SKF 799-000-3035 Series User manual

EN
Electrical  lling pump
for the re lling of pumps
in centralized lubrication systems
Original operating instructions
acc. to EC Dir. 2006/42/EC for machinery
Version 02

Page 2
EN
Notes
Masthead
The original operating instructions with associ-
ated operating instructions in accordance with
EC Machinery Directive 2006/42/EC are an in-
tegral part of the described product and must
be kept for future use.
These original operating instructions were
compiled in accordance with the established
standards and rules for technical documenta-
tion, VDI 4500 and EN 292.
© SKF Lubrication Systems Germany AG
This documentation is protected by copyright.
SKF Lubrication Systems Germany AG re-
serves all rights, including those to the photo-
mechanical reproduction, duplication, and dis-
tribution by means of special procedures
(e.g., data processing, data media, and data
networks) of this documentation in whole or in
part.
Subject to changes in contents and technical
information.
Service
If you have technical questions, please contact
the following addresses:
SKF Lubrication Systems Germany AG
Berlin Plant
Motzener Strasse 35/37
12277 Berlin
Germany
Tel. [phone]
Fax [phone]
www.skf.com/lubrication
Hockenheim Plant
2. Industriestrasse 4
68766 Hockenheim
Germany
Tel. [phone]
Fax [phone]
www.skf.com/lubrication

Page 3 EN
Operating instructions table of contents
Table of contents
Information concerning EC Declaration
of Conformity 4
Explanation of symbols and signs 5
1. Safety instructions 6
1.1 General information 6
1.2 Intended use 7
1.3 Authorized personnel 7
1.4 Electric shock hazard 8
1.5 System pressure hazard 8
1.7 Hydraulic pressure hazard 8
1.8 Explosion protection information 9
1.9 Pre-commissioning information 9
1.10 Replacing the grease reservoir 9
2. Lubricants 10
2.1 General information 10
2.2 Selection of lubricants 10
2.3 Approved lubricants 11
2.4 Lubricants and the environment 12
2.5 Lubricant hazards 12
3. Overview 13
4. Assembly 14
4.1 Assembly drawing 14
4.2 Setup and attachment 15
4.3 Electrical motor connection 16
4.4 Note on the rating plate 17
4.5 Dismantling and disposal 17
5. Transport, delivery, and storage 18
5.1 Lubrication units 18
5.2 Electronic and electrical devices 18
5.3 General notes 18
6. Design and function 19
6.1 Pump operation 19
7. Commissioning 20
7.1 General commissioning 20
7.2 Commissioning 21
7.3 Commissioning malfunctions 22
8. Shutdown 23
8.1 Temporary shutdown 23
8.2 Permanent shutdown 23
9. Faults, causes and remedies 24
Operational malfunctions 24
10. Maintenance 25
10.1 General information 26
10.2 Visual inspection 27
11. Technical data 28
12. Spare parts 29

