SKF LINCOLN ZPU 01 Version E User manual

951-171-016-EN
Version 03
2018/11/30
EN
Installation instructions
following machinery directive 2006/42/EC
Lubrication pump
ZPU 01/ ZPU 02
Version E Version V Version F

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951-171-016
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Jürgen Kreutzkämper
Manager R&D Germany
SKF Lubrication Business Unit
EC Declaration of incorporation following machinery directive 2006/42/EC, annex II, part 1 B
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 lubrication pump to supply lubricants
Type: ZPU 01 / ZPU 02
Part number: 661-XXXXX-X
Year of construction: See type identification plate
complies with the following basic safety and health requirements of the EC machinery directive 2006/42/EC at the time when first being launched in the
market.
1.1.2, 1.1.3, 1.3.2, 1.3.4, 1.5.1,·1.5.6, 1.5.8, 1.5.9, 1.6.1, 1.7.1, 1.7.3, 1.7.4
The special technical documents were prepared following Annex VII part B of this directive. Upon justifiable request, these special technical documents can be
forwarded electronically to the respective national authorities. The person empowered to assemble the technical documentation on behalf of the manufacturer
is the head of standardization. See manufacturer's address.
Furthermore, the following directives and harmonized standards were applied in the respective applicable areas:
2011/65/EU RoHS II
2014/30/EU Electromagnetic compatibility | Industry
2006/28/EC Electromagnetic compatibility | Automotive
Standard Edition Standard Edition Standard Edition Standard Edition
DIN EN ISO 12100 2011 DIN EN 60947-5-1 2010 DIN EN 61000-6-2 2006 DIN EN 61000-6-4 2011
DIN EN ISO 809 2012 DIN EN 61131-2 2008 Amendment 2011 DIN EN 60947-5-1 2010
DIN EN 60204-1 2007 Amendment 2009 DIN EN 61000-6-3 2011
Amendment 2010 DIN EN 60034-1 2011 Amendment 2012
DIN EN ISO 50581 2013 DIN EN 61000-6-1 2007
The partly completed machinery must not be put into service until the final machinery into which it is to be incorporated has been declared in conformity with
the previsions of machinery directive 2006/42/EC and any other applicable directives.
Walldorf, 02/02/2016
EC Declaration of incorporation
Stefan Schürmann
Manager R&D Hockenheim/Walldorf
SKF Lubrication Business Unit

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Legal disclosure
Training courses
In order to provide a maximum of safety and
economic viability, SKF carries out detailed
training courses. It is recommended that the
training courses are attended. For more in-
formation please contact the respective SKF
Service address.
Copyright
© Copyright SKF.
All rights reserved.
Warranty
The instructions do not contain any informa-
tion on the warranty. This can be found in
our general terms and conditions.
Disclaimer
The manufacturer shall not be held respon-
sible for damages caused by:
○non appropriate use,
faulty assembly, operation, setting, main-
tenance, repair or accidents
○improper or late response to
malfunctions
○unauthorized modifications of the
product
○intent or negligence
○the use of non-original
SKF spare parts
Liability for loss or damage resulting from
the use of our products is limited to the
maximum purchase price. Liability for con-
sequential damages of whatever kind is
excluded.
Legal disclosure
Manufacturer
SKF Lubrication Systems Germany GmbH
Manufacturer's facilities
Headquarters
Walldorf Facilities
Heinrich-Hertz-Str. 2-8
69190 Walldorf
Deutschland
Phone: [phone]
Fax: [phone]
Berlin Facilities
Motzener Straße 35/37
12277 Berlin
Germany
Phone [phone]
Fax [phone]
www.skf.com/lubrication
Hockenheim Facilities
2. Industriestraße 4
68766 Hockenheim
Germany
Phone [phone]
Fax [phone]
E-mail: [e-mail]
www.skf.com/lubrication

