Central Lubricating System X-1

Method of operation of the central grease lubrication system

1 Method of operation of the BEKA-MAX central grease lubrication system:

The BEKA-MAX central grease lubrication system operates on a progressive

basis and is capable of using grease to NLGI Class 2. "Progressive" signifies that
the bearings are lubricated in a progressive sequence, i.e. one after the other. This
design principle permits easy monitoring of the system by means of an in-built
pressure relief valve in the pump element. If any lubrication point cannot be
lubricated from the distributor, a back pressure of up to 280 bar will be built up in
system and at that point, a controlled discharge will be effected by the pressure
relief valve. A micro switch on the relief valve of the pump element send a warning
signal to a pilot light in the driver's cabin.
Normally, progressive systems are operated using commercially available
standard greases to NLGI Class 2.

Design of the BEKA-MAX central grease lubrication system:

An electrically actuated piston pump, with up to three pump elements, supplies

lubricant to the main progressive distributor (if installed) which, in turn,
distributes grease to the secondary distributors in the correct ratio. These
secondary distributors then supply the lubricant to the various bearings on the
vehicle. If there are less than twenty lubrication points on the vehicle, only one
distributor will be required. An electronic control module will trigger lubricating
and "off" times of the pump and hence the total quantity of lubricant supplied.

1 central grease pump EP-1

2 transparent lubricant reservoir 2 3
3 filling nipple
4 relief valve with micro switch
5 main progressive distributor 1
6 auxiliary progressive distributor
7 main pipe
8 lubricant pipes
9 lubrication points
7

4
5

}9

6
8

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 Central Lubricating System X-1
Function description, central lubricating pump EP-1

2 Function description, central lubricating pump EP-1:

Ø180

Ø153 Method of Operation:

The DC motor (10) provides a continuos
drive to the eccentric (5) with thrust ring (6).
This cam arrangement produces the suction
and pressure stroke of the primary piston (7)
and the integrated check value (8) prevents
return of lubricant.
The rotating charging arm (2) forces
281

lubricant from the reservoir (1) via the

236

perforated base plate (4) into the pump

housing at the bottom end of the pump
body. The combination of charging arm and
perforated plate serves to reduce air
bubbles to insignificant dimensions. A
rubber wiper blade on the charging arm (2).
137

152

130
107
197,5

1 2

4
177 138
320
8

Permits visual check of grease 9

level in the transparent
reservoir (1).
3
Filling of the reservoir is
6
effected via the hydraulic
grease nipple.
The pressure relief valve (9), 7
is pre-set to 280 bar 5
operating pressure, to provide
protection for the pump and
piping system.

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 Central Lubricating System X-1
Installation of pump elements

Adjusting output of the pump element PE-120 V:

Adjustability of the Supply rate (percentage)

output allows use of 100
this pump element 90
for supplying 80
lubrication systems 70
of different sizes. 60
50
Adjusting pump unit:
40
- Remove plug (2) 30
using Allen key. 20
- Adjustment of the 10
va´riable rate pis- 0
ton 1 2 3 4 5 6 Stop grooves
- The piston is set Revol.
at maximum out- 0 0,5 1 1,5 2 2,5 3
put, when leaving Setting piston 2
the factory, i.e.
stop groove 0. Supply piston
- Clockwise rota-
tion decreases
the output (1
stop groove
equals approx.
11 % of output) 1
- Counter-clockwi- Max. variation of stroke
se rotation will in- 3
crease the output
- Maximum stroke of the adjustable output piston equals 6 stop
grooves (approximately 66%)
- 1 revolution of the adjustable output piston equals 2 stop
grooves (approximately 22%)
- Replace and tighten blanking plug (2) including the washer.

Installation of pump elements into the electric pump EP-1:

- Removal and installation of pump unit must be

carried out when the pump is not working.
- Remove blanking plug. Fig. I
- Install pump element with piston partially extended.
- Insert with pump piston angled upwards.
- When the piston head touches thrust ring, move
to horizontal position (Fig. 11).
- Tighten pump element in place.
- Removal is effected by a reserve sequence of
operations.
- During removal of the pump element, ensure that
the piston (1) is not left behind within the housing.
- When installing pump element, carry out pump
rotation test to establish that the unit is correctly
installed. Fig. II
- With every revolution of the pump, clearly visible
quantity of grease must be seen to be leaving the
pump outlet
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 Central Lubricating System X-1
Function Description of Control unit S-EP 4
3 Integrated electronic control unit S-EP 4 with data memory for pump type
EP-1 and OC-1:
The electronic control unit S-EP 4 is used for control of a central lubrication system, governed
according to operating times, both for progressive systems (EP-1 pumps) and for multi-line
systems (OC-1 pumps).

