................................................................. 2
GENERAL INDICATIONS ............................................................................................................................. 3
APPLICABLE SAFETY STANDARDS ......................................................................................................... 3
DECLARATION OF CONFORMITY.............................................................................................................. 4
1.1.0) EXPECTED USE ................................................................................................................................. 5
1.2.0) SAFETY WARNINGS .......................................................................................................................... 5
1.3.0) DESCRIPTION OF THE SYSTEM ...................................................................................................... 5
1.4.0) TECHNICAL SPECIFICATIONS ......................................................................................................... 6

1.4.1) PNEUMATIC PUMP ........................................................................................................................ 6
1.4.2) "INTERCHANGEABLE" GREASE RESERVOIR ........................................................................... 8
1.4.3) OPERATION .................................................................................................................................... 9
1.4.4) EXPLODED VIEW OF PUMP EUR 1 ............................................................................................ 10
1.4.5) 12/24 V DC PROGRAMMABLE TIMER ........................................................................................ 11
1.4.6) 24 V DC PROGRAMMABLE TIMER FOR TRAILERS AND SEMI-TRAILERS ........................... 13
1.4.7) WIRING DIAGRAMS ..................................................................................................................... 15
1.4.8) METERS ........................................................................................................................................ 16
1.5.0) STORAGE ......................................................................................................................................... 17
1.6.0) ASSEMBLING THE SYSTEM ........................................................................................................... 17

1.6.1) OPERATING PROCEDURE ......................................................................................................... 18
1.7.0) LUBRICANTS.................................................................................................................................... 20
1.8.0) STARTING THE SYSTEM ................................................................................................................ 20

1.8.1) OPERATING PROCEDURE .......................................................................................................... 20
1.9.0) MAINTENANCE OPERATIONS ....................................................................................................... 21

1.9.1) SCHEDULED MAINTENANCE ..................................................................................................... 21
1.10.0) TROUBLESHOOTING .................................................................................................................... 22
1.11.0) TUBING ........................................................................................................................................... 22
1.12.0) FITTINGS......................................................................................................................................... 24
1.13.0) DISPENSERS .................................................................................................................................. 27
1.14.0) ACCESSORIES ............................................................................................................................... 28
1
COMPANY OVERVIEW
CIAPONI LUBRIFICAZIONE CENTRALIZZATA s.r.l. is specialized in the design, manufacture and

installation of centralized lubrication systems. After initially focusing exclusively on automotive lubrication
systems, the company progressively acquired a wide-ranging experience and started to develop a series of
products designed to be installed on earth moving machines and industrial equipment.
Over the years, this highly dynamic company has progressively implemented state-of-the-art design,
production and quality assurance systems.
In 2001 its corporate quality assurance system was certified as compliant with standard UNI EN ISO 9001 by
Det Norske Veritas Italia s.r.l.
Its corporate mission is to supply customers with a full range of support services, from the supply and
installation of reliable products to on-site reparation and maintenance.
CIAPONI LUBRIFICAZIONE CENTRALIZZATA s.r.l., a leading company with over 35 years of experience,
has progressively extended its activities beyond Italian borders and now successfully operates in several
European countries.
IDENTIFICATION DATA OF MANUFACTURER
Corporate name - CIAPONI LUBRIFICAZIONE CENTRALIZZATA s.r.l.
Address - Via Vittorio Alfieri, 10 – San Miniato Basso

56028 - Pisa - ITALY
Telephone - +39 0571 42661
Fax - +39 0571 42244
Web site - www.ciaponi.it
E-mail - info@ciaponi.it
VAT – Tax-payer code - IT01160480503
CUSTOMER SERVICE
CIAPONI LUBRIFICAZIONE CENTRALIZZATA s.r.l. works in close contact with its customers by providing
them with a qualified post-sales service.
To request additional information or order spare parts, it is sufficient to contact the Customer Service at the
telephone and fax numbers shown above.
2
GENERAL INDICATIONS
© All rights reserved. First edition, November 2005

This operation and maintenance manual has been written by CIAPONI LUBRIFICAZIONE
CENTRALIZZATA s.r.l. and is supplied without warranties.
Therefore, this document cannot be copied, reproduced, distributed, transmitted or transcribed in whole or in
part without the prior written authorization of CIAPONI LUBRIFICAZIONE CENTRALIZZATA s.r.l.
In addition, the manufacturer is authorized to change the content of this manual at any time and without
warning, for technical or commercial reasons, or for compliance with current regulations and standards.
The aim of the manual is to provide the user with all the information required to install, use, service and
dismantle the centralized lubrication system.
CIAPONI LUBRIFICAZIONE CENTRALIZZATA s.r.l. declines all responsibility for damage or faults
resulting from the failure to comply with the warnings and indications provided below.
Therefore, it is always advisable to:
• Carefully read all the sections of the Operation and Maintenance Manual.
• Store this manual in a safe location, next to the system, so that it can be easily consulted for reference.
APPLICABLE SAFETY STANDARDS
Centralized lubrication systems are designed, manufactured and installed in compliance with the
requirements of Directive 89/392/EEC. The EC marking label, placed in the location shown in Figure 1,
contains the following information:
• Identification data of manufacturer
• Model
• Voltage
• Serial number
• Month and year of manufacture
Figure 1
3
DECLARATION OF CONFORMITY
CIAPONI LUBRIFICAZIONE CENTRALIZZATA s.r.l.