Page 4
EN
The product,
electrical lling pump
series 799-000-3035
is hereby confirmed to comply with the essen-
tial protection requirements stipulated by the
following Directive(s) of the Council on the ap-
proximation of laws of the Member States:
Machinery Directive 2006/42/EC
Low Voltage Devices 2006/95/EC
Electromagnetic Compatibility 2004/108/EC
Notes:
(a) This declaration certifies compliance with
the aforementioned Directives, but does
not constitute a guarantee of
characteristics.
(b) The safety instructions in the documenta-
tion included with the product must be
observed.
Information concerning EC Declaration of Conformity
(c) The commissioning of the products here
certified is prohibited until such time as the
associated documentation has been read
and understood and all safety precautions
have been observed.
(d) The operation of the products at non-
standard supply voltage, as well as non-
adherence to the installation instructions,
can negatively impact the EMC characteris-
tics and electrical safety.
We further declare:
The aforementioned product may, with
reference to EC Directive 97/23/EC con-
cerning pressure equipment, only be used
in accordance with its intended use and in
conformity with the instructions provided
in the documentation. The following must
be observed in this regard:
The product is not designed or certified for use
with fluids from Group I (Hazardous Fluids), as
defined in Article 2, Par. 2 of Directive
RL 67/548/EEC, dated June 27, 1967.
The product is neither designed nor approved
for use in conjunction with gases, liquefied
gases, pressurized gases in solution, vapors
and such fluids whose vapor pressure exceeds
normal atmospheric pressure (1013 mbar) by
more than 0.5 bar at their maximum permis-
sible temperature.
When used in conformity with their intended
use, the products supplied by SKF Lubrication
Systems Germany AG do not reach the limit
values listed in Article 3, Para. 1, Clauses 1.1
to 1.3 and Para. 2 of Directive 97/23/EC. They
are therefore not subject to the requirements
of Annex 1 of the Directive. Consequently, they
do not bear a CE marking in respect of
Directive 97/23/EC. SKF Lubrication Systems
Germany AG classifies them according to
Article 3, Para. 3 of the Directive.
The Declaration of Conformity forms part of
the product documentation and is supplied to-
gether with the product.
Information concerning EC Declaration of Conformity

Page 5 EN
Informational symbolsIndicators used with safety instructions
and their meaning
Hazard symbols
Explanation of symbols and signs
You will  nd these symbols, which warn of
speci c dangers to persons, material assets, or
the environment, next to all safety instructions
in these operating instructions.
Please heed these instructions and proceed
with special care in such cases. Please forward
all safety instructions to other users.
General hazard
DIN 4844-2-W000
Electrical voltage/current
Hot surface
Indicator Use
Danger! Danger of bodily injury
Warning! Danger of damage to
property and the
environment
Note! Provides additional
information
Note
Prompts an action
Used for itemizing
Points out other facts, causes, or
consequences
Provides additional information
Instructions placed directly on the machines/
grease lubrication pump units, such as:
Arrow indicators
Labels for fl uid connections must be
followed and kept in a fully legible
condition.
You are responsible!
Please read the assembly and operating
instructions thoroughly and follow the safety
instructions.
Danger of being drawn into machinery
DIN 4844-2-W008
DIN 4844-2-W026
BGV 8A
Slipping hazard
DIN 4844-2-W028
Warning of potentially explosive
atmosphere
DIN 4844-2-W021
Explanation of symbols

Page 6
EN
The operator of the described prod-
uct must ensure that the operating
instructions are read and understood
by all persons responsible for assembly,
operation, maintenance, and repair of
the product. The operating instructions
must be kept readily available.
Note that the operating instructions
form part of the product and must
accompany the product if sold to a new
owner.
1. Safety instructions
The described product is manufactured in ac-
cordance with the generally accepted rules and
standards of industry practice and with occu-
pational safety and accident prevention regula-
tions. Risks may, however, arise from its usage
and may result in physical harm to persons or
damage to other material assets. Therefore the
product may only be used in proper technical
condition and in observance of the operating
instructions. In particular, any malfunctions
which may affect safety must be remedied
immediately.
Operating manual
Warning!
These operating instructions must be
read and properly understood by the
assembler and the responsible techni-
cal personnel/operator before assembly
and commissioning.
The safety instructions listed in Chapter 1,
"Safety instructions," of the assembly instruc-
tions also apply without restrictions to these
operating instructions.
1.1 General information
In addition to the operating instructions,
general statutory regulations and other
binding regulations for accident preven-
tion and for environmental protection
(recycling/disposal) must be observed
and applied.
Disclaimer of liability
SKF Lubrication Systems shall not be held
liable for damages:
Caused by contaminated or unsuitable
lubricants
Caused by the installation of non-original
SKF components or SKF spare parts
Caused by inappropriate usage
Resulting from improper assembly, con gu-
ration or  lling
Resulting from improper response to mal-
functions
Independent modi cation of
system components
Only media approved for these types of
pump units may be used. Unsuitable
media may result in pump unit failure and
potentially severe bodily injury and property
damage.