Sequence of steps of operation:

(Time of lubrication; inoperative periods): After ignition has been turned ON, the yellow LED will
be lighted for approx. 2,5 sec., this signalling that the system is ready for operation. If a
function test is to be performed, an intermediate lubrication cycle has to be started by means of
a push button at the engine housing or in the dashboard.
When that push button in the dashboard or at the engine housing is actuated, the time of
lubrication is started and the pump is turned ON. After the time lubrication is completed, the
pump motor will be turned OFF and the inoperative time begins. All subsequent steps of
lubrication will be started automatically in accordance to the rhythm of the pre-selected
inoperative times.

If the ignition is turned off while an inoperative time or a lubrication cycle is going on, the time
will be interrupted and stored in the memory. When the ignition is turned on again, the dates
stored in the memory will be re-activated and the sequence of operations will be continued at
that point where it was interrupted before.
When the ignition is turned ON, an intermediate lubrication cycle can be started at any time by
means of the push button at the engine housing or in the dashboard.
Whenever the control unit is connected for the first time, a lubrication cycle will be started.
Each control unit is equipped with a yellow LED, indicating the following functions:

Ignition ON: > Diode is lighted for approx. 2,5 sec.

Lubrication cycle: > Diode is flashing

The functions of the LED may be shown also at an external point, by a pilot lamp in the dashboard
of the driver's cab.

Push button

EA/PA Controller Typ S-EP 4

Schmierzeit (min.)
Pausenzeit (h)
Kontroll
4 2
2 6 1 3 LED
1 0,5
Connection cable, 16 8 8 4

approx. 10 m 14 10 7 5
12 6

LED, yellow

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 Central Lubricating System X-1
Technical details

Technical details:

Supply voltage: 10 30 Volts

Max. current load: I = 6,0 A
Fuse (not supplied with the unit) F 6,3 A (5x20) medium inertia
Output for signal lamp: I = 0,4 A
Temperature range: from-35°C up to +75°C
Enclosure: IP 65

Inoperative period: 2
1 3
0,5
0,5 h - 8 h 8 4

7 5
6

4
Time of lubrication: 2 6
1
Time range I: 1 min. - 16 min. 16 8

14 10
12

8
4 12
2
32 16
Time range II: 2 min. - 32 min.
28 20
24
To enable setting of the time, remove the red frame, using a flat screwdriver, and
detach the 4 crosshead screws. After that, the transparent cover can be removed,
if the cover should not be closed in the correct way, water may penetrate the
system which then may be destroyed. In any such case, warranty claims cannot
be accepted. When ordering part, please state the range of lubrication times
required by you.

Intermediate lubrication cycle:

An intermediate lubrication cycle can be started by means of the push button at

the engine housing or in the dashboard of the vehicle.

Push button, red for intermediate

ubrication at the engine housing

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 Central Lubricating System X-1
Special execution electric grease level control
Special execution electric grease level control

Optional grease pumps can be equipped with an electric grease level control.
In this case, there is assembled in the pump container an capacitive
approximation switch which sends at high level of grease a signal to the
electronic control S-EP 4 which is evaluated by the control device.

to the control device

S-EP 4

Capacitive approximation switch

min. grease level

The control device evaluates the signal and the yellow LED slowly blinks (1
sec. on, 2 sec. off).
To prevent any air from being pumped into the system, the pump shuts down.
Once the container has been filled, a lubricate signal can be triggered through
the centralised lubrication system.

Terminals diagram:
brown
1 6 - mass terminal 31
black F1
7 + ignition terminal 15
2 5 signal lamp
3
4 yellow
+
green
+
Push button for inter-
mediate lubrication
view of plug-incontacts no.1
1 6 brown
+ low level control
7 blue
2 5 - low level control
3
4 black
Input low level control

view of plug-incontacts no.2

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 Central Lubricating System X-1
Signals of the control device S-EP 4

Signals of the LED and the external signal lamp:

Signal of operating readiness:

1,5 sec.

0,5 sec.

Signals lubricating procedure:

0,5 sec.

2 sec.

Malfunction
Operation of electric grease
level indicator
1 sec.
2 sec.

Malfunction
Operation of pressure relief
valve

4 sec.

