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Operating Principle of the BEKA-MAX Progressive Central Lubrication System

The BEKA-MAX central lubrication system is a progressive system, which can work with grease up to NLGI cl. 2.
Progressive means, that the lubrication points are lubricated one after the other. Therefore, the function of the
lubrication system can be easily monitored with a pressure relief valve. If a lubrication point takes no grease from the
distributor, the distributor will be blocked. A pressure of more than 250 bar is built up and the grease is pressed out
from the pressure relief valve.

Structure of the BEKA-MAX Progressive Central Lubrication System:


The electrical piston pump EP-1 delivers the lubricant to the main distributor. From here it is distributed to the secondary
distributors in the correct proportion. From here the lubricant will be conveyed to the lubrication points. The electronical
controller regulates lubrication times and break times depending on time, number of strokes or number of revolutions.

Central lubrication pump


with integrated electronical controller

Main distributor

Secondary distributor

Secondary distributor Secondary distributor

General View
1
Electric pump EP-1

The BEKA-MAX central lubrication pump model EP-1 is Electric pump EP-1 with 1.9 kg container:
electrically actuated and has up to a maximum of 3
independently operating lubricant outlets. A separate
pump unit is required for each outlet. Two pump units are
available, PE-120 or PE-120 V, (see Page 5) so that the
lubricant volume can be adapted to the requirements of
individual progressive distribution circuits.
These pumps enable the delivery of commercial lubricants
up to NLGI-Cl. 2 at a working pressure of maximum 280
bar (pressure relief valve setting).

The EP-1 series pumps differ in container size and control


type. EP-1 can be controlled externally e.g. via PLC or an
additional control unit, S-EP 6, whereby the pump can also
be delivered with a number of differently integrated
controllers.

Integrated controllers:
- S-EP 4
- S-EP 5
- S-EP 7
- S-EP 8
- S-EP 10
- EP-tronic
- EP-tronic T1 Electric pump EP-1 with 4 kg container and integrated
electronic controller:
Technical data:
Motor:
Operating voltage: 12 V DC / 24 V DC
Rpm: 15 rpm
Current consumption:
Idling at +20°C: 0.8 A / 0.4 A
Full load at +20°C: 2.2 A / 1.1 A
Fuse: 5A/3A

Pumps:
Max. operating pressure: 280 bar
(Pressure relief valve setting)
Permissible operating temperature: -35° C to +80° C
Container volume:
Transparent container: 1.9 kg, 2.5 kg, 4 kg or 8 kg
Steel container: 2 kg or 4 kg
Stirrer direction: clockwise
Mounting position: Container vertical position
Delivery rate of pump units:
PE-120: 120 mm3/stroke or rev.
PE-120V (adjustable): 40 to 120 mm3/stroke or rev.
Protection class: IP5K9K as per DIN 40050

Lubricant: Greases up to NLGI-Cl. 2


(excluding solid lubricants)
Mineral oils up to 40 mm2/s (cSt)
FU2152000902GB

Integrated controller

1
General View
Operation:

A DC motor (10) continually operates the eccentric cam (5) reduces any air bubbles, to the suction area in the pump
and pressure ring (6). This eccentricity effects the suction housing (3). A scraper on the stirrer (2) enables a visual
and pressure strokes of the delivery piston (7), whereby the check of the lubricant volume still present in the transparent
integrated non-return valve (8) prevents the delivery supply container (1).
media from being sucked back out of the main line. The pressure relief valve (9) is pre-set to 280 bar.
The stirrer (2) pushes the lubricant out of the supply
container (1) through a screen (4), which

8
5
9
3

10

Pump unit intake: Pump unit delivery:

2
Pump units PE-120 and PE-120 V

PE-120: Pump unit PE-120: Pressure relief valve


set at 280 bar
Technical data: permanently
Delivery rate: 0.12 cm³ / stroke or rev.
Article No. (inc. pressure relief valve): 2152 9906 10000
Article No. (pressure relief valve for PE-120): 2152 0062

PE-120 V:

Delivery rate:

M 20 x 1.5
- All pump units are default set to full stroke
- Unit with piston diameter 6 mm SW 24
- max. delivery rate 0.12 cm³ at full stroke Pipe connection Ø 6
- Reduction 0.013 cm³ per detent = 1/2 revolution
66

Delivery rate control: Pump unit PE-120 V:


- Remove plug screw (2) with Allen key (SW 5) Pressure relief valve
- Turn adjusting screw (3) with a screwdriver set at 280 bar
- Turn clockwise to reduce delivery rate permanently
M 20 x 1.5

- Turn anti-clockwise to increase delivery rate


- Maximum stroke of adjusting screw is 2.4 mm - 6 SW 24
detents 2
- 1 turn of adjusting screw is 0.8 mm = 2 detents
- Tighten plug screw (2), inc. sealing ring.

Installation of pump unit in electric pump EP-1:


- Only install/remove when pump is off Delivery rate (cm³)
3
- Install pump unit with piston partially extended (4), 0.12
0.11
insert at angle in top of housing bore (see diagram A) 0.10

- When piston head rests on pressure ring - move unit into 0.09
0.08 32
vertical position (see diagram B) 0.07
0.06
. Piston head must run in guide ring groove 0.05 Pipe connection Ø 6
- Tighten pump unit 0.04
0.03
- Removal occurs in reverse sequence 0.02
0.01
- When removing the pump unit, ensure that the piston (4) 0

is not left behind in the pump housing. 0 1 2 3 4 5 6 Detents


0 0.5 1 1.5 2.0 2.5 3.0 Rev.

Installation instructions:
Technical data:
Delivery rate:between 0.04 and 0.12 cm³ / stroke Diagram A:
Delivery rate control:
6 detents, each 1/2 revolution 4
Reduction: 0.013 cm³ per detent
Delivery media:Greases from NLGI-Cl. 00/000 to NLGI-Cl.
2
Piston return: forced
Article No. (inc. pressure relief valve): 2152.99063.0000
Article No. (pressure relief valve for PE-120 V): 2152 0063

Diagram B

6
Electric pump EP-1

Filling the pump:

Standard filling via ball lubrication nipple with manual or


pneumatic grease gun.

Top up lubrication nipple

Top up via top up coupling:

Remove lubrication nipple


Replace with grease coupling plug
EDP No.: 2159 0061 012

Grease feed plug


EDP No.:
2159 0061 011 Grease coupling bush
EDP No.: 2159 0062 011

Top up via top filling gun:

Filling gun
EDP No.: 2081 030 26

Straight feed connector


EDP No.: 2152 0150

9
Progressive distributor MX-F

The progressive piston distributors are distributor devices Progressive distributor MX-F with four output elements and
with a hydraulic sequence control, the pistons of which are eight outlets:
regulated by the supplied lubricant in a way that the
lubricant inevitably and successively escapes at the
individual outlets. In the case of malfunctions during the flow
of lubricant, e.g. clogging of lubricating line or lubricating
points, the distributors will block up. This blockage is used
for the monitoring of the distributors. In the case of manually
operated pumps a virtually insurmountable counter
pressure occurs during the blockage. In the case of
automatic pumps such as e.g. the electropump EP-1 the
lubricant escapes at the excess pressure valve.

The progressive distributors are manufactured in a variable


disk construction, which offers the advantage that the
distributor can be extended or shortened at random
according to the amount of lubricating points. Due to this
disk construction there is also the possibility of constructing
an overall progressive distributor from individual
distributor disks with different outputs per piston stroke.
The difference in output per piston stroke is achieved by
different piston diameters.
To ensure the proper functioning of a progressive distributor
a minimum of three pistons, i.e. a minimum of three output
elements is required.
Dimension drawing:
Technical data:
"A" 50
22.4 14.9 14.9 6.5 6.5
Working pressure:-Inlet: max. 300 bar
Temperature range: -35°C to +100°C
Carrier vehicle: oil - viscous oil - grease
23.5
30

Outlet for Ø6 mm
Size: M10x1 Inlet for Ø6mm
Min. MX-F 3/6 (3 piston elements)
Max.: MX-F 12/24 (12 piston elements)
17

