BEKA EP-1 Product guide

BAL_2152_EP1_Central grease lubrication pump_0816_EN EDV-Nr. 1090200430
Original operating and assembly
manual
for grease lubrication pumps
EP-1
FKGGM-EP DC
FKGGM-EP with power supply unit, AC 1
without control unit
with integrated control units:
BEKA-troniX1
EP-tronic
EP-tronic T1
EP-T2
EN
BEKA 2016 All rights reserved!

BEKA 2016 All rights reserved!
...a product of BEKA
BAL_2152_EP1_Central grease lubrication pump_0816_EN EDV-Nr. 1090200430
Contents 2+3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Declaration of incorporation
1. Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. Warranty and extent of warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
4. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8+9
5. Assembly manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6. Overview and installation dimensions:
6.1. Central lubrication pump EP-1 and FKGGM-EP with steel reservoir. . . . . . 10
6.2. Central lubrication pump EP-1 and FKGGM-EP w. transpar. reservoir . 11+12
7. Terminal diagrams:
7.1. Central lubrication pump EP-1 and FKGGM-EP without control unit. . . . . . 13
7.2. Central lubrication pump EP-1 without control unit
Special model with bayonet connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.3. Central lubrication pump EP-1 and FKGGM-EP
with integrated control unit BEKA-troniX1 . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.4. Central lubrication pump EP-1
with integrated control unit EP-tronic T1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7.5. Central lubrication pump EP-1
with integrated control unit EP-T2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.6. Central lubrication pump EP-1 and FKGGM-EP
with integrated control unit EP-tronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.7. Central lubrication pump FKGGM-EP with power supply unit . . . . . . . . . . . 16
8. Function and design of the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9. Function of the central lubrication pump:
9.1. Without control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
9.2. With PE-120 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
9.3. Special equipment of the central lubrication pump without control unit:
9.3.1 Grease level monitoring with plug-type connection M12x1 . . . . . 17+18
9.3.2. Grease level monitoring with cubic plug acc. to DIN 43650 . . . . . . . 18
9.3.3. Micro switch at the pressure relief valve . . . . . . . . . . . . . . . . . . . . . . 19
10. Pump elements:
10.1. Pump element PE-60, PE-120 and PE-170. . . . . . . . . . . . . . . . . . . . . . . . . 20
10.2. Pump element PE-120 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20+21
10 Installation and removal 21.3. of the pump elements . . . . . . . . . . . . . . . . . . . . . .
10.4 Ventilation of the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
10.5 Special accessory malfunction indicator at pressure relief valve. . . . . . . . . 22
2
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BAL_2152_EP1_Central grease lubrication pump_0816_EN EDV-Nr. 1090200430
11. Function of the control units:
11.1. Control unit BEKA-troniX1 and EP-tronic. . . . . . . . . . . . . . . . . . . . . . . . . . . 22
11.1.1. Operating mode time control and rotary control. . . . . . . . . . . . . 22+23
11.1.2. Operating mode cycle control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
11.1.3. Special equipment - internal data memory. . . . . . . . . . . . . . . . . . . . 24
11.1.4. Adjustment of the operating mode and the adjustment ranges . 24+25
11.1.5. Optional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Grease level monitoring for BEKA-troniX1 and EP-tronic . . . . . . . . 26
Pressure relief valve monitoring for BEKA-troniX1 and EP-tronic. . 26
Starter release or collective fault signal at EP-tronic . . . . . . . . . . . . 27
Adaption to the application conditions at EP-tronic . . . . . . . . . . . . . 27
11.2. Function of the control unit EP-tronic T1
11.2.1 Function sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
11.2.2. Extras . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
11.3. Function sequence of the control unit EP-T2. . . . . . . . . . . . . . . . . . . . . . . . 30
12. Adjustment of the control units:
12.1. Adjustment of the parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
13. Filling of the pump:
13.1. Standard filling via lubrication nipple with manual or pneum. grease gun . . 32
13.2. Filling via filler coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
13.3. Filling via filling press. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
14. Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
15. Ventilation of the pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
16 Service and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
17. Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
18. Spare parts drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-37
19. Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-41
20. Order key of level monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
21. Order key of integrated control unit:
21.1 Control unit EP-tronic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
21.2 Control unit EP-tronic T1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
21.3 Control unit BEKA-troniX1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
21.4 Control unit EP-T2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
22. Error - Cause - Remedy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45+46
Details on the manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3
EN
BEKA 2016 All rights reserved!

