BEKA Stream H Original Operating And Assembly Manual

...a product of BAL2522_2523_Barrel_pump_Stream_H_0619EN Barrel pump BEKA Stream H Article no. 2522 ….; 2523 …. Issue 06-2019 Original operating and assembly manual

...a product of BAL2522_2523_Barrel_pump_Stream_H_0619EN Table of contents 1. Technical data ................................................................................................................................................................................ 4 1.1  General ...................................................................................................................................................................................... 4 1.2  Pump individually ....................................................................................................................................................................... 4 1.3  Pump – barrel version ................................................................................................................................................................ 4 1.4  Pump – container version .......................................................................................................................................................... 4 1.5  Solenoid valve – single-line version ........................................................................................................................................... 4 1.6  Level monitoring ........................................................................................................................................................................ 4 2. Applicable documents..................................................................................................................................................................... 5 3. Code ............................................................................................................................................................................................... 5 4. Versions .......................................................................................................................................................................................... 7 5. General safety instructions ............................................................................................................................................................. 9 5.1  Safety instructions ..................................................................................................................................................................... 9 5.2  Qualification and training of staff ............................................................................................................................................... 9 5.3  Hazards in case of non-observance of the safety instructions ................................................................................................ 10 5.4  Obligations of the operator / user ............................................................................................................................................ 10 5.5  Safety instructions for maintenance, inspection and assembly ............................................................................................... 10 5.6  Unauthorized modification and production of spare parts ....................................................................................................... 10 5.7  Inadmissible modes of operation ............................................................................................................................................. 11 5.8  Electrostatic discharge ............................................................................................................................................................. 11 5.9  General hazard warning – residual risk ................................................................................................................................... 11 6. Intended use ................................................................................................................................................................................. 12 7. Scope of warranty ......................................................................................................................................................................... 12 8. Transport and storage .................................................................................................................................................................. 13 8.1  Pump ....................................................................................................................................................................................... 13 8.2  Beka Stream H barrel version .................................................................................................................................................. 13 8.3  Beka Stream H container version ............................................................................................................................................ 13 9. Assembly instructions ................................................................................................................................................................... 14 9.1  Prefilling of return connection (lubricant) ................................................................................................................................. 14 9.2  Assembly of Beka Stream H barrel version ............................................................................................................................. 16 9.3  Assembly of Beka Stream H container version ....................................................................................................................... 16 9.4  Hydraulic connection of the motor ........................................................................................................................................... 17 9.5  Power connection .................................................................................................................................................................... 18 10.  Start up ......................................................................................................................................................................................... 19 10.1  Lubricants ................................................................................................................................................................................ 19 10.2  Ventilation of the lubrication system ........................................................................................................................................ 19 10.3  Adjustment of the level monitoring (barrel version) ................................................................................................................. 19 10.4  Setting the level monitoring (container version) ....................................................................................................................... 19 10.5  Initial filling of container with lubricant ..................................................................................................................................... 20 10.6  Delivery volume ....................................................................................................................................................................... 21 11.  Functional description ................................................................................................................................................................... 22 11.1  General .................................................................................................................................................................................... 22 11.2  Pump ....................................................................................................................................................................................... 22 11.2.1  Hydro motor .................................................................................................................................................................... 22 11.3  Add-on parts ............................................................................................................................................................................ 23 11.3.1  Level monitoring .............................................................................................................................................................. 23 11.3.2  Ventilation valve .............................................................................................................................................................. 23 11.3.3  Grease level dipstick ....................................................................................................................................................... 23 11.3.4  Single-line block (optional) .............................................................................................................................................. 23 11.3.5  Pressure limiting valve (optional) .................................................................................................................................... 23 12.  Maintenance ................................................................................................................................................................................. 24 12.1  General maintenance .............................................................................................................................................................. 24 12.2  Lubricant change ..................................................................................................................................................................... 24 12.3  Filling of the container .............................................................................................................................................................. 25 12.4  Exchange of barrel ................................................................................................................................................................... 26 12.5  Exchange of pump ................................................................................................................................................................... 27 13.  Repair ........................................................................................................................................................................................... 28 13.1 Exchange of pump element ............................................................................................................................................ 28

...a product of BAL2522_2523_Barrel_pump_Stream_H_0619EN 13.2 Exchange of motor .......................................................................................................................................................... 32 13.3 Exchange of sealing bush ............................................................................................................................................... 33 14.  Shutdown ...................................................................................................................................................................................... 35 15.  Disposal ........................................................................................................................................................................................ 35 16.  Troubleshooting ............................................................................................................................................................................ 35 17.  Spare part list and drawing ........................................................................................................................................................... 35 18.  Dimensional drawing of pump without accessories ...................................................................................................................... 36 19.  Dimensional drawing of pump with accessories ........................................................................................................................... 37 20.  Accessories .................................................................................................................................................................................. 38 20.1 Filling zerk ....................................................................................................................................................................... 38 20.2 Pressure limiting valve for progressive and dual-line systems ....................................................................................... 38 20.3 Pressure limiting valve / relief valve for single-line system ............................................................................................. 38 20.4 Control unit Tronic-e ....................................................................................................................................................... 39 20.5 10 m connection cable incl. 1x AMP bushing ................................................................................................................. 39 20.6 10 m connection cable for BEKA Stream H incl. 1x cubic bushing (socket acc. to EN175301-803 A) ........................... 39 20.7 Module with pressure limiting valve for progressive systems for direct installation on BEKA Stream H ........................ 40 21.  Details of the manufacturer........................................................................................................................................................... 41

