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Assembly instructions Lubrication pump P653M following machinery directive 2006/42/EC for multi-line lubrication systems LINCOLN LINCOLN LINCOLN LINCOLN LINCOLN LINCOLN LINCOLN 951-171-063-EN Version 01 14/04/2020...
EC Declaration of incorporation EC Declaration of incorporation acc. to machinery directive 2006/42/EC The manufacturer, SKF Lubrication Systems Germany GmbH, Walldorf Facilities, Heinrich-Hertz-Str. 2-8, DE - 69190 Walldorf, hereby declares that the partly completed machinery Designation: Electrically driven pump to supply lubricant during intermittent operation within a centralized lubrication system...
Annex to the declaration of incorporation following 2006/42/EC, annex II, no 1 B Description of the essential health and safety requirements according to 2006/42/EC, Annex I, which have been applied and complied with. Any basic health and safety requirements not listed are not relevant to this product. Number Basic safety and health requirements Applicable...
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Description of the essential health and safety requirements according to 2006/42/EC, Annex I, which have been applied and complied with. Any basic health and safety requirements not listed are not relevant to this product. Number Basic safety and health requirements Applicable Complied with 1.5.8...
○ Intent or negligence Warranty Berlin Facilities The instructions do not contain any informa- ○ use of non-original SKF spare parts Motzener Straße 35/37 tion on the warranty. This can be found in ○ Faulty planning or layout of the central- 12277 Berlin our general terms and conditions.
Table of contents Table of contents EC Declaration of incorporation acc. to machinery directive 2006/42/EC ...2 Annex to the declaration of incorporation following 2006/42/EC ....3 Legal notice ....................5 Explanation of symbols, signs and abbreviations ........9 Safety instructions ..............11 1.20 Cleaning ....................17 General safety instructions ..............11 1.21...
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Table of contents 4.7.1 Visualization of a low-level indication ..........33 Installing the pump elements ..............49 4.7.2 Remaining run time of pump in case of a low-level indication ..33 Mount pressure control valve ..............50 Tightening torques ................34 Lubrication line connection ..............51 4.8.1 Pumps with plastic reservoir ...............34 6.10...
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Table of contents Maintenance ................63 Electrical connections ..............71 15.1 Cable colours following IEC 60757 .............71 Troubleshooting ................64 15.2 Legend of the connection diagrams ...........71 15.3 Connection of signal line to reservoir lid ..........72 Repairs ..................66 15.4 Recommended contact protection measure for 12.1 Replace pump element and pressure control valve ......66...
Explanation of symbols, signs and abbreviations Explanation of symbols, signs and abbreviations The following abbreviations may be used within these instructions. Symbols within safety notes mark the kind and source of the hazard. General warning Dangerous electrical voltage Risk of falling Hot surfaces Unintentional intake Crushing hazard...
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Explanation of symbols, signs and abbreviations Fig. 1 Abbreviations and conversion factors regarding °C degrees Celsius °F degrees Fahrenheit approx. approximately Kelvin ounce i.e. that is Newton fl. oz. fluid ounce poss. possibly hour inch if appl. if applicable second pounds per square inch incl.
1. Safety instructions 1. Safety instructions 1.1 General safety instructions 1.2 General behaviour when handling the product ○ The owner must ensure that safety infor- ○ The product may be used only in aware- ○ Responsibilities for different activities mation has been read by any persons en- trusted with works on the product or by ness of the potential dangers, in proper must be clearly defined and observed.
1. Safety instructions 1.3 Intended use ○ to supply, transport, or store hazardous 1.5 Modifications of the product substances and mixtures in accordance Supply of lubricants within a centralized lu- Unauthorized conversions or modifica- with annex I part 2-5 of the CLP regula- brication system following the specifications, tions may result in unforeseeable impacts tion (EG 1272/2008) respectively GHS...
1. Safety instructions 1.6 Prohibition of certain activities 1.10 Other applicable documents Reference on Low Voltage Directive 2014/35/EU Due to potential sources of faults that may In addition to these instructions, the fol- not be visible or due to legal regulations The protective regulations of Low Voltage lowing documents must be observed by the the following activities may be carried out...
1. Safety instructions 1.12 Notes related to the type identifica- 1.11 Markings on the product tion plate SKF Lubrication Systems Germany GmbH Model: P653M-xxxxx-xxx-xx-xxxxx The type identification plate states important P. No.: 645-xxxxx-x characteristics such as type designation, or- S. No.:...