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951-171-016
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EN Table of contents
Table of contents
Legal disclosure...........................................................................................3
Explanation of symbols and signs ...............................................................6
1. Safety instructions.........................................................................8
1.1 General safety instructions....................................................................8
1.2 General behaviour when handling the product...................................8
1.3 Intended use............................................................................................ 9
1.4 Foreseeable misuse................................................................................9
1.5 Painting of plastic parts..........................................................................9
1.6 Modifications of the product................................................................10
1.7 Prohibition of certain activities............................................................10
1.8 Inspections prior to delivery ................................................................10
1.9 Other applicable documents................................................................10
1.10 Markings on the product......................................................................11
1.11 Notes related to the type identification plate.....................................11
1.12 Notes related to the CE marking .........................................................11
1.13 Persons authorized to operate the pump ..........................................12
1.13.1 Operator.................................................................................................12
1.13.2 Specialist in mechanics ........................................................................12
1.13.3 Specialist in electrics ............................................................................12
1.14 Briefing of external technicians...........................................................12
1.15 Provision of personal protective equipment......................................12
1.16 Operation...............................................................................................13
1.17 Emergency stopping of the pump station..........................................13
1.18 Transport, installation, maintenance, malfunctions, repair,
shutdown, disposal...............................................................................13
1.19 Initial commissioning / daily start-up.................................................14
1.20 Cleaning .................................................................................................15
1.21 Residual risks ........................................................................................16
2. Lubricants................................................................................... 17
2.1 General information .............................................................................17
2.2 Selection of lubricants..........................................................................17
2.3 Material compatibility...........................................................................18
2.4 Ageing of lubricants..............................................................................18
3. Overview, functional description ................................................ 19
4. Technical data ............................................................................. 23
4.1 General technical data..........................................................................23
4.2 Motors 380 - 480 V AC ........................................................................24
4.3 Motors 380 - 480 V AC with gear ......................................................25
4.4 Motors 500 V AC....................................................................................27
4.5 Motors 500 V AC with gear ..................................................................28
4.6 Ultrasonic Sensor 664-853xx-x ........................................................30
4.7 Tightening torques ...............................................................................31
4.8 Type identification code........................................................................32
5. Delivery, returns, and storage .................................................... 33
5.1 Delivery..................................................................................................33
5.2 Returns .................................................................................................33
5.3 Storage...................................................................................................33
6. Assembly..................................................................................... 34
6.1 General information .............................................................................34
6.2 Place of installation...............................................................................34
6.3 Mechanical connection.........................................................................35
6.3.1 Minimum assembly dimensions .........................................................35
6.3.2 Installation bores ..................................................................................36

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Table of contents
6.4 Electrical connection ............................................................................37
6.5 Connection of the lubrication line .......................................................38
6.5.1 Filling via the reservoir lid ....................................................................39
7. Initial start-up ............................................................................ 40
7.1 Inspections prior to initial start-up.....................................................40
7.2 Inspections during initial start-up ......................................................40
8. Operation.................................................................................... 41
8.1 Refill lubricant .......................................................................................41
9. Cleaning...................................................................................... 42
9.1 Cleaning agents.....................................................................................42
9.2 Exterior cleaning...................................................................................42
9.3 Interior cleaning....................................................................................42
10. Maintenance ............................................................................... 43
10.1 Maintenance of gear unit.....................................................................44
10.1.1 Required oil quality ...............................................................................44
10.2 Motor maintenance ..............................................................................44
10.2.1 Inspection of the bearings ...................................................................44
10.2.2 Required grease quality .......................................................................44
10.2.3 Replacement of the bearing grease....................................................44
11. Troubleshooting.......................................................................... 45
12. Repairs........................................................................................ 46
12.1 Replace the pump element..................................................................46
12.1.1 Pump version E .....................................................................................47
12.1.2 Pump versions F and V.........................................................................48
13. Shutdown and disposal............................................................... 49
13.1 Temporary shutdown ...........................................................................49
13.2 Final shutdown and disassembly ........................................................49
13.3 Disposal..................................................................................................49
14. Spare parts................................................................................. 50
14.1 Motors 380 - 480 V AC ........................................................................50
14.2 Motors 380 - 480 V AC with gear .......................................................50
14.3 Motors 500 V AC....................................................................................51
14.4 Motors 500 V AC with gear ..................................................................51
14.5 Check valve assy. for pump versions F and V .....................................51
14.6 Pump element for pump version E.....................................................52
14.7 Pressure control valve for pump version E ........................................52
14.8 Gear........................................................................................................52
14.9 Bridge assy. for version F with one pump element...........................53
14.10 Closure screw for pump version E ......................................................53
14.11 Ultrasonic sensor..................................................................................53
14.12 Bridge assy. for version F with two pump elements .........................54
14.13 Bridge assy. for version V with one pump element...........................54
14.14 Bridge assy. for version V with two pump elements .........................55
14.15 Sealing ring............................................................................................55
14.16 Parts for strainer for version F ............................................................56
14.17 Pressure gauge for pump versions V and F .......................................56
14.18 Sealing ring............................................................................................56

