BECHEM 125 User manual
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BECHEM Lubricator 125
technical manual
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1. Introduction and intended use
2. Safety instructions
2.1 Use
2.2 Safety and warning instructions
2.3 Reports and certificates
3. Product setup and technical data
3.1 Setup and functionality of the BECHEM Lubricator
3.2 Technical data
4. Storage
5. Installation
6. Start of operation
6.1 Putting the BECHEM lubricator into operation
6.1.1 Activation of lubricator
6.1.2 Runtime setting
6.1.3 Interruption and recommissioning
6.2 Use of extension tubes
7. Maintenance
8. Optional component parts
9. Disassembly and replacement
10. Environment, disposal and recycling
11. Error search and error correction
Table of contents
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These instructions contain impor-
tant information on function, appli-
cation possibilities, assembly and
disposal of the BECHEM lubrica-
tor and shall contribute to a maxi-
mum of safety during use and an
efficient product application.
The BECHEM Lubricator 125 is
an electrochemically driven device
for automatic supply of lubrication
points with lubricating grease or
lubricating oils. For this purpose, the
lubricator is screwed into the thread
hole of the previously removed
lubrication fitting. Over a certain
period of time it dispenses a pre-
set amount of lubricant quantity.
The lubricator is particularly suit-
able for supplying lubricant to
(difficult to access) single lubri-
cation points. It can be used at
lubrication points of plain and
roller bearings, linear guides,
shafts, spindles, roller and toothed
chains, seals, ropes and open
gears. If necessary, extension
tubes can also be used.
These safety instructions make no
claim to completeness. If you have
any questions or problems please
contact your BECHEM sales part-
ner. The BECHEM Lubricator 125
has been developed and manu-
factured according to the state of
the art and the accepted safety
regulations. Please read the follo-
wing general safety and warning
instructions carefully before putting
the lubricator into operation to
avoid personal injury or damage
to property.
When reselling this product, the
technical manual must always be
included or accessible. The latest
version can be downloaded from
https://www.bechem.de/bechem_
lubricator in several languages.
Resellers are obliged to provide
the information properly in the
respective national language.
1. Introduction and
intended use 2. Safety instructions
2.1 Use
The intended use requires that
these instructions and especi-
ally chapter 2 on safety instruc-
tions are read and observed. The
BECHEM Lubricator 125 is a pro-
duct according to the machine-
ry directive 94/9/EC. Assembly,
commissioning, operation and
maintenance should principal-
ly be carried out by trained and
qualified personnel only, as this
requires basic knowledge of me-
chanics, related technical terms
as well as of pertinent standards,
regulations and accident preven-
tion measures.
2.2 Safety and warning
instructions
The safety instructions point out
dangers of personal injury and
damage to property. Please pay
particular attention to sections
marked with this symbol:
Indicates a danger to the health of
persons, which can lead to seri-
ous injuries.
General safety instructions:
• Please note the country-specific
regulations for accident preven-
tion, environmental protection
and workplace.
• Use the lubricator only in techni-
cally flawless.
• Check the product for obvious
defects such as cracks in the ca-
sing, missing covers and seals.
• The lubricator must not be
changed, opened or modified,
otherwise the manufacturer‘s
warranty will become void and
personal injury or application
damage may occur.
• Opening the top part by remo-
ving the anthracite-colored ring
may only be performed by quali-
fied personnel.
• Please pay attention to the safety
data sheets and the technical
data sheets of the filled BECHEM
lubricants.
• Use the device exclusively in the
area of application specified in
chapter 1, introduction and in-
tended use.
• Always switch off the power
supply before assembly/disas-
sembly.
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Safety instructions for handling
batteries:
• Avoid contact of eyes, skin and
clothing with battery substances.
• Do not swallow leaking battery
substances.
• All relevant safety data sheets
must be observed.
• Do not throw batteries into open
fire. The temperature specifica-
tions of the batteries must be
observed.
• Do not open the batteries.
• The batteries must be disposed
of according to the regulations.
Safety instructions for installation
and use:
• Wear protective gloves, protec-
tive clothing and eye protection
during installation.
• During assembly, ensure that the
lubricator and its components
are securely fastened.
• During installation and mainte-
nance on machines and systems,
the relevant operating instruc-
tions and safety instructions must
be observed and complied with.
• Ensure that all seals and covers
are correctly installed and unda-
maged to prevent the intrusion
of foreign objects.
