Operation instruction for

Lubrication system

E
SUP

R!

Bauer Dok-Nr.:

ZSA 013 EN_00

Contens

Operation instruction
Table of contents:
1. Function description
2. Function description, central lubricating pump

3. Function description, progressive distributor

4. Function description, controls
5. Pipes and routing

Central Lubricating System

Method of operation of the central grease lubrication

BAUER
Maschinen GmbH
86522 Schrobenhausen

system

Method of operation of the Central grease lubrication system:

The 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 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.
Technical data:
Motor:
Operating voltage:
Revolutions:
Current consumption:
Idling at + 20C:
Full load at + 20C:
Fuse:

24 V DC
15 rpm
0.4 A
1.1 A
3A

Pump:
Max. operating pressure:
280 bar
(Adjusting of pressure relief valve)
Permissible operating temperature:
-35C to +80C
Reservoir size:
Transparent reservoir:
1.9 kg, 2.5 kg, 4 kg or 8 kg
Steel reservoir:
2 kg or 4 kg
Stirrer direction:
counterclockwise
Mounting position:
Reservoir in vertical position
Delivery rates: depending on pump element (see page 7)
Protection type:
IP5K9K as per DIN 40050
Lubricant:

2
1
4

Greases up to NLGI-cl. 2
(excluding solid lubricants)
Mineral oils from 40 mm2/s (cSt)

5
1
2
3
4
5
6
7
8
9

central grease pump EP-1

transparent lubricant reservoir
filling nipple
relief valve with micro switch
main progressive distributor
auxiliary progressive distributor
main pipe
lubricant pipes
lubrication points

9
6
8

Contents

Central Lubricating System

Function description, central lubricating pump EP-1

2
2

BAUER
Maschinen GmbH
86522 Schrobenhausen

Function description, central lubricating pump EP-1

180

256

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
lubricant from the reservoir (1) via the
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).

179.2

9.5

152
130

107

197.5

235

4
8

9
341

3
6

Permits visual check of grease level

in the transparent reservoir (1).
Filling of the reservoir is effected via
the hydraulic grease nipple.
The pressure relief valve (9), is preset to 280 bar operating pressure, to
provide protection for the pump and
piping system.

7
5

Contents

Central Lubricating System

Installation of pump elements

BAUER
Maschinen GmbH
86522 Schrobenhausen

Adjusting output of the pump element PE-120 V:

Adjustability of the
output allows use of
this pump element for
supplying lubrication
systems of different
sizes.

Supply rate (percentage)

100
90
80
70
60
50

40
Adjusting pump unit:
30
- Remove plug (2) using
20
Allen key.
10
- Adjustment of the
variable rate piston.
0
1
2
3
4
5
6
The piston is set at
maximum output, when
0
0,5
1 1,5 2
2,5 3
leaving the factory, i.e. stop
Setting piston
groove 0.
Supply piston
- Clockwise rotation decreases
the output (1 stop groove
equals approx. 11 % of
output)
- Counter-clockwise rotation will increase
1
the output Maximum stroke
of the adjustable output piston
Max. variation of stroke
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.

Stop grooves
Revol

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.
- 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.
- With every revolution of the pump,
clearly visible quantity of grease must
be seen to be leaving the pump outlet

Fig. I

Fig. II

Method of operation of progressive distributors MX-F:

A
15

50
15

6,5

6,5

23

Outlet for dia. 6 mm

22,5

30

M10x1 inlet for dia. 6 mm

16

BAUER
Maschinen GmbH
86522 Schrobenhausen

Central Lubricating System

Method of operation of progressive distributors MX-F

17

Technical detail:
Operating pressure-inlet:
Temperature range:
Lubricants:
Modular range:
min.:
max.:

7,5

Elements
code
MX-F 25
MX-F 45
MX-F 75
MX-F 105

300 bar
-35C to +100C
oil , soft grease or
standard grease

MX-F 3/6 (3 elements)

MX-F 10/20 (10 elements)

Output
per outlet per element
25 mm3
50 mm3
3
45 mm
90 mm3
75 mm3
150 mm3
105 mm3
210 mm3

Piston

3 mm
4 mm
5 mm
6 mm

Outlets

2 4 6 8 10 12 14 16 18 20

dimension A 70 70 70 85 100 115 130 145 160 175

dimension B 58 58 58 73 88 103 118 133 148 163

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.