1. Safety instructions 1.14 Briefing of external technicians 1.13 Persons authorized to operate the 1.16 Operation pump The following must be observed during com- Prior to commencing the activities, external missioning and operation: technicians must be informed by the opera- 1.13.1 Operator ○...
1. Safety instructions 1.18 Transport, installation, maintenance, ○ Ensure through suitable measures that ○ Carry out electrical connections only ac- malfunctions, repair, shutdown, movable or detached parts are immobi- cording to the information in the valid disposal lized during the work and that no limbs wiring diagram and taking the relevant ○...
1. Safety instructions 1.19 Initial commissioning / daily start-up 1.20 Cleaning ○ Risk of fire and explosion when using ○ All components used must be designed Ensure that: inflammable cleaning agents Only use ○ All safety devices are completely available according to the maximum operating non-flammable cleaning agents suitable pressure and the maximum respectively...
1. Safety instructions 1.21 Residual risks Residual risk Possible in life cycle Prevention/ remedy Personal injury/ material damage due to Keep unauthorized persons away. No people may remain under suspended loads. Lift A B C G H K falling of raised parts parts with adequate lifting devices.
2.3 Material compatibility 2.2 Selection of lubricants Lubricants are used specifically for certain SKF considers lubricants to be an element Lubricants must generally be compatible application purposes. In order to fulfil their of system design. A suitable lubricant is se-...
When handling lubricants the tems (e.g. "bleeding"). relevant safety data sheets and hazard designations, if any, on Please contact SKF. if you have further ques- the packaging have to be ob- tions regarding lubricants. served. You may request an overview of the lubri- cants tested by SKF.
3. Overview, functional description 3. Overview, functional description Fig. 2 Overview, functional description of pumps with plastic reservoir and follower plate 3.1 Pumps with plastic reservoir Types of connections 1 Reservoir The lubricant is stored in the reservoir. Depend- Square plug ing on the pump version there are different types of reservoirs and reservoir sizes.
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3. Overview, functional description Fig. 3 Overview, functional description of pumps with plastic reservoir without follower plate 2 Pump housing The pump housing accommodates the motor, the electrical connections, the filler fitting and the pump elements. Types of connections 3 Pump elements Square plug The pump can be equipped with up to 3 pump elements.
3. Overview, functional description Fig. 4 Overview, functional description of pumps with 30 L sheet steel reservoir 3.2 Pumps with sheet steel reservoir 1 Reservoir The lubricant is stored in the reservoir. De- Types of connections pending on the pump version there are differ- ent types of reservoirs.
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3. Overview, functional description Fig. 5 Overview, functional description of pumps with 30 L sheet steel reservoir 15 Blind plug The blind plug serves for the manufacturer’s purposes exclusively and must not be un- screwed by the operator. Types of connections 4 Filling connection Square plug Serves to fill the pump.
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4. Technical data Fig. 6 Overview, functional description of pumps with 100 L sheet steel reservoir 1 Reservoir The lubricant is stored in the reservoir. De- pending on the pump version there are differ- Types of connections ent types of reservoirs. Square plug 1.2 Reservoir venting device It provides air for the reservoir while the pump...
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4. Technical data Fig. 7 Overview, functional description of pumps with 100 L sheet steel reservoir 15 Blind plug The blind plug serves for the manufacturer’s purposes exclusively and must not be un- screwed by the operator. 4 Filling connection Serves to fill the pump.
* The existing filling options depend on the actual pump configuration. Suitable track conditioners have to be agreed upon SKF prior to using them. The minimum admissible ambient temperature assumes that the lubricant used can be pumped. The maximum admissible ambient temperature de- pends on the load and is mainly determined by the runtime and the operating pressure.
4. Technical data 4.2 Electrical data 4.3 Hydraulic connection diagram V DC pump V AC pump Rated voltage 24 V DC ± 10 % 110 - 240 V AC (± 10 %) Frequency 50-60 Hz (± 5 %) | 1-phase Recommended back-up fuse 3.0 A (slow-blow) 6.0 A (slow-blow) | 110 - 260 V...