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EN Explanation of symbols, signs and abbreviations
Explanation of symbols and signs
General warning Dangerous electrical voltage Risk of falling Hot surfaces
Unintentional intake Crushing hazard Pressure injection Suspended load
Electrostatically sensitive
components
Wear personal protective
equipment (goggles)
Wear personal protective
equipment (face shield)
Wear personal protective
equipment (gloves)
Wear personal protective
equipment (protective clothes)
Wear personal protective
equipment (safety shoes) Release the product. General notes Keep unauthorized persons away.
Disposal, recycling
Disposal of waste electrical and
electronic equipment
Warning level Consequence Probability Symbol Meaning
DANGER Death, serious
injury imminent lChronological guidelines
WARNING Serious injury possible ¡Lists
CAUTION Minor
injury possible üIndicates the prerequisites that have to be fulfilled for the activities described in the following
ATTENTION Property damage possible

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Explanation of symbols, signs and abbreviations
Abbreviations and conversion factors
re. regarding °C degrees Celsius °F degrees Fahrenheit
approx. approximately K Kelvin Oz. Ounce
i.e. that is N Newton fl. oz. fluid ounce
etc. et cetera h hour in. inch
poss. possibly s second psi pounds per square inch
if appl. if applicable d day sq.in. square inch
a.a.r. as a rule Nm Newtonmeter cu. in. cubic inch
incl. including ml millilitre mph miles per hour
min. minimum ml/d millilitre per day rpm revolutions per minute
max. maximum cc cubic centimetre gal. gallon
min minute mm millimetre lb. pound
etc. et cetera l litre hp horse power
e.g. for example dB (A) sound pressure level kp kilopound
kW kilowatt > greater than fpsec feet per second
U Voltage < less than Conversion factors
R resistance ± plus/minus length 1 mm = 0.03937 in.
I current Ø diametre Area 1 cm² = 0.155 sq.in
V volt kg kilogram Volume 1 ml = 0.0352 fl.oz.
Wwatt rh relative humidity 1 l = 2.11416 pints (US)
AC alternating current ≈approximately Mass 1 kg = 2.205 lbs
DC direct current = equal to 1 g = 0.03527 oz.
A ampere % per cent Density 1 kg/cc = 8.3454 lb./gal(US)
Ah Ampere hour ‰ per mille 1 kg/cc = 0.03613 lb./cu.in.
Hz Frequency [Hertz] ≥greater than Force 1 N = 0.10197 kp
nc normally closed contact ≤less than Pressure 1 bar = 14.5 psi
no normally open contact mm2square millimetre Temperature °C = (°F-32) x 5/9
rpm-1 revolutions per minute output 1 kW = 1.34109 hp
acceleration 1 m/s² = 3.28084 ft./s²
speed 1 m/s = 3.28084 fpsec.
1 m/s = 2.23694 mph