Contents

Central Lubricating System

Combination of outlets on the MX-F distributor

BAUER
Maschinen GmbH
86522 Schrobenhausen

Combination of outlets
2 outlets per distributor element
(standard model)

1 outlet per distributor element

Threaded pin SW2

single

double

Combination of several outlets:

4 outlets

for ex. 3 outlets

triple

quadruple

single

The metered volume of lubricant is combined output of all pistons.

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.

BAUER
Maschinen GmbH
86522 Schrobenhausen

Central Lubricating System

Function description, controls

ntegrated electronic control unit BEKA-troniX1

The electronic control unit BEKA-troniX1 is used for control of a central lubrication system, governed according to
operating times, both for progressive systems (EP-1 pumps)

Function sequence
Whatever program is being used, once the ignition has been switched on the green and the red LED or the green and the
red signal lamp (optional) lights up on the control panel for 1.5 sec. and shows that the controller is operational (activation
control).
Every time the controller is activated for the first time, a lubrication process begins. The green LED in the control half shell is
lit during the entire lubrication procedure.
The BEKA-troniX1 integrated electronic controlling device has memory at its disposal. This also serves to keep a record of
time elapsed. Should the ignition be switched off during lubrication or operational pauses occur, then the time is stopped
and recorded. Once the ignition is switched on again the remaining lubrication or pause time is read from the memory and
the sequence will be resumed where it was interrupted.
At any time when the ignition is on, an interim lubrication occurs when the button on the side of the pump motor housing or
the illuminated button on the control panel is activated, this serves as a check of functionality. The pump then immediately
starts its lubrication cycle, the lubrication or cycle duration recorded up to that point is reset and starts from the beginning.
An interim lubrication can also be triggered via an external button, and the indication of the red and green LEDs can also be
displayed by a red and green signal lamp in the drivers cab.
A error can be reset by pressing the interim lubrication button and the pump starts the lubrication process anew.
The lamp on the illuminated button (green) shows the functionality of the controller and the current lubrication sequence.

A) Time controller:

Diagram of cycle sequence:

When the central lubrication processor is time controlled,

the cycle duration and the lubrication time can be adjusted.
Cycle duration means the period from the beginning of one
lubrication process to the beginning of another lubrication
process.

Lubrication time
Cycle duration

Button for
activating
interim
lubrication

Red LED showing faults

Green LED showing function

Inhalt

Central Lubricating System

Technical data for the controller:

BAUER
Maschinen GmbH
86522 Schrobenhausen

Technical data for the controller:

Operating voltage:
10 to 60 V DC
Maximum current load:
I = 6,0 A
Fuse (not included in device):
F 6,3 A (5x20) medium
slow-blow fuse
Signal lamp outlet:
I = 0,4 A
Temperature range:
-35C to +75C
Degree of protection:
IP 65

noperative period:
0,5 h - 8 h

0,5
8

4
7

Time of lubrication:
Time range: 2 min. - 32 min.

2
32

12
16

28

24

20

To enable setting of the time, remove the red frame, using a flat screwdriver, and detach the 4 crosshead
crews. 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
lubrication at
the engine housing

BAUER
Maschinen GmbH
86522 Schrobenhausen

Central Lubricating System

Summary of Signal Indicators

Summary of Signal Indicators

The pumps functions are indicated via two control LEDs
(green/red) in the display on the pumps motor casing,
where the red LED always indicates an error in the program
sequence.

BEKA-troniX1 integrated electronic controller:

These control LED functions may be indicated in the

drivers cap of the vehicle via built-in signal lamps. These
must be specially ordered.

Red LED error indicator

Green LED function indicator

Standby indicator:
a)

Standby

LED rot
LED grn

Standby: 1.5 sec.

ON
OFF
ON
OFF

Lubrication sequence:
LED red

b)

ON
OFF
During whole lubrication

Lubrication activated
LED green

ON
OFF

Grease level too low:

Until reservoir is filled

c)

Grease level error

LED red
LED green

ON
OFF
ON
OFF

Excess pressure in main system:

1 sec.

LED red

d)

ON
OFF

Excess pressure error

1 sec.