16

Element Output Piston


denomination per outlet per element Ø
MX-F 25 25 mm³ 50 mm³ 3 mm 7.5 "B"

MX-F 45 45 mm³ 90 mm³ 4 mm


MX-F 75 75 mm³ 150 mm³ 5 mm
MX-F 105 105 mm³ 210 mm³ 6 mm

Outlets 2 4 6 8 10 12 14 16 18 20 22 24
Dimension "A" 69.2 69.2 69.2 83.95 98.7 113.45 128.2 142.95 157.7 172.45 187.2 201.95
Dimension "B" 57.2 57.2 57.2 72.0 86.7 101.5 116.2 131 145.7 160.5 175.3 190.1
PU4010010902GB

1
General View
Integrated electronic controls
Type S-EP 4

The electronic control device S-EP 4 is used for the time- Electropump EP-1 with integrated control
dependent or cycle-dependent control of a central
lubrication device both for the progressive system (EP
pumps) and for the multiple line system (OC pumps).
BE
KA-MAX

The integrated electronic control S-EP 4 is available with


two types of control:

A) Time-program control
B) Time-relay control

The type of control must be indicated with the order.

Time-program control:

Operational sequence:
(Lubrication time, waiting time) After turning on the ignition,
the yellow LED is illuminated for ca. 2.5 sec. and signals the Display of readiness for operation
readiness for operation. Ready for operation: 2.5 sec.
ON
LED yellow
OFF

Lubrication time Integrated electronic control S-EP 4


Waiting time

For a functional check an intermediate lubrication must be


initiated by operating the pressure switch on the motor
casing or dashboard.

Yellow LED to indicate the functions


Pressure switch to initiate
an intermediate lubrication
MU2147000902GB

1
General View
When operating the pressure switch on the dashboard or Elapsed time chart
the motor casing of the pump, the lubrication cycle is
started. When the lubrication cycle is completed, the pump
motor is switched off and the waiting time begins. All
subsequent lubrications are automatically initiated
Lubrication time
according to the rhythm of the preset waiting time.
Waiting time

When the ignition is switched off during the waiting or Integrated electronic control S-EP 4
lubrication time sequence, the cycle is stopped and the time
stored. When the ignition is switched on again, the
operation process will continue on the basis of the stored
data from the point, where it has been interrupted before.

By operating the pressure switch on the motor casing or the


dashboard when the ignition is switched on, an intermediate Pressure switch to
lubrication can be initiated any time. initiate an
intermediate lubrication
As soon as the control device is connected for the first time, a
lubrication cycle will be initiated.
Yellow light-emitting
diode to indicate the
function
Catch switch to Catch switch to
set up the set up the
lubrication time waiting time

All control devices have a yellow light-emitting diode, on


which the functions are indicated. Indication of a lubrication cycle:
The functions of the light-emitting diode can also be 0.5 sec.
indicated with an external signal lamp on the dashboard. ON
Yellow LED
OFF
0.5 sec.
Cable connection plan for the connection of an external
signal lamp: Cable connection plan for the connection of an external
pressure switch

6 6
1 7
5
brown - Earth terminal 31 1 7
5
brown - Earth terminal 31
2 2
3 3
4
black + Ignition terminal 15
4
black + Ignition terminal 15
F1 F1
yellow + green +
Pressure switch for
Signal lamp intermediate lubrication
F1 = 6,3 A (5x20) medium inert F1 = 6,3 A (5x20) medium inert

2
Technical data:

Supply voltage: 10-55 V


Maximum power load: I = 6,0 A
Fuse unit (not included in device):
F 6,3 A (5x20) medium inert
Output for signal lamp: I=1A
Temperature range: - 35°C to +75°C
Protective system: IP 65

Different non-variable waiting and lubrication time ranges


can be set up in the control.