Page 7 EN
In addition to the operating instructions,
statutory regulations and other general
regulations for accident prevention
and environmental protection must be
observed and applied.
1.3 Authorized personnel
Only qualified technical personnel may install,
operate, maintain, and repair the products de-
scribed in the operating instructions. Qualified
technical personnel are persons who have
been trained, assigned and instructed by the
operator of the final product into which the de-
scribed product is incorporated. Such persons
are familiar with the relevant standards, rules,
accident prevention regulations, and assembly
conditions as a result of their training, experi-
ence, and instruction. They are authorized to
identify and perform necessary actions while
avoiding any risks which may arise. The
definition of qualified personnel and the prohi-
bition against employing non-qualified person-
nel are laid down in DIN VDE 0105 and
IEC 364.
1.2 Intended use
The filling pumps deliver greases up
to NLGI Grade 2.
Only media approved for these types of pump
units may be used. Unsuitable media may re-
sult in pump unit failure and potentially severe
bodily injury and property damage.
Operating manual

Page 8
EN
1.5 System pressure hazard
Lubrication systems are pressurized
during operation. Centralized lubrication
systems must therefore be depressur-
ized before starting assembly, main-
tenance or repair work, or any system
modi cations or system repairs.
1.6 Hoisting hazard
The  lling pump can be transported
using a crane. Never stand under the
load during transport. Ensure that
nobody is present below the load during
transport.
1.7 Hydraulic pressure hazard
The described product is pressurized
during operation. The product must
therefore be depressurized before
starting assembly, maintenance or re-
pair work, or any system modi cations
or system repairs.
Depending on the model design, the
product may be able to be operated
hydraulically.
1.4 Electric shock hazard
Significant bodily injury and property damage
may result from improperly connected
products.
Danger!
Work on products that have not been
de-energized may result in bodily injury.
Assembly, maintenance and repair work
may only be performed on products
that have been de-energized by
quali ed technical personnel. The
supply voltage must be switched off
before opening any of the product's
components.
Operating manual

Page 9 EN
1.8 Explosion protection information
Danger!
Only the pump models tested and
approved by SKF Lubrication Systems
Germany AG in accordance with ATEX
Directive 94/9/EC are permitted to be
used in areas with explosion protec-
tion. The relevant class of protection is
engraved on the pump's rating plate.
When  lling lubricant into the pump, make
sure the lubricant is clean. The reservoir
must be  lled in good time.
1.9 Pre-commissioning information
Commissioning is prohibited until these
operating instructions have been read
and understood.
Inspect the  lling pump for external
damage before each use. See Chapter
10.2.
1.10 Replacing the grease reservoir
When replacing the grease reservoir,
ensure that the palm grips are tight-
ened and have been secured against
loosening using the spring clips.
Operating manual