• Make sure that all electrical con-
nections are in use or closed.
Only put a fully installed product
into operation.
• Make sure that the lubricant
supply is ensured.
Safety instructions for
maintenance:
• Do not clean the lubricator with
solvents or aggressive cleaning
agents.
• Avoid electrostatic charges by
cleaning the lubricator from the
outside with an antistatic cloth
using little pressure.
• The lubricator must be disposed
of in accordance with the rele-
vant national regulations.
Obligations of the operator:
The operator of the lubricator must
regularly inform his personnel
about the following topics:
• Observance of the technical
manual and the legal regulations.
• Correct operation and use of the
lubricator.
• Observe the instructions of the
factory security and the opera-
ting instructions of the operator.
• Behavior in case of emergency.
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2.3 Reports and certificates
The lubricator has been tested by
the following testing institutes:
• Fraunhofer-Institut für Grenzflä-
chen und Bioverfahrenstechnik
• FMPA Forschungs- und Material-
prüfungsanstalt Baden-Württem-
berg
•Food testing values and food law
regulations were met
• Prüflabor ELMAC GmbH
CE test certificate No. 76087-
1BCD
• Physikalisch-Technische Bun-
desanstalt (PTB) Certificate of
conformity
• DEKRA EXAM GmbH
• Specialist office for safety of
electrical equipment
• EC type-examination certificate
for explosion endangered areas
BVS 03 ATEX E 223 according to
directive 94/9/EC
• 2nd supplement to the test
report BVS PP 03.2138 EC
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3.1 Setup and functionality of
the BECHEM Lubricator
The BECHEM Lubricator 125 is
activated by closing the con-
tacts by using the jumper. This
triggers an electrochemical re-
action, producing nitrogen as an
intermediate product, which leads
to a pressure build-up in the ni-
trogen chamber. This pressure
is transferred to the piston by a
bellow. The piston displaces the
lubricant, which is supplied to
the lubrication point via the outlet
opening. The lubricant delivery
quantity can be regulated by four
jumper positions (see setting the
running time under 6.1.2).
3. Product setup and
technical data
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The lubricator can be used inde-
pendent of the position. A visual
control of the filling level is possible.
After expiration of the operating
time the lubricator will be replaced
by a new unit. The housing is
weatherproof, splash-proof, corro-
sion resistant and offers protection
against temporary submersion
(IP67).
Basic concept
BECHEM Lubricator 125
Cover
Jumper
Electronic board
Battery chamber
Batteries
Nitrogen chamber
Electrochemical
pressure buildup
Piston
Fill level indicator
Lubricant
Outlet threat
Screw cap
Fassung 4 – nur EN US
BECHEM Lubricator 125
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Type BECHEM Lubricator 125
Content 100 ml
Measurements:
height x diameter
130 x 80 mm
Connection thread G ¼
Tare weight approx. 230 g
Operating pressure up to max. 5 bar
Operating voltage 3 V
Battery capacity 3000 mAh
IP 67
Battery (standard version) Varta Industrial 4006 (firmly
installed, no change intended)
Service temperature range approx. -20 °C – +50 °C
Relative air humidity 30 % – 80 %, non-condensing
Lubrication duration, adjust-
ment range
3, 6, 9 and 12 months
Explosion protection BVS 03 ATEX E 223
Identification 8II 2G Ex ib IIC T4 / T3 Gb
I M2 Ex ib I Mb
3.2 Technical data
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Observed standards and guidelines
RL 94/9/EG Devices and protective systems for
use as intended in potentially explosive
atmospheres
RL 98/37/EG „Safety of machines“
RL 97/23/EG „Safety of pressure equipment“
RL 89/336/EWG „Electromagnetic compatibility“
EMC Guideline
Storage conditions for the lubri-
cator and its components:
• Relative air humidity 30 % – 80 %,
non-condensing.
• No direct sunlight.
• Storage temperature
-20 °C – +50 °C.
• The storage period depends on
the intended duration: based on
a total sum of 24 months, this
results in for 9 months running
time a storage time of 15 months,
4. Storage
for 12 months a storage time of
12 months.
• The lubricant may leak if stored
improperly.
• Store the lubricator with the
opening pointing downwards.
• Before storage, check lubricator
for leak-tightness.
• Too long storage time or improper
storage can lead to malfunctions
of the lubricator.
