Central Lubrication System for

Commercial Vehicles

Operating instructions
for the central lubrication pump
PICO with integral controller S-EP 4
BAL2185.X.X.X.200 0201GB
 Page

List of contents 2

1. System`s assembly groups, pump sizes 3

2. Technical data 4
3. Adjusting the integral controller 4-5
4. How the system functions 6-7
5. Lubricants 7
6. Filling the pump 8-9
7. Bleeding the system 10
8. Pump order codes 11
9. Installation instructions for the pump elements 12
10. Description of the PE-120F / PE-120FV pump elements 13-15

2 11. Description of the PE-5 / 10/15/25/50 pump elements 16-17

12. Order codes of the PE-5 / 10/15/25/50 pump elements 18
13. Function check 19
14. System maintenance and care 19
15. Warranty 19
16. Spare parts and Spare parts list 20-21
17. Troubleshooting 22-23
18. For your notes 23
1. System`s assembly groups:
1. BEKA-MAX - Grease-lubrication pump typ PICO with 1,2 kg grease container.

2. BEKA-MAX - progressive distributors MX-F

3. Main and secondary tubes

4. Installation materials and fixings

5. Pump integral controller S-EP 4

Scale drawing:
Top view
Front view rotated by 90°

3
ø 128 ±1

ca. 148
4
35
40

80 ±1

ca. 135
ca.

2 3
1
5
6
185 ±2

7
ca.259

150 ±0,5
171 ±1,5

9
35 ±0,5

10
76 ±1

157± 2
39 ±2

9,5 ± 0,4

242 ±2 Pressure
111 ±1
connection Ø6
124 ±1

Nr. 1 to 10 = outletposition
 2. Technical data:
Operating temperature:
Lubricant:
Number of outlets:
Output outlet max.:
-25°C to +70°C
Consistency class 2 greases
Pump elements PE-120F + PE-120 VF:max. 2
Pump elements PE-5 / 10/15/25/50:max. 8

pump elements PE 120F PE 120FV PE 5 PE 10 PE 15 PE 25 PE 50

cm³ / stroke 0,12 max. 0,12 0,005 0,01 0,015 0,025 0,05

cm³ / min. 1,8 max. 1,8 0,075 0,15 0,225 0,375 0,75

Direction of rotation: clockwise

Installation location: Normal type: container vertical
(See conversion instruction No.: 2158....0999D)
Protective class: IP 65
Drive type: 12 V or 24 V DC n = 15 rpm
Power consuption at 280 bar counter pressure: 3,8 A
Container size: 1,2 kg
4
3. Integral Controller
Technical data:
Supply voltage: 10 - 30 V
Max power load: I = 6,0 A
Signal lamp output: I = 0,4 A
Temperature range: -25°C to +75°C
Protection rating: IP 65

Setting the delay and lubrication times:

1. Remove red frame on pump`s motor housing, using a flat screwdriver, unscrew 4 Phillips
screws and remove transparent cover.
2. Set the delay (off) and lubrication (on) times to required periods with the two catch switches.
3. Ensure that transparent cover and red frame ae replaced to avoid water ingress. Failure to do
so will invalidate warranty.
Setting the cycle / lubrication time:

Red Button for additional lubrication on

the motor housing

PICO-Controller S-EP 4
Time of Lubrication (1-16 min)
Cycletime (0,5-8 h)

1 0,5
LED red

LED green
16 8

Standby1.5 sec. 1,5 sec.

Standby (green)
Until lubricant container
is refilled
Lubricant level error (red)
During whole lubrication

Lubricating active (green) 5

0,5 1
Cycletime:
0,5 h to 8 h
1 min.to 30 min. 8 30
Time of Lubrication:
1 2
1 min. to 16 min.
2 sec. to 32 sec.

16 32

Terminal diagram: lamp

- Lamp malfunction (for example grease level) colour of cable
red (No. 4)
- +
lamp
- lamp lubrication colour of cable green (No. 3) -
2

+
3

- Mass, terminal 31, colour of cable brown (No. 2) button

7

Intermediate Lubrication, colour of cable orange (yellow/green)

4

+
6
5

+ Ub ignition, terminal15, colour of cable black (1)

(...) = Cable No. for single-coloured cables

Connecting the illuminated button:

4
Pin 6: ZS, orange (yellow/green)
N P
PIN 5: +Ub terminal 15, black (cable 1)
3
PIN 1: ->, green (cable 3)

(...) = Cable No. for single-coloured cables

 4. How the system functions:
The PICO central lubricating pump is a combination of progressive system and multi-routing
system, which can supply NLG class 2 grease. Progressive means that the lubrication points in the
central system are lubricated in sequence. The sequential lubrication means that a pressure relief
valve can easily monitor the progressive central lubrication system. If a lubrication point were to
take no grease from the distributor, the progressive distributor would block and a pressure of 280
bars would build up in the central lubrication system. If the system blocks in spite of the fact that the
electric pump is working properly, the lubricant will be discharged through the pressure relief valve
on the PE-120F/PE-120 VF pump element. This is to make the system safe and for monitoring
purposes.On deployment of the multi-routing system, the pump elements PE 5 to 50 supply directly
to the point of lubrication or serve as an extension.