Setting of parameters:
Set-up of waiting time:
(16 catches, 0.5 h each)
2
Waiting time: 1 3
0.5
0.5 h to 8 8 4

7 5
6

Lubrication time: Set-up of lubrication time, time range I:


(16 catches, 1 min. each)

4
2 6
1
Time range I: 1 min. to 16 min. 16 8

14 10
12

Set-up of lubrication time, time range II:


(16 catches, 2 min. each)
8
4 12
2
Time range II: 2 min. to 32 min. 32 16

28 20
24

For time adjustment remove the red frame with a flat


screwdriver and loosen the four cross-recessed screws.
Subsequently, the transparent cover can be removed. If the
cover is not closed properly, water enters into the control
and it will be destroyed. In this case the guarantee will
become void.

Please indicate the desired time range when ordering.

3
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Alemite Lubrequip PTY Ltd. AVI-Cranes Ltd BEKA AHWON Holland Transtrade
15 Green Street Crane Service+Heavy Transp. 146-65 Anyoungri Taean Up Far East SDNBHD
2100 Brookvale NSW 4 Katsenelson Whasung Gun Kyungi Do Korea 28 Jalan Delima 1/3
Tel.: 0061 / 2 / 99 38 29 99 58016 St. Azor Tel.: 0082 / 31 / 225 / 06 28 Subang Hi-Tech Ind Park
Fax: 0061 / 2 / 99 38 66 05 Tel.: 00 97 23 / 55 72 222 0082 / 31 / 225 / 06 29 40000 Shan Alam
e-mail: info@alemite- Fax: 00 97 23 / 55 83 333 Fax: 0082 / 31 / 225 / 06 84 Tel.: 00 6303 / 734 28 88
lubrequip.com.au web: www.avi-cranes.co.il e-mail: jhleeahwon@yahoo.co.kr Fax: 00 6303 / 734 55 88
e-mail: htfemy@po.jaring.my

Brasilien Japan Kuwait Südafrika


V&R Comércio e Sonne Co., Ltd. Bahrain BEKA-MAX SA PTY Ltd.
Participacoes LTDA Katar
Kyuhhoen 2-31-34. Yao City Oman 300 Kuit Street
Rua 2 n° 431 Centro Osaka Pref. 5810817 Saudi-Arabien Waltloo / Pretoria
Rio Claro SP Brasil Tel.: 0081 / 729 / 23 05 85 Vereinigte Arabische Emirate Tel.: 0027 / 832 882 791
Tel.: 0055 / 19 / 35 34 21 90 Fax: 0081 / 729 / 23 43 95 ITE Ipticar Technologies Gen. Fax: 0027 / 128 035 080
0055 / 19 / 35 34 00 22 e-mail: sonne@juno.ocn.ne.jp e-mail: brigitte@bekamax.co.za
Fax: 0055 / 19 / 35 34 49 79 Alsoor St. Abdulatif Almnays
e-mail: vr@claretianas.com.br PO box 86 Hawalli Code 23001
Al-Munais Building
3rd floor office no. 9
China Kanada Kuwait City Salhya Abdulatif USA
East Tsanhair Company Ltd. BEKA-LUBE Products Inc. Tel.: 009 65 / 244 49 49 BEKA-MAX of America
Room 206, 2840 Argentia Road, Unit 6 Fax: 009 65 / 244 47 47 2600 North America Drive Suite8
No. 9 Hangfeng Road Mississauga ON L5N 8G4 e-mail: beka@beka-kuwait.com P.O. Box 615
Fengtai Science City ipticar@beka-kuwait.com West Seneca, NY 14224
Beijing 100070, P.R. China Canada toll free:
1 / 888 / 862 / 7461 North America Toll free:
Tel.: 0086 / 10 / 83 681 526 Fax: 001 / 905 / 858 / 0597 1 / 888 / 862 / 74 61
0086 / 10 / 83 681 527 e-mail: info@beka-lube.com
Fax: 0086 / 10 / 83 681 520 Fax: 001 / 905 / 858 / 05 97
e-mail: east-tsanhair@263.net e-mail: info@beka-lube.com

BAIER + KÖPPEL GmbH + CO BEETHOVENSTR. 14 POSTFACH 1320 TEL.: +49 9241 729-0 WEB: www.beka-lube.de
PRÄZISIONSAPPARATEFABRIK D-91257 PEGNITZ D-91253 PEGNITZ FAX: +49 9241 729-50 E-MAIL: beka@beka-lube.de

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