Operation instruction for

Lubrication system

UPER!
S

Bauer Doc.-No.:
ZSA 010 0E

Contents
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

 BAUER
Central Lubricating System
Maschinen GmbH
1 Method of operation of the central grease lubrication 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.

2 3

1 central grease pump EP-1

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

6
8

Contents
 BAUER
Central Lubricating System Maschinen GmbH
2 Function description, central lubricating pump EP-1 86522 Schrobenhausen

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
281
236

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
137

insignificant dimensions. A rubber wiper blade on

the charging arm (2).

152
130
107
197,5

177 138
320
2

4
Permits visual check of grease
8
level in the transparent reservoir
(1).
9
Filling of the reservoir is effected
via the hydraulic grease nipple. 3
The pressure relief valve (9), is 6
pre-set to 280 bar operating
pressure, to provide protection
for the pump and piping system.
7
5

Contents
 BAUER
Central Lubricating System
Maschinen GmbH
2 Installation of pump elements 86522 Schrobenhausen

Adjusting output of the pump element PE-120 V:

Supply rate (percentage)
Adjustability of the 100
output allows use of 90
this pump element for 80
supplying lubrication
70
systems of different
60
sizes.
50

Adjusting pump unit: 40

30
- Remove plug (2) using
Allen key. 20
- Adjustment of the 10
variable rate piston. 0
1 2 3 4 5 6 Stop grooves
The piston is set at
maximum output, when 0 0,5 1 1,5 2 2,5 3 Revol
leaving the factory, i.e. stop Setting piston
2
groove 0.
- Clockwise rotation decreases Supply piston

the output (1 stop groove

equals approx. 11 % of
output)
- Counter-clock-
wise rotation will increase 1
the output Maximum stroke
of the adjustable output piston Max. variation of stroke
3
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 Fig. I

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. Fig. II
- 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
 BAUER
Central Lubricating System
Maschinen GmbH
3 Method of operation of progressive distributors MX-F 86522 Schrobenhausen

3 Method of operation of progressive distributors MX-F:

„A“ 50
22,5 15 15 6,5 6,5
30

Outlet for dia. 6 mm

23
M10x1 inlet for dia. 6 mm

Technical detail:
Operating pressure-inlet: 300 bar
17

Temperature range: -35°C to +100°C

Lubricants: oil , soft grease or
16

standard grease
Modular range:
min.: MX-F 3/6 (3 elements)
max.: MX-F 10/20 (10 elements)
7,5 „B“

Elements Output Piston 2 4 6 8 10 12 14 16 18 20

code per outlet per element Ø Outlets
MX-F 25 25 mm3 50 mm3 3 mm
3 dimension „A“ 70 70 70 85 100 115 130 145 160 175
MX-F 45 45 mm 90 mm3 4 mm
MX-F 75 75 mm3 150 mm3 5 mm dimension „B“ 58 58 58 73 88 103 118 133 148 163
3
MX-F 105 105 mm 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.

Contents
 BAUER
Central Lubricating System
Maschinen GmbH
3 Combination of outlets on the MX-F distributor 86522 Schrobenhausen

Combination of outlets

2 outlets per distributor element 1 outlet per distributor element

(standard model)

Threaded pin SW2

single double

Combination of several outlets:

for ex. 3 outlets 4 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
Central Lubricating System
Maschinen GmbH
4 Function Description of Control unit S-EP 4 86522 Schrobenhausen

4 Integrated electronic control unit S-EP 4 with data memory for pump type EP-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 Co ntroller Typ S-EP 4

Lubricating period (min.)
Pause period (h)
Connection cable, approx. 10 m Controll
4 2
2 6 1 3 LED
1 0,5
16 8 8 4

14 10 7 5
12 6

LED, yellow

Contents
 BAUER
Central Lubricating System
Maschinen GmbH
4 Technical details 86522 Schrobenhausen

Technical details:

Supply voltage: 10 - 60 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

2
1 3
Inoperative period:
0,5
8 4
0,5 h - 8 h
7 5
6

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

14 10
12

8
4 12
Time range II: 2 min. - 32 min.
2
32 16

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 lubrication at
the engine housing
 BAUER
Central Lubricating System
Maschinen GmbH
4 Signals of the control device S-EP 4 86522 Schrobenhausen

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
 BAUER
Central Lubricating System
Maschinen GmbH
4 Special execution electric grease level control 86522 Schrobenhausen

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 5 + ignition terminal 15
2 signal lamp
3
4 yellow
+
green
view of plug-incontacts no.1 -
Push button for inter-
+
mediate lubrication

1 6 brown
+ low level control
7 blue
2 5
3
- low level control
4 black
Input low level control

view of plug-incontacts no.2

 BAUER
Central Lubricating System
Maschinen GmbH
5 Types of pipings 86522 Schrobenhausen

Installation of pipework:

Types of pipings:

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.

EDV-Nr.: 1001 20 100

Ø 3 mm

Ø 6 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 unti
the dimension shown in the drawing (11 mm) is attained.

Threaded sleeve Hose

11
Contents
 BAUER
Central Lubricating System
Maschinen GmbH
5 Fitting the hose insert 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 Hose ferrule

EDP-No.: 1001 21 201 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 High-pressure hose with double cone, sleeve nut,
cone and 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