SKF P203 Assembly Instructions Manual
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SKF P203 Assembly Instructions Manual

Lubricant feed pump
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Assembly Instructions
Lubricant feed pump P203
for progressive systems
DC designs with control circuit board H
Created on:
12.12.2022
Document no.:
951-171-028-EN
Version:
03
Read these instructions before
installation or start-up of the
product and keep them readily
available for later consultation!

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  • Page 1 Assembly Instructions Lubricant feed pump P203 for progressive systems DC designs with control circuit board H Created on: 12.12.2022 Document no.: 951-171-028-EN Version: Read these instructions before installation or start-up of the product and keep them readily available for later consultation!
  • Page 2 The special technical documents were prepared following Annex VII part B. Upon justifiable request, these special technical documents can be forwarded electronically to the respective national authorities. The authorized company for the compilation of the technical documentation is SKF (U.K.) Limited, 2 Canada Close, Banbury, Oxfordshire, OX16 2RT, GBR.
  • Page 3 Appendix to Declaration of Incorporation in accordance with 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 fulfilled. Any essential health and safety requirements not listed here are not relevant to this product. Table 1 Appendix to Declaration of Incorporation Valid for P2x3 lubrication pumps...

  • Page 4: Masthead

    Training www.skf.com/lubrication We conduct detailed training in order to enable maximum safety and efficiency. We recommend taking advantage of this Berlin Plant training. For further information, contact your authorized SKF Motzener Strasse 35/37 dealer or the manufacturer. 12277 Berlin Germany Tel.

  • Page 5: Table Of Contents

    4.7 Tightening torques ..............24 Table of contents 4.8 Type identification code............25 4.8.1 Basic parameters and reservoir version ....25 Masthead ....................4 4.8.2 Pump elements ............27 Table of contents .................. 5 4.8.3 Voltage supply and electrical connections ..... 28 Safety alerts, visual presentation, and layout .........
  • Page 6 15. Appendix ..................53 15.1 Connection diagrams ............53 15.1.1 Overview of cables and possible connections ..53 15.1.2 Terminal diagram P203 VDC, with control circuit board H and rectangular connector ........54 15.1.3 Terminal diagram P203 VDC, with control circuit board H and bayonet connector .........

  • Page 7: Safety Alerts, Visual Presentation, And Layout

    1. Instruction steps: These indicate a chronological sequence Safety alerts, visual of instruction steps. The numbers of the steps are in bold and are followed by a period. If a new activity follows, the presentation, and layout numbering starts again at “1.” –...

  • Page 8: Safety Instructions

    • Ensure proper connection of the protective conductor for modifications and changes are therefore prohibited. Only products with protection class I. Observe the specified original SKF spare parts and SKF accessories may be used. enclosure rating. • Any unclear points regarding proper condition or correct •...

  • Page 9: General Behaviour When Handling The Product

    1.3 General behaviour when handling the 1.5 Persons authorized to use the product product • Familiarize yourself with the functions and operation of the Operator product. The specified assembly and operating steps and their A person who is qualified by training, knowledge and experience sequences must be observed.

  • Page 10: Referenced Documents

    1.7 Referenced documents 1.10 Safety markings on the product In addition to this manual, the following documents must be observed by the respective target group: Fig. 1 • Company instructions and approval rules If applicable: • Safety data sheet of the lubricant used Risk of wrapping, pinching, crushing, or •...

  • Page 11: Note On The Type Plate

    1.11 Note on the type plate 1.14 Note on Pressure Equipment Directive The type plate provides important data such as the type designation, order number, and sometimes regulatory Due to its performance characteristics, the product does not characteristics. To avoid loss of this data in case the type plate reach the limit values defined in Article 4, Paragraph 1, becomes illegible, it should be entered in the manual.

  • Page 12: Note On Eac Marking

    1.19 Note on EAC marking 1.22 Assembly, maintenance, fault, repair The EAC conformity marking confirms the product’s conformity with the applicable legal Prior to the start of this work, all relevant persons must be provisions of the Eurasian customs union. notified of it.

  • Page 13: Residual Risks

    1.24 Residual risks Table 3 Residual risks Residual risk Possible in lifecycle Avoidance / Remedy Personal injury / property damage due A B C G H K • Unauthorized persons must be kept away. to falling of hoisted parts • Personnel are not permitted to stand under hoisted parts.

  • Page 14: Lubricants

    Solid lubricants may only be used after prior consultation with make the selection in consultation with the supplier of the SKF. When solid lubricants are used in lubrication systems, the lubricant. If you have no or little experience in selecting following rules generally apply: lubricants for lubrication systems, please contact us.