4. Technical data 4.4 Nominal output volumes The stated nominal outputs per stroke and pump element refer to NLGI 2 lubrication greases at an ambient temperature of + 20 °C [68 °F] and a back pressure of 100 bar [1450 psi] on the pump element. Deviating operating conditions or deviating pump configuration result in a changed motor speed and thus in a change of the output per time unit.
4. Technical data 4.4.2 Output diagrams of typical NLGI 2 lubricants Low temperature lubrication grease High temperature lubrication grease °C °C 86 104 122 °F 86 104 122 °F The output diagrams represent the average value of the different high- respectively low-temperature lubrication greases. Calculation of the output using the example of a high-temperature lubrication grease Nominal speed of the pump motor per minute x nominal output of pump element 7 per stroke x efficiency in percent at an assumed ambient temperature of -10 °C [14 °F] = 20 rpm x 0.22 cc (0.0134) x 80 % = 3.5 cc/min [0.214 cu.in./min.].
4. Technical data 4.5 Functioning principle of the intermittent low-level indication The intermittent low-level indication operates free of contact. Its main components are the following: ○ firmly positioned magnetic switch (I) inside of the reservoir bottom ○ flexible guide plate (II) connected to the stirring paddle with a magnet (III) and a control cam (IV) If the reservoir is filled with a lubrication grease suitable for the intermittent low-level indication and the pump is operating, then the guide plate (II) is de- flected by the resistance of the lubrication grease.
4. Technical data 4.6 Limits of use of the intermittent low-level indication The following lubricant consistencies have to be complied with in order to ensure the correct functioning of the intermittent low-level indication. Above the stated range of temperature a correct functioning of the intermittent low-level indication cannot be ensured. The inferior temperature ranges require the suitability of the lubricant for the respective temperature range.
4. Technical data 4.7 Processing of the low-level signals in case of external controller and monitoring of the pump To avoid early low-level indication (e.g. caused by air inclusions or wave formation in the lubricant) in case of external controller or monitoring the following conditions have to be fulfilled by programming the external controller accordingly.
4. Technical data 4.8 Tightening torques 4.8.1 Pumps with plastic reservoir [ft.lb.] A Install the pump 18 ± 1.0 13.3 ± 0.74 B Pump element in pump housing 40 ± 2.0 29.5 ± 1.5 LINCOLN C Cap screw in valve body 35 ±...
4. Technical data 4.8.2 Pumps with 30 L sheet steel reservoir ft.lb. Install the pump 20 ± 2.0 14.8 ± 1.5 Pump element in pump housing 40 ± 2.0 29.5 ± 1.5 Cap screw in valve body 35 ± 2.0 25.8 ±...
4. Technical data 4.8.3 Pumps with 100 L sheet steel reservoir ft.lb. Install the pump 40 ± 5.0 29.50 ± 3.7 Pump element in pump housing 40 ± 2.0 29.50 ± 1.5 LINCOLN Cap screw in valve body 35 ± 2.0 25.8 ±...
4. Technical data 4.9 Type identification code The type identification code facilitates selection/ identification of important features of the product. For the type identification code of the respective prod- uct, see the type identification plate on the pump. P 6 5 3 M 8 X L F - 3 Z 7 - 2 4 - 1 A 7.
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4. Technical data P 6 5 3 M 8 X L F - 3 Z 7 - 2 4 - 1 A 7. 1 6 P 6 5 3 M - U - 2 0 X L B O - 3 Z 7 - 2 4 - 1 A 7. 1 6 Example P 6 5 3 M - 2 0 X L B 0 - 1 K 7 - A C - 2 A 1.
5.3 Storage 5.4 Storage temperature range ○ In case of parts not filled with lubricant After receipt of the shipment, check the SKF products are subject to the following shipment for damage and completeness storage conditions: the admissible storage temperature according to the shipping documents.
5. Delivery, returns, and storage 5.5 Storage conditions for parts filled 5.5.3 Storage period exceeding 18 Metering device with lubricant months • Remove all connection lines and closure To avoid dysfunctions consult the manufac- The conditions mentioned in the follow- screws, if any turer before commissioning.
6. Installation 6. Installation 6.2 Transport of the pumps 6.3 Place of installation 6.1 General information In filled condition, the pumps stated in these Protect the product against humidity, dust Only qualified technical personnel may install instructions may be transported vertically and vibrations and install it in an easily ac- the products described in these Instructions.
