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Summary of Contents for SKF ZPU 01
- Page 1 Assembly Instructions Lubricant feed pump ZPU 01 and ZPU 02 Created on: 14.12.2023 Document no.: 951-171-016-EN Version: Read these instructions before installation or start- up of the product and keep them readily available for 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. Designation:...
- 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: Table 1 Appendix to Declaration of Incorporation Piston pumps with reservoir, with/without external motor, without control unit Types: P205, P208, P212, P215, P230, ZPUxx, JM, FF, FB, FK, RA, TA, TB No.:...
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Page 4: Masthead
We conduct detailed training in order to enable maximum safety and efficiency. We recommend taking advantage Berlin Plant of this training. For further information, contact your Motzener Strasse 35/37 authorized SKF dealer or the manufacturer. 12277 Berlin Germany Tel. +49 (0)30 72002-0 Fax +49 (0)30 72002-111... -
Page 5: Table Of Contents
13.3 Disposal ................38 4.4 Tightening torques ............. 21 14 Spare parts ................. 39 4.5 Pump type identification code ZPU 01…02 ....22 4.5.1 Basic parameters and reservoir design ..22 14.1 Motors 380 - 480 VAC ............. 39 14.2 Motors 380 - 480 VAC with gearbox ......39 5 Delivery, returns, storage ............ - Page 6 14.17 Check valve for pump designs F and V, complete ......................43 14.18 Ultrasonic sensor ............43 15 Accessories................. 44 15.1 Button-head lubricating nipple (optional fill connection).................. 44 15.2 Fill connection ZPU 01/02 ..........44 16 Appendix ..................45 16.1 China RoHS Table ............45...
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Page 7: Safety Alerts, Visual Presentation, And Layout
1. Instruction steps: These indicate a chronological Safety alerts, visual sequence of instruction steps. The numbers of the steps are in bold and are followed by a period. If a new presentation, and layout activity follows, the numbering starts again at “1.” –... -
Page 8: Safety Instructions
• Safety-related protective and safety equipment must Unauthorized modifications and changes are therefore not be removed, modified or affected otherwise in its prohibited. Only original SKF spare parts and SKF function and is to be checked at regular intervals for accessories may be used. -
Page 9: Persons Authorized To Use The Product
1.8 Prohibition of certain activities 1.5 Persons authorized to use the • Replacement of or modifications to the pistons of the product pump elements • Repairs or modifications to the drive. Operator A person who is qualified by training, knowledge and 1.9 Painting plastic components and experience to carry out the functions and activities related to normal operation. -
Page 10: Note On The Type Plate
1.13 Note on UKCA marking 1.11 Note on the type plate The UKCA conformity marking confirms the The type plate provides important data such as the type product’s conformity with the applicable designation, order number, and sometimes regulatory legal provisions of Great Britain. characteristics. -
Page 11: First Start-Up, Daily Start-Up
Avoid mixing up or incorrectly assembling disassembled parts. Label parts. Clean any dirty parts. 1.18 First start-up, daily start-up Ensure that: • All safety devices are fully present and functional • All connections are properly connected • All parts are correctly installed •... -
Page 12: Residual Risks
1.19 Residual risks Table 3 Residual risks Residual risk Possible in lifecycle Avoidance / Remedy Personal injury / property damage A B C G H K • Unauthorized persons must be kept away. due to falling of hoisted parts Nobody is allowed to be present below hoisted parts. -
Page 13: Lubricants
Solid lubricants may only be used after prior consultation supplier of the lubricant. If you have no or little with SKF. When solid lubricants are used in lubrication experience in selecting lubricants for lubrication systems, systems, the following rules generally apply: please contact us. -
Page 14: Overview, Functional Description
3 Pump housing (optional) 4 Gearbox ZPU 01 / ZPU 02 pumps of the “E” design are mainly used for progressive lubrication systems with one or two Pumps of the type ZPU 01/ ZPU 02 are comprised lubrication circuits. -
Page 15: Design "F
The “F” design includes a bridge to merge the lubricant flow, a filter block, a pressure gauge, and a pressure limiting valve. ZPU 01 / ZPU 02 pumps of the F design are mainly used for dual-line systems with one lubrication circuit. 3.2.4 Fill level monitoring (XYBU) -
Page 16: Technical Data