...a product of BAL2522_2523_Barrel_pump_Stream_H_0619EN 1. Technical data 1.1 General Pump Delivery rate: ......................................................................................................................................................................... 120 cm³/min Lubricant: ...................................................................... greases up to NLGI class 2 without solid contents (other lubricants on request) Operating pressure basis system: ........................................... max. 5076 psi / 350 bar (pressure limiting valve not in scope of delivery) Operating pressure single-line system: ................................. max. 5076 psi / 350 bar (pressure limiting valve set to 3480 psi / 240 bar) Operating temperature: ..................................................................... -22°F up to +149°F / -30°C up to +65°C (depending on lubricant) Number of outlets: ................................................................................................................................................................................... 1 Outlet type: ....................................................................................................................................................................................... G 1/2 Return connection (integrated in pump pipe): .................................................................................................................................. G 1/2 Sound pressure level: ................................................................................................................................................................ <70 dB(A) Motor Drive type: ................................................................................................................................................................................... hydraulic Hydraulic oil inlet: ............................................................................................................................................................................. G 3/8 Hydraulic oil outlet: ........................................................................................................................................................................... G 3/8 Drive pressure (P): ..................................................................................................................................... 290 – 3625 psi / 20 – 250 bar Return pressure (T): .................................................................................................................................................... max. 43 psi / 3 bar Volume flow* of the drive medium: ....................................................................................................... 0,53 – 3,2 gal/min / 2 – 12 l/min** Purity class of the drive medium: ........................................................................................................................... ISO 4406: ≤ 21/19/16 1.2 Pump individually Weight: ................................................................................................................................................................................ max. 21.3 kg 1.3 Pump – barrel version Barrel capacity: ..................................................................................................................................................... 213 l (180 kg / 400 lbs) 1.4 Pump – container version Container capacity: .................................................................................................................... 41 l (60 lbs) / 54 l (90 lbs) / 68 l (120 lbs) 1.5 Solenoid valve – single-line version Operating voltage: ....................................................................................................................................................................... 24 V DC Nominal power: ................................................................................................................................................................................. 26 W Degree of protection: ......................................................................................................................................................................... IP 65 1.6 Level monitoring Operating voltage: ......................................................................................................................................................... 10 up to 30 V DC Electric version: ..................................................................................................................................................................... DC PNP NO Connection plug: .............................................................................................................................................................. M12x1; 4-poles Functional principle: ................................................................................................................................................................... ultrasonic Degree of protection: ......................................................................................................................................................................... IP 67 * Delivery volume depending on volume flow (see also figure 23 – page 21). ** The volume flow of the drive medium is internally limited to max. 3,2 gal/min / 12 l/min. Please see the attached data sheets and manuals of the corresponding manufacturers for missing details and further technical data. The barrel pump is subsequently called a device.

...a product of BAL2522_2523_Barrel_pump_Stream_H_0619EN 2. Applicable documents Technical documentation of individual parts enclosed: Level monitoring Please observe these documents for all work with and at the device! 3. Code Caution!

...a product of BAL2522_2523_Barrel_pump_Stream_H_0619EN 4. Versions Pump Pump - container version Pump - barrel version Symbol Symbol (basis system) Symbol (single-line system) Figure 2 Figure 1 Figure 3 Figure 5 Figure 4 Figure 6

...a product of BAL2522_2523_Barrel_pump_Stream_H_0619EN Symbol hydro motor Figure 7

...a product of 5. General safety instructions Everybody who is in charge of the assembly, start-up, maintenance and operation of the device must read these instructions carefully prior to assembly and start-up of the device at the machine! Furthermore, this manual must always be available at the site of operation! Basic instructions for setup, operation and maintenance can be found below. 5.1 Safety instructions Observe the general safety instructions within this key chapter as well as the special safety instructions in other chapters of this operating and assembly manual. Warning of electrical voltage. Safety instructions, which might cause hazards to persons in case of non-observance, are marked with the general danger symbol. This symbol warns of hot surfaces. Warning of suspended loads. Warning of material damage due to electrostatic discharge! Marks potential risks which may result in material damage, if not avoided. This heading is used if improper or general non-observance of the operating and assembly manual, instructions, specified workflow and the like might result in damage. This term is used to point out particular details. Instructions and notes directly attached to the device have to be strictly observed and kept in readable condition! 5.2 Qualification and training of staff The staff in charge of operation, maintenance, inspection and assembly have to be qualified accordingly. Competence, responsibilities and supervision of staff must be clearly defined by the operator. In case the staff does not have the necessary knowledge it has to be instructed and trained accordingly. The operator is obliged to ensure that the staff fully understands the contents of this user information. Notice! Caution!