6. Installation 6.4 Mechanical connection 6.4.1 Installation bores 6.5 Minimum assembly dimensions Pumps with 10-, 15- or 20-litre plastic reservoir Ensure sufficient space for maintenance NOTICE 4 hexagon screws M8 (8.8) work or for attachment of further compo- 4 hexagon nuts M8 (8.8) nents to build a centralized lubrication sys- Risk of damage to the superior...
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6. Installation Fig. 8 Minimum installation dimensions 4 L [1.06 gal.] and 8 L [2.11 gal.] Litres plastic reservoir Pumps with follower plate Pumps with stirring paddle 4 Litres 8 Litres 4 Litres 8 Litres [1.06 gal.] [2.11 gal.] [1.06 gal.] [2.11 gal.] V DC V AC...
6. Installation Fig. 12 Electrical connection 6.6 Electrical connection Types of connections WARNING Square plug Electric shock Make sure to disconnect the product from the power supply before carrying out any works on electrical components. Carry out the electrical connection accor- Bayonet plug ding to the connection type of the pump, 7/7 poles...
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6. Installation Fig. 13 Electrical connection of the low-level indication for pumps with follower plate The electrical connection of the low-level indication (5.3) of pumps with follower plate is made according to the pump’s connection type. See chapter Connection of the signal line to the reservoir lid. In case of connection type 1A5.
6. Installation 6.7 Installing the pump elements Fig. 14 Installing the pump element To carry out the assembly proceed as fol- lows: If the pump is operated with 2 pump elements only, these have to be installed at posi- tions A and B. When using one pump element only, any in- stallation position is possible.
6. Installation Fig. 15 Mount pressure control valve 6.8 Mount pressure control valve Protect each pump element by means of a pressure control valve suitable for the planned maximum admissible operating pressure of the centralized lubrication system. To carry out the assembly proceed as fol- lows: •...
6. Installation 6.9 Lubrication line connection ○ The lubricant flow should not be impeded Observe the following installation instruc- CAUTION tions for safe and smooth operation. by the installation of sharp elbows, angle valves, gaskets protruding to the inside, ○ Use clean components and filled lubrica- Risk of falling or cross-section changes (big to small).
6. Installation 6.10 Filling with lubricant Fig. 16 Filling via the reservoir lid • Fill the reservoir from the top up to the MAX marking. Make sure to fill in Only adequate lubricant with- the lubricant without air inclusions, if out contaminations may be possible filled into the pump.
6. Installation 6.10.2 Filling via filler fitting Fig. 17 Filling via filler fitting • Connect filling connection of filler pump with filler fitting (4) • Switch on filler pump and fill reservoir until shortly below the MAX marking • Switch filler pump off and remove it from filler fitting (4) of pump LINCOLN 951-171-063...
6. Installation Fig. 18 Filling via filler fitting 6.10.3 Priming of pumps with follower plate In case of pumps without grease fill- ing, before commissioning the space below the follower plate must be filled with grease. Any further fillings take place only via the filler fitting (4) or the optional filling connection on the pump CAUTION...
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6. Installation Fig. 19 Filling via filler fitting • Lightly oil the reservoir inside and the sealing lip of the follower plate • Slightly tilt the follower plate (6) in the reservoir so that the side opposite of the filler fitting (4) is at the highest point.
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6. Installation Fig. 20 Filling via filler fitting • Reinstall the spring (6.1) and the con- tact rod (6.2). • Close the reservoir lid (1.1) clockwise • Fill the pump via the filler fitting up to the MAX marking. 951-171-063 - 56 - Version 01...
6. Installation 6.10.4 Filling of the pumps with Fig. 21 Filling via filling connection 30-litre sheet steel reservoir • Unscrew protective cap from filling connection (20) anticlockwise. • Connect filling connection of filler pump with filler fitting (20). • Switch on filler pump and fill reservoir. •...
6. Installation 6.10.5 Installation of the reservoir Fig. 22 Installation of the reservoir venting device venting device The loosely enclosed reservoir vent- ing device must not be installed until the pump has reached its final in- stallation position and is vertical. NOTICE LINCOLN Possible damage to the pump...
6. Installation 6.10.6 Filling of pump with 100-litre Fig. 23 Filling via filling connection sheet steel reservoir • Unscrew protective cap from filling connection (4) anticlockwise. max. • Connect filling connection of filler pump with filler fitting (4). • Switch on filler pump and fill reservoir. LINCOLN •...