Page 10
EN
2. Lubricants
2.1 General information
All products from SKF Lubrication
Systems may be used only for their
intended purpose and in accordance
with the information in the product's
operating instructions.
Intended use is the use of the products for the
purpose of providing centralized lubrication/
lubrication of bearings and friction points using
lubricants within the physical usage limits
which can be found in the documentation for
the devices, e.g., operating instructions and the
product descriptions, e.g., technical drawings
and catalogs.
Particular attention is called to the fact that
hazardous materials of any kind, especially the
materials classified as hazardous by EC
Directive 67/548/EEC, Article 2, Para. 2, may
only be filled into SKF centralized lubrication
systems and components and delivered and/or
distributed with the same after consultation
with and written approval from SKF
Lubrication Systems Germany AG.
No products manufactured by SKF Lubrication
Systems are approved for use in conjunction
with gases, liquefied gases, pressurized gases
in solution, vapors, or such fluids whose vapor
pressure exceeds normal atmospheric pres-
sure (1013 mbar) by more than 0.5 bar at
their maximum permissible temperature.
Other media which are neither lubricants nor
hazardous substances may only be fed after
consultation with and written approval from
SKF Lubrication Systems .
SKF Lubrication Systems considers lubricants
to be a component of the system design which
must be factored into the selection of compo-
nents and the design of centralized lubrication
systems. The lubricating properties of the lu-
bricants are critically important in these
considerations.
2.2 Selection of lubricants
Observe the instructions from the
machine manufacturer regarding the
lubricants that are to be used.
Warning!
The amount of lubricant required at
a lubrication point is speci ed by the
bearing or machine manufacturer. It
must be ensured that the required
quantity of lubricant is provided to the
lubrication point. The lubrication point
may otherwise not receive adequate
lubrication, which can lead to damage
and failure of the bearing.
The selection of a lubricant suitable for the lu-
brication task is made by the machine/system
manufacturer and/or the operator of the ma-
chine/system in cooperation with the lubricant
supplier.
The bearings/friction points that require lubri-
cation, their expected load during operation,
and the expected ambient conditions are taken
into account during selection, with consider-
ation of economic and environmental aspects.
Operating manual

Page 11 EN
Where necessary, SKF Lubrication
Systems supports customers in the
selection of suitable components for
feeding the selected lubricant and in
the planning and design of a centralized
lubrication system.
Please contact SKF Lubrication Systems if you
have further questions regarding lubricants.
Lubricants can be tested in the company's lab-
oratory for their suitability for pumping in cen-
tralized lubrication systems (e.g., "bleeding").
You can request an overview of the lubricant
tests offered by SKF Lubrication Systems from
the company's service department.
2.3 Approved lubricants
Warning!
Only lubricants approved for the prod-
uct may be used. Unsuitable lubricants
can lead to failure of the product and
damage to property.
Warning!
Different lubricants must not be mixed,
as mixing may result in damage and
necessitate costly and complicated
cleaning of the product/lubrication sys-
tem. It is recommended that an indica-
tion of the lubricant in use be attached
to the lubricant reservoir in order to
prevent accidental mixing of lubricants.
The product described here can be operated
using lubricants that meet the specifications in
the technical data. Depending on the product
design, these lubricants may be oils, fluid
greases, or greases.
Oils and base oils may be mineral, synthetic
and/or rapidly biodegradable. Consistency
agents and additives may be added depending
on the operating conditions.
Note that in rare cases, there may be lubri-
cants whose properties are within permissible
limit values but whose other characteristics
render them unsuitable for use in centralized
lubrication systems. For example, synthetic lu-
bricants may be incompatible with elastomers.
Operating manual

Page 12
EN
2.5 Lubricant hazards
Danger!
Filling pumps must always be free of
leaks. Leaking lubricant is hazardous
due to the risk of slipping and injury.
Beware of any lubricant leaking out
during assembly, operation, mainte-
nance, and repair of centralized lubrica-
tion systems. Leaks must be sealed
without delay.
Lubricant leaking from centralized lubrication
systems is a serious hazard. Leaking lubricant
can create risks that may result in physical
harm to persons or damage to other material
assets.
Warning!
Follow the safety instructions on the
lubricant's safety data sheet.
Lubricants are a hazardous substance. The
safety instructions on the lubricant's safety
data sheet must be strictly followed. The safety
data sheet for a lubricant can be requested
from the lubricant manufacturer.
Operating manual
2.4 Lubricants and the environment
Warning!
Lubricants can contaminate soil and
bodies of water. Lubricants must be
properly used and disposed of. Observe
the local regulations and laws regarding
the disposal of lubricants.
It is important to note that lubricants are envi-
ronmentally hazardous, flammable substances
which require special precautionary measures
during transport, storage, and processing.
Consult the safety data sheet from the lubri-
cant manufacturer for information regarding
transport, storage, processing, and environ-
mental hazards of the lubricant that will be
used.
The safety data sheet for a lubricant can be re-
quested from the lubricant manufacturer.