BEKA 2016 All rights reserved!
...a product of BEKA
BAL_2152_EP1_Central grease lubrication pump_0816_EN EDV-Nr. 1090200430
4
EN
Declaration of incorporation for incomplete machinery
(acc. to EC-directive 2006/42/EG)
The manufacturer: BAIER + KÖPPEL GMBH+CO. KG
Beethovenstrasse 14
91257 Pegnitz / Germany
Tel.: [phone]
declares hereby, that the following partly completed machinery:
Product description: FETTSCHMIERPUMPE
Type designation: EP-1, FKGGM_EP
Article number: 2018...; 2037...; 2152...; 2157...; 2175...; 2183...; 2184...
Serial number: from 930000 to 999999
is complying with all essential requirements of the above mentioned machinery
directives (2006/42/EG):
Annex I, article 1.1.2, 1.1.3, 1.1.5, 1.3.2, 1.3.4, and 1.5.1.
The following coordinated standards have been used:
DIN EN 809
DIN EN ISO 12000
The following other specifications and standards have been used:
VDE 0530
The protection targets of the directive for have beenelectric equipment 2006/95/EG
observed according to the annex I, no. 1.5.1 of the machine directive.
The incomplete machine may only be put into service as soon as there has been stated
that the machine, into which the incomplete machine shall be installed, responds to the
determinations of the machine directive (2006/42/EG).
The special documentation that responds to the machine, has been prepared according to
annex VII part B.
The manufacturer (documentation department, phone [phone], email:
[email protected]) obliges itself to pass on electronically the special documentation for
partly completed machinery to individual national authorities upon request.
Pegnitz, 27.03.2013
ppa. A. Zapf (sales manager)

BAL_2152_EP1_Central grease lubrication pump_0816_EN EDV-Nr. 1090200430
1. Legend:
Safety instructions which, if not complied with, may endanger persons, are
m rked specifically with the general hazard symbol:a
This heading is used if inaccurate compliance or non-compliance with the
Operating Instructions or specified work procedures etc. may result in
damage:
Points out special information:
2. Warranty and extent of warranty:
Inappropriate intervention will rule out your warranty claim!
Warranty regarding operational safety, reliability and performance of the lubricating pump is
only accepted by the manufacturer under the following conditions:
· Assembly, connection, setting, maintenance and repair are carried out by authorized and
specialized staff.
· The limits stipulated in the technical data must never be exceeded.
· Only original components or components approved by the manufacturer may be used for
repair and maintenance work.
All guarantees and warranties expire for damages to central lubrication
systems that are caused by operation with improper lubricants (e.g. piston
wear, piston jamming, pluggings, embrittled sealings).
BEKA does not assume liability on damages caused by lubricants, even
if these lubricants have been tested
and released by laboratory tests, as damages caused by lubricants
(e.g. by expired or improper stored lubricants, batch variations etc.) can
not be retraced to their root cause in retrospect.
3. Safety information:
General information
Any safety-related faults must be eliminated without delay.
Below, please find fundamental instructions to be complied with, regarding assembly,
operation and maintenance. The mechanical and the competent specialists / staff of the
operating company must read the Operating Instructions on all accounts prior to starting
assembly and commissioning. Moreover, the Operating Instructions must permanently be
available on site.
Not only the safety instructions included under this item, but also the specific safety
instructions appearing in other parts of this manual must be complied with.
General risk reference
All system components have been designed in view of operational safety and accident
prevention according to the applicable provisions for the design of technical equipment.
Nevertheless, utilization thereof may result in risks for the user or third parties and/or technical
equipment. Thus, the system may only be used in proper technical working within its intended
fields of application and in compliance with the safety provisions and the Operating
Instructions.
Note!
Note!
Attention!
Attention!
5
EN
BEKA 2016 All rights reserved!