Via Vittorio Alfieri, 10 - San Miniato Basso
The
manufacturer 56028 – Pisa
ITALY
Declares, in compliance with Directive 89/392/EEC, Annex II, paragraph B, that the equipment identified as
follows:
Model - Pneumatic pump

Type - EUR 1
• Is designed to be incorporated in a machine compliant with Directive 89/392/EEC.
• Is compliant with the requirements of Directive 89/392/EEC and subsequent amendments (Directives
91/368/EEC, 93/44/EEC, 93/68/EEC)
Furthermore, the manufacturer declares that the system can only be started after the machine in which it is
designed to be installed has been appropriately identified and declared compliant with the requirements of
Directive 89/392/EEC.
San Miniato Basso, December 2005

The Legal Representative
Ciaponi Lido
It is important to remember that the declaration of conformity is valid only and if:
• All the precautions, warnings and instructions detailed in the operation and maintenance manual are
followed
• The system is used for the purposes for which it has been designed
• Adjustment operations are carried out by authorized, competent and duly qualified personnel
• Maintenance operations are carried out by qualified and authorized technicians
Failure to comply with the validity conditions of the declaration of conformity shall automatically entitle the
manufacturer to disclaim any warranty condition.
4
1.1.0) EXPECTED USE
Centralized lubrication systems are designed to be used to automatically lubricate specific friction points.
Therefore, they must be exclusively used to lubricate the points to which they are connected.
• It is forbidden to apply unauthorized changes to the system after its installation. Changes are authorized
only when carried out directly by or approved by the manufacturer.
• The system must always be used within the parameters specified in paragraph 1.4.0) TECHNICAL
SPECIFICATIONS.
• The system must be used only with the liquid and substances specified in paragraph 1.7.0)
LUBRICANTS.
• For additional information or feasibility studies, please contact the technical department of CIAPONI
LUBRIFICAZIONE CENTRALIZZATA s.r.l.
The manufacturer shall not be responsible for damage originating from an improper use or unauthorized
alterations to the system or its parts.
The manufacturer also declines all responsibility for damages originating from the use of non original spare
parts or of the spare parts that are not specifically approved by the manufacturer, or for damage originating
from the use of lubricants other than those recommended.
1.2.0) SAFETY WARNINGS
• An improper use of the centralized lubrication system may cause damage due to an excessive or
improper lubrication of the points to which it is connected.
• Always follow the industrial accident prevention and environmental regulations in force in the country
where the system is installed.
1.3.0) DESCRIPTION OF THE SYSTEM
Figure 2 shows a layout of the centralized lubrication system in its basic

configuration.
E
D The system is constituted by the following components:
A A – Pneumatic supply pump with reservoir
B – Main tube
C – Dispenser with several ways
B C D – Secondary tube
E – Timer
Centralized lubrication systems significantly reduce the
maintenance costs for the equipment on which they are
Figure 2
D installed, thus eliminating the downtime associated to
lubrication and extending the life cycle of lubricated parts.
Lubrication systems also enable to reach all the points that
need lubricating, including those that cannot be easily
5
reached by operators.
On start-up the pump supplies, by means of the main tube, lubricant to a linear dispenser that in turn splits
and adjusts the amount of lubricant supplied to the friction points.
The lubricant is then conveyed through the
secondary tubes and distributed to the fittings,
which replace the lubricating nozzles in the
friction points.
The chart in Figure 3 shows the operating cycle
of a centralized lubrication system.
The centralized lubrication system can be
operated manually or automatically, controlled by
the machine on which it is installed or by a
control timer placed outside the pump.
Each system has a unique serial number that is
visible under section "Serial number/Year of
manufacture" on the EC label.
Figure 3
• When requesting technical information or ordering spare parts, always remember to specify the serial
number of the system.
1.4.0) TECHNICAL SPECIFICATIONS
The following paragraphs detail the technical specifications of each part of the system.
1.4.1) PNEUMATIC PUMP
The EUR 1 pneumatic pump is a single-acting pump

suitable for all types of applications. The maximum amount
of grease supplied during every pumping cycle is 30 cm³
(an amount that is approximately sufficient for 100
Figure 4
lubrication nozzles). The pump supplies, during each cycle,
2
the amount of grease required by the meters, thus
1 preventing the output of additional amounts both while the
4
cycle is running and in idle mode. The pump does not
require specific calibration and can be used to supply a
5
number of meters ranging from 1 to 100. A low grease
level and system faults are signaled by the lighting of the
3 yellow LED on the timer, which is in turn controlled by the

piston limit switch contact placed inside the pump.
6 Figure 4 shows the main components of pump EUR 1,
7
which are also described in detail in the following TABLE:
6
1 Pneumatic pump Code 00447

2 Grease reservoir Code 00371
3 Solenoid valve Code 00366
4 Reservoir filling nozzle Code 00414
5 Main grease discharge line Code 00630
6 Electric cable Code 00710
7 Air supply tube Code 00442
The following TABLE provides the general technical specifications for pump EUR 1.
- Operating temperature ……………….……………… From – 20°C to + 80°C
- Number of discharges.…………………………………. 1
- Pumping system ..…..………..………………….…….. With Ø 29 mm piston, air-driven
- Main tube fitting ……..................……..…….………... Threaded, M11x1
- Reservoir capacity ……………………………….…….. 1.8 liters with minimum and maximum level indication
- Lubricant ………………………….....………………….. Oil and greases up to grade NLGI 0
By means of A / M10x1 UNI7663 greasing nozzle or
- Reservoir filling……………………............……………
through the replacement of the whole reservoir.
- Maximum capacity for single discharge ….…….…… 30 cm3/cycle
- Compression ratio ………….……………..….............. 10/1
- Operating pressure of solenoid valve….………....….. 6-10 bar
- Grease discharge pressure..………………………….. 65-115 bar
- Maximum air consumption...………..…………….…… 0.5 liters/cycle
• Rated voltage …………………………......……… 12V DC ; 24V DC
• Rated absorption ……………….........…………… 12V DC ± 10% ; 24V DC ± 10%
- Power supply ……………..............…….……………... 12V DC ; 24V DC

