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Assembly Instructions Lubricant feed pump P203 for progressive systems DC designs with control circuit board V10-V23 Created on: 24.11.2023 Document no.: 951-171-023-EN Version: Read these instructions before installation or start- up of the product and keep them readily available for...
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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:...
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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...
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...
4.6.2 Remaining running time of the pump with a Table of contents low-level signal ..............24 4.7 Ultrasonic sensor ..............25 Masthead ..................... 4 4.7.1 Switching points with BIBO reservoir design 27 Table of contents ................5 4.8 Reservoir designs ............... 28 Safety alerts, visual presentation, and layout .......
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..........74 15.1.3 Overview of cables and possible connections ....................74 15.1.4 Terminal diagram 1/7 for P203 VDC with control circuit board V10-V23 ........76 15.1.5 Terminal diagram 2/7 for P203 VDC with control circuit board V10-V23 ........77 15.1.6 Terminal diagram 3/7 for P203 VDC with...
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.” –...
Do not touch cables or electrical Unauthorized modifications and changes are therefore components with wet or moist hands. prohibited. Only original SKF spare parts and SKF • Fuses must not be bridged. Always replace defective accessories may be used.
1.3 General behaviour when handling 1.5 Persons authorized to use the the product product • Familiarize yourself with the functions and operation of Operator the product. The specified assembly and operating A person who is qualified by training, knowledge and steps and their sequences must be observed.
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: Risk of dangerous electrical voltage •...
1.11 Note on the type plate 1.16 Note on ECE mark The type plate provides important data such as the type The ECE test mark (E1) confirms that an ECE designation, order number, and sometimes regulatory type approval (components requiring characteristics.
clearly visible. Observe the mounting position 1.21 Assembly, maintenance, fault, requirements. Drill required holes only on non-critical, non-load- repair bearing parts of the operator's infrastructure. Use existing Prior to the start of this work, all relevant persons must be holes where possible. Avoid chafe points. Immobilize any notified of it.
1.23 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 • Personnel are not permitted to stand under hoisted parts.
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.
3.2 Pumps with a follower plate 3.3 Display and control elements Fig. 4 Fig. 5 P203 with a follower plate 1 Contact rod 2 Follower plate or double- lip follower plate Display and control elements of the control circuit board...
3.4 Pumps with an ultrasonic sensor 3.5 Electrical connections Fig. 6 Fig. 7 Ultrasonic sensor on the P203 1 Ultrasonic sensor 3 LED indicators 2 M12 connector Ultrasonic sensor (BIBO reservoir) Used for monitoring the fill level in the reservoir. The...
3.6 Hydraulic connection diagrams Fig. 8 Pumps with follower plate and low-level signal Pump without follower plate and with low-level signal Pumps with follower plate, without low-level signal Pump without follower plate and without low-level signal Hydraulic connection diagrams 1 Reservoir 5 Pressure limiting valve* 2 Pump 6 Follower plate...
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]...
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 <...
4.4 Principle of operation of the Fig. 12 intermittent low-level signal Components of the intermittent low-level signal The intermittent low-level signal uses a contactless mechanism, comprised essentially of the following parts: • Stationary reed switch (Fig. 11 to 13/1) in the reservoir bottom •...
4.5 Operational limits of the intermittent empty signal For the correct functioning of the intermittent empty signal, the following lubricant consistencies must be maintained. The correct functioning of the intermittent empty signal is not guaranteed above the specified temperature range. The lower temperature ranges are contingent on the suitability of the respective lubricant for these temperatures.
– A minimum of 6 reed switch signals are required per 4.6 Processing of the low-level signals work cycle. • Work cycle ≥ 24 seconds ≤ 32 seconds: with external control and monitoring of – A minimum of 4 reed switch signals are required per the pump work cycle.
4.7 Ultrasonic sensor Table 11 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.
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Table 12 Electrical connection Cable colors in accordance with IEC 60757 Brown (BN) Blue (BU) Black (BK) White (WH) D3 / Com Gray (GY) Table 13 Display of the circuit states Parameter Switching points Display of the LEDs D1 (up D2 (up to 10/21) (from 10/21...