BEKA 2016 All rights reserved!
...a product of BEKA
BAL_2152_EP1_Central grease lubrication pump_0816_EN EDV-Nr. 1090200430
Personal:
The staff in charge of operation, maintenance, inspection and assembly must be qualified
accordingly for this work. The operating company must stipulate competences,
responsibilities and the supervision of staff precisely. If the staff does not dispose of the
appropriate knowledge, they must be trained and instructed. The operating company must
ensure that the staff have understood the contents of the Operating Instructions.
Danger due to non-observance of the saftey information:
Non-compliance with the safety information may put persons at risk and
endanger the environment and/or the machine. Non-complinace with the
safety instructions may rule out any claims for damages.
. Non-compliance may lead, e. g. to the following dangers:
· Failure of important system functions.
· Failure of the specified maintenance and servicing methods.
· Endangering people due to electrical, mechanical and chemical effects.
· Endangering the environment due to leakages of dangerous materials.
Use in conformity with the intended purpose:
The pumps of the series EP or FKGGM-EP serve only for the supply of central lubrication
pumps at vehicles, systems and machines.
Any use beyond this scope is regarded as being not in conformity with the intended purpose.
Disclaimer of liability;
BEKAis not liable for damage caused by:
· lack of lubricant
· contaminated or unsuitable lubricants
· any use which is not in conformity with the intended purpose
· inappropriate installation and filling
· wrong electrical connection
·wrong setting of the control unit
· improper reactions to malfunctions
· non-observance of the operating instructions
Assembly works:and maintenance
Observe for all assembly works at vehicles, systems and machines the valid local accident
prevention regulations and safety instructions as well as the specifications for operation and
maintenance.
All maintenance, inspection and assembly work may only be carried out by
trained specialists.All work must only be carried out when the plant is at a
standstill and while wearing appropriate protective clothing.
All the safety and protective equipment must be replaced immediately after completing work.
Media that endangers the environment must be disposed in accordance with pertinent official
specifications.Secure the system during maintenance and repair works, against intentional or
unintentional reoperation.
6
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BAL_2152_EP1_Central grease lubrication pump_0816_EN EDV-Nr. 1090200430
Dispose of process materials in accordance with the safety data sheets of the lubricant
manufacturer.
Safety information for operators/operating staff:
· If hot or cold machine parts lead to hazards, the customer must secure
them from being touched. The guards on moving or rotating parts must not
be removed.
· Drain leakages of dangerous materials in a way, that people or the
environment are not endangered.
· Comply with legal regulations.
· Exclude any hazards by electric energy.
Unauthorized modification and spare part production :
Modifications and alterations of the system require the manufacturer’s prior
approval. Original spare parts and accessories authorized by the
manufacturer serve for higher safety. The use of other parts may rule out
liability for the consequences of such use. For components, which are
retrofitted by the operator, BEKA does not assume liability nor claims for
compensation.
Danger caused by the electrics:
The units may be connected to the power supply exclusively by appropriately trained qualified
personal in conformity with the local connection conditions and regulation (e. g. DIN, VDE)!
Improperly connected equipment may lead to serious personal injury and damage to property!
Danger caused by system pressure:
The units might be under pressure.
Make them pressureless before you start with repairs, changes or extensions.
Use of hydraulic hose lines:
Installing hydraulic hose lines at the pump, the operator has to observe
respectively ensure the following items:
·Checks for proper assembly and function have to be carried out according to the regional
valid guidelines.
·Checks for a safe provisioning and use have to be carried out according to the regional
valid guidelines.
·The check deadline must not be exceeded.
·Exchange defect hydraulic hose lines immediately and professional.
·Hydraulic hose lines subject to a wear process and have to be exchanged regularely and
according to the manufacturer’s details.
7
EN
BEKA 2016 All rights reserved!

