SKF GSJB User manual

Motor-driven pump
unit GSJB
Installation and operation manual
Version 03
Date of issue November 2014
Publication number 951-130-189
Languages EN
Country/Countries ...

2

Imprint
In accordance with the EU Machine Directive
2006/42/CE, the installation and activation
instructons are an integral part of a lubrica-
tion system and must be kept close to the
equipment for future reference.
The original installation and activation
instructions were drafted in compliance with
the applicable standards and rules governing
technical documentation.
© SKF
This documentation is protected by copy-
right. All rights reserved. The photomecha-
nical reproduction, copying, and distribution
of this documentation or parts thereof by
means of processes such as data processing,
data carriers, and data networks is strictly
prohibited without the express permission of
SKF.
Subject to editorial or technical
modifications.
Service
For all technical questions, please contact:
SKF France
Lubrication Product Division
Bld Charles de Gaulle
B.P. 239
37540 St-Cyr-sur-Loire
FRANCE
Tel. [phone]
[e-mail]
Or an SKF Service Centre, the addresses of
which are given on our website:
www.skf.com/lubrication
Content
Imprint.......................3
Service.......................3
Safety instructions. . . . . . . . . . . . . . 4
Lubricants ....................6
Versions ......................9
Design ......................11
Function.....................15
Installation...................16
Pump element................17
Mounting the pump elements ...18
Level monitoring ..............19
Commissioning ...............21
Adjusting the discharge volume ..21
Reservoir filling ...............22
Maintenance .................23
Failures .....................24
Technical data ................25
Spare parts ..................27
Shutdown ...................28
Service......................28
3

Safety instructions
The described product was manufactured in
accordance with all generally acknowledged
regulations pertaining to technology, occu-
pational safety, and accident prevention.
However, dangers that can cause physical
injury to persons or damage to other mate-
rial assets might still occur during the use of
the product.
Intended use
The described product is projecting oil wit-
hout air for the lubrication of chains and is
intended for use in centralized lubrication
systems. Other use or use beyond this pur-
pose is considered unintended.
Products of SKF must not be used in
conjunction with substances and mixtures
classified as hazardous by the Annex I part
2-5 of the CLP regulation (EC 1272/2008),
and identified with hazard pictograms
GHS01-GHS06 and GHS08.
None of the products manufactured by
SKF can be used in conjunction with gases,
liquefied gases, pressurized gases in solution
and fluids with a vapor pressure exceeding
normal atmospheric pressure (1013 mbar)
by more than 0.5 bar at their maximum per-
missible temperature.
Unless otherwise noted, products of SKF
must not be used in conjunction with explo-
sive atmospheres according to the ATEX-Di-
rective 2014/34/EU.
!These instructions must be read
and understood by all persons
who are involved with the installation,
operation, maintenance, and repair of
the product. The mounting and opera-
ting instructions must be kept close to
the equipment for future reference.
Note that these installation instruc-
tions is an integral part of the product. It
must be handed over to the new opera-
tor of the product if the product is sold.
!In addition to the information pro-
vided in the installation instruc-
tions, all generally applicable regulations
on accident prevention and the environ-
ment must be observed.
!All products from SKF may be
used only for their intended pur-
pose as described in these instructions
and in any brochures.
4

DANGER!
Working on products that have
not been disconnected from the power
supply can cause serious injury or death
to persons. Installation, maintenance,
and repair work may only be carried out
by qualified experts on products that
have been disconnected from the power
supply. The supply voltage must be
turned off before any product compo-
nents are opened. .
DANGER!
Centralized lubrication systems
are under pressure when they are being
operated. Such systems must therefore
be depressurized before starting instal-
lation, maintenance, or repair work and
before making any changes to the
system.
Authorized personnel
The products described in the installation
instructions may only be installed, operated,
maintained, and repaired by qualified ex-
perts. Qualified experts are persons who
have been trained, instructed, and familia-
rized with the end product into which the
described product is installed.
These persons are considered capable of
such tasks due to their education, training,
and experience with valid standards, condi-
tions, accident prevention regulations in ef-
fect, and installation conditions. They should
be able to carry out the required tasks and to
recognize – and thus avoid – any dangers
that might otherwise occur.
A definition of what constitutes a qualified
person and who are unqualified persons are
stipulated in DIN VDE 0105 and IEC 364.
Danger relating to electric
current
The electrical connection for the described
product may only be established by qualified,
instructed persons who have been autho-
rized by the operator or owner to carry out
this task. If the product is improperly
connected, substantial material or personal
damage my be the consequence.
Danger relating to system
pressure
5