Page 13 EN
3. Overview
Item Description
1. Gear pump unit
2 Remote control
3 Mains plug
4 Grease pail
5 Grease pail bottom with tie-rod
6 Handle
7 Suspension point
8 Pressure regulating valve
9 Vent
10 Cotter pin
Operating manual
Pump components
1
2
3
7
6
8
9
10
4
5

Page 14
EN
Ø265...272
Ø300
375...380
Ø345
Ø40
ca. 900
4. Assembly
4.1 Assembly drawing
General
If specifically requested, the gear pump, intake
tube and filling hose can be pre-filled with a
lubricating grease specified by the customer.
Operating manual
Gear pump
with grease pail cover
Filling hose
Grease follower plate
Tie-rod with palm grip
16 kg Mobil Oil pail
or
18 kg SKF pail
Intake tube
approx. 900
Grease pail bottom
Cotter pin

Page 15 EN
Operating manual
Item Description
1 Palm grip
2 Tie-rod
3 M10 hexagon nut
4 Metal bracket
5 Grease pail
6 Grease follower plate
7 Pump element
8 Cotter pin
4.2 Setup and attachment
• Unscrew palm grip (item 1) (4x) from tie-
rod (item 2).
• Remove lower hexagon nuts
(4xM10-WAF17) from tie-rod (item 2).
• Screw all tie-rods (item 2) with metal
brackets (item 4) into tapped holes on
bottom of pail.
• Center the lled grease pail (item 5).
• Align all four metal brackets (item 4) with
diameter of grease pail and tighten by xing
the hexagon nuts (WAF17) using a tool.
• Remove cover of grease pail and insert
grease follower plate (item 6) (lifting bracket
on top).
• Open intake hole on pump (item 7) by re-
moving adhesive tape/cap. Place the pump
with reservoir cover centered by the four
tie-rods and the hole in the grease follower
plate onto the grease pail.
• Screw all four palm grips removed in rst
step onto the tie-rods and tighten by hand.
• Secure each palm grip using the cotter pins
xed to the reservoir cover. Insert the cot-
ter pins (item 8) into the appropriate holes
in the tie-rods.
• The pump with grease pail may only be
transported by the handle. For crane
hooks, use the available suspension point.
Handle Suspension
point
Mounting direction
Lifting bracket
(top side)
Intake hole
6
1
2
5
7
8
4
3

Page 16
EN
Operating manual
4.3 Electrical motor connection
Connect the pump unit motor to the mains
plug according to the voltage specifications on
the motor rating plate. The pump is actuated
by pressing the button on the remote control.
The pump delivers lubricant as long as the
button is pressed. A circuit breaker on the mo-
tor's terminal box protects the motor against
overload.
4.3.1 Motor ratings
Motor output ....... 0.18 kW
Operating voltage ... 1 x 230 V; 50 Hz
(with running capacitor)
Motor speed........ 1400 rpm
Operating mode..... S1
Insulation class ..... - F
Protection class ..... IP 54
Circuit breaker
push-button for Remote control
Mains plug
for pump

Page 17 EN
Warning!
These operating instructions must be
read and properly understood by the
assembler and the responsible technical
personnel/operator before assembly.
Operating manual
4.4 Note on the rating plate
The rating plate on the pump unit provides
important data such as the order number,
barcode, operating voltage and serial number.
To avoid loss of this data in case the rating
plate becomes illegible, these characteristics
should be entered in the following table.
Enter key data from rating plate in the
following table.
Order number
Barcode
Power supply
Serial number
Warning!
The applicable national environmen-
tal regulations and statutes are to
be adhered to when dismantling and
disposing the pump units.
The product can also be returned to
SKF Lubrication Systems for disposal, in
which case the customer is responsible
for reimbursing the costs incurred.
4.5 Dismantling and disposal