BEKA 2016 All rights reserved!
...a product of BEKA
BAL_2152_EP1_Central grease lubrication pump_0816_EN EDV-Nr. 1090200430
Lubricant:
The system has been designed for commercially available multi-purpose greases of
NLGI class 2 for operation in summer and winter.
- Use greases with high-pressure additives (EP greases).
- Only use greases of the same saponification type.
- Lubricants containing solid contents must not be used (lubricants like graphite or MoS on
2
request).
- Observe the vehicle manufacturer’s specifications, when you select the lubricant.
Hazards to environment cause by lubricants:
The lubricants which are recommended by the manufacturer of your vehicle, system or machine
correspond in their composition to the common safety regulations. Mineral oils and greases are
generally hazardous to ground water and their storage, processing and transport requires
special precautions.
Inadmissible methods of operation
Operational security of the plant is only guaranteed if it is operated in accordance with the
operating instructions. The limit values stated in the technical data must not be exceeded under
any circumstances.
Transport and storage of the pump:
The pumps of the series EP are packed commercially, according to the regulations of the
recipient country and to the wish of the customer.
There are no limitations with respect to land, air or sea transport.
Store in a dry place at a temperature of -40° C to +70°C.
Handle with care!
4. Technical data:
Motor EP-1, FKGGM-EP:
Operating voltage: 12 V DC / 24 V DC
Speed: 15 rpm.
Current consumption:
Idle running at +20° C: 0.8 A / 0.4 A
Full load at +20° C: 2.2 A / 1.1 A
Fuse: 5A/3A
Motor FKGGM-EP with PSU:
Operating voltage: 24 V DC
Connection voltage: 230 V AC / 50 Hz
115 V AC / 60 Hz
(via installed PSU)
Current consumption: max. 0.2 A (230 V AC)
Speed: 15 U / min.
Duty cycle: 10 % ED (10 min)
Operating temperature: -20° C to +70° C
Attention!
8
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BAL_2152_EP1_Central grease lubrication pump_0816_EN EDV-Nr. 1090200430
Pump:
max. operating pressure: 350 bar
Adjustment of overpressure valve: 280 bar
Operating temperature: -35° C to + 0° C7
Reservoir size :
Transparent reservoir: 1,9 kg, 2,5 kg, 4 kg, 8 kg or 16 kg
Steel reservoir: 2 kg or 4 kg
Direction of agitator blade: counter-clockwise
Installation position: reservoir in vertical position
Output rate: depending on pump element
Protection type: IP5K9K at DIN 40050
Weight: EP-1, FKGGM-EP DC: approx. 5.1 kg
FKGGM-EP with PSU: approx. 5.8 kg
Control units BEKA-troniX1, EP-tronic, EP-tronic T1:
Operating voltage: 10 to 60 V DC
Max. current load: I = 6 A
Fuse (not including in device): F 6.3 A (5x20) medium
Signal lamp outlet: I = 0.4 A
max.
Operating temperature: -35° C to +7 ° C0
Sound pressure level: < 70dB(A)
Control unit EP-T2:
Operating voltage: 10 to 33 V DC
Max. current load: I = 6 A
Fuse (not included in device): F 6.3 A (5x20) medium
Signal lamp outlet: I = 0.4 A
Operating temperature: -35° C to +7 ° C0
9
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BEKA 2016 All rights reserved!

BEKA 2016 All rights reserved!
...a product of BEKA
BAL_2152_EP1_Central grease lubrication pump_0816_EN EDV-Nr. 1090200430
130
152
172 137 5.
321
107
185
Ø150
184
304
137
239
Ø9.5
Pipe
connection
dia.6
“X”
Connecting cable
length 10 m
Model with
4 kg reservoir
Model with
2 kg reservoir
View “X”
6. Overview and installation dimensions:
6.1. Central lubrication pump EP-1 and FKGGM-EP with steel reservoir:
5 Assembly manual.:
The following conditions have to be satisfied during the assembly of this
grease lubrication pump, thus it can be assembled, with other parts, to a
complete machine without affect the safety and health of human.
Set up the grease lubrication pump horizontally on both sides at the place where it has to be
installed! Pay also attention to the mentioned data regarding the fastening bore in the
dimensioned drawing.
Special measures for the noise prevention and for the vibration reduction of the grease
lubrication pump during the installation don't have to be taken.
Pipeline and hydraulic hose line assembly
·Layout must be expert.Assemble free from distortion.
·Comply with the pressure seal tightness of the threaded joints.
·Please observe the permitted pressure range of the pipeline and the hydrauc hose line.
Electrical connection
· Current supply may only be made by professional electricians
· The electrical components of the system must be wired expert.
· Compare the voltage details with the existing mains voltage
10
EN

BAL_2152_EP1_Central grease lubrication pump_0816_EN EDV-Nr. 1090200430
11
EN
6.2. Central lubrication pump EP-1 and FKGGM-EP with transparent reservoir:
140
176
239
172
322
Model with
1 9 kg reservoir.
Model with
2 5 kg reservoir.
Option with screw cover
Ø151
207
175
Model with
integrated control unit
integrated
control unit
130
152
107
197
143
325
172,5
Model with
1,9 kg reservoir
Model with
2,5 kg reservoir
Option
with screw cover
Ø153
209,5
174
Pipe
connection
dia. 6
132
239
Ø9,5
Connecting cable
length 10 m
Ø150,5
Model with
4 kg reservoir
Option
with screw cover
Ø180
255
132
239
Ø9,5
Pipe
connection
dia. 6
Connecting cable
length 10 m
130
152
107
1 9 kg a. 2 5 kg =182 5.. .
143172,5
325
4 kg a. 8 kg 2-parts kg =182 5.
BEKA 2016 All rights reserved!