...a product of 5.3 Hazards in case of non-observance of the safety instructions Results of non-observance of the safety instructions can be hazards to persons, for the environment and the device. Non-observance of the safety instructions may result in the loss of any liability claims. The non-observance could more specifically result in the following hazards (for example):  Failure of important device functions.  Failure of prescribed methods regarding maintenance and repair.  Danger to persons by electrical, mechanical and chemical effects.  Danger to the environment by leakage of hazardous substances. 5.4 Obligations of the operator / user  If movable, rotating, hot or cold parts of the device bear risks, the customer must protect these parts against contact. This protection must not be removed.  Any leakages of hazardous substances must be drained in a way that no risks for persons or the environment arise. Please also refer to the data or safety data sheets of the respective manufacturers.  Observe all legal provisions.  Hazards due to electricity are to be excluded.  Examination of pipes and hoses regarding safe provision, use, proper assembly and function has to be carried out according to regionally applicable directives. Inspection intervals may not be exceeded.  Defective pipes or hoses must be replaced immediately and professionally.  Hydraulic hoses and polyamide pipes are subject to natural aging and have to be exchanged in regular intervals according to the manufacturer’s specifications.  A safety data sheet of the currently used lubricant must be provided at the device.  Observe the universally valid Ordinance on Hazardous Substances in its latest version. 5.5 Safety instructions for maintenance, inspection and assembly All maintenance, inspection and assembly work may only be carried out by qualified personnel who is sufficiently informed by thorough reading of the user information. Any work at the device may generally only be carried out at complete standstill and in pressureless as well as disconnected condition. Furthermore, appropriate personal protective equipment (goggles among others) is necessary. The shutdown procedure of the device as described in the manual must be strictly followed. Secure the device against intentional or unintentional recommissioning during maintenance or repair. All safety and protection arrangements have to be put back in place again immediately after completion of the work. Environmentally hazardous media must be disposed of professionally and according to the relevant legal provisions. Polluted and contaminated surfaces have to be cleaned before maintenance. Please wear protective equipment to that purpose. See the lubricant manufacturers‘ safety data sheets hereto, respectively the data sheets provided by the manufacturers of auxiliaries and working materials. Check the surface temperature of the device as a possible heat transfer bears the risk of burns. Wear heat resistant protective gloves! Open flame and fire are strictly forbidden during maintenance, inspection and repair due to fire hazard. 5.6 Unauthorized modification and production of spare parts Modification, repair and alterations of the device are only accepted after manufacturer feedback. Original spare parts and authorized accessories from the manufacturer contribute to safety. The use of other parts can result in the loss of any liabilities for the resulting consequences. BEKA does not assume liability for parts that are retrofit by the operator.

...a product of 5.7 Inadmissible modes of operation Operational safety of the device is only guaranteed when it is appropriately applied as indicated in the operating and assembly manual. Never exceed or fall below the limit values, as stated in the technical data. 5.8 Electrostatic discharge Avoid electrostatic discharge! There are electronic components integrated into the devices which might be destroyed by electrostatic discharge. Observe the safety precautions against electrostatic discharge according to DIN EN 61340- 5-1/-3. Ensure that the environment (persons, workplace and packing) is well grounded when handling these devices. 5.9 General hazard warning – residual risk All components are designed according to valid regulations for the construction of technical systems with regard to operational safety and accident prevention. Nevertheless, their use can lead to hazards for the user or third parties as well as other technical facilities. Therefore, the device may only fulfill its intended purpose in a technically perfect and faultless condition. This has to happen in adherence to the relevant safety regulations as well as the operating and assembly manual. Inspect the device and its attachment parts regularly and check them for possible damage or leakages. Liquids could escape under high pressure from pressurized components which become leaky.

...a product of 6. Intended use The device is only approved for the industrial use. Only operate the device if it is installed in/to another machine and operated together with it. Use only lubricant according to the machine manufacturer’s specification, that is suitable for the central lubrication system. The device must only be used according to the technical data (see chapter 1 „technical data”). Never exceed or fall below the mentioned values. Never operate the device without lubricant. Unauthorized modifications of the device are not permitted. BEKA is not liable for personal injury or damage of machine resulting thereof. The intended use also includes:  paying attention to all chapters and notes in the operating and assembly manual.  carrying out all maintenance work.  observing all relevant instructions for work safety and accident prevention during all life cycles of the device.  having the necessary professional training and authorization of your company to operate the device and to carry out the necessary work on the device. Another use or a use beyond this scope is deemed improper. 7. Scope of warranty Warranties regarding operational safety, reliability and performance will only be granted by the manufacturer if the device is used according to the regulations and under the following conditions:  Assembly, connection and maintenance are only carried out by authorized and qualified staff.  The device is only used according to the operating and assembly manual.  Never exceed or fall below the limit values as defined in the technical data.  Modifications and repairs at the device may only be done by BEKA. Guaranty and warranty will expire for any damage of the device caused by improper lubricant (e.g. wear of piston, piston jamming, blockades, brittled sealings etc.). BEKA will generally not accept guaranty claims for any damage caused by lubricants, even though those have been laboratory tested and released by BEKA, as such damage (e.g. by over-stored or incorrectly stored lubricants, batch fluctuations, etc.) cannot be verified or reconstructed later. Caution! Caution! Caution!