The differences between the reservoir designs may not be visible in the illustrations, as the differences lie in the internal structure (e.g. with and without low-level signal). Table 15 P203 reservoir designs Reservoir size in liters and [gal.] Figure Designation [0.53]...
4.9 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.
4.10 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.
4.12 Type identification code 4.12.1 Basic parameters and reservoir design P203 X X - LL X X XX - 123 - DC - 11 22 33 44 - V23 L SSSS Type series: P203 P203 pump for grease or oil with...
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P203 X X - LL X X XX - 123 - DC - 11 22 33 44 - V23 L SSSS Reservoir design: (For design combinations, see Table 22) Filling from above Filling from above, lockable cover Flat reservoir With standard follower plate...
4.12.2 Pump elements P203 X X - LL X X XX - 123 - DC - 11 22 33 44 - V23 L SSSS Pump elements Position sequence: Right (Fig. 17/1), Center (Fig. 17/2) and Left (Fig. 17/3). For coding, see Table 23 Fig.
• The first digit in a two-digit number indicates the plug/socket on the housing • The second digit in the two-digit number specifies the accompanying plug/socket with/without cable P203 X X - LL X X XX - 123 - DC - 11 22 33 44 - V23 L SSSS Power supply:...
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Table 24 Possible connection types: Housing position Left Right Bottom Bottom Description Coding and connection on the pump housing: No connection Rectangular connector - control circuit board/supply line, V10-V13 (pins 2 and 3 occupied) Rectangular connector - control circuit board/supply line, V10-V13 (pins 1 and 3 occupied) Rectangular connector - control circuit board/supply line, V20-V23...
4.12.4 Control, lubricant, and additional specifications P203 X X - LL X X XX - 123 - DC - 11 22 33 44 - V23 L SSSS Control circuit boards (12 V / 24 V): V10 to V13 or V20 to V23: depending...
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.
6 Assembly 6.1 General safety instructions 6.2 Transporting the pumps Observe the safety instructions and the technical data in CAUTION this manual. Additionally, during assembly pay attention Injury or pump damage due to improper to the following: securing or handling when transporting to •...
6.3.2 Assembly holes Fig. 21 NOTICE Damage to the main machine and the pump The assembly holes should be created only on non- load-bearing parts of the main machine. Do not fasten on two parts which move in opposite directions to one another (e.g., machine base and machine assembly).
6.3.3 Assembly holes for 15 l, 20 l, and 25 l Fig. 22 reservoirs NOTE The pump is fastened using 2 fastening points at the bottom of the pump housing and 1 fastening plate (XBD 15 l) or 2 fastening plates (XBD 20 l /XID 20 l and 25 l) in the pump's aluminum profile.
6.4 Electrical connection WARNING Electric shock Fig. 23 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 •...
6.5 Setting the delivery rate on pump element R Fig. 24 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 4.3.2.
6.6 Installing the pressure limiting Fig. 26 valve 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"...
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 lubricants.
6.8.2 Filling via filler nipple 6.8.3 Filling via the optional fill connection Fig. 28 Fig. 29 Filling via the optional fill connection Filling via the filler nipple 1. Switch on the pump and allow it to run during filling. 2. Unscrew the protective cap (Fig. 29/2) from the fill 1.
Fig. 31 6.8.4 Initial filling of an empty pump with follower plate NOTE For pumps without grease filling, the space underneath the follower plate must be filled with lubricant prior to first start-up. All additional filling is done exclusively via the filler nipple (Fig. 30/5) or the optional fill connection on the pump.
NOTE For initial filling of a pump delivered without lubricant, the pump is fitted with a bleed thread P203 with control circuit board V10-V23 (Fig. 33/1) and a “Read instructions” sticker (Fig. 33/2). The bleed thread ensures that the air...