BEKA 2016 All rights reserved!
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BAL_2152_EP1_Central grease lubrication pump_0816_EN EDV-Nr. 1090200430
12
EN
9
Ø9,5
49,5
130
152
View “Z”
7,5
“Z”
281,5
M8
13
525,5
Model with
kg reservoir16
212
303,5
132
239
Ø9,5
Pipe
connection
dia. 6
Connection cable
length 10 m
Model with
8 kg reservoir Ø225
“X”
Ø225
“X”
View “X”
(2)11 ,5
107
143
152,5

BAL_2152_EP1_Central grease lubrication pump_0816_EN EDV-Nr. 1090200430
7. Terminal diagrams:
7.1. Central lubrication pump EP-1 and FKGGM-EP without control unit:
7.2. Central lubrication pump EP-1 without control unit:
Special model with bayonet connector:
(PIN ...) = Assignement of the line socket
- (Ground) brown
+blue
- (Ground) brown (PIN 2)
+blue (PIN 1)
13
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BEKA 2016 All rights reserved!
...a product of BEKA
BAL_2152_EP1_Central grease lubrication pump_0816_EN EDV-Nr. 1090200430
7.3. Central lubrication pump EP-1 and FKGGM-EP with integrated control unit
BEKA-troniX1:
(no. ...) = Cable-no. at uni-colored cables
(PIN ...) = Assignment of the line socket
7.4. Central lubrication pump EP-1 with integrated control unit EP-tronic T1:
(no. ...) = Cable-no. at uni-colored cables
(PIN ...) = Assignment of the line socket
- (Ground, terminal 31)
+ (Ignition, terminal 15) black (no. 3) (PIN 5)
brown (ye/gr) (PIN )7
Intermediate lubrication
switch
orange (no. 6)
red (no. 2)
Signal lamp red
green (no. 1)
Signal lamp green
External signal lamps
Option
Switch for grease
level monitoring
Option
micro switch for
pressure relief valve
monitoring
green
red
(PIN 1)
(PIN 2)
(PIN 6)
green (no. 1) (PIN 1)
Flasher left, terminal L
Flasher right, terminal R
Rear light, terminal 58
Brake light, terminal 54
red (no. 2) (PIN 2)
white (no. 3) (PIN 3)
grey (no. 4) (PIN 4)
black (no. 5) (PIN 5)
orange (no. 6) (PIN 6)
brown (no. 7) (PIN 7)
free
Circulating blinker light
Ground, terminal 31
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BAL_2152_EP1_Central grease lubrication pump_0816_EN EDV-Nr. 1090200430
7.5. Central lubrication pump EP-1 with integrated control unit EP-T2:
(PIN ...) = Assignment of the line socket
7.6. Central lubrication pump EP-1 and FKGGM-EP with integrated control unit EP-tronic:
(no. ...) = Cable-no. at uni-colored cables
(PIN ...) = Assignment of the line socket
brown (PIN 7)
blue (PIN 5)
- (Ground, terminal 31)
+ (Brake light, terminal 54)
green
blue
yellow
red
- (Ground, terminal 31)
+ (Ignition, terminal 15) black (no. 5) (PIN 5)
brown (ye/gr) (PIN 7)
Intermediate lubrication
switch
orange (no. 6) (PIN 6)
red (no. 2) (PIN 2)
Signal lamp red
green (no. 1) (PIN 1)
Signal lamp green
max.
min.
Three-grade switch
for adjustment to
application conditions
External signal lamps
white (no. 3) (PIN 3)
grey (no. 4) (PIN 4)
Option
Switch for
grease level monitoring
Terminal 50 starter
and ignition
optional
Option
Ignition release
Option
Collective
malfunction
report
black
blue blue
black
Proximity
switch
for stroke
control
Option
Micro switch for
pressure relief valve
monitoring
+
-
15
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BEKA 2016 All rights reserved!
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BAL_2152_EP1_Central grease lubrication pump_0816_EN EDV-Nr. 1090200430
7.7. Central lubrication pump FKGGM-EP with power supply unit (PSU):
Pay attention to the voltage of the power supply unit when connecting. The voltage
is indicated on a sticker in the inspection window of the lower motor shell (115 V or
230 V).
N
L1
8. Function and design of the system:
The central lubrication system into which an electrical pump EP-1 or FKGGM-EP is installed, is a
progressive system. Progressive means that the lubrication points are lubricated in sequence.
The sequential lubrication means a pressure relief valve can easily monitor the progressive
central lubrication system.
The central lubrication pump EP-1 delivers the lubricant to the main distributor. The main
distributor’s task is to distribute the lubricant to the secondary distributors in the right proportions.
The secondary distributors then deliver the lubricant to the individual lubrication points.
Should a lubrication point do not receive lubricant from the distributor, the system would block
and a pressure of up to 280 bar is built up in the line system. Does the system block but is
nevertheless operating properly, the lubricant comes out of the pressure relief valve of the pump.
This serves for the system protection and monitoring.
Installation example:
Central lubrication
pump EP-1
Main
distributor
Secondary distributor
Secondary distributor
Secondary distributor
16
EN
3
4
56
7
1
2