...a product of 8. Transport and storage Use suitable lifting devices for transport. Do not throw the device or expose it to shocks. Secure the device against toppling down or slipping during transport. 8.1 Pump If the device is lifted at the pump bracket, the maximum load of 100 kg must be observed. The device must always be lifted without barrel or container. 8.2 Beka Stream H barrel version The pump, the barrel cover and the follower plate must always be transported in a disassembled state (separately). 8.3 Beka Stream H container version The device must be lifted at the transport eyelets (fig. 9, red arrows). In addition, it must be fixed to the pump bracket so that it cannot tip over. The device must only be transported when it is completely empty. Observe all valid safety and accident prevention regulations for the transport. Wear suitable protective equipment if necessary. Keep adequate distance to suspended loads. The transport help or the elevating device must have the adequate carrying capacity. When storing the device pay attention that the storage area is cool and dry in order to avoid corrosion of the individual parts of the device. Observe the storability of the contained lubricant for devices which are filled with lubricant. Exchange the lubricant when it is over-stored (separation of oil and soap). Notice! Caution! Figure 8 Figure 9

...a product of 9. Assembly instructions Check the device for possible transport damage and for completeness before the assembly. Any installed equipment for transportation safety has to be removed. Comply with the following conditions when assembling a complete machine from this device and other components. Mind a proper and eco-friendly assembly without impairment of persons’ health and safety: Assemble the device in balance on the installation location in order to ensure safe operation. Observe the information on the fastening holes given in the dimensional drawing. When selecting the set-up location, please mind that the device should be protected against ambient and mechanic influences. Ensure full access, e.g. for filling with lubricant. Special measures concerning noise prevention or oscillation reduction do not have to be taken. 9.1 Prefilling of return connection (lubricant) This chapter must only be observed when the return connection for the lubricant is used. If the device is operated without this option, continue with chapter 9.2. In order to avoid that air is pumped into the container / barrel, when the lubricant flows back, the return connection in the pump pipe must be prefilled with lubricant. Always ensure utmost cleanliness during the prefilling. Step 1: If the return connection (fig. 10, pos. 1) is sealed, the screw plug (fig. 10, pos. 2) has to be unscrewed with an Allen key AF10. The return connection is marked with an „R“ at the pump (fig. 11). Notice! 1 2 Caution! Notice! Figure 10 Figure 11

...a product of Step 2 Then screw the filling nipple (fig. 12, pos. 3) with AF 27 into the return connection (G1/2). The filling nipple is not included in the scope of delivery (see chapter accessories). Step 3: Fill the return connection (G1/2) with a filling press until the lubricant escapes from the pump pipe (figure 13 and 14). Step 4: After the filling, the filling zerk can be disassembled again. If the return connection is not used, it has to be closed again. 3 Figure 12 Figure Figure 14

...a product of 9.2 Assembly of Beka Stream H barrel version Step 1: Push the follower plate (fig. 15, pos. 6) into the barrel. Step 2: Attach suitable lifting straps or chains to the bracket (fig. 15, pos. B). Step 3: Push the pump (fig. 15, pos. 1) with a suitable lifting device through the central bore in the barrel cover (fig. 15, pos. 3). Step 4: Push the pump pipe (fig. 15, pos. 7) through the follower plate (fig. 15, pos. 6). Make sure that the barrel cover (fig. 15, pos. 3) does not slide downwards. Step 5: Push the pump (fig. 15, pos. 1) with cover (fig. 15, pos. 3) down until the cover rests on the barrel. Step 6: Tighten the wing screws (fig. 15, pos. 4) until the cover (fig. 15, pos. 3) is firmly fixed on the barrel. Step 7: If available, fold the tie rods (optional accessory) upwards and fix them with the straps (fig. 15, pos. 5) of the cover (fig. 15, pos. 3). Step 8: Push the pump (fig. 15, pos. 1) completely down until the pump pipe (fig. 15, pos. 7) rests on the bottom of the barrel. Then pull the pump up again by approx. 1 cm. Step 9: Fix the pump (fig. 15, pos. 1). Tighten the two clamping screws (hexagonal socket AF 6 – fig. 15, pos. 2). Step 10: Remove lifting straps or chains. 9.3 Assembly of Beka Stream H container version Screw the device securely to the ground using the 4 fastening bores (fig. 16). The ground has to be as even as possible. The fasteners must be matched to the ground. 6 1 5 7 3 2 4 B Figure 15 Figure 16

...a product of 9.4 Hydraulic connection of the motor The connection line of the hydraulic supply pressure must be connected to thread P (fig. 17, pos. P). The connection line of the hydraulic return must be connected to thread T (fig. 17, pos. T). All components must be approved for the maximum operating pressure (see chapter 1 “Technical data”). The connections P and T must not be interchanged. An incorrect assembly will damage the components. T P Caution! Figure 17

...a product of 9.5 Power connection  Power supply must be done by a professional electrician!  Electrical device components must be wired professionally!  Compare voltage details with the existing mains voltage!  Equipotential bonding must be done professionally by the operator via an according ground connection!  Connect the device according to the terminal diagram! Terminal diagram of level monitoring Terminal diagram 3/2-way change-over valve Terminal diagram of solenoid valve (only for single-line version) 1 2 PE Figure 18 Figure 19 Figure 20