- Insulation class ………………………………….....….. Class H
- Control system ……………………………………....... None or with timer
- Weight without load ………………....…………….…… 2.5 Kg
Figure 5 shows the maximum overall

dimensions of pump EUR 1 in mm.
Figure 5
7
1.4.2) "INTERCHANGEABLE" GREASE RESERVOIR
The main feature that distinguishes pump

EUR 1 from other commercial lubrication pumps is its
GREASE
"INTERCHANGEABLE" grease reservoir (code
RESERVOIR
00371).
The grease reservoir of pump EUR 1 shown in Figure
6 is made in transparent plastic material (high density
polyurethane) and can contain up to 1.8 kg of grease.
The grease in the system reservoir can be topped up
in two ways:
1. By replacing the empty reservoir with a full one,
which can be done by loosening (A) the empty
reservoir and by fitting and fixing in place the full one
(B), as shown in Figure 6.
2. By using the pump shown in Figure 7 to fill the
empty reservoir with the greasing nozzle 4 shown in
Figure 4, which is situated on the front side of pump
Figure 6 EUR 1.
When performing this operation, always MAKE SURE
that the grease used does not exceed the following
recommended grade:
NLGI 0
And that it does not contain impurities that could
affect the operation of the system.
During these two distinct operations, it is
important to VERIFY that the ignition key on the
control panel has been removed.
Figure 7
PUMP
8
1.4.3) OPERATION
Pump EUR 1 is constituted by a robust metal body manufactured in a light alloy with a high resistance
(treated Avional aluminum alloy) (code 00506) and an internal brass piston (code 00507).
The lubrication cycle starts when the timer enables the opening of the air circuit in direction of the solenoid
valve (code 00366) inside the pump body.
The air conveyed towards chamber A pushes the piston (code 00507) forward with an immediate action.
The grease inside chamber B is pushed towards the main tube and then fed into the plant meters.
The pressure of the supply air is the same as the one in the service reservoir from which it is taken (app. 9
bar), while the pressure of the output grease is approximately 100 bars.
The supply pressure in chamber A is maintained for 10", then the timer closes the solenoid valve and returns
the piston to its initial position by means of a spring (code 00419).
This leads to the formation of a vacuum inside chamber B, which is automatically compensated by the
grease sucked by the reservoir (code 00371), so that the grease is ready to be injected with the new
lubrication cycle.
03371
00506
A B
00507 00366
00419
Figure 8
9
1.4.4) EXPLODED VIEW OF PUMP EUR 1
The following TABLE, which refers to

Figure 9, lists and provides the
codes of the parts of pneumatic
pump EUR 1.
QUANTITY NAME CODE Figure 9

1 Pump body in light alloy 00506
1 Control piston 00507
1 O -Ring 70 NBR 4362 -Plate- 00409
2 O-Ring 70 NBR 4093 -Piston- 00513
1 Valve tray 00508
1 Elastic ring 19 UNI 7437 00512
1 O - Ring 70 NBR 4325 –Piston- 00410
1 Closing tray 00509
1 Elastic ring for pump, 90 UNI 7437 00406
1 Spring 00419
1 Copper gasket, 24 x 19 x 1 00412
1 Fitting 00404
1 Bonded Seals gasket, 3/4 00417
1 Reference guide 00514
1 Copper gasket, 12 x 8,5 x 1 00515
1 Copper gasket, 19 x 10 x 1 00413
1 Grease filling fitting 00414
1 O - Ring 70 NBR 2021-104 00421
1 Solenoid valve, 24 V DC 00366
2 Screws, M 4x80 00416
1 Fitting 00398
1 Connector 00500
10
1.4.5) 12/24 V DC PROGRAMMABLE TIMER
This device is very important because it

Power supply: 20 - 30 Vdc (24V timer) 10 -20 Vdc (12V timer)
Absorption in standby mode: 10 mA controls the whole lubrication system.
Max. solenoid valve output current: 1.5 A In addition to programming the lubrication
Limitation for output short-circuit: 5 A
cycle, the TIMER also provides
Time buffer: digital, unlimited storage
4 pause mode (selectable by means of a dip switch) information on the operation of pump
Lubrication time: 10 seconds EUR 1 by means of the yellow LED,
Protection: polarity inversion, overheating and overload placed on the front of the TIMER.
Figura 10
The TIMER also has a button that enables the lubrication cycle to
be started manually without selecting a specific program.
The TIMER contains a micro-switch, identified with numbers 1 and
2, which is used to set the interval between two lubrication cycles,
depending on work requirements.
Figure 11
MANUAL TEST
FUNCTION REAR ADHESIVE FIXING
1 2 TIME
5-WIRE
OFF OFF 20 min
CONNECTOR MICROSWITCH TIME SETTING
ON OFF 40 min
OFF ON 60 min
ON ON 120 min
Figura 12
Figure 13 DIMENSION
11
TECHNICAL SPECIFICATIONS
CONNECTIONS
1 + Positive, power supply (red/green - keyed)