  • Page 15: Overview, Functional Description

    Used for filling the pump from below. Once the filler nipple is removed, corresponding accessories can be used to connect the external grease return from the pressure limiting valves to the pump elements through this port. P203 without a follower plate 1 Reservoir cover 5 Pump housing 2 Reservoir ventilation...

  • Page 16: Display And Control Elements

    4 Pushbutton for additional time lubrication Control circuit board H is used to control P203 lubrication pumps on vehicle trailers without permanent voltage supply. Activation of control circuit board H is effected by the first braking of the vehicle after it has been switched on.

  • Page 17: Electrical Connections

    The pause time starts again from the beginning when the Electrical connections of the P203 brake is actuated once again. This is to be taken into account with vehicle trailers which are moved only briefly...

  • Page 18: Hydraulic Connection Diagram

    3.4 Hydraulic connection diagram Fig. 8 Hydraulic connection diagram of the pump 1 Reservoir 4 Check valve 2 Pump 5 Pressure limiting valve 3 Filler nipple P Pressure line...

  • Page 19: Technical Data

    4. Technical data 4.1 General technical data Table 6 Technical data Parameter Values Operating pressure max. 350 bar [5076 psi] Pump elements Max. 3 Direction of rotation Clockwise Sound pressure level < 70 dB (A) Nominal speed 20 rpm Cyclic duration factor S3 25 ON time 120 min Ambient temperature -40 °C to +70 °C [-40 °F to +158 °F]...

  • Page 20: Electrical Data

    4.2 Electrical data Table 8 Electrical data Parameter Values 12 VDC pump 24 VDC pump Enclosure rating IP6K9K IP6K9K Protection classes • Rectangular connector SELV / PELV / FELV SELV / PELV / FELV • Bayonet connector SELV / PELV SELV / PELV Rated voltage ±10 % 12 VDC...

  • Page 21: Influencing Factors On The Delivery Rate

    4.3.1 Influencing factors on the delivery rate Table 10 Influencing factors on the delivery rate Influencing factors Increasing the delivery rate Reducing the delivery rate Ambient temperature > + 20 °C < + 20 °C Consistency class of the lubricating grease <...

  • Page 22: Reservoir Versions

    The differences between the reservoir versions may not be visible in the illustrations, as the differences lie in the internal structure (e.g. with and without low-level signal). (● = available reservoir sizes) Table 11 P203 reservoir versions XNFL [0.53] [1.06] [2.11] [2.9]...

  • Page 23: Usable Reservoir Volume

    4.5 Usable reservoir volume NOTE The usable reservoir volume in the reservoir design without follower plate is strongly dependent on the consistency (NLGI Grade) of the lubricant used and the ambient temperature. With high consistency and a low working temperature, more lubricant typically adheres to the inner surfaces of the reservoir and the pump, leaving less lubricant available for feeding.

  • Page 24: Lubricant Volume When An Empty Pump Is Filled For The First Time

    4.6 Lubricant volume when an empty pump is filled for the first time The following volumes of lubricant are required in order to fill a new empty pump up to the -MAX- mark on the reservoir. NOTE The difference between the lubricant volume required for initial filling and the nominal volume of the reservoir is due to the filling of the space in the pump housing up to the -MIN- mark on the reservoir.

  • Page 25: Type Identification Code

    4.8 Type identification code 4.8.1 Basic parameters and reservoir version P203 X X - LL X X XX - 123 - DC - 11 22 33 44 - H__ L SSSS Type series: P203 P203 pump for grease or oil with...
  • Page 26 P203 X X - LL X X XX - 123 - DC - 11 22 33 44 - H__ L SSSS Reservoir design: (Combination of the versions: see Table 15) Filling from above Flat reservoir Intermittent in the case of grease, float switch in the case of oil...

  • Page 27: Pump Elements

    4.8.2 Pump elements P203 X X - LL X X XX - 123 - DC - 11 22 33 44 - H__ L SSSS Pump elements: Position sequence: Right (Fig. 11/1), Center (Fig. 11/2) and Left (Fig. 11/3). For coding, see Table 16 Fig.

  • Page 28: Voltage Supply And Electrical Connections

    • The second digit in a two-number group defines the plug/socket included in the scope of supply with/without cable P203 X X - LL X X XX - 123 - DC - 11 22 33 44 - H__ L SSSS...