...a product of 10. Start up 10.1 Lubricants The device is designed for commercial multipurpose greases up to NLGI class 2 without solid contents. A detailed description of the barrel change or the container filling can be found in chapter 12 „Maintenance“. Observe the following notices:  Use greases with high pressure additives (EP-grease).  Observe the machine manufacturer’s lubricant details! Only use lubricants according to machine manufacturer’s specifications!  Collect leaking lubricant in a suitable reservoir and dispose it professionally!  The lubricant viscosity changes with the operating temperature.  Check the level several times in equal intervals during the first hours of operation and refill clean lubricant or change barrel, if necessary.  Ensure utmost cleanliness when filling the lubricant!  Use only greases with the same saponification.  Observe the safety data sheet of the lubricant manufacturer! 10.2 Ventilation of the lubrication system  Ventilate the whole lubrication system on first start-up and after each lubricant change!  Ventilation is done by operating the system in pressureless condition and with open system outlets!  Operate the pump until lubricant escapes from the pressure connection without air inclusions. 10.3 Adjustment of the level monitoring (barrel version) Step 1: Identify the barrel height (fig. 21, dimension B) Step 2: Set the level monitoring (ultrasonic sensor) to dimension B – 7 cm (empty signal). If a prewarning should also be set, the second switching point of the visual sensor can be set to a random height before the empty signal. Observe the separate technical documentation of the level monitoring enclosed. 10.4 Setting the level monitoring (container version) For the container version, the level monitoring (ultrasonic sensor) is already set ex works (empty signal). Caution! B Figure 21

...a product of 10.5 Initial filling of container with lubricant The pump must be depressurized and secured against unintentional start-up. Step 1: Open the ventilation screw (fig. 22, pos. 3) on the back side of the container at initial filling (hexagonal socket AF 10) and remove the screw plug on the filling connection G1 (fig. 22, pos. 1) (hexagonal socket AF 17). Step 2: Connect a suitable filling pump to the filling connection G1 (fig. 22, pos. 1) of the device. Step 3: Fill the container with clean lubricant via the filling connection G1 (fig. 22, pos. 1) until lubricant escapes from the ventilation screw (fig. 22, pos. 3)! Step 4: Retighten the ventilation screw (fig. 22, pos. 3) and dispose of excess lubricant environmentally friendly. Step 5: Fill the device slowly with clean lubricant via the filling connection G1 (fig. 22, pos. 1) until lubricant escapes from the overfill protection (fig. 22, pos. 2). Dispose of leaked lubricant environmentally friendly. Step 6: Remove the filling pump again and close the filling connection G1 (fig. 22, pos. 1). 2 3 1 Figure 22

...a product of 10.6 Delivery volume The device delivers a constant delivery volume of 120 cm³/min from a volume flow of the drive medium of 12 l/min (The volume flow of the drive medium is internally limited to max. 12 l/min). If the volume flow of the drive medium is lower, the volume flow changes as shown in the figure (fig. 23). Delivery volume depending on volume flow: Figure 23

...a product of 11. Functional description 11.1 General The device is used to supply the central lubrication system or individual lube points with lubricant. Depending on the type of application, the pump can be used for single-line, dual-line or progressive systems. There are various accessories available for the barrel pump BEKA Stream H (see chapter 20 “Accessories”). 11.2 Pump The pump is driven by a hydro motor. The rotary movement of the motor is converted into a stroke movement of the piston rod by an eccentric located in the housing. The delivery piston of the pump is firmly connected to the piston rod, which forcedly triggers a suction and pressure stroke. Thus, the lubricant is sucked in at the suction bore at the lower end of the delivery pipe and delivered to the pressure outlet. A non-return valve prevents that the lubricant is sucked back. The integrated return connection on the pump can be used to return lubricant quantities from relief processes and pressure relief valves directly via the pump pipe into the lubricant barrel. 11.2.1 Hydro motor A valve block (fig. 24, pos. 4) is flanged to the hydro motor (fig. 24, pos. 2). The valve block (fig. 24, pos. 4) contains a pressure limiting valve (fig. 24, pos. 1), a flow control valve (internal) and a 3/2-way change-over valve (fig. 24, pos. 3). The 3/2-way change-over valve (fig. 24, pos. 3) controls the hydro motor (fig. 24, pos. 2). If it is applied with voltage, the drive medium is delivered to the hydro motor. The lubrication cycle begins. Even if the hydro motor (fig. 24, pos. 2) is not in operation, the drive medium flows through the valve block (fig. 24, pos. 4). The 3/2-way change-over valve (fig. 24, pos. 2) is not applied with voltage and the drive medium flows via a bypass valve to the return connection (fig. 24, pos. T). The advantage at cold ambient temperatures is that a shock load caused by a sudden inrush of hot drive medium is avoided. Notice! T 1 3 4 2 Figure 24