2 - Negative, power supply (brown)
3 Blu End of grease (blue)
4 E Positive, solenoid valve (black)
5 E Negative, solenoid valve (brown)
NOTE
If an output overload occurs (for example because of a fault of Figura 14

the solenoid valve), the timer automatically limits the current to
prevent it from being damaged. Therefore, if the solenoid valve
fails to energize during a lubrication cycle, it is necessary to
verify that it is in good working order and replace it if necessary.
• OPERATION
Figure 15
The TIMER is generally installed on the control panel
for machines or on the dashboard for vehicles using
the rear adhesive. The TIMER starts as soon as the
start circuit of the machine/vehicle is enabled.
Depending on the programmed pause time, the
TIMER automatically energizes the pump solenoid
valve that opens the air circuit, thus starting the
lubrication cycle that lasts 10”. During the lubrication
GROUNDING PIN cycle, the yellow LED on the timer flashes and
switches off only after the cycle has ended. The
yellow LED switches on permanently when there is no more grease in the reservoir of pump EUR 1. If the
reservoir is not empty, the lighting of the yellow LED indicates a fault of the system. The permanent lighting
of the yellow LED occurs due to the contact between the pump piston and the grounding pin of the solenoid
valve. In ordinary operating conditions, these two components never come into contact. A contact occurs
only when the pump piston has completed all the useful stroke, which means that the pump has not
managed to complete the regular lubrication cycle. Even if the control panel is off, the TIMER is still enabled
and thus maintains the pause time in its memory, which means that it will not be possible to correctly count
the time that elapses between two lubrication cycles.
12
• ELECTRIC SYSTEM EUR 1
Standard cabling
1. RED-GREEN – The positive terminal VOLT (+) of this wire is keyed and must be disabled when the
vehicle engine or the machine power supply is disconnected.
2. BROWN – General earth (-)
3. BLUE – This wire is used when the piston comes into contact with the earth pin, which causes the
automatic lighting of the yellow LED.
4. BLACK – This wire supplies voltage to the solenoid valve in order to allow it to be opened and air to be
supplied to the pump.
5. BROWN – Solenoid valve earth PNEUMATIC PUMP SOLENOID VALVE
Figure 16
CONNECTOR
BLUE
1-RED-GREEN 2-BROWN BROWN - BLACK
1.4.6) 24 V DC PROGRAMMABLE TIMER FOR TRAILERS AND SEMI-TRAILERS
Trailers and semi-trailers are always lubricated with a pneumatic pump EUR 1 fitted with all the standard
components and with a more specific TIMER (code 00534). This device enables to independently lubricate
the driven and driving units. The TIMER is enclosed in a sealed housing that can be fixed to the trailer by
means of 4 screws. The housing must be opened only for occasional programming operations. Even this
TIMER is fitted with a control button for the system and a 1.6 A safety fuse.
13
• OPERATION
As trailers and semi-trailers don't have a continuous power supply, the housing of the TIMER for these
vehicles contains a condenser that acts as accumulator. This device is connected to the power supply wires
of the stops (+) so that every time the vehicle is stopped, the condenser is recharged so that it intervene
during the next braking phase.
The TIMER has a preset operating time set to a pause of 1 hour.
Therefore, its operation is not influenced by the number of braking
operations of the driving unit. The actual active operating time of
the timer is 10 seconds.
TIME SETTING
1 2 3 4 TIME
Figure 17
ON OFF OFF OFF 30 min
BUTTON OFF ON OFF OFF 60 min
OFF OFF ON OFF 90 min
MICROSWITCH
OFF OFF OFF ON 120 min
FUSE
DIMENSION
ELECTRIC SYSTEM Figure 18
Figure 19
CONNECTOR
BROWN - BLACK
PNEUMATIC PUMP SOLENOID VALVE
14
1.4.7) WIRING DIAGRAMS
TIMER code 00720 24V

TIMER code 00721 12V
24V TIMER FOR TRAILERS code 00534
15
1.4.8) METERS
00432
00377 00565 00635
00569
00566 e0564 097000

00373
00567 00520
Figure 22
At preset interval of times, pump EUR 1 supplies grease to the meters, which are responsible for determining
the correct amount of grease that has to be supplied to the lubricating points.
However, as the mechanical organs do not require the same amount of lubricant, the flow rates of meters
have been adjusted in order to meet the requirements of all possible applications.
The amount of grease supplied by each meter can be easily determined by observing the lines engraved on
the brass body of the meter (Figure 22).
The amount of supplied grease depends on the actual stroke of the small piston (code 00520) of the meter.
The position of the elastic ring (code 00567) is used to adjust the stroke of the piston or, in other words, to
increase or reduce the delivered volume of grease. The grease coming from the dispenser is pressurized.
When the piston is pushed down towards the bottom of the cylinder, it forces the grease volume in the
chamber below to move towards the plastic tube and reach the lubrication point.
The meter reloads the grease leveraging the pressure difference generated by the pump. The ball (code
00566) closes the delivery duct so that when the piston returns to its idle position, it moves the grease from
upstream to downstream, thus preparing for the next lubrication cycle.
Figure 23 DIMENSION
16
Type Flow rate (cm³) Usage
A 0.01 (1 line), code 00372 Braking organs

0.03 (2 lines), code
B Suspensions
00373
C Steering organs
00374
D Fifth wheels
00454
0.20 (5 lines), code Special
E
00455 equipment
Figura 24
A B C D E
1.5.0) STORAGE
The centralized lubrication plant is generally supplied disassembled.