  • Page 29: Control, Lubricant, And Additional Specifications

    4.8.4 Control, lubricant, and additional specifications P203 X X - LL X X XX - 123 - DC - 11 22 33 44 - H__ L SSSS Control circuit boards (12 V / 24 V): H_ _ H control circuit board for trailer...

  • Page 30: Delivery, Returns, Storage

    5.5 Storage conditions for products filled 5. Delivery, returns, storage with lubricant 5.1 Delivery For products filled with lubricant, the permitted storage temperature range is: After receipt of the shipment, it must be inspected for any minimum + 5 °C [+41 °F] shipping damage and for completeness according to the maximum...

  • Page 31: Assembly

    6. Assembly 6.2 Transporting the pumps 6.1 General safety instructions CAUTION Injury or pump damage due to improper Observe the safety instructions and the technical data in this securing or handling when transporting to manual. Additionally, during assembly pay attention to the the installation location following: •...

  • Page 32: Mechanical Connection

    Fig. 13 Minimum mounting dimensions Table 18 P203 minimum mounting dimensions Reservoir Reservoir size Reservoir size Reservoir size version Approx.

  • Page 33: Assembly Holes

    The pumps are fastened at the three lower fastening points (Fig. 14/1) or (Fig. 14/2) and (Fig. 14/3) of the pump housing: C1 = 83 mm [3.27 in.] Electrical connections of the P203 C2 = 95 mm [3.74 in.] 1 Power supply (rectangular 2 Power supply (bayonet Fig.
  • Page 34 WARNING Electric shock Work on electrical components may be performed only by qualified electricians. At a minimum, the following safety measures must be taken before any work on electrical components is done: • Isolate, lock and tag out • Check to ensure the absence of voltage •...

  • Page 35: Setting The Delivery Rate On Pump Element R

    6.5 Setting the delivery rate on pump element R Fig. 16 Setting the delivery rate on pump element R 1 Spindle S Spindle setting dimension 2 Locknut V Delivery volume per stroke NOTE Be sure to observe the formula for temperature-dependent calculation of the delivery rate using the example of a high-temperature grease, in the section Delivery rate charts for typical NLGI 2 lubricants, 21.

  • Page 36: Installing The Pressure Limiting Valve

    6.6 Installing the pressure limiting valve Fig. 18 Each pump element must be secured with a pressure limiting valve that is suitable for the projected maximum approved operating pressure of the centralized lubrication system. NOTE For the 2L XNFL reservoir versions and for all 4L and 8L reservoirs, the adapter 226-14105-5 (see "Spare parts"...

  • Page 37: Connection Of The Lubrication Line

    6.7 Connection of the lubrication line 6.8 Filling with lubricant < 6.8.1 Filling via the reservoir cover CAUTION Risk of slipping < WARNING Exercise caution when handling lubricants. Crushing hazard Immediately remove and bind any leaked Crushing hazard on the rotating stirring paddle. lubricants.

  • Page 38: Filling Via Filler Nipple

    6.8.2 Filling via filler nipple 6.8.3 Filling via the optional fill connection Fig. 20 Fig. 21 Filling via the filler nipple 1. Connect the fill connection of the filling pump to the filler Filling via the optional fill connection nipple (Fig. 20/1). 2.

  • Page 39: Setting The Lubrication Time

    NOTE The newly set lubrication time does not take effect until you switch the power supply to the pump off and back on again. P203 with control circuit board H 6.9.1 Possible settings for lubrication time Table 20 Settings for lubrication time...

  • Page 40: First Start-Up

    7. First 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. 7.1 Inspections before first start-up Table 21 Checklist: Inspections before first start-up Inspections to be performed...

  • Page 41: Operation

    8. Operation SKF products operate automatically to the greatest possible extent. Basically, activities during standard operation are limited to: • Regular function checks • Checking the fill level on pumps without low-level signal • Timely refilling of lubricant • Cleaning the exterior if dirty 8.1 Top up lubricant...

  • Page 42: Maintenance And Repair

    9. Maintenance and repair Careful and regular maintenance is required in order to detect and remedy possible faults in time. The operator must always determine the specific intervals according to the operating conditions, review them regularly, and adjust them where necessary. If necessary, copy the table for regular maintenance activities.

  • Page 43: Cleaning

    10. Cleaning 10.1 Basics < Cleaning should be carried out in accordance with the operator's WARNING own company rules, and cleaning agents and devices and the Risk of fatal electric shock personal protective equipment to be used should likewise be selected in accordance with those rules.