6
The design of the BEKA-MAX grease-lubrication
system:
The PICO electric piston pump can be fitted with two types of pump element. The pump conveys the
lubricant via the PE-120 F and the PE-120 VF pump elements to the main progressive distributor.
The distributor is responsible for distributin the grease to the progressive sub-distributors at the
correct ratio. The lower progressive distributor then releases the grease to the individual points of
lubrication. The PE-5 /10/15/25/50 pump elements deliver the grease to the individual lubrication
points. The cycle (interruption) and lubricating duration of the pump is controlled by the S-EP 4
integrated automatic controller. (See pages 4 and 5).
Installation example:
Pump element
PE-5 bzw. 10/15/25/50
Centralised lubrication direct to the lubrication
pump PICO points

Pump
element
PE-120F

direct to the lubrication

points
to the to the
lubrication lubrication
points points

Secondary
distributor 7
Main
distributor
to the to the
lubrication lubrication
points points
to the
lubrication Secondary
points distributor

5. Lubricants:
The system has been designed to use commercially available multi-purpose NLGI-Cl.2 greases for
summer and winter use.
- Greases with high-pressure additives (EP greases)
- Preferably use lithium-based greases.
- Only use greases with the same base soap
- Lubricants with solids may not be used. (Lubricants such as graphite or MoS2 in inquiry.)
- Also refer to the vehicle manufacturer`s instructions when selecting the type of grease to be
used.
 6. Filling the pump:
The PICO central lubrication pump is filled with a normal grease gun (lever-type hand gun) connec-
ted to the filling nipple on the pump housing.A rapid filling coupling with barrel pump is also optional-
ly available.

Attention: It is important to keep everything clean when filling! Do not fill the pump above the max.
Grease level as otherwise the overfilling protection device will trigger and discharge grease.

a) Standard filling through the conical lubricant nipple with a

8 manual or pneumatic grease gun.

Refill lubricant nipple

 b) Refilling through refill coupling

Remove lubricant nipple replace

grease, Computer No. 2159 0061
012, via coupling holes

c) Filling via fill gun

For simple and safe filling of the grease container, we have developed the PICO FILL filling
set. On the PICO FILL the filling connection and the fill gun are enclosed together. Computer
No. 208103027 9

Fill connection level with non-return valve Detach fastening screw

Computer No. 21520152 and screw on fill connection

Fill gun
Computer No. 208103026

To refill: unscrew the dust cap from the fill connection and fully attach the fill gun port to the
filling connection. Squeeze grease until maximum fill level attained.
 7. Ventilating the System

Should the grease level switch not be functioning and the pump
has been running completely empty, it may be necessary to
ventilate the system. This is done as follows:

1. Refill the pump via the lubricating nipple until the grease piston
is about 4cm above the support.

2. Unscrew main pipe to pump outlet.

3. Remove pump elements PE-120F/PE-120VF or fastening

screw (M20x1.5) and leave open until grease flows out without
bubbles.

4. Replace pump element or fastening screw.

10 5. Initiate additional lubricating impulse until lubricant flows from

pump outlet without bubbles.

6. Re-attach main pipe.

7. Initiate additional lubricating process..

8. Order Code:
Order example:
Type No.: 2185 . 1 . 1 . 1 . 2 . Z . 0000

Motor voltage 12 V 24 V
Code 1 2

Pump Outlet position

element 1 2 4+10 without
PE-120 F 1 2 3
PE-120 FV 4 5 6
PE-120 F + X 7 0
PE-120 FV X 11
PE-120 F + X 8
PE-120 FV X

Container size 1,2 kg

Code 1

Control with
Code 2

Cycle time 0,5 h - 8 h 0,5 h - 8 h

Lubrication time 1 min. - 16 min. 2 sec. - 32 sec.
Code Z W

Special design 0000

Attention: PE-5/10/15/25/50 pump elements must be ordered separately
(see Page 16).
 9. Installation of Pump Elements
Pump elements PE-120F or PE-120VF can be mounted in outlet positions 4 and 10. Pump
elements PE-5 or 10/15/ 25/50 can be attached in outlet positions 1 to 3 and 5 to 9. A
maximum of 10 pump elements can be installed. The choice of installation position is fully
optional.