Before shipping the product CIAPONI LUBRIFICAZIONE CENTRALIZZATA s.r.l. adopts all the necessary
precautions to ensure that all the system components are appropriately packaged.
• The user will have to store all the disassembled parts of the system, as received by CIAPONI
LUBRIFICAZIONE CENTRALIZZATA s.r.l., indoors, in a clean and dry area free from chemical and/or
corrosive substances.
• CIAPONI LUBRIFICAZIONE CENTRALIZZATA s.r.l. shall not be responsible for damages caused to
packaged material or originating from the failure to comply with the above-described storage instructions.
• It is important to remember that the user is directly responsible for the loading, unloading and handling of
all the system parts.
1.6.0) ASSEMBLING THE SYSTEM
The following operating procedure details the steps that have to be followed to assemble a centralized
lubrication system.
For information on the overall dimensions, the weights and technical specification of the system components,
see Chapter 1.4.0) TECHNICAL SPECIFICATIONS
It is also important to remember that:
• These operations must always be performed by duly qualified technicians.
• The protection devices fitted on vehicles and industrial equipment must not be altered nor tampered with.
These devices can only be removed during the installation of the system and must be refitted in place
once the installation procedure has been completed.
• All centralized lubrication systems must always be installed away from heat sources.
• Centralized lubrication systems must not be installed in particularly aggressive environments,

characterized by the presence of chemical substances that could damage the plant components.
17
• The welding and/or drilling operations required to fix the centralized lubrication system in place must
always be performed in compliance with the manufacturer's technical specifications of the vehicle or
equipment.
• Centralized lubrication systems must always be fixed in place using the accessories supplied or
approved by their respective manufacturers.
1.6.1) OPERATING PROCEDURE
0 Remove all the packaged parts of the plant from the packing.
1 Visually inspect all the plant parts in order to ensure that they have not been damaged during
transportation and that they have been correctly packaged.
All damages must be immediately reported to the Customer Service of CIAPONI LUBRIFICAZIONE
CENTRALIZZATA s.r.l.
• PNEUMATIC PUMP
2
It is advisable:
• Not to install the submersed pump in
liquids or place it on supports with high
vibrations.
• Not to install the pump close to heat
sources or electric equipment that could
affect the operation of the control timer.
• Not to install the pump in areas
characterized by the presence of explosive
or inflammable mixtures.
• To place electropump EUR 1 in the
location shown in the figure.
• To install the pump at a minimum distance
of 100 mm from other equipment or objects
that could prevent access to the pump.
• To assemble the pump so that the
reservoir filling nozzle and control timer are
always easily accessible.
Figura 25 • To fix the pump on its base using the Ø 6.5

mm holes and the 3 M6 UNI5931 – 8.8
screws.
• To fix the pump in place with the UNIVERSAL ROD (code 00610) supplied as optional.
• To fix the dispensers in place using the UNIVERSAL ROD
(code 00607/A) supplied as optional.
18
• FITTINGS
3 Remove the lubrication nozzle from the bearing points that have to be lubricated by the automatic
system.
4 Tighten the selected fittings.
Note: in case of difficulties arising from the lack of space, use extensions to fix the fittings in place on
the bearing.
• MAIN AND SECONDARY TUBING
5 Cut the tubing at a straight angle using a shearing cutter.
Note: the length of tubing should be determined taking into account the minimum bending radius and
selecting a length that is slightly above the required one for tubing connected to mobile parts.
6 Fix the main and secondary tubing in place using commercial clips or straps.
ATTENTION: do not fix or thread tubing onto/through vehicle or equipment parts that could overheat (for
example exhaust pipes, engine, etc.).
7 Connect the tubing to their respective fittings.

Note: the main tube connects the pomp to the dispensers, while the secondary one is used to connect
the dispensers to the bearing points that have to be lubricated.
UNIVERSAL FIXING ROD, UNIVERSAL FIXING ROD,

code 00610, FOR PUMPS EUR 1 AND EUR 3 code 00607/A, FOR DISPENSERS
Figure 27
Figure 26
19
1.7.0) LUBRICANTS
• All systems manufactured by CIAPONI LUBRIFICAZIONE CENTRALIZZATA s.r.l. are designed to be

operated with lubricants with a maximum grade of NLGI 0
• Use only lubricants compatible with NBR gaskets
• Self-lubricated parts of the system are supplied by CIAPONI LUBRIFICAZIONE CENTRALIZZATA s.r.l.
with a NLGI 0 grade lubricant.
ASTM The comparative table on the side shows the differences

Description of NLGI penetration at between NLGI (National Lubricating Grease Institute) and
family grade 25°C in 1/10 of ASTM (American Society for Testing and Materials) grades,
mm with reference only to the type of lubricants used for the
Liquid greases 000 445 – 475
lubrication systems manufactured by CIAPONI
Semi-liquid fluids 00 400 – 430
LUBRIFICAZIONE CENTRALIZZATA s.r.l..
Semi-liquid fluids 0 355 – 385
For further information on the technical specifications and
safety measures, refer to the Product Safety Data Sheet (Directive 93/112/EEC) related to the type of
selected lubricant and supplied by the manufacturer.
1.8.0) STARTING THE SYSTEM
The following operating procedure briefly describes the tasks and operations that have to be performed to
start the system.
Note: this procedure must be performed:
• When starting the system for the first time after installation
• After maintenance operations
• After long periods of inactivity
1.8.1) OPERATING PROCEDURE
# Task Consequence
Verify that:
• All the operations described in Chapter 1.6.0) ASSEMBLING THE SYSTEM have been regularly
performed.
• The control timer has be set in pause mode.
• The lubricant level inside the pump reservoir is above the minimum level.
Partially loosen the caps at the end of the main Verify that the lubricant reaches the point where
0
line. the cap has been removed.
1 Press the manual start button (TEST). The pump runs a work cycle.
20
Repeat the operation described above until the The lubricant dispensing system is now working
2
lubricant reaches all the caps. correctly.
The system is now ready to be operated

3 Tighten the caps.
automatically.
• ATTENTION: if the system is not working correctly, refer to Chapter 1.10.0) TROUBLESHOOTING.
1.9.0) MAINTENANCE OPERATIONS
This paragraph provides essential information to allow the technical personnel responsible for maintenance
operations to safely perform ordinary maintenance operations.
Before performing any maintenance operation, maintenance technicians should always:

• Verify that the system is not running
• Open the disconnecting switch on the main electric panel of the vehicle/equipment.
all the measures prescribed by current regulations related to industrial accidents and
• Implement
specifically those required to signal that maintenance operations are in progress.
1.9.1) SCHEDULED MAINTENANCE
Because of the simple, robust and reliable design of the parts used to manufacture the centralized lubrication
system manufactured by CIAPONI LUBRIFICAZIONE CENTRALIZZATA s.r.l., the system generally
requires a limited number of checks and programmed maintenance operations.
The following table lists the checks that have to be performed regularly and their frequency, along with the
type of operation that the must carried out in order to guarantee the efficiency of the plant over time.
CONTROL FREQUENCY REQUIRED ACTION

Tightening of parts After the first 500 hours Verify that all the parts are correctly tightened.
Fixing of tubes After the first 500 hours Verify that the fittings have been installed.
Every 1,500 hours Verify that the tubes are firmly connected to the
relevant parts of the equipment.
Pump Every 2 months Press Test to test the operation of the pneumatic
operation pump.
Reservoir level As needed Top up the reservoir.
21
1.10.0) TROUBLESHOOTING
This chapter provides information specifically addressed to the technicians responsible for maintenance; in
particular it describes:
• The anomalies that may occur during the operation of the system
• The cause that has prevented the system from being started or stopped
• The recommended corrective action
Note: the timer of the lubrication system is fitted with a yellow LED that can be controlled remotely If the
button continues to be lit after an ordinary operating cycle, this is probably due to the fact that:
• The grease in the reservoir has fallen below the minimum level
• A fault has occurred in the system
# Fault Cause Corrective action
1. Verify that the solenoid valve is not shorted

The system is not
01 Burnt fuse and replace it if necessary.
working
2. Replace the fuse.
The reservoir is empty Replace or fill the reservoir with clean lubricant
Leak of grease on the Correct the cause that has caused the leak.
main line
The yellow LED of
Excessive lubricant in a Replace the meter.
02 the timer is
lubricated point
permanently lit
Air in pump 1. Remove the reservoir.
2. Fill the grease pump using the filling fitting.
3. Reinstall the grease reservoir.
Disconnected pipes Check the conditions of the tubes and the fitting
Mechanical part not
03 connections. Replace the tubes if worn.
lubricated
Faulty meter Replace the meter.
1.11.0) TUBING
The main tubes are supplied by meters and fitted with reusable bushings that have to be fitted during the
assembly of the system or, alternatively, with snap-on bushings.
The assembly procedure for reusable bushings is described in paragraph 1.12.0) FITTINGS.
Even secondary tubes are supplied by meters.
22
In all cases tubes are supplied pre-filled with lubricant in order to prevent the formation of dangerous air
pockets. The characteristics of the lubricant used are specified in paragraph 1.12.0) LUBRICANTS.
The following table provides the codes for the main and secondary tubes used in the centralized lubrication
systems.
Code Description Length

00630 Main tube By meters
097000 Secondary tube By meters
To order a main tube with snap-on bushings, specify after the code "snap-on bushings" and provide a
length in meters.
• MAIN TUBE (code 00630)
The main tube is used to connect the pumping unit to the downstream
dispenser. It consists in an anti-abrasive pneumatic tube with premium
chemical and physical characteristics, consisting of a substrate in
thermoplastic polyester , by a reinforced element consisting of 2 braids, also
in polyester, and finally by a coating in black thermoplastic and micro-drilled
Figure 28 polyurethane. The polyurethane used for the external coating has a high
resistance to abrasion and environmental agents (like sea water, micro-
bacteria, ozone, etc.). The technical specifications are the following:
- Compliance with standards ……………………………. SAE J517, sect. SAE 100 R7 – EN855 – ISO3949
- External diameter ...…………………………………….. Ø 9.6 mm
- Operating temperature ….............…………………….. From – 40°C to + 93°C
- Minimum burst pressure at 20°C .........………………. ~ 820 bar
- Minimum bending radius ……………....……………… 25 mm
- Weight …………………………………………………… 60 g/m
• SECONDARY TUBE (code 097000)
The secondary 6x1.5 tube is a single-layer type A tube in Hytrel elastomeric

polyester, with characteristics equivalent to those specified in standards
ISO, SAE, DIN, N.F., UTAC.
The technical specifications of the secondary tubes are the following:
Figure 29
- Dimensions ...…..……………………………………….. Ø 6 mm x 1.5 mm

- Operating temperature .............……………………….. From – 40°C to + 80°C
- Minimum burst pressure at 20°C .........………………. ~ 150 bar
23
1.12.0) FITTINGS
The centralized lubrication system uses both quick coupling fittings and extensions, for secondary tubes with
a diameter of Ø 6 mm, and reusable fittings for R7 main tubes.
The following paragraphs detail the technical specifications and dimensions of the available fittings in
millimeters.
• REUSABLE FITTINGS
These fittings, which are available in steel or nickel-plated brass are

the assembly of the main tube.
L
Code Description Ø Ø1 CH CH1 L
Reusable straight fitting,
00591 6 9.6 10 14 59
Ø1
Ø
Ø6, for 3/16 tubes
CH CH1
L2
Code Description Ø Ø1 CH CH1 L1 L2
90° reusable fitting, Ø6, for
Ø1
00592 6 9.6 12 14 36 57
3/16 tubes
L1
CH CH1
Boccola Tubazione
recuperabile primaria Figure 30 shows the tasks that have to be carried out in
1 order to install the reusable fittings on the main tube.