4 Technical data 4.1 Pump ZPU 01 … 02 Table 4 Technical data of the pump Parameter ZPU 01 ZPU 02 Number of pump elements Delivery rate • With transmission ratio 1:490 (M490): 160 cm 320 cm • With transmission ratio 1:100 (M100):... -
Page 17: Drive Motors
4.2 Drive motors 4.2.1 Motors 380 – 480 V AC Table 5 Technical data Parameter For gearboxes M100, M490 For gearbox M049 Item number 245-13913-1 245-13914-1 Manufacturer, model See the name plate on the motor or ask us Operating mode Voltage 230 / 400 265 / 460... -
Page 18: Motors 500 V Ac
4.2.3 Motors 500 V AC Table 7 Technical data Parameter For gearboxes M100, M490 For gearbox M049 Item number 245-13919-1 245-13920-1 Manufacturer, model See the name plate on the motor or ask us Operating mode Voltage 290 / 500 290 / 500 Circuit Frequency f [Hz]... -
Page 19: Ultrasonic Sensor 664-853Xx-X
4.3 Ultrasonic sensor 664-853xx-x Table 9 Technical data Parameter Value Blind zone 0-65 mm Sensing range 600 mm Ultrasonic frequency Approx. 400 kHz Sonic frequency 3.7 Hz Resolution 0.18 mm Accuracy ± 1 % Reproducibility ± 15 % Sensing range in centimeters The dark gray areas (A) indicate the range in which the standard reflector (a tube) is reliably detected. - Page 20 Table 10 Electrical connection Cable colors in accordance with IEC 60757 Brown (BN) Blue (BU) Black (BK) White (WH) D3 / Com Gray (GY) Table 11 Display of the circuit states Parameter Switching points Display of the LEDs D1 (up D2 (up to 10/21) (from 10/21...
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Page 21: Switching Points Of Ultrasonic Sensor For Reservoir Design Xybu
Table 13 4.3.1 Switching points of ultrasonic sensor All pump designs for reservoir design XYBU Component Tightening torque Fig. 8 <Content > Plug screw for housing 30 ±3 22.1 ±2.2 Button-head lubricating nipple 20 ±3 14.8 ±2.2 Fill connection 30 ±3 22.1 ±2.2 Table 14 Pump design E... -
Page 22: Pump Type Identification Code Zpu 01
4.5 Pump type identification code ZPU 01…02 4.5.1 Basic parameters and reservoir design ZPU 0 1 – M 1 0 0 – 10 XYBU – F – 380- 440- Type designation: ZPU Centralized lubrication pump Number of pump elements: 1 pump element... -
Page 23: Delivery, Returns, Storage
5 Delivery, returns, storage 5.5 Storage conditions for products 5.1 Delivery filled with lubricant After receipt of the shipment, it must be inspected for any shipping damage and for completeness according to the For products filled with lubricant, the permitted storage shipping documents. -
Page 24: Assembly
“Technical data” chapter. Observe the following points for internal transportation of the pump: • SKF recommends that the customer use a height- adjustable pallet jack or a forklift for transport to the installation or storage location. • During transportation, use at least two ratchet straps to secure the pump against the tipping over. -
Page 25: Mechanical Connection
6.3 Mechanical connection 6.3.1 Minimum mounting dimensions Fig. 10 Minimum mounting dimensions To ensure sufficient space for maintenance work or clearance for possible disassembly of the product, clearance of at least 100 mm [3.9 in.] should be provided in every direction in addition to the dimensions specified. Table 17 Minimum mounting dimensions in mm [in.] Pump design... -
Page 26: Assembly Holes
6.3.2 Assembly holes 6.4 Electrical connection < NOTICE < WARNING Possible damage to the main machine and the pump Electric shock The assembly holes should be created only on non- Work on electrical components may be load-bearing parts of the main machine. Do not performed only by qualified electricians. -
Page 27: Filling With Lubricant
8. Switch the pump back on. 6.5 Filling with lubricant 6.7 Filling via the fill connection Fig. 13 (optional) Optional fill connections available: • Button-head lubricating nipple • Fill connection 6.7.1 Pumps with an ultrasonic sensor 1. If necessary, unscrew the protective cap on the fill connection in counterclockwise direction. -
Page 28: Connection Of The Lubrication Line
• Secure every lubricant line on the pump against 6.9 Connection of the lubrication line excessive pressure through the use of a suitable pressure limiting valve (only in the case of pumps < without an internal pressure limiting valve). CAUTION •... -
Page 29: 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 18 Checklist: Inspections before first start-up Inspections to be performed... -
Page 30: Operation
8 Operation see the system documentation for the centralized SKF products operate largely automatically. lubrication system. The activities required during normal operation are limited primarily to inspection of the fill level, timely refilling of lubricant, and cleaning the exterior of the 8.2 Top up lubricant... -