Malfunction
Overloading of the electric
Motor

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 Central Lubricating System X-1
Method of operation of progressive distributors MX-F

4 Method of operation of progressive distributors MX-F:

„A“ 50
22,5 15 6,5 6,5
30

23

Outlet for dia. 6 mm

M10x1 inlet for dia. 6 mm

Technical detail:
Operating pressure-inlet: 300 bar
Temperature range: -35°C to +100°C
17

Lubricants: oil , soft grease or

standard grease
16

Modular range:
Min.: MX-F 3/6 (3 elements)
Max.: MX-F 10/20 (10 elements)
7,5 „B“

Elements Output Piston

Outlets 2 4 6 8 10 12 14 16 18 20
code per outlet per element dia.
MX-F 25 25 mm3 50 mm3 3 mm
3 3 dimension “A" 70 70 70 85 100 115 130 145 160 175
MX-F 45 45 mm 90 mm 4 mm
3 3
MX-F 75 75 mm 150 mm 5 mm dimension “B" 58 58 58 73 88 103 118 133 148 163
MX-F 105 105 mm3 210 mm3 6 mm

Progressive distributors are defined as assemblies containing a series of pistons, whose

function is to deliver lubricant to bearings; the lubricant itself provides an hydraulic force
to operate these pistons in a progressive sequence: thus, each bearing connected to a
piston receives a measured supply of lubricant, one after the other.
Should there be an obstacle to the flow of lubricant, e.g. crushing of the lubricant delivery
pipe or excessive back pressure in the bearing, the progressive distributor block will be
unable to proceed with this cycle. This blockage can be used to monitor the operation of a
distributor assembly. On automatic pumps, e.g. EP-1 electric pump, lubricant will escape
from the pressure limiting valve.
The progressive distributors are assembled in modular form and can suit the relevant
number of lubrication points by extension or reduction in the number of individual
elements. This modular design allows for combinations of various element with differing
rates of lubricant delivery.
Delivery outputs per piston stroke are achieved by the use of different piston
diameters. In order to achieve a complete and correct cycle of operation, a
progressive distributor assembly must always comprise a minimum of three operating
elements.

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 Central Lubricating System X-1
Combination of outlets on the MX-F distributor

Combination of outlets:

2 outlets per distributor element 1 outlet per distributor element

(standard model) Threaded pin SW2 Plugscrew SW5

single double

Combination of several outlets:

for ex. 3 outlets 4 outlets

triple quadruple

single

Check valve for progressive distributor MX-F:

SW 12

This check valve is used in conjunction with primary distributors and has the purpose of
counteracting high back pressure.

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 Central Lubricating System X-1
Types of pipings

5 Installation of pipework:

Types of pipings:

From the progressive distributor to the lubricant point, a nylon pipe of Polyamide
PA 12 is recommended. In the progressive system, the standard diameter of tail
pipes is 6 mm. The wall thickness of this tube is 1,5 mm, so tube inserts are not
necessary.

EDP-no.: 1001 20 100

Ø 6 mm
Ø 3 mm
From the pump to the main distributor, and from the main distributor to the
secondary distributor, or where movement is expected, a high pressure hose of
nominal 4 mm bore is used. This hose has an outside diameter of 8.3 mm and is
used with re-usable ferrules and inserts.

Fitting of the hose ferrel:

Grip the hose, using tube pliers. Lubricate the end of the hose with either oil or
grease

Grip tongs

Threaded sleeve Hose

Place the threaded sleeve on to the hose and turn in an anti-clockwise direction
until the dimension shown in the drawing (11 mm) is attained.

Threaded sleeve

Hose
11

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 Central Lubricating System X-1
Fitting the hose insert
Fitting the hose insert:

The threaded portion, as well as the cone-shaped should be oiled carefully.

The insert is then screwed into the ferrule up to the stop position.

Rohrstutzen Schraubhülse
EDV-Nr.: 1001 21 201 EDV-Nr.: 10001 21 200

komplett montierte Verschraubung

EDV-Nr.: 1001 20 200

Important note:

From time to time, the outside diameter of the hose can vary slightly,
because of manufacturing tolerances. When required to assemble hose at
the bottom end of the permissible tolerance, with a hose ferrule at the top
end of its tolerance scale, a successful joint can be made by flattening the
ferrule (at the point where the hose enters) by 1 or 2 mm into an oval shape.

Joints are made at the distributor by means of a sleeve nut and cone fitting.

Polyamidrohr mit Doppelkegelring Hochdruckschlauch mit Doppelkegelring,

und Überwurfschraube Überwurfschraube, Rohrstutzen
und Schraubhülse.

Notes concerning installation:

- Avoids points where chafe can occur against other parts of the vehicle.
- Install pipes with adequate clearance from heat sources (such as exhaust,
engine etc.): where necessary, use steel pipe 6 mm x 1 mm.
- When fitting lubrication pipes to moving components, such as part of axles,
tail lifts, cranes, hoists etc., particular care must be taken to avoid damage or
chafing.

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