Warranty
The instructions do not contain any informa-
tion on the warranty. This can be found in
the General Conditions of Sales, which are
available at: www.skf.com/lubrication.
Lubricants
General
!All SKF products must only be
used for their intended purpose
and in accordance with the specifications
of the installation instructions for the
product in question.
The intended use of this product is for the
centralized lubrication/lubrication of bea-
rings and wear points with lubricants. All
physical limitations of use stipulated in the
documentation of the product such as the
owner’s manual, technical drawings and ca-
talogs must be observed.
More specifically, we call your attention to
the fact that substances and mixtures classi-
fied as hazardous by the Annex I part 2-5 of
the CLP regulation (EC 1272/2008), and
identified with hazard pictograms GHS01-
GHS06 and GHS08, can only be used to feed
the SKF centralized lubrication systems,
transported or distributed by these systems
after consultation with SKF and obtaining
written permission.
All products manufactured by SKF are not
approved for use in conjunction with gases,
liquefied gases, pressurized gases in solution
and fluids with a vapor pressure exceeding
normal atmospheric pressure (1013 mbars)
by more than 0,5 bar at their maximum per-
missible temperature.
Should there be a need to use the product
to convey media other than lubricants or ha-
zardous substances, this must be discussed
with SKF first and the company must give
express written permission.
In the opinion of SKF, lubricants constitute
a design element that must be considered
when selecting components and designing
centralized lubrication systems.The lubrica-
tion properties of the lubricants in question
must be considered.
6

While the machinery/bearing manufacturer
usually specifies lubricants, it is the owner/
operator (or maintenance person) who must
finally select the appropriate lubricant, with
the help of the lubricant supplier. When se-
lecting a lubricant, the type of bearing/wear
point, the stresses and strains to be expected
during operation, and anticipated ambient
conditions must be taken into account. All fi-
nancial/economic aspects must also be
considered.
!You must observe the machinery
manufacturer's information on
the lubricants to be used in the
machinery.
DANGER!
The manufacturer of the bearing
or machinery to be lubricated will specify
the lubricant requirements for each
point to be lubricated. You must make
sure that the required quantity of lubri-
cant is provided to the relevant lubrica-
ting point. If a lubricating point is insuffi-
ciently lubricated, the bearing may
become damaged or jammed. If you have further questions, you can
contact SKF.
We can test lubricants in our own labora-
tory to establish their suitability for
!If required, SKF can help cus-
tomers to select suitable compo-
nents for the conveyance of the selected
lubricant and to plan and design their
centralized lubrication system.
Selection of lubricants conveyance (e.g. 'oil separation' behavior) in
centralized lubrication systems.
You can request an overview of lubricant
tests offered by SKF from our Service Center.
7

Approved lubricants
DANGER!
Only lubricants that have been
approved by SKF for use with the pro-
duct may be used. Unsuitable lubricants
can cause product malfunctions and da-
mage to property.
DANGER!
Different lubricants must not be
mixed together. Doing so can cause da-
mage and require extensive cleaning of
the products/centralized lubrication sys-
tem. To prevent confusion, we recom-
mend that you attach information indi-
cating the lubricant to be used on the
lubricant reservoir.
The described product can be operated with
lubricants that comply with the specifications
in the technical data.
Note that some lubricants may have pro-
perties that lie within the permitted limit va-
lues and yet not be suitable for use in cen-
tralized lubrication systems for other
reasons. For example, some synthetic lubri-
cants are not compatible with elastomers.
Lubricants and the
environment
DANGER!
Lubricants can contaminate the
ground and watercourses. Lubricants
must be used and disposed of in com-
pliance with the rules. Instructions and
local regulations must be observed when
handling lubricants.
Note that lubricants are harmful to the envi-
ronment and flammable; their transporta-
tion, storage, and processing are subject to
special precautionary measures. For specifi-
cations on transportation, storage, proces-
sing, and dangers to the use and the envi-
ronment for the lubricant, refer to the
material safety data sheet provided by or
available from the lubricant manufacturer.
You can ask the manufacturer of the lubri-
cant for the material safety data sheet.
8

DANGER!
Centralized lubrication systems
must be absolutely leak-free. Leaking
centralized lubrication systems can
cause a slip hazard. When performing
installation, maintenance, and repairs
test the centralized lubrication system
for leaks. Leaky parts of the centralized
lubrication system or components of the
lubrication equipment have to be sealed
immediately.
Danger relating to lubricants
Leaking centralized lubrication systems or
components of the lubrication equipment
are a source of danger in relation to slip ha-
zard and the risk of injury.These dangers
can cause physical injury to persons or da-
mage to other material assets.
Refer to safety precautions in the lubricant
manufacturer's material safety data sheet.
Lubricants are hazardous substance. It is
essential to respect any safety instructions
given in the lubricant safety data sheet. You
can ask the manufacturer of the lubricant for
the material safety data sheet.
Versions
Motor-driven pumps GSJB are available in
different designs. They differ in their electri-
cal specifications.
How your motor-driven pump is equipped
is indicated on the nameplate and delivery
papers.The following table describes every
model.
!If a pump unit is not listed in table
1, please refer to the delivered
technical sheet to know the specific tech-
nical data of the unit.
9