Page 31: Maintenance
9 Maintenance adjust them where necessary. If necessary, copy the table Careful and regular maintenance is required in order to for regular maintenance activities. detect and remedy possible faults in time. The operator must always determine the specific intervals according to the operating conditions, review them regularly, and Table 20 Checklist: Maintenance activities... -
Page 32: Maintenance Of The Gearbox
To replace the bearing grease, proceed as follows: 9.1 Maintenance of the gearbox 1. Switch off the pump and secure it to prevent it being switched back on (lock it out). The gearboxes are largely maintenance-free and come 2. Access the bearing and remove the old grease from the filled with synthetic oil. -
Page 33: Cleaning/Replacing The Lubricant Filter (Pump Design F)
9.3 Cleaning/replacing the lubricant filter (pump design F) Fig. 14 Cleaning/replacing the lubricant filter Clean the lubricant filter: 1. Remove the plug screw (1). 2. Remove and clean the filter insert (3). If heavily clogged or damaged, replace it completely. 3. -
Page 34: Cleaning
10 Cleaning < 10.1 Basics WARNING Risk of fatal electric shock Cleaning should be carried out in accordance with the operator's own company rules, and cleaning agents and devices and the personal protective equipment to be Cleaning work may only be performed on used should likewise be selected in accordance with products that have been de-energized first. -
Page 35: Faults, Causes, And Remedies
11 Faults, causes, and remedies Table 21 Fault table Fault Possible cause Remedy Pump does not run • Power supply to pump interrupted • Check whether one of the specified faults – Main machine is switched off exists, and remedy it according to –... -
Page 36: Repairs
12 Repairs < 12.1.2 Pump design "E" WARNING Risk of injury Fig. 16 At a minimum, the following safety measures must be taken before any repairs: • Unauthorized persons must be kept away • Mark and secure the work area •... -
Page 37: Pump Designs F And V
12.1.3 Pump designs F and V 12.2 Replace pressure regulating valve. Fig. 17 12.2.1 Pump design "V" Fig. 18 Replacing the pressure limiting valve – design “V” Installing the pump elements of designs F and V 1 Bridge 3 Pressure gauge 2 Pressure limiting valve 1. -
Page 38: 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 39: 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 Motors 380 - 480 VAC Designation Pcs. Item number Figure Motors for gearbox M100/M 490 | 0.18 kW / 0.21 kW 245-13913-1 Motors for gearbox M049 | 0.25 kW / 0.29 kW 245-13914-1... -
Page 40: Gearboxes
14.5 Gearboxes Designation Pcs. Item number Figure Transmission ratio i = 100:1 246-14145-1 Transmission ratio i = 490:1 246-14146-1 Transmission ratio i = 049:1 246-14145-2 14.6 Packing ring, motor – gearbox Designation Pcs. Item number Figure Packing ring Ø 60 x 90 x 0.5 306-19415-1 14.7 Packing ring, gearbox –... -
Page 41: Pump Element For Pump Design E
14.8 Pump element for pump design E Designation Pcs. Item number Figure Pump element, complete 500-30018-3 14.9 Plug screw for pump design E Designation Pcs. Item number Figure Plug screw for pump element 303-17431-1 14.10 Pressure limiting valve for pump design E Designation Pcs. -
Page 42: Bridge For Pump Design F2 (Zpu02) Complete With Two Pump Elements
14.12 Bridge for pump design F2 (ZPU02) complete with two pump elements Designation Pcs. Item number Figure Bridge version F2 complete with two 350 bar pump 600-26788-1 elements Bridge version F2 complete with two 400 bar pump 600-77913-1 elements Comprising: 1 Bridge with filter block and pressure gauge 2 Valve, complete 3 Pump cylinder, complete... -
Page 43: Filter For Pump Design F
14.15 Filter for pump design F Designation Pcs. Item number Figure Packing ring Usit Ø 34.3 x 43 x 2 220-12238-3 Filter, coarse (410 µm mesh size) 428-21544-1 Filter, fine (270 µm mesh size) 428-21545-1 14.16 Pressure gauge for pump designs F and V Designation Pcs. -
Page 44: Accessories
15 Accessories 15.1 Button-head lubricating nipple (optional fill connection) Designation Pcs. Item number Figure Button-head lubricating nipple ST AG (G3/8) 251-14040-3 15.2 Fill connection ZPU 01/02 Designation Pcs. Item number Figure Fill connection (preassembled) ZPU 01/02 (G3/8) 561-32455-1... -
Page 45: Appendix
16 Appendix 16.1 China RoHS Table Table 22... - Page 46 Notes / Notizen / Apuntes...
- Page 47 Notes / Notizen / Apuntes...
- Page 48 ® SKF and Lincoln are registered trademarks of the SKF Group. ™ eLube is a trademark of the SKF Group. © SKF Group 2024 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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