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Before mounting the lubricator
the bearing/lubrication point has
to be greased properly with a
hand operated grease gun. Possi-
ble blockages and resin deposits
have to be removed professional-
ly before. The applied pressure for
lubrication of the bearing or actu-
ator should not exceed 0.5 bar.
Then remove the grease fitting
from the casing.
Screw in a suitable adapter (con-
nection thread BECHEM Lubricator
125: G ¼). Before screwing in
the lubricator the adapter must
be completely filled with the lu-
bricant. Mount the lubricator by
screwing it down with a tightening
torque of 6 Nm (at 20 °C). If a hose
extension to the lubricating point
is used, it should be filled with the
same BECHEM lubricant as the
lubricator.
5. Installation
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Remove the transparent protec-
tive cover from the lubricator cas-
ing and activate the lubricator first
by short-circuiting contacts A with
the jumper provided. For setting
the running time, please refer to
ch a pte r 6 .1. 2.
At temperatures above +50 °C,
the lubricator must be distanced
from the heat source by means of
a tube extension (Attention: Note
the length of the line), see chap-
ter 6.2. For lateral mounting of the
lubricator we recommend a pipe
clamp (see chapter 8).
• The lubricator may only be in-
stalled by qualified personnel
(see general safety instructions
on page 3).
• Wear protective gloves, protec-
tive clothing and eye protection
during assembly.
• Do not install the lubricator direct-
ly on vibration sources.
• Do not install the lubricator on
heat sources.
• A protective cover is recom-
mended for outdoor installation.
• The lubricator must not be in-
stalled in electromagnetic areas.
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6.1 Putting the BECHEM lubri-
cator into operation
Before the lubricator is installed,
the lubrication points must be pre-
lubricated sufficiently to remove
possible blockages and resin de-
posits. For this purpose a hand
operated grease gun with nano-
meter is suitable.
6.1.1 Activation of lubricator
If the lubricator is mounted on
the lubrication point, remove the
transparent protective cover from
the upper part of the casing and
activate the lubricator with the
supplied loose jumper. To do this,
plug it into position A as shown in
the illustration. The jumper on the
slot not marked with a letter is a
spare jumper.
6. Start of operation
A
B
C
D
A
B
C
D
6.1.2 Runtime setting
Within 24 hours the pressure is
built up in the lubricator. After
pressure build-up place the jumper
to the desired running time A, B, C
or D.
Position Duration Daily lubricant release at
filling with grease (appro-
ximate values)
A 1 month 3,33 cm3
B 3 months 1,11 cm3
C 6 months 0,55 cm3
D 12 months 0,28 cm3
A
B
C
D
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After setting the running time, the
sealing cover must be carefully re-
placed. The installation date and
running time can be marked on
the label.
1 3 6 12
Installed: Expired:
When filled with lubricating oil, the
running time is extended by up to
40 %. Due to various influencing
variables such as ambient tempe-
rature, length of the extension line
and different lubricant properties,
e.g. density, the above values are
only a rough guide. If the lubrica-
tor is not activated by occupying
slot A, but the jumper is plugged
directly into the desired running
time, the pressure build-up times
are extended: A = 1 day, B = 3 days,
C = 6 days, D = 10 days.
The running time and lubricant
delivery quantity of the lubricator
may vary if the optimum operating
temperature/ambient temperature
changes over a longer period
of time. Short-term temperature
deviations up or down have little
or no influence on the total running
time of the lubricator.
6.1.3 Interruption and recom-
missioning
By removing the jumper, the lubri-
cant delivery is interrupted. The
pressure built up in the nitrogen
chamber is maintained for about
five days. After reactivation of the
lubricator the lubricant delivery
starts again with a short time delay.
The slot (the running time) can be
changed if required when reacti-
vating the lubricator.
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• Check the lubricator for external
damage.
• Check the installation of the lubri-
cator.
• Check the filling level and func-
tion of the lubricator regularly.
• Check whether the jumpers are
set correctly.
• Protect the lubricator from direct
overheating.
6.2 Use of extension tubes
If supply lines are installed between
lubricator and lubrication point,
these must be filled with the same
lubricant used in the lubricator
before installation. A mixing of dif-
ferent lubricants must be avoided
at all costs. The length of the supply
lines depends on the consistency
of the lubricating grease or the
viscosity of the lubricating oil as
well as on the respective environ-
mental parameters. When using
lubricators with oil filling, it is re-
commended to install a 0.2 bar
non-return valve upstream of the
lubrication point to prevent the
line from running empty.