BAL_2152_EP1_Central grease lubrication pump_0816_EN EDV-Nr. 1090200430
17
EN
9. Function of the central lubrication pump:
The central lubrication pump EP-1 or FKGGM-EP is designed for delivering lubricant up to NLGI
class 2. The agitator blade pushes the lubricant through a grease sieve to the intake section of
the pump element. The pump element is positively driven by an eccentric so that function is also
ensured at low temperatures. The output rate depends on the installed pump element (see page
20).
9.1. Without control unit:
At pumps without control unit can the lubrication cycle be controlled by an on-board controller, a
machine control or PLC.
9.2. With PE-120 V:
For trailers and semi-trailers, it is not possible to ensure a permanent current supply of the pump
or the control unit. Therefore is a central lubrication pump without control and with adjustable
pump elements installed into such vehicles. The pump gets its operating voltage via the brake
light and thus the pump always lubricates with each braking. The lubricant can be reduced with
the adjustable pump element (see adjustment of the pump element on page 21).
9.3. Special equipment of the central lubrication pump without control unit:
9.3.1. Grease level monitoring with plug-type connection M12x1 (Standard):
At the electrical pump EP-1 or FKGGM-EP can the
grease level be checked visually through the
transparent reservoir.
However, there is also the possibility to monitor the
grease level in the reservoir electronically. A capacitive
proximity switch is installed into the reservoir for this
purpose. This switch emits a signal as long as there is
sufficient grease in the reservoir. If the grease falls
below a certain level, the proximity switch stops this
signal.
The signal can be evaluated by an external control or
PLC. Evaluation should only be done after a period of
approx. 10 sec. If there is no signal for longer than 10
seconds, the reservoir is empty and the pump should
be switched off.
Not keeping to the period of 10 sec. can cause level errors although the
reservoir is filled with grease.
Attention!
for 2,5 kg
container
Capacitive
proximity switch
min.
grease level
BEKA 2016 All rights reserved!

BEKA 2016 All rights reserved!
...a product of BEKA
BAL_2152_EP1_Central grease lubrication pump_0816_EN EDV-Nr. 1090200430
18
EN
Terminal diagram for connecting the
capacitive proximity switch to an external
control unit:
The brown wire (+U ) and the blue wire (ground) are used for voltage supply
b
of the sensor.
If the black wire is used as output of the sensor, it works as a closing contact,
and +U is issued if the reservoir is empty (OK-signal, line break monitoring).
b
If the white wire is used as sensor output it works as opening contact and
+U is issued if the reservoir is empty (empty message).
b
9.3.2. Grease level monitoring with cubic plug acc. to DIN 43650:
The grease level monitoring can also be connected via a cubic
plug.
The functions correspond to those described on the previous
page, of the grease level monitoring with plug connection
M12x1.
Die Schließer- oder Öffnerfunktion muss bei Bestellung
ausgewählt werden.
Wiring diagram with supply voltage of
10-60 V DC:
Technical data:
Supply voltage: 10 to 60 V DC
Connection method: PNP-NO (normally open contact)
Switching current: at 70°C: 250 mA
Current consumption: without load: <20 mA
Protection class: switch: IP 67
switch: IP 54
Ambient temperature range: -20°C - +70°C
Note!
Technical data:
Standard version -20°C - +70°C
Supply voltage: 10 to 60 V DC
Connecting method: PNP-NO (normally
open contact)
Switching current, max.: 250 mA
Protection class of switch: IP 67
Connection: 4-pole M12x1 pluggable
Low temperature version -40°C - +70°C
Supply voltage: 12-30 V DC
Connecting method: PNP-NO (normally
open contact)
Switching current: min. 20 mA
Protection class of switch: IP 67
Connection: 4-pole M12x1 pluggable
Capacitive
proximity switch
min.
grease level
for kg4
reservoir
brown
white
blue
black
Ground
+ Ub
Signal lamp
„empty“
Signal lamp
„level OK“
GND
brown
blue
white
black
+ U
b
1
2
3
can be selected
when ordering
Signal lamp