6.9.1 Possible settings of the lubrication time and pause time for control circuit board V10- Table 28 Setting of the lubrication and pause times Position of the rotary switch (blue) Pause time in minutes* Pause time in hours* Position of the rotary switch (red) Lubrication time in seconds* Lubrication time in minutes *...
6.9.3 Modifying the lubrication time and pause time using jumpers Fig. 35 Location of the jumpers on the control circuit board 1 Jumpers for “time range” for rotary switches 2 Jumper for “bridge at terminal 15/30” NOTICE Damage to the main machine The jumper settings on the control circuit board should not be modified if possible.
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Table 30 Jumper settings Control Jumper, Fig. 35/2 Jumpers, Fig.35/1 Pause time Lubrication time circuit Bridge at Pause/lubrication 4 – 60 min. 1 – 15 h 8 – 120 s 2 – 30 min. board terminal 15 / 30 time range = jumper set = jumper not set...
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 31 Checklist: Inspections before first start-up Inspections to be performed...
8 Operation SKF products operate automatically to the greatest 8.3 Resetting an error message possible extent. Basically, activities during standard operation are limited Fig. 37 • Regular function checks • Checking the fill level on pumps without low-level signal • Timely refilling of lubricant •...
9 Maintenance 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. Table 33 Checklist: Maintenance activities Activity to be performed...
10 Cleaning < WARNING Risk of fatal electric shock Cleaning work may only be performed on products that have been de-energized first. When cleaning electrical components, be mindful of the IP enclosure rating. < WARNING Serious injury from contact with or inhalation of hazardous substances Wear personal protective equipment.
11 Faults, causes, and remedies Table 34 Fault table Fault Possible cause Remedy Pump does not run • Power supply to pump interrupted. • Check whether one of the specified faults exists, and remedy it according to – Main machine is switched off responsibility –...
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. 38 LEDs on the control circuit board Table 35 Meaning of the LED displays Display Possible causes...
12 Repairs < WARNING NOTE Risk of injury The characteristics of the new pump element must At a minimum, the following safety match the characteristics of the pump element to be measures must be taken before any repairs: replaced. • Unauthorized persons must be kept away •...
12.2 Replacing the control circuit board Fig. 40 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 NOTE Checks after replacing the control circuit board...
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.
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...
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.
14.8 Replacement kit for control circuit board Designation Pcs. Item number Figure Replacement kit for control circuit board V1x P203 544-60217-1 Replacement kit for control circuit board V2x P203 544-60218-1 Delivery including housing cover, dewatering hose, and the appropriate number of screws for installation 14.9 Reed switch...
A,B,C,F 544-32696-1 -MIN- Delivery includes: A = Lincoln/SKF logo, B = rotation arrow, C = O-ring, D = reservoir cover, E = pinch point warning sticker, F = reservoir cover non-detachable (screwed onto the reservoir) NOTE Other transparent reservoirs on request.
14.14 Connection sockets and cables Code* Designation Pcs. Item number Figure Connection socket with seal and screw 544-32850-1 Connection socket with seal and screw 544-33843-1 Connection cable 10 m (33 ft.) with connection 664-36078-7 socket Connection cable 10 m (33 ft.) ADR with 664-36862-1 connection socket Connection cable 10 m (33 ft.) with bayonet...
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. Table 36 Cable colors in accordance with IEC 60757 Abbreviation Color Abbreviation Color Abbreviation Color...
15.1.1 Connection diagram of the signal line on the reservoir cover NOTE The signal line can be connected using a PG9 screwed gland on the pump housing. The signal l ine can be connected usin g a PG9 s crewed gland on the pump housing. Fig.
Connection diagram of the signal line on the reservoir cover 15.1.2 Recommended contact protection for switching inductive loads Fig. 42 Contact protection 1 Contact of the low-level signal 3 Load 2 Interference suppression diode (free-wheeling diode) When switching inductive loads with direct voltage, the operator should provide the contact protection measure shown in Figure 42 to protect the contacts of the low-level signal.
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