Lubri-
cant
Max. length of
the line
Required min.
inner diameter of
the line
Greases,
pastes
0,5 m 6 mm
Oil 2 m 6 mm
Only one lubricator should be used
per lubrication point. A lubrication
point requiring more lubricant can
be additionally supplied with 2 lubri-
cators via a T-lead-in-connector.
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• The lubricator must not be
opened.
• Make sure that no liquid can in-
gress.
• Clean the lubricator only from
the outside.
• Clean the lubricator only with a
damp cloth.
• Do not use any aggressive sol-
vents or cleaning agents.
• Check the grease level and func-
tion of the lubricator regularly.
7. Maintenance
Please contact us regarding pos-
sible component parts for the
BECHEM Lubricator 125.
8. Optional
component parts
Installation dimensions „pipe
clamp“ for mounting the BECHEM
Lubricator 125:
Mounting dimensions in mm
Typ A B C D
125 112 95 6,5 16
• Switch off the lubricator and the
system before carrying out any
assembly work.
• Deactivate the lubricator by re-
moving the jumper.
• If the lubricator is fixed with a
pipe clamp, loosen the clamping
screw of the pipe clamp.
• Remove the lubricator and close
the outlet opening.
• Now install a new lubricator,
retighten the clamping screw.
9. Disassembly and
replacement
B
C
A
D
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• Avoid contact with possibly lea-
king lubricant. The lubricant can
cause irritation of the skin and
mucous membranes and conta-
minate clothing.
• Wear protective gloves, protec-
tive clothing and eye protection.
• When using oil, the outlet open-
ing should point upwards after
removing the lubricator and be
closed with a cover.
• BECHEM lubricators must be dis-
posed of according to the natio-
nal regulations of the respective
country.
• Used BECHEM lubricators can
be returned to the manufacturer
ALS, where they will either be
recycled or disposed of by a
certified waste management
company.
• Lubricant residues must be dis-
posed of according to the safe-
ty data sheets of the respective
lubricant.
10. Environment, disposal
and recycling
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11. Error search and error correction
Observation Possible causes Proposed solution
There is no lubricant
release.
The lubricator is not activa-
ted or the jumper is inserted
incorrectly or the contact is
short-circuited.
Plug the jumper in
correctly according
to the operating
instructions.
The jumper was not placed
on slot A for activation but set
directly to a longer running
time B, C or D. Result:
pressure build up 3 to 10 days.
Change the jumper to
A and plug it into the
slot for the desired
running time after
pressure is built up.
The bearing to be greased is
blocked.
If necessary, clean
the bearing properly
and lubricate it with a
hand operated grease
gun.
Batteries have no charge. Replace the lubricator.
Water in the plastic
cover/condensation
water.
Aggressive cleaning by high-
pressure cleaner.
Replace the lubricator.
The cover was not placed
correctly (does not seal).
Replace the lubricator.
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The information, data and
notes provided in this technical
manual corresponded to the
atest status at the time of publi-
cation. Details, illustrations and
descriptions may differ from
those of lubricators already
supplied. Claims based on them
cannot be asserted. BECHEM
does not assume any liability
for damages and malfunctions
resulting from improper hand-
ling, improper use or disregard
of the technical manual of the
BECHEM lubricator.
© Copyright ALS Schmiertech-
nik GmbH & Co. KG and CARL
BECHEM GMBH
BECHEM and BECHEM Rhus-
blüte are registered trademarks
of CARL BECHEM GMBH.
Logos, pictograms, and illus-
trations depicted in this ma-
nual are subject to copyright
protection. Any authority of
disposal, such as copying and
passing on rights, is with ALS
Schmiertechnik GmbH & Co. KG
and CARL BECHEM GMBH.
We reserve the right to make
changes.
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MADE IN GERMANY
CARL BECHEM GMBH
Weststr. 120 · 58089 Hagen · Germany · Phone +49 2331 935-0 · Fax +49 2331 935-1199
Manufactured for BECHEM by ALS Schmiertechnik GmbH & Co. KG
Maybachstr. 32 · 71332 Waiblingen · Germany · Phone +49 7151 5020830
+49 (0) 6131-232466 (Poison Emergency Call Mainz)
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