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Northwest Automatic Lubrication, Inc.

Trouble Shooting - Beka-Max EP-1 with SEP-4 Controller

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Beka-Max EP-1 with SEP-4 Controller Trouble Shooting Guide

 

BEKA – MAX EP-1 with SEP-4 Controller

 

 TROUBLE SHOOTING and DIAGNOSTIC GUIDE

 

NW Automatic Lubrication, Inc.  (888) 267-7695

 

 

  Trouble                   Possible Cause               Test Procedure­                    Remedy

Pump does not work.

A blown fuse.

Test fuse.  Fuse may be located in-line with pump power supply cord or in warning light junction box----------------------

 

Replace fuse.

A defective SEP-4 Integrated controller, located in the lower motor housing.

Press extra lube cycle button on the side of the pump motor housing.  If yellow LED light in window at the base of the does not blink, check for voltage at the Hirschman connector at pin number 5 (+) and 7 (-).  If no voltage ---------

 

If there is voltage at pin number 5 and 7-------------------

 

 

 

 

 

 

 

Check fuse and/or power source.

 

Replace lower housing of motor in which is located the control unit.

 

Break in pump wire.

Check for voltage across pins 13 and 14 at controller.  If voltage present, check for voltage at wire at base of pump.  If no voltage-------------

Locate break in wire and repair.  On units equipped with plug in connectors, check integrity of wire connector and plug in.

 

A defective pump.

 

 

Check for voltage at the wire at base of pump.  If  there is voltage present and paddle is not turning------------------------

Replace pump gear-motor assembly at base of pump.

 

An improperly installed pumping unit.

There is voltage at wire at base of pump but pump does not turn--------------------------------

Remove pumping unit and run pump.  If pump turns reinstall pumping unit making sure cam is correctly engaged.

 


 

Pump is turning but no output.

There is air in the pumping chamber.

Connect grease gun to reservoir fill point and start filling pump.  If grease takes time to start filling reservoir, air was in pump cavity----------

 

Check reservoir over-flow tube if pump has been overfilled.  If plugged, may cause a vacuum and hold grease in reservoir----

 

The pumping Unit is cavitating

Fill pump reservoir

 

 

 

 

 

Remove reservoir lid and clean overflow tube.

 

 

Remove pumping unit and prime by hand or remove line from pumping unit and run pump until a bubble free flow of grease appears.

 

The reservoir is empty.

Check reservoir level------------

 

In cold temperatures check to see if grease is suspended in top of reservoir-------------------

Fill pump reservoir.

 

Clean out reservoir and fill with cold temperature grease or grease of lower NLGI rating.

 

The pumping unit internal check valve is not working.

Check pumping unit internal check valve by Installing 0 – 10,000 psi gauge on output of pumping unit. Turn on the pump, the pressure should reach approximately 4,000 psi at pressure relief if not----------

 

Replace pumping unit or add external check valve.

The rotation of the pump is incorrect.

Pump is rotating clockwise-----

Reverse wires at pump controller or power supply.

 

All lubrication points are dry.

See Note:

Pump is not working.

Check the pump operation------

See:  Pump does not work.

 

Pump off-time interval is to long.

Pump is operating fine but to little grease is present at lube points------------------------------

 

Shorten off-time interval.

Pump on-time interval is to short.

Shortening off-time interval would over lubricate system---

Lengthen on-time interval.

 

A blockage is in the system.

Check for grease at pressure relief-------------------------------

Refer to leakage at pressure relief.

 

The pump is operating, there is no grease at the pressure relief and all points are still dry.

Remove line at primary block inlet and attach 0-10,000 psi pressure gauge.  Operate pump, if pressure does not reach 4,000 psi or relief pressure---------------------------

 

If pumping unit check valve is good check for leak in primary line---------------------------------

Check pumping unit internal check valve.

Check on-time interval.

 

 

 

Repair leak.

 

Note:

If lubrication points have been dry for an extended period, purge system from the by-pass zerk fitting located on top of primary block or from top of each secondary block until sufficient grease appears at points.

 

 

 

 

 

Points are dry in one area.

The line from the primary distribution block to the secondary distribution block is leaking or broken.

 

Remove secondary feed line and cycle pump.  If there is no grease present--------------------

Repair or replace line.

A fitting is leaking at a block inlet.

Check fittings for leakage------

 

Repair or replace fitting.

 

Single point is dry.

A line is broken.

Check for leakage along line---

Repair or replace line.

 

There is leakage at a fitting.

Look at fitting--------------------

Tighten or replace fitting.

 

A point is not receiving enough grease.

Check integrity of line, if point is still to dry----------------------

Contact Beka-Max representative for help.

 

Pump rotates slowly.

There is high pressure in the system.

Check pressure relief valve for grease.  If no grease present, loosen each secondary block inlet fitting one at a time.  If pressure relieves at a fitting, check individual points for restriction-------------------------

Free up restriction at point. 

 

 

 

System is operating at extremely cold temperatures.

Check grease to see if hard-----

Clean out reservoir and fill with low temperature grease or grease of lower NLGI rating.

 

Grease coming out of pressure relief.

There is excessive pressure in the system.

Place pressure gauge in-line with pump output line.  Locate area causing high pressure------

 

Repair area causing high pressure.

Progressive distribution system has a blockage.

If there is grease coming out of the pressure relief.  Start at the distribution block farthest from the primary block.  Loosen the inlet fitting and see if there is pressure.  If there is no pressure there is no problem in that block assembly.  Work your way back to the primary block until you locate the block with pressure at the inlet fitting.  If the block has pressure, re-tighten the inlet fitting and re-pressurize the system.  Loosen each line coming from the block.  If a line has pressure when loosened the blockage is at the end of that line.  If there is no pressure at any of the lines then the blockage is internal.

 

If the blockage is at the end of a distribution line, free up inlet to bearing.

 

If blockage is internal in the distribution block, identify and replace block segment with seized piston.

 

See:  Trouble shooting

A series progressive distribution block.

 

 

 

 

 

 

 

Contamination in system.

If distribution blocks are sticking repeatedly contamination may be present in system--------------------------

Clean distribution system or replace affected lines and block assemblies.

Contact your Beka-Max representative for more options.

 

Bearing point is blocked.

Check for high pressure in system using previous step-----

Clear blockage in point.

 

Weak pressure relief valve spring.

Place a 0-10,000 psi gauge at pumping unit outlet.  If  the pressure relief relieves at less then 4,000 psi--------------------

 

 

 

Replace pressure relief valve.

 

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