...a product of 11.3 Add-on parts 11.3.1 Level monitoring An ultrasonic sensor monitors the lubricant level in the container or the barrel and sends a signal at minimum level. The ultrasonic sensor sends a signal for barrel exchange as soon as the barrel is empty. The signal evaluation is done by the customer. Two TEACH modes are available to configure the sensor:  Individual programming of the lower and upper limit values, or  Use of the “Auto-Window” feature to create an acquisition window around the programmed position. Also observe the technical documentation of the ultrasonic sensor enclosed. In order to avoid that air is sucked into the lubrication circuit, the device should be switched off at an empty signal. 11.3.2 Ventilation valve The ventilation valve in the reservoir cover is used to filter the incoming air during the pressure compensation that is caused by a varying level. The ventilation filter element has to be checked at regular intervals and renewed if it is visibly polluted. 11.3.3 Grease level dipstick If the grease level dipstick is pulled out of the reservoir, the lubricant level is displayed at the stick. In order to avoid that dirt enters the reservoir, the dipstick has to be completely inserted into the bore. 11.3.4 Single-line block (optional) A relief valve can be attached as a block at the pump pipe at a device for single-line systems. It is directly flanged to the pressure and return connection. The single-line block is equipped with a pressure relief valve, which enables the pressure line to be relieved as required for single-line systems. 11.3.5 Pressure limiting valve (optional) Optionally, a pressure limiting valve can be attached to the device for progressive and dual-line systems. It is available as component for a customer-specific attachment in the entire system or as a module for direct attachment at the pump pipe. It has an opening pressure of 280 bar. Caution!

...a product of 12. Maintenance Disconnect the device from power supply before maintenance or repair. Only carry out maintenance and repair in complete device standstill and pressureless condition. Check the surface temperature of the device, as there is the risk of burns by radiant heat. Wear heat-resistant gloves and safety goggles! Clean soiled or contaminated surfaces before maintenance, wearing protective equipment if necessary! Secure the device against recommissioning during maintenance and repair work! Further information and technical details regarding the components can be found in the enclosed operating manuals of the components. 12.1 General maintenance  Retighten all fittings 6 weeks after start up!  Check all components for leakages and damage at least every four weeks! If leakages are not repaired, lubricant might escape under high pressure. Remove possible puddles of lubricant immediately. 12.2 Lubricant change Observe utmost cleanliness when refilling lubricant!  Check the level regularly and refill clean lubricant as necessary, see chapter start-up.  Change the lubricant according to the specifications of the lubricant manufacturer. Environmental influences like increased temperature or pollution may shorten these intervals!  Please make sure to only use lubricants that are suitable for the device as well as the lubricated machine and that comply with the requirements of the particular operating conditions.  In case of different lubricant manufacturers, ensure that the lubricant quality corresponds to the quality of the previously used one! As precautionary measure, drain the lubricant reservoir professionally and clean it! Caution!

...a product of 12.3 Filling of the container The pump must be depressurized and secured against unintentional start-up. Step 1: Remove the screw plug from the filling connection G1 (fig. 25, pos. 1) (hexagon socket AF 17) and connect a suitable filling pump at the filling connection G1. Step 2: Fill the device slowly with clean lubricant via the filling connection G1 (fig. 25, pos. 1) until lubricant escapes from the overfill protection (fig. 25, pos. 2). Dispose of leaked lubricant environmentally friendly. Step 3: Remove the filling pump again and close the filling connection G1 (fig. 25, pos. 1). 2 3 1 Figure 25

...a product of 12.4 Exchange of barrel The pump must be depressurized and secured against unintentional start-up. Step 1: Attach suitable lifting straps or chains to the bracket (fig. 26, pos. B). Step 2: Disassemble the tie rods (if available – optional accessory) from the straps (fig. 26, pos. 5) of the cover (fig. 26, pos. 3) and fold them down. Step 3: Unscrew the wing screws (fig. 26, pos. 4) until the cover (fig. 26, pos. 3) can be removed from the barrel. Step 4: Pull the pump (fig. 26, pos. 1) incl. cover (fig. 26, pos. 3) out of the grease barrel using a suitable lifting device. The relevant regulations on lifting loads must be observed. The grease barrel must not be lifted at the same time. Ensure that the pump pipe (fig. 26, pos. 3) is not damaged or soiled. Step 5: Pull the grease follower plate (fig. 26, pos. 6) out of the empty grease barrel and press it into the new barrel. Step 6: Now reinsert the pump pipe (fig. 26, pos. 7) through the follower plate (fig. 26, pos. 6) into the barrel. Step 7: Push the pump (fig. 26, pos. 1) with cover (fig. 26, pos. 3) downwards until the cover rests on the barrel. If the height of the new barrel differs from that of the old one, adjust the immersion depth of the pump pipe (fig. 26, pos. 1) to the new barrel. First, loosen the two clamping screws (hexagon socket AF 6 - fig. 26, pos. 2). Then proceed as described in chapter 9.2 "Assembly of Beka Stream H barrel version" (steps 4 to 8). The following steps 9 and 10 in this chapter are then omitted. Step 8: Tighten the wing screws (fig. 26, pos. 4) until the cover (fig. 26, pos. 3) is firmly fixed on the barrel. Step 9: If available, fold the tie rods (optional accessory) upwards and fix them with the straps (fig. 26, pos. 5) of the cover (fig. 26, pos. 3). Step 10: Remove lifting straps or chains. Use grease barrels only with original grease filling! Do not use refillable barrels! 6 1 5 7 3 2 4 Caution! B Caution! Caution! Figure 26