- The pump should not be running during mounting and demounting of pump elements.
- Remove the fastening screw from the desired threaded hole. Ensure washer is present.
- Screw in pump element.
- Tighten pump element.
- Proceed in reverse order when demounting pump elements.
- Once a pump element is attached, start test run to check if pump turns and supplies
grease.
- Grease without bubbles should flow from the pump outlet at each evolution
(See also “ventilating the system” on page 8).

12

blanking screw M14x1

blanking screw
M20x1,5

(PE 120F already attached)

(PE 5 already attached)

10. Description of the PE-120F und PE-120FV
Pump Elements:

Pump element PE-120 F

Set excess pressure valve to 280 bar

13
M 20 x 1,5

SW 24

6 mm diameter
tube connection

Technical Data:
Supply quantity: 0,12 cm³ /stroke

Order- / EDV-No.: 2185.99061.0000

 Pump element PE-120 FV
(adjustable output)

Set excess pressure valve to 280 bar

SW 24
2
M 20 x 1,5

3
14 6 mm diameter
tube connection

1. On the pump element PE-120FV the quantity supplied is adjustable and comes into use
with trailers and appendages, since the pumping duration is the breaking duration, the
amount of lubricant can be re.duced in cases of excess lubricating.
2. This permits one pump unit to feed lubrication systems of different sizes, by virtue of its
adjustability

Specification:
- All pump elements are pre-set in the factory to maximum stroke capacity
- Element with 6 mm piston diameter
- Maximum output 0,12 cm³ with full stroke
- Reduction in output 0,013 cc per set position (180°)
Regulation of output:
- Remove plug (2) using an allen key ( 5 mm).
- Use a screwdriver to adjust set screw (3).
- Clockwise rotation will reduce the output.
- Anti-clockwise rotation will increase the output
- The maximum travel of the set screw is 2,4 mm = 6 set positions
- One rotation of the set screw 0,8 mm = 2 set positions
- Replace and tighten blanking plug (2) including the washer.

Technical data:
Supply quantity: from 0.04 to 0.12 cm³ / stroke
Regulating supply quantity: 6 fold grating every ½
Revolution reduction: 0.013 cm³ per grate
Medium supplied:
Order/Computer No.:
grease up to NLGI class 2
2185.99063.0000
15

Supply quantity: (cm³)

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
0 1 2 3 4 5 6 set positions
0 0,5 1 1,5 2,0 2,5 3,0 rotations
 11. Description of the PE - 5/10/15/25/50
Pump Elements:
Up to eight PE-5/10/15/25/50 pump elements can be fitted to the PICO electric pump. These are
connected directly to the lubrication points with a polyamide tube (four millimetres in diameter x
0.85 semi-rigid, or six millimetres in diameter x 1.5, semi-rigid). The pump should be fitted in
such a way that the individual tubes are no longer than eight metres.

The PE-5/10/15/25/50 pump elements are available with five different outputs per stroke:

PE- 5 = 5 mm³/stroke;
PE-10 = 10 mm³/stroke;
PE-15 = 15 mm³/stroke;
PE-25 = 25 mm³/stroke;
PE-50 = 50 mm³/stroke;

The PE-5/10/15/25/50 pump elements are also available with five different connectors:

16

With 6 mm diamter tube connector

with union screw and double conical ring:
tube connection
6 mm diamter

22
With M10x1 thread:

M10x1
With straigt plug connector for
6 mm diameter tube:

Plug connector Ø6
16,7

Plug connector Ø6
17

25,2
With 90° plug connector
for 6 mm diameter tube:

17

With 4 mm diameter tube connctor with union

screw and double conical ring.
tube connection
4 mm diameter

21
 12. Order code:
for pump elements PE-5/10/15/25/50:

Type No.: 2154 . 9000 . 01

Conveyed
Designation quantity/stroke
PE-5 5 mm³ 9001
PE-10 10 mm³ 9002
PE-15 15 mm³ 9003
18 PE-25 25 mm³ 9000
PE-50 50 mm³ 9010

Connection description

Thread connection M10x1 00

Tube connection,6 mm diameter
with ÜS6 and DKR6
01

Straight plug connector for 6 mm tube 02

90° connector for 6 mm tube 03
Tube connector, 4 mm diameter with 04
ÜS4 and DKR4

Attention: The PE-5 /10/15/25/50 pump elements must be ordered separately!

13. Function check:
To check the function, trigger as many lubrication pulses as necessary until lubricant is discharged
from all connected lubricationpoints.

When the system is blocked, but according to the functions of the PICO central lubricating pump,
the lubricant escapes from the upper pressure valve on pump elements PE-120F or PE-120 VF.
This serves as a safety and regulation mechanism

14. System maintenance and care:

In the first weeks after commissioning, the system should be checked frequently at the following points::

- Check for sufficient lubricant at the bearings - grease collar (depending

on the type of bearing and application condidtions)

- Check tubes (lubrication points, loose tubes, leaks) 19

- All BEKA-MAX - components are maintenance-free.