LED green

ON
OFF

Memory error:
0,5 sec.

f)

Memory error

LED red

ON
OFF

LED green

ON

0,5 sec.

OFF

Test lubrication:
f)
Test lubrication (constant lubrication)
To adjust the time controlling to continual lubrication for
servicing purposes, the lubrication time must be set to a
higher value than the cycle duration.

LED red

ON
OFF

1 sec.

LED green

ON
OFF

1 sec.

Central Lubricating System

System excess pressure monitoring

BAUER
Maschinen GmbH
86522 Schrobenhausen

BEKA-troniX1
System excess pressure monitoring

With the BEKA-troniX1 integrated electronic controller, the maximum operating pressure of progressive lubrication
system can be monitored.
For this puropose a micro switch has been attached to the excess pressure valve of pump element.
Should a fault occur in the system, e.g. a blockage at the point of lubrication, a pressure of more than 250 bar builds up. A
micro switch in the excess pressure valve is activated and sends a signal to the controller. This switches the pump off
and the fault is indicated by the flashing red LED and permanent illumination of the green LED or the externally attached
signal lamps.

Technical data for the micro switch:

Operating voltage:
10 to 60 V DC
Maximum current load:
I = 1,7A
Contact type:
1 changer
Temperature range:
-25C to +85C
Degree of protection:
IP 67
Connection:
Cable, length 0.5 m, heat-sealed
with 4-pole right-angle plug
Connection to the controller:

green
marking
ring

Connection to the controller is effected via the four-pole plug-and-socket connector marked with a green ring, to the
pump motors lower casing; to this effect, the contact plug cover must be removed.

Central Lubricating System

Grease level controller

BAUER
Maschinen GmbH
86522 Schrobenhausen

Grease level controller

The integrated electronic controller BEKA-troniX1 facilitates monitoring of the grease level in the storage tank.
To this effect, a capacitive proximity switch has been installed in the pumps storage tank.
For purpose a capacitive proximity switch has been built in to the pumps reservoir.
As long as there is enough grease available in the reservoir, the proximity switch sends a signal to the controller. If the grease
level sinks below minimum the proximity switch turns the signal off.
If the signal remain off for more than 10 sec. then the controller switches the pump off, so that no air is pumped into the
system.
The red LED on the controller display, situated on the pumps motor housing or a built-in red signal lamp, if available, starts to
illuminate.
Once the grease has been refilled, the controller restarts itself.
Connection to the controller is effected via the four-pole plug-and-socket connector marked with a red ring, to the pump
motors lower casing; to this effect, the contact plug cover must be removed.
Connection to the controller:
Connection cable
length 0.6 m
EDP no.:
1000912998

The grease level controller can be attached to the BEKAtroniX1 controller with any selected program.

Technical data for the capacitive proximity switch:

Operating voltage:
10 to 60 V DC
Switching type:
PNP-turnkey
Maximal current load:
250 mA
Degree of protection:
IP 67
Ambient temperature range:
-25C to +70C
Connection:
4-pole, M12x1 pluggable
red
marking
ring

Terminal diagram of all connections

Fill level switch for
grease level controller

Micro switch for

excess pressure controller

green (no. 1)
Signal lamp green
red (no. 2)

green
Signal lamp red
External signal lamps
orange (no. 4)
Push button for
intermediate lubrication

Ignition, terminal 15
Ground, terminal 31

black (no. 3)
brown (ye/gr)

(no. ...) = Cable-no. at unicolored cables

red

BAUER
Maschinen GmbH
86522 Schrobenhausen

Central Lubricating System

Types of pipings
Installation of pipework:
Types of pipings:

EDV-Nr.: 1001 20 100

6 mm

From the progressive distributor to the lubricant point, a nylon pipe of Polyamide PA 12
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.

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

Hose

Threaded sleeve

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

Threaded sleeve

Hose
11

Contents

Central Lubricating System

Fitting the hose insert

BAUER
Maschinen GmbH
86522 Schrobenhausen

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.

Hose insert
EDP-No.: 1001 21 201

Hose ferrule
EDP-No.: 10001 21 200

Hose end assembly, fully assembled

EDP-No.: 1001 20 100

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.

Nylon tube with double

cone and sleeve nut

High-pressure hose with double cone, sleeve nut,

hose insert and hose ferrule

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