...a product of 12.5 Exchange of pump The pump must be depressurized and secured against unintentional start-up. Shut off the circuit of the drive medium. Step 1: Attach suitable lifting straps or chains to the bracket (fig. 27, pos. B). Step 2: Disassemble hydraulic lines. Collect any leaking drive medium and dispose of it environmentally friendly. Step 3: Disconnect the electrical wiring from the pump. Step 4: Loosen the clamping screw (hexagon socket AF 6 – fig. 27, pos. 2). Step 5: Lift the pump (fig. 27, pos. 1) out of the barrel or the container using a suitable lifting device. The relevant regulations on lifting loads must be observed. The grease barrel must not be lifted at the same time. Ensure that the pump pipe (fig. 27, pos. 3) is not damaged or soiled. Step 6: Remove lifting straps or chains from the pump and attach them to the new pump. Step 7: Insert the new pump (fig. 27, pos. 1) into the container or the barrel. Carefully insert the pump pipe (fig. 27, pos. 3) into the opening in the middle of the cover and the follower plate. Step 8: Container version: Push the pump (fig. 27, pos. 1) all the way down until the pump rests on the clamping block (fig. 27, red arrow). Barrel version: Push the pump (fig. 27, pos. 1) all the way down until the pump pipe (fig. 27, pos. 3) rests on the bottom of the barrel. Then pull the pump up again by approx. 1 cm. Risk of crushing between clamping block and pump body (Fig. 27, red arrow). Slowly lower the pump. Step 9: Fix the pump (fig. 27, pos. 1). To do this, tighten the two clamping screws (fig. 27, pos. 2). Step 10: Connect the electrical wiring to the pump and install the hydraulic lines (see chapter 9 "Assembly instructions"). Step 11: Remove lifting straps or chains. Caution! B 1 3 2 Figure 27

...a product of 13. Repair Always ensure utmost cleanliness during repair works. Repair works that you can perform yourself are listed in the following. Other repair works may only be done by BEKA. 13.1 Exchange of pump element Step 1: Disassemble 4 cylinder screws (A) with an Allen key AF 6 (figure 28). Step 2: Pull off pump pipe (B) (figures 28 and 29). Step 3: Disassemble 2 motor fastening screws (C) with an Allen key AF 10 (figure 30). A B C Caution! Figure 28 Figure 29 Figure 30

...a product of Step 4: The hydro motor (D) has to be turned clockwise or counterclockwise until the suction piston (E) reaches the lower final position (figures 31 and 32). Step 5: Remove both lock screws F (hexagon socket screw AF 4) and G (hexagon socket screw AF 2,5) (figure 33) one after the other. Step 6: Unscrew the conveyor pipe (H) with an open-ended wrench AF26 from the pump and pull it out until the stop (figure 34). D G F H E Figure 31 Figure 32 Figure 33 Figure 34

...a product of Step 7: Knock out the locking pin with a punch Ø3mm and a hammer and remove it completely (figures 35 and 36). This is only possible if the suction piston is in the lower final position (see step 4). Step 8: Unscrew the conveyor pipe (H) via the hexagon (AF10) at the suction piston (E) from the pump and remove it (figures 37 and 38). Step 9: Unscrew the pump element (K) with an open-ended wrench AF28 from the conveyor pipe (H). Hold against the pipe with another wrench AF26 (figure 39). Pull the pump element with suction piston (E) out of the conveyor pipe (figure 40). E H H K H K E Caution! Figure 35 Figure 36 Figure 37 Figure 38 Figure 39 Figure 40

...a product of Step 10: Disassemble the locking pin (L) at the suction piston (E) with a punch Ø3mm and a hammer and remove it completely (figures 41 and 42). Step 11: Unscrew the pump element (K) via the hexagon (AF10) at the suction piston (E) from the piston rod and remove it (figure 43). Step 12: The pump element can be changed now and the pump has to be reassembled in reverse order. All seals must fit correctly at installation and must not be damaged. L E K E Caution! Figure 41 Figure 42 Figure 43

...a product of 13.2 Exchange of motor Step 1: Disassemble motor fastening screws (C) with an Allen key AF 10 (figure 44). Step 2: The motor (D) has to be lifted up now (figure 44). Step 3: Reassemble new motor in reverse order (figure 45). Figure 44 Figure 45 C D C D

...a product of 13.3 Exchange of sealing bush Please follow steps 1 to 8 from chapter 13.1 „Exchange of pump element“. Step 9: Disassemble the 4 cylinder screws (M) at the housing cover (N) (hexagon AF5). The pump must be in a vertically upright position to avoid that oil flows uncontrolled out of the pump housing (O) (figure 46). Step 10: Remove the housing cover (N) and drain the oil in the pump housing (figure 47). The oil is intended to be used for the entire life cycle of the pump and can therefore be reused. If the cover seal (S) is damaged, it must be replaced. In this case, fresh oil must also be filled in. The used oil cannot be reused. Step 11: Remove the 4 cylinder screws (P) from the pump housing (figure 48). P M N O Caution! S N Figure 46 Figure 47 Figure 48

...a product of Step 12: For an easier disassembly, the housing cover (N) can be refastened to the pump housing using the 4 cylinder screws (M). Now pull off the connection body (Q) from the pump housing (O) (figures 49 and 50). Step 13: Pull out the sealing bush (R) with a gripper from the connection body (Q) (figure 51). Now the sealing kit can be replaced by a new one. Step 14: Reassemble the device in reverse order. All seals must fit correctly at installation and must not be damaged. Furthermore, the pump housing (O) must be filled with oil up to the “max. level” (figure 53). Also observe the notices in step 10. N O Q Q R Caution! O Figure 49 Figure 50 Figure 51 Figure 52 Figure 53