BAL_2152_EP1_Central grease lubrication pump_0816_EN EDV-Nr. 1090200430
Wiring diagram with supply voltage of 90-250 V AC:
Pole assignment:
Compact plug connection, 3 poles+ PE
No. 1 = L1
No. 2 = free
No.3=Q
= yellow/green (only for max.)
Technical data:
Supply voltage: 90 to 250 V AC
Connecting method: NO contact (Tyristor outlet)
Switching current: at 70°C: min. 5 mA
max. mA250
Protection class: switch: IP 67
plug: IP 54
Ambient temperature range: -25°C to +70°C
9.3.3. Micro switch at pressure relief valve:
The micro switch at the pressure relief valve is used for
monitoring the maximum operating pressure in the central
lubrication system.
If a malfunction occurs in the system, the micro switch is
actuated.
The micro switch signal can be processed by any already
existing signal encoder, e. g. an on-board controller, or by
an external or integrated control unit.
The lubricant comes out under high pressure (250 bar)!
Wear safey goggles and also do not stay otherwise within the area of the pressure
relief valve in the case of a malfunction of the central lubrication unit!
Never work when the voltage (ignition) of central lubrication system or pump is
connected! Relieve the central lubrication system before you start the works!
Terminal diagram for connecting the micro switch
to an external control unit:
brown
blue
L1
Q
Micro switch
black
brown
blue
Apparent ohmic
resistance
NC (normally closed
contact)
NO (normally open
contact)
Technical data:
Supply voltage: 10 to 60 V DC
max. current load: I = 1,7 A
Contact type: 1 changeover switch
Temperature range: -25° C to +85° C
Protection class: IP 67
Connection: Cable, length 0.5 m, welded
P
brown
blue black
19
EN
BEKA 2016 All rights reserved!

BEKA 2016 All rights reserved!
...a product of BEKA
BAL_2152_EP1_Central grease lubrication pump_0816_EN EDV-Nr. 1090200430
10. Pump elements:
There are different pump elements available for the installation
into a central lubrication pump EP-1 or FKGGM-EP. You cannot
adjust the output rate at the pump elements PE-60, PE-120 and
PE-170 but at the pump element PE-120 V this is possible.
10.1. PE-60, PE-120 and PE-170:
Technical data:
Delivery medium: Grease from NLGI-Kl. 00/000 to NLGI-Kl. 2
Piston return: positively controlled
10.2. PE-120 V:
Technical data:
Output rate: 0,04 to 0,12 cm /stroke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Output rate regulation: 6 notches with 1/2 a revolution each. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reduction: 0,013 cm per notch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Delivery medium: grease from NLGI-Kl. 00/000 to NLGI-cl. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston return: positively controlled. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Order-no. (incl. pressure relief valve): 2152.99063.0000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Order-no. pressure relief valve for PE-120 V: 2152 0063. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PE-120
PE-60
PE-170
0.12
0.06
0.17
Output rate
(cm / stroke or rev.)
3
2152 99061 0000
2152 99067 0000
2152 99069 0000
Order-no.
(incl. pressure relief valve)
Order-no.
Pressure relief valve
2152 0062
M 20 x 1 5.
Pressure relief valve
set at 280 bar
permanently
A/F 24
Pipe connection Ø 6
66
PE-60, PE-120, PE-170:
Pressure relief valve
set at 280 bar
permanently
A/F 24
Pipe connection Ø 6
M 20 x 1 5.
2
3
32
13 0.
0 12.
0 11.
0 10.
0 09.
0 08.
0 07.
0 06.
0 05.
0 04.
0 03.
0 02.
0 01. 0
2 0.25.
Output rate (cm³)
00 5. 1 5.
135 24
0Notches
Revolutions
6
20
EN