To simplify the assembly of the reusable fitting, lubricate the
internal and external surfaces of the tube next to the
2 Avvitare in senso
antiorario insertion point.
17
Inserto
recuperabile
Avvitare
4 in senso
orario
Figure 30
24
• QUICK COUPLING FITTINGS
These fittings are made in nickel-plated brass.

The fitting connection, with metrical-conical or gas threading, guarantees a perfect seal without the use of
gaskets.
Code Description Ø A B CH L Ø
096015 Straight fitting, M6x1, conical 6 M6x1 con. 6 12 24.5
CH
threading
L
096016 Straight fitting, M8x1, conical 6 M8x1 con. 6 12 23.5
B
threading A
096017 Straight fitting, M10x1, conical 6 M10x1 con. 6 12 21

threading
096022 Straight fitting, G1/8” 6 G1/8” 7.5 12 21
Code Description Ø CH L
096021 Joint 6 12 33
Code Description Ø A B CH L1 L2 L2
CH
096018 90° fitting, M6x1, conical 6 M6x1 con. 6 11 17 21
Ø
threading L1
096019 90° fitting, M8x1, conical 6 M8x1 con. 6 11 16.5 21 B
threading A
096020 90° fitting, M10x1, conical 6 M10x1 con. 6 11 16 21

threading
096023 90° fitting, G1/8” 6 G1/8” 7.5 11 17.5 21
L2
Ø
L1
CH
B
A
Code Description Ø A B CH L1 L2
00426 Revolving 90° fitting, G1/8” 6 G1/8” 7.5 12 21 22
Quick fittings are ideal to simplify the assembly and disassembly

Raccordo
ad innesto of pipes onto/from the system.
"Click"
rapido Tubo Ø6 Figure 31 shows all the tasks that have to be performed to
Spingere
quickly assemble and disassemble pipes.
Quick coupling fittings can be used with both reusable fittings
A B and snap-on bushings and installed on both main and secondary
Premere
tubes.
Tirare
Premere
25
C D
Figure 31
• EXTENSIONS
The tables that follow list all the codes for straight and 90° fittings in brass, designed to be fitted on the
secondary tubes of centralized lubrication systems.
Code Description A A1 B B1 CH L
Straight extension, L
M6x1
00460 M6x1, conical M10x1 4.5 8 12 20 B CH
con.
threading - M10x1
A
Straight extension
M8x1 B1 A1
00499 M8x1, conical M10x1 7 6 12 18
con.
threading – M10x1
Straight extension,
M10x1
00448 M10x1, conical M10x1 7 6 12 18
con.
threading – M10x1
Code Description A A1 B B1 CH L1 L2
90° extension, M6x1,
00380 conical threading – M6x1 con. M10x1 7 4 12 20 12
M10x1
90° extension, M8x1,
00473 conical threading – M8x1 con. M10x1 7 4 12 20 12
M10x1
90° extension,
M10x1
00430 M10x1, conical M10x1 7 4 12 20 12
con.
threading – M10x1
B1
A1 CH
L2
B
L1
The technical specifications of fittings are the following:

- Operating temperature .........…………………………….. From – 30°C to + 80°C
- Minimum pressure ...…………………….………………... -0.99 bar
- Maximum pressure …………....…………………………. 150 bar
- Gas threading ………………..……………………………. Compliant with ISO7.1, BS 21, DIN 2999
- Metric/conical threading ………...……………………….. Compliant with UNI7707
26
.13.0) DISPENSERS
Dispensers, which are connected to the pump through the

main line, are used as assembly base for the dispensers that
are in turn connected to the secondary tube and used to
dispense grease. These parts are made in aluminum bars and
are available in different dimensions, as shown in the following
tables.
2 HOLES,
ø5.5
Material: anodized aluminum
Standard version
Code A B Dispenser
00376 38 2 ways
00377 95 38 4 ways
00378 114 57 5 ways
Figure 32 00379 133 76 6 ways
00600 152 95 7 ways
Material: anodized aluminum

2 HOLES,
Dual version
ø5.5
Code A B Dispenser
00443 38 2+2 ways
00444 95 38 4+4 ways
00445 114 57 5+5 ways
00446 133 76 6+6 ways
00601 152 95 7+7 ways
Figura 33
27
1.14.0) ACCESSORIES
NAME CODE IMAGE
Complete pump kit, EUR 1 - 24 V DC 00368
Complete pump kit, EUR 1 - 24 V DC

00498
for TRAILERS AND SEMI TRAILERS
Complete pump, EUR 1 - 24 V DC 00420
Standard grease cartridge, kg 1,8 00371
Complete electric cable, 7.5 m 00710
Timer EUR 1 24 V DC
00720
(with rear cable outlet)
Timer EUR 1 12 DC
00721
(with rear cable outlet)
28
Timer EUR 1 24 V DC
00534
for TRAILERS AND SEMI TRAILERS
Grease meter, 0.01 cm³

00372
- 1 line -
00373
- 2 lines -
00374
- 3 lines -
00454
- 4 lines -
00455
- 5 lines -
Standard 2-way dispenser 00376
Dual 2-4-way dispenser 00443
Bundy steel tube, ø 6, for main line 00385
Main flexible tube with two braids, ø 3/16,

00630
and grease
Flexible secondary tube in Hytrel, ø 6x1.5,

097000
with grease
29
Rilsan tube, PA 12, ø 6x4, for air 00442
Straight reusable fitting, ø 6, for 3/16 tubes 00591
90° reusable fitting, ø 6, for 3/16 tubes 00592
3-way sprint shunt