- Cleaning with HP washers and steam cleaners is permitted.

15. Warranty:
One year without kilometre limit for the entire system. The warranty becomes
void in the event of incorrect procedures.
 16. Spare parts:

20
Spare parts list:
1 1 Pump housing incl. 12V motor mounted finished (2185-010) 2185G0010
Pump housing incl. 24V motor mounted finished (2185-011) 2185G0011
2 1 Tank cover FMZ00478-00
3 1 Bleeding tube FMZ00486-00
4 1 Pressure compensation element 100150140145
5 1 Surface sealing between tank and cover 080100171
6 1 Tank sealing below 100150020167
7 1 Clear view tank 1,2kg FMZ00479-01
8 1 Cone bolt spring 080150571
9 1 Follow piston mounted finished (FAZ03150-00) 2185G0005
10 1 Exzenter unit mounted finished (FAZ03151-00) 2185G0006
11 1 Savety device for to muck filling complete (FAZ03152-00) 2185G0007
12 1 Motor cover incl. citcuit board (FAZ03153-01) 2185G0008
Motor cover incl. control unit S-EP 4 (FAZ03153-02)
Time of lubrication: 2 sec. 32 sec. / cycle time 0,5 h -8 h 2185G0003W
Number of cycles: 1 cycle 16 cycles / cyc le time 0,5 h -8 h 2185G0003X
Time of lubrication: 2 sec. 32 sec. / cycle time 1min. - 30 min.
Time of lubrication: 1 min. 16 min. / cycle time 0,5 h - 8 h
2185G0003Y
2185G0003Z
21
13 1 Sealing for motor cover 080100170
14 0 to 8 Blanking screw M14x1 DIN 908 090090801450
15 9 USIT-ring U dia.18,7x14x1,5 100150010148
16 0 to 2 Blanking screw M20x1,5 DIN 908 090090800850
17 2 USIT-ring U dia.28x20,70x1,5 100150010149
18 3 Hex. socket screw M4x20 090091201423
19 3 Lock washer A4 DIN 127 0900127008131
20 1 Towbar 0802000565
21 1 Hex. hat nut M8 0802000582
22 1 USIT-ring U dia.8,5x13,4x1 100150010146
23 1 Cap for form grease nipple 1004010021
24 1 Form grease nipple R1/4” H1 DIN 71412 097141201111
25 1 Socket set with cable FAZ02977-00
26 0 to 2 Pump element PE-120F 2185.99061.0000
Pump element PE-120FV ( adjustable ) 2185.99063.0000
 17. Troubleshooting:

Malfunction Origin Remedies

Pump not working Fuse blown Replace fuse

Controller defective Change controller
Electrical connection broken Renew electrical
connection
Pump defective Replace pump

Pump works, but not Air pocket in the Bleed pump

delivering lubricant delivery piston
Grease-level switch Replace switch
defective
Pump element defective Replace pump element
22 No grease collar at all Pump not working See “Pump not working””
lubrication points
Delay time too long Reduce delay time
Pump`s running time too Increase pump running time
short
System blocked See”Grease Escaping from
pressure relief valve”

No grease collar at all Pipe to secondary distributor Replace pipe

lubrication points burst or leaking
Union leaking Tighten union or replace

No grease collar at a Corresponding pipe Replace pipe

single location burst or leaking
Union leakin Tighten union or replace
 Malfunction Origin Remedies

Pump speed low High system pressure Check system/bearings

Low ambient temperature Initiate one or two additional

lubrication cycles

Greae escapes from System pressure too high Check system

pressure relief valve
Progressive distributor Change distributor
blocked
System blocked Repair blocked / frozen
bearings
Ventilfeder defekt Change pressure relief
valve

18. For your notes: 23

BEKA

BAIER + KÖPPEL
BEETHOVENSTR: 14
D- 91257 PEGNITZ / GERMANY
TEL. +49(0)9241 / 729-0
FAX +49(0)9241 / 729-50
P.O.BOX 1320
D- 91253 PEGNITZ
http://www.beka-lube.de
E-Mail: beka@beka-lube.de
beka@beka-max.de

Also available:

Gear pumps
Multi-line pumps for oil
Multi-line pumps for grease
Single-line central lubrication systems
Double-line central lubrication systems
Oil-circulation central lubrication systems
Oil/air and spray lubrication
Wheel-flange lubrication
Central lubrication systems for commercial vehicles
Central lubrication systems for rolling mills
Progressive distributors
Control and monitoring equipment

Subject to change!