  • Page 44: Faults, Causes, And Remedies

    11. Faults, causes, and remedies Table 24 Fault table Fault Possible cause Remedy Pump does not run • Power supply to pump interrupted. • Check whether one of the specified faults exists, – Main machine is switched off and remedy it according to responsibility –...

  • Page 45: Indication Of Operational And Fault States By The Leds On The Control Circuit Board

    11.1 Indication of operational and fault states by the LEDs on the control circuit board Certain operational and fault states are indicated by the LEDs on the control circuit boards. Fig. 23 LEDs on the control circuit board Table 25 Meaning of the LED displays Display Possible causes...

  • Page 46: Repairs

    12. Repairs NOTE < The characteristics of the new pump element must match WARNING the characteristics of the pump element to be replaced. Risk of injury At a minimum, the following safety measures Replace the pump element as instructed below: must be taken before any repairs: 1.

  • Page 47: Replacing The Control Circuit Board

    12.2 Replacing the control circuit board Fig. 25 Replacing the control circuit board 1 Screws (10×) for lower housing cover 4 Control circuit board 2 Housing cover 5 Groove on the dewatering hose 3 Plug on the control circuit board 6 Dewatering hose The scope and results of the inspection after replacement of the NOTE...

  • Page 48: Shutdown, Disposal

    13. Shutdown, disposal 13.1 Temporary shutdown Temporary shutdowns should be done by a course of action to be defined by the operator. 13.2 Permanent shutdown, disassembly Permanent shutdown and disassembly of the product must be planned properly by the operator and conducted in compliance with all applicable laws and regulations.

  • Page 49: Spare Parts

    14. Spare parts Spare parts may be used exclusively for replacement of identical defective parts. Modifications with spare parts on existing products are not allowed. 14.1 Housing cover, complete Designation Pcs. Item number Figure Housing cover, complete 544-32217-1 Housing cover, complete, for UL-certified pumps 544-60207-1 Delivery including dewatering hose and the appropriate number of screws for installation...

  • Page 50: Adapter D6 Ax 1/8Npt I C

    14.4 Adapter D6 AX 1/8NPT I C Designation Pcs. Item number Figure Adapter for pressure limiting valve 270864 | C3 304-19614-1 14.5 Adapter with lubricant nipple Designation Pcs. Item number Figure Adapter with lubricant nipple ST 1/4 NPTF incl. seal 519-33840-1 Adapter with lubricant nipple A2 AR 1/4 incl.

  • Page 51: Replacement Kit For Control Circuit Board

    2l XN A,B,C 544-31996-1 4l XNBO 544-31998-1 A,B,C 8l XNBO A,B,C 544-31999-1 Delivery includes: A = Lincoln/SKF logo, B = Rotation arrow stickers, C = O-ring NOTE Other transparent reservoirs on request. 14.10 Fixed paddle Designation Pcs. Item number Figure...

  • Page 52: Reservoir Cover

    14.11 Reservoir cover Designation Pcs. Item number Figure C) Reservoir cover 2 l [0.53 gal.] XNBO 544-85156-1 14.12 Screw cap Designation Pcs. Item number Figure Screw cap on the pump housing 544-32851-1 14.13 Connection sockets and cables Feature* Designation Pcs. Item number Figure Connection socket...

  • Page 53: Appendix

    15. Appendix 15.1 Connection diagrams NOTE • You can find the right terminal diagrams for each specific pump version by referring to the type identification code features applied on the terminal diagrams. Type identification code, Page 25 Table 26 Cable colors in accordance with IEC 60757 Abbreviation Color Abbreviation...

  • Page 54: Terminal Diagram P203 Vdc, With Control Circuit Board H And Rectangular Connector

    15.1.2 Terminal diagram P203 VDC, with control circuit board H and rectangular connector Fig. 26 Terminal diagram 1 of 2...

  • Page 55: Terminal Diagram P203 Vdc, With Control Circuit Board H And Bayonet Connector

    15.1.3 Terminal diagram P203 VDC, with control circuit board H and bayonet connector Fig. 27 Terminal diagram 2 of 2...

  • Page 56: China Rohs Table

    15.2 China RoHS Table Table 28...
  • Page 57 Notes / Notizen / Apuntes...
  • Page 58 ® SKF and Lincoln are registered trademarks of the SKF Group. ™ eLube is a trademark of the SKF Group. © SKF Group 2023 Reprint or reproduction of the contents of this information - even in part - is permitted only with SKF's prior written consent.

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