7. Initial start-up 7. Initial start-up In order to warrant safety and function, a person assigned by the operator must carry out the following inspections. Immediately eliminate detected deficiencies. Deficiencies may be remedied by an authorized and qualified specialist only. Fig.
8. Operation 8. Operation SKF products operate automatically to the greatest possible extent. Basically, activities during standard opera- tion are limited to the control of the filling level of pumps without low-level indication and the timely refilling of lubricant. 8.1 Refill lubricant...
• Thorough cleaning of all outer surfaces uct will be required. Thoroughly remove residues with a damp cloth To do so, contact the SKF Customer Service. of cleaning agents from the Make sure to keep the reservoir product and rinse off with clear closed during the cleaning pro- water.
10. Maintenance Maintenance Regular and appropriate maintenance is a prerequisite to detect and clear faults in time. The specific time lines have to be determined, veri- fied at regular intervals and adapted, if necessary, by the operator based on the operating conditions. If needed, copy the table for regular maintenance activities.
11. Troubleshooting Troubleshooting Fig. 26 Fault table 1 Fault Possible cause Remedy Pump does not run Power supply to pump interrupted Check whether one of the indicated faults is present and rem- edy it in the frame of responsibilities. - Superior machine is switched off - Connection cable of pump is loose or defective Faults outside of your own responsibility have to be reported to your superior to initiate further measures.
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11. Troubleshooting Fig. 27 Fault table 2 Fault Possible cause Remedy Blockade, fault within the centralized lubrication system Defective check valve Defective pressure relief valve Suction bore of pump element is clogged Check whether one of the indicated faults is present and rem- edy it in the frame of responsibilities.
12. Repairs Repairs 12.1 Replace pump element and pressure Fig. 28 Replace pump element WARNING control valve Risk of injury The characteristics of the new Before carrying out any repair work, pump element must correspond take at least the following safety to the characteristics of the pump measures: element to be replaced.
13. Shutdown and disposal Shutdown and disposal 13.1 Temporary shutdown 13.3 Disposal Countries outside the European Union Temporarily shut the system down by: Countries within the European Union The disposal has to be done according to the ○ Switching off the superior machine Disposal should be avoided or minimized valid national regulations and laws of the wherever possible.
14. Spare parts Spare parts The spare parts assemblies may be used exclusively for replacement of identical defective parts. Modifications with spare parts on existing products are not allowed. Exceptions to this are the pump elements and the optional filling connection. 14.1 Pressure relief valves Fig.
14. Spare parts 14.4 Connection sockets and cable Fig. 32 Qty. Part number Designation Connection cable 10 m [33 ft.] with bayonet socket (7/7 poles) 664-34428-3 Connection cable 20 m [66 ft.] with bayonet socket (7/7 poles) 664-34741-9 14.5 Pump elements Fig.
14. Spare parts 14.7 Plastic reservoir Fig. 35 Designation Qty. Part number 4 l XLF 545-33752-1 LINCOLN LINCOLN 4 l XLB 545-33758-1 LINCOLN LINCOLN 8 l XLF 545-33753-1 8 l XLBO 545-33759-1 15 l XLF 545-33756-1 15 l XLBO 545-33754-1 XLBO 20 l XLF 545-33757-1...
15. Connection diagrams Electrical connections 15.1 Cable colours following IEC 60757 Abbreviation Colour Abbreviation Colour Abbreviation Colour Abbreviation Colour black green white pink brown yellow orange turquoise blue violet ----- ----- The assignment of the following electrical connection diagrams is done according to the respective referenced type identification code characteris- tics.
15. Connection diagrams 15.3 Connection of signal line to reservoir lid Fig. 36 Connection diagram of the signal line Connection diagram (lubrication grease) Connection diagram (lubrication grease) Follower plate and contact rod Magnetic switch Depiction of unactuated condition Maximum switching capacity 60 VA Maximum switching capacity 60 VA...
15. Connection diagrams 15.4 Recommended contact protection measure for switching inductive loads Fig. 37 Recommended contact protection measure for switching inductive loads For protection of the relay contacts the following contact protection measure should be carried out by the operator. V AC V DC 1 Magnetic switch...
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