Page 18
EN 5. Transport, delivery, and storage
5. Transport, delivery, and storage
Warning!
The product must not be tilted or
dropped.
SKF Lubrication Systems products are pack-
aged in accordance with standard commercial
practice according to the regulations of the re-
cipient's country and DIN ISO 9001. During
transport, safe handling must be ensured and
the product must be protected from mechani-
cal effects such as impacts. The transport
packaging must be marked "Do not drop!".
There are no restrictions for land, air or sea
transport.
After receipt of the shipment, the product(s)
must be inspected for damage and for com-
pleteness according to the shipping documents.
The packaging material must be kept until any
discrepancies are resolved.
SKF Lubrication Systems products are subject
to the following storage conditions:
5.1 Lubrication units
Ambient conditions: dry and dust-free
surroundings, storage in well ventilated
dry area
Storage time: max. 24 months
Permissible humidity: < 65%
Storage temperature: 10 - 40°C
Light: avoid direct sun or UV exposure
and shield nearby sources of heat
5.2 Electronic and electrical devices
Ambient conditions: dry and dust-free
surroundings, storage in well ventilated
dry area
Storage time: max. 24 months
Permissible humidity: < 65%
Storage temperature: 10 - 40°C
Light: avoid direct sun or UV exposure and
shield nearby sources of heat
5.3 General notes
The product(s) can be enveloped in plastic
film to provide low-dust storage
Protect against ground moisture by
storing on a shelf or wooden pallet
Bright-finished metallic surfaces, espe-
cially wearing parts and assembly surfac-
es, must be protected using long-term
anti-corrosive agents before storage
At approx. 6-month intervals: Check
forcorrosion. If there are signs of corro-
sion, reapply anti-corrosive agents
Drives must be protected from mechanical
damage

Page 19 EN
3. Transport, delivery, and storage
6. Design and function
6.1 Pump operation
The pump operates according to the same
principle as an external gear pump. The pump
is driven by a worm gear drive motor. The ro-
tary motion of the gears generates a negative
pressure in the gear chamber. The pumped
medium is now delivered into the filling hose
with coupling socket through the intake tube
and the gear chamber. Air pockets can be de-
tected through the inspection window and re-
moved by opening the ball valve. A fixed pres-
sure regulating valve secures the pump against
overpressure.
Worm gear drive motor
Ball valve vent
Intake tube
Pressure regulating valve
Filling hose with
coupling socket
External gear pump
Gears/Gear chamber

Page 20
EN 7. Commissioning
7. Commissioning
The product described here functions auto-
matically. The lubricant transport in the lubri-
cation lines should, however, be subjected to
regular visual inspection.
The lubricant fill level in the lubricant reservoir
should likewise be subjected to regular visual
inspection. If the lubricant fill level is too low,
lubricant needs to be added up to the maxi-
mum mark or the grease pail needs to be
replaced.
Observe the instructions from the
machine manufacturer regarding the
lubricants that are to be used.
Warning!
Only  ll using clean lubricant and an
appropriate device. Contaminated
lubricants can result in severe system
malfunction. The lubricant reservoir
must be  lled without introducing
bubbles.
Warning!
Different lubricants cannot be mixed,
as mixing may result in damage and
necessitate costly and complicated
cleaning of the product/centralized
lubrication system.
It is recommended that an indication of
the lubricant in use be attached to the
lubricant reservoir in order to prevent
accidental mixing of lubricants.
7.1 General commissioning
Before the product is commissioned, all elec-
trical connections must be inspected.
The lubricant may only be fed without bubbles.
The lubricant reservoir must be filled with
clean lubricant without introducing bubbles.
The product is then operated until lubricant
without bubbles is discharged at the lubricant
outlet.
The process of venting the centralized lubrica-
tion system can be facilitated by:
Opening the ball valve for venting.
Opening the ends of the main pipes until
lubricant without bubbles is discharged.
Filling long pipe sections before connect-
ing to the lubrication points.