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1. Safety instructions
1.1 General safety instructions
○The owner must ensure that safety infor-
mation has been read by any persons en-
trusted with works on the product or by
those persons who supervise or instruct
the before-mentioned group of persons.
In addition, the owner must also ensure
that the relevant personnel are fully fa-
miliar with and have understood the con-
tents of the Instructions. It is prohibited to
commission or operate the product prior
to reading the Instructions.
○These Instructions must be kept for fur-
ther use.
○The described products were manufac-
tured according to the state of the art.
Risks may, however, arise from a usage
not according to the intended purpose
and may result in harm to persons or
damage to material assets.
○Any malfunctions which may affect safety
must be remedied immediately. In addi-
tion to these Instructions, general statu-
tory regulations for accident prevention
and environmental protection must be
observed.
1.2 General behaviour when handling the
product
○The product may only be used in aware-
ness of the potential dangers, in proper
technical condition, and according to the
information in these instructions.
○Familiarize yourself with the functions
and operation of the product. The speci-
fied assembly and operating steps and
their sequences must be observed.
○Any unclear points regarding proper
condition or correct assembly/ operation
must be clarified. Operation is prohibited
until issues have been clarified.
○Keep unauthorized persons away.
○Wear personal protective equipment
always.
○Precautionary operational measures and
instructions for the respective work must
be observed.
○Responsibilities for different activities
must be clearly defined and observed.
Uncertainty seriously endangers safety.
○Safety-related protective and emergency
devices must not be removed, modified
or affected otherwise in their function
and are to be checked at regular intervals
for completeness and function.
○If protective and safety equipment has to
be dismantled, it must be reassembled
immediately after finishing the work, and
then be checked for correct function.
○Remedy occurring faults in the frame of
responsibilities. Immediately inform your
superior in the case of faults beyond your
competence.
○Never use parts of the centralized lu-
brication system or of the machine as
standing or climbing aids.

1
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1. Safety instructions
1.3 Intended use
Supply of lubricants within a centralized lu-
brication system following the specifications,
technical data and limits stated in these
Instructions:
Usage is allowed exclusively for professional
users in the frame of commercial and eco-
nomic activities.
1.4 Foreseeable misuse
Any usage differing from the one stated in
these Instructions is strictly prohibited, par-
ticularly a usage:
○outside the indicated temperature range
○of non-specified means of operation
○without adequate pressure relief valve
○in continuous operation
○in areas with aggressive or corrosive ma-
terials (e.g. high ozone pollution)
○in areas with harmful radiation (e. g. ion-
ising radiation)
○in an explosion protection zone
○to supply, transport, or store hazardous
substances and mixtures in accordance
with annex I part 2-5 of the CLP regula-
tion (EC 1272/2008) and marked with
GHS 01 to GHS 06 and GHS 08 hazard
pictograms.
○Use to feed, forward, or store gases,
liquefied gases, dissolved gases, va-
pours, or fluids whose vapour pressure
exceeds normal atmospheric pressure
(1013 mbar) by more than 0.5 bar at
the maximum permissible operating
temperature.
1.5 Painting of plastic parts
Painting of any plastic parts or seals of the
described products is expressly prohibited.
Remove or completely tape parts concerned
before painting the superior machine.

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EN 1. Safety instructions
1.6 
Unauthorized conversions or modifica-
tions may result in unforeseeable impacts
on safety. Therefore, any unauthorized
conversions or modifications are expressly
prohibited.
1.7 Prohibition of certain activities
Due to potential sources of faults that may
not be visible or due to legal regulations
the following activities may be carried out
by manufacturer specialists or authorized
persons only:
○Repairs, changes to the drive
○Replacement of or changes to the pistons
of the pump elements
1.8 Inspections prior to delivery
The following inspections were carried out
prior to delivery:
○Safety and functional tests
○In case of electrically driven products:
electrical inspections following DIN EN
60204-1:2007 / VDE 0113-1:2007.
1.9 Other applicable documents
In addition to these instructions, the fol-
lowing documents must be observed by the
respective target group:
○Operational instructions and approval
rules
○Safety data sheet of the lubricant used
Where appropriate:
○Project planning documents
○Instructions of the suppliers of purchased
parts
○Any documents of other components
required to set up the centralized lubrica-
tion system
○Other relevant documents for the inte-
gration of the product into the machine
or system