...a product of 14. Shutdown  Relieve the device from pressure!  Turn off power supply!  A qualified electrician has to disconnect electrical components from the power supply!  Remove all pipes and hoses from the device and loosen all fastenings for disassembly! 15. Disposal Observe the disposal instructions of the lubricant manufacturer when lubricant is changed! Lubricants or cloths contaminated with lubricant, etc. must be collected in specially marked reservoirs and disposed of accordingly. Disposal of the device must be done properly and professionally and according to the national and international laws and regulations. Moreover, BEKA devices could contain batteries. Professionally and properly disposed batteries will be recycled. They contain important raw materials. 16. Troubleshooting Malfunction Possible cause Possible remedy Pump does not supply lubricant Barrel empty Exchange barrel Air inclusions in lubricant Ensure that pump can prime lubricant Level monitoring glows Barrel / container empty Change barrel / fill up container Level monitoring glows, although barrel is full Ultrasonic sensor defective Replace ultrasonic sensor Supply line to ultrasonic sensor defective Insert new line No pressure is build up in pump Sealing bush of drive piston defective Renew sealing bush Suction valve in pump defective or polluted Renew or clean suction valve or pump (see 13.1) Air inclusions in lubricant Ensure that pump can prime lubricant Hydro motor does not operate Drive lines interchanged Connect drive lines correctly Hydro motor defective Exchange hydro motor 17. Spare part list and drawing Spare part lists and drawings are available on request. Notice!

...a product of 18. Dimensional drawing of pump without accessories Table for dimension L1 Container capacity (l / lbs) L1 (mm) 41 / 60 494 54 / 90 640 68 / 120 786 Barrel capacity (l / lbs) L1 (mm) 231 / 200 975 Figure 54

...a product of 19. Dimensional drawing of pump with accessories Container version Barrel version Container capacity (l / lbs) H1 (mm) H2* (mm) H3 (mm) L (mm) D (mm) 41 / 60 449 560 884 504 Ø437 54 / 90 595 706 1030 504 Ø437 68 / 120 741 852 1176 504 Ø437 * Dimension up to the pressure outlet or return connection Figure 55

...a product of 20. Accessories 20.1 Filling zerk Connection thread: ........................................................................................................................................................................... G 1/2 Article number: .......................................................................................................................................................................... 10118925 20.2 Pressure limiting valve for progressive and dual-line systems Opening pressure: ......................................................................................................................................................................... 280 bar Connection thread: ...................................................................................................................................................................... 2x G 1/2 Article number: .......................................................................................................................................................................... 10123881 A pressure limiting valve with an opening pressure of 240 bar is always built in for single-line versions. 20.3 Pressure limiting valve / relief valve for single-line system Article number: .......................................................................................................................................................................... 10120291 Technical data 2/2-way valve Operating voltage: ....................................................................................................................................................................... 24 V DC Nominal power: ................................................................................................................................................................................. 26 W Degree of protection: ......................................................................................................................................................................... IP 65 Connection cable incl. AMP bushing not included. Please order separately! Note!

...a product of 20.4 Control unit Tronic-e It is possible to control the barrel pumps BEKA Stream E and Stream H for progressive or single-line central lubrication systems by the external control unit Tronic-e. Further information on the external control unit Tronic-e is available in the corresponding description (chapter 9 “Control and monitoring devices”) and operating manual (on request). Supply voltage: .............................................................................................................................................................. 10 up to 60 V DC Current load max.: ....................................................................................................................................................................... I = 6,0 A Fuse (not included in device): ...................................................................................................... F 6,3 A (format 5x20) medium time lag Temperature range: ................................................................................................................................................... -30° C up to +70° C Degree of protection: ......................................................................................................................................................................... IP 41 Article number: ............................................................................................. modification via code necessary (see description Tronic-e) 20.5 10 m connection cable incl. 1x AMP bushing for the 2/2-way valve, open cable end. Article number: .......................................................................................................................................................................... 10138802 20.6 10 m connection cable for BEKA Stream H incl. 1x cubic bushing (socket acc. to EN175301-803 A) for the 3/2-way change-over valve 24 V DC (standard equipment), open cable end. Article number: ......................................................................................................................................................................... 10124967

...a product of 20.7 Module with pressure limiting valve for progressive systems for direct installation on BEKA Stream H Opening pressure: ......................................................................................................................................................................... 280 bar Connection thread: ...................................................................................................................................................................... 2x G 1/2 Article number: .......................................................................................................................................................................... 10126444

...a product of 21. Details of the manufacturer BEKA BAIER + KÖPPEL GmbH + Co. KG Beethovenstraße 14 91257 PEGNITZ / Bayern Germany Tel. +49 9241 729-0 FAX +49 9241 729-50 POSTFACH 1320 91253 PEGNITZ / Bayern Germany http://www.beka-lube.de E-Mail: [email protected] [email protected] Our range of supply: Gear pumps Multi-line oil pumps Multi-line grease pumps Single-line central lubrication systems Dual line central lubrication systems Oil circulation central lubrication systems Oil-air and spray lubrication Wheel flange central lubrication systems Rolling mill central lubrication systems Commercial vehicle lubrication Progressive distributors Control and monitoring units Subject to alterations! We do not accept liability for errors, technical mistakes and misprints!