00390
for ø 6 air tubes
3-way shunt
00375
for ø 6 main tube
Joint for ø 6 main tube 00387
Sprint joint
096021
for ø 6 secondary tube
Straight sprint fitting, 6x1, for ø 6 tube 096015
Straight sprint fitting, 1/8 gas, for ø 6 tube 096022
90° sprint fitting, 6x1, for ø 6 tube 096018
90° sprint fitting, 1/8 gas, for ø 6 tube 096023
90° sprint fitting, 1/8 gas, revolving, for ø 6

00426
tube
Straight extension, 6x1 x 10x1 00460

Straight extension, 8x1 x 10x1 00499
Straight fitting 10x1 x 10x1 00448
90° fitting 6x1 x 10x1 00380
90° fitting, 8x1 x 10x1 00473
90° fitting 10x1 x 10x1 00430
30
Fitting for ø 4.7 tube 00635
Dispenser joint 00516
Cap for main tube end 00381
Meter bypass cap 00382
Fitting for main tube 00573
Nose for main tube 00571
Tube clamp 180x5 00388
Tube clamp, 368x5 00384
Adhesive stick for anchoring 00550
Spiralite-coated protection, ø6 00580
Spiralite-coated protection, ø8 00680
Complete quick coupling 00299
Universal rod for pumps

00610
EUR 1 and EUR 3
31
Protection gasket 00485
Universal rod for dispensers 00607/A
To order special parts or complete kits, contact our technical department and authorized personnel.
32
PRODUCT ( Benefits)
Centralized Lubrication Ciaponi ….
… lubrication even inaccessible points
… reduces wear
… reduces costs of repair and maintenances
… increases the duration of the media
… increases the availability of financial
… save the lubricant
… respects the environment
… it pays off in a short time
Centralized Lubrication System Ciaponi …

… save costs more than cost
… work in a completely automatic way
… they are robust and reliable
… do not fear the most difficult working conditions
… do not require virtually maintenance
Sede: Via V. Alfieri, 10 - 56028 S. Miniato Basso (PI) - ITALY

Tel. 0039 0571 42661 – Fax 0039 0571 42244
Sito internet: www.ciaponi.it - e-mail: info@ciaponi.it
Cod. Fis. / Partita I.V.A. n° IT01160480503

Manuale EUR1-en

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CUSTOMER SERVICE .................................................................................................................................. 2

GENERAL INDICATIONS ............................................................................................................................. 3

APPLICABLE SAFETY STANDARDS ......................................................................................................... 3

1.1.0) EXPECTED USE ................................................................................................................................. 5

1.2.0) SAFETY WARNINGS .......................................................................................................................... 5

1.3.0) DESCRIPTION OF THE SYSTEM ...................................................................................................... 5

1.4.0) TECHNICAL SPECIFICATIONS ......................................................................................................... 6

1.5.0) STORAGE ......................................................................................................................................... 17

1.6.0) ASSEMBLING THE SYSTEM ........................................................................................................... 17

1.7.0) LUBRICANTS.................................................................................................................................... 20

1.8.0) STARTING THE SYSTEM ................................................................................................................ 20

1.9.0) MAINTENANCE OPERATIONS ....................................................................................................... 21

1.10.0) TROUBLESHOOTING .................................................................................................................... 22

1.11.0) TUBING ........................................................................................................................................... 22

1.12.0) FITTINGS......................................................................................................................................... 24

1.13.0) DISPENSERS .................................................................................................................................. 27

1.14.0) ACCESSORIES ............................................................................................................................... 28

CIAPONI LUBRIFICAZIONE CENTRALIZZATA s.r.l. is specialized in the design, manufacture and

IDENTIFICATION DATA OF MANUFACTURER

Corporate name - CIAPONI LUBRIFICAZIONE CENTRALIZZATA s.r.l.

Address - Via Vittorio Alfieri, 10 – San Miniato Basso

Fax - +39 0571 42244

Web site - www.ciaponi.it

VAT – Tax-payer code - IT01160480503

© All rights reserved. First edition, November 2005

APPLICABLE SAFETY STANDARDS

• Identification data of manufacturer

• Month and year of manufacture

CIAPONI LUBRIFICAZIONE CENTRALIZZATA s.r.l.

Model - Pneumatic pump

San Miniato Basso, December 2005

• Maintenance operations are carried out by qualified and authorized technicians

1.1.0) EXPECTED USE

1.2.0) SAFETY WARNINGS

1.3.0) DESCRIPTION OF THE SYSTEM

Figure 2 shows a layout of the centralized lubrication system in its basic

1.4.0) TECHNICAL SPECIFICATIONS

1.4.1) PNEUMATIC PUMP

The EUR 1 pneumatic pump is a single-acting pump

3 yellow LED on the timer, which is in turn controlled by the

1 Pneumatic pump Code 00447

- Power supply ……………..............…….……………... 12V DC ; 24V DC

Figure 5 shows the maximum overall

1.4.2) "INTERCHANGEABLE" GREASE RESERVOIR

The main feature that distinguishes pump

1.4.4) EXPLODED VIEW OF PUMP EUR 1

The following TABLE, which refers to

QUANTITY NAME CODE Figure 9

1.4.5) 12/24 V DC PROGRAMMABLE TIMER

This device is very important because it

FUNCTION REAR ADHESIVE FIXING

1 + Positive, power supply (red/green - keyed)

If an output overload occurs (for example because of a fault of Figura 14

• ELECTRIC SYSTEM EUR 1

1-RED-GREEN 2-BROWN BROWN - BLACK

1.4.6) 24 V DC PROGRAMMABLE TIMER FOR TRAILERS AND SEMI-TRAILERS

ELECTRIC SYSTEM Figure 18

PNEUMATIC PUMP SOLENOID VALVE

1.4.7) WIRING DIAGRAMS

TIMER code 00720 24V

24V TIMER FOR TRAILERS code 00534

00566 e0564 097000