Table 1 Motor-driven pump unit GSJB
Order No. Reservoir
capacity
[kg]
Grease, NLGI grade Min.
level
Power supply Voltage
[V]
Frequency
[Hz]
000, 00,
0 and 1
2 Single
phase
three-
phase
GSJB0-2K+428 2 • • • 230 50
GSJB0-2K+140 2 • • • 230/400 50
GSJB0-2K1+428 2 • • • 230 50
GSJB0-2K1+140 2 • • • 230/400 50
GSJB0-2K5+428 2 • • • 230 50
GSJB0-2K5+140 2 • • • 230/400 50
GSJB0-6K+428 6 • • • 230 50
GSJB0-6K+140 6 • • • 230/400 50
GSJB0-6K1+428 6 • • • 230 50
GSJB0-6K1+140 6 • • • 230/400 50
GSJB0-6K5+428 6 • • • 230 50
GSJB0-6K5+140 6 • • • 230/400 50
10

Design
Figure 1 shows the essential design of the
motor-driven pump unit GSJB.
The lubricant reservoir is located on the
pump housing. It is equipped with a stirrer in
order to homogenize the grease. There is a
grease nipple on the side of the pump hou-
sing in order to fill up the reservoir by means
of a transfer pump. It is very easy to visually
check the lubricant level with the transpa-
rent reservoir. It is equipped as option with
an electric minimal level switch, such as a
capacitive switch (greases NLGI grade 000,
00,0 and 1) or as a rocker switch (grease
NLGI grade 2).
An eccentric cam is inside the pump hou-
sing. It is actuating the different pumping
elements. An electric gear-motor, single or
thee-phase, drives the eccentric cam.
Motor
Reducing
gear
Transparent
reservoir
Pumping element
Pump housing with
eccentric cam
Stirrer
Min. level switch
Outlet
Grease nipple
Fig. 1 Motor-driven pump unit GSJB0-2k1+..
11

~ 326
Ø 184
45°
~220
~307
4 holes Ø6,5 at 90°
on a circle Ø85
GSJB0-2K+...
~ 346
Ø 224
~240
45°
~425
4 holes Ø6,5 at 90°
on a circle Ø85
GSJB0-6K+...
12

~220327
~
Ø184
~326
45°
4 holes Ø6,5 at 90°
on a circle Ø85
GSJB0-2K1+...
~240 ~485
~346
224Ø
45°
4 holes Ø6,5 at 90°
on a circle Ø85
GSJB0-6K1+...
13

~ 326
184Ø
45°
~220
~307
4 holes Ø6,5 at 90°
on a circle Ø85
GSJB0-2K5+...
~ 346
224Ø
~240
45°
~425
4 holes Ø6,5 at 90°
on a circle Ø85
GSJB0-6K5+...
14

Function
When the motor-driven unit is switched on,
the primary shaft is driving via a reduction
gear (1/100) a vertical shaft, on which an
eccentric is mounted.
The pump elements are fitted around the
pump housing. They are metering and deli-
vering lubricant quantities by means of pis-
tons. Every pump element is connected to
the eccentric as the piston heel is put into the
eccentric groove († fig. 7). Every rotation
(≈15 min-1) of the eccentric actuates the
pump elements.
When the eccentric is pulling out the pis-
ton to its maximum, a suction hole is ope-
ning and a quantity of lubricant is sucked in
the metering chamber of the pumping ele-
ment. During its rotation the eccentric will
push back the piston into the pumping ele-
ment. Under the pressure of the piston, the
lubricant in the metering chamber is fed out
through the pumping element outlet.
The pump element outlet is either directly
connected to a lubrication point, or to a pri-
mary line, which is delivering the lubricant to
progressive feeders.
Control (manometer, pressure switches,
flow indicators) and safety devices (over-
pressure valve) have to be independently
installed on every line in regard to the requi-
rements and surrounding conditions of eve-
ry lubrication point.
The stirrer in the reservoir is reducing the
risk of malfunctions, which are due either to
pumping element unpriming (air pockets or
bubbles in the lubricant), or to lubricant
component separation.
15

Installation
The motor-driven pump unit should be ins-
talled in a location that is protected from
moisture and vibration, but should be readily
accessible.
The main lines to the lubrication points
should be laid with an upward inclination if
possible (air bleeding). Lubricant distributors
at the end of the lubrication system should
be installed with the lubrication point lines
pointing upward.
Hand tighten the tube fittings, then
tighten them by 1 1/2 turn.
!The supply voltage on site must
agree with the information on the
nameplate. Check the fusing of the cir-
cuit. Use only the original fuse with the
required ampere value. If other fuses are
used, damage to property of personal
injury may be the consequence.
The motor-driven pump unit can be directly
mounted on a flat and horizontal surface.
Four fixation holes Ø6,5 are on the base of
the unit, set on a circle Ø85 at 90° from each
other (†fig. 2)
The motor-driven pump unit GSJB can
also be mounted on the vertical wall with the
support plate GSJ1096 (†fig. 3).
Ø6,5Ø85Fig. 2
Drilling template for pump unit.
416Ø92324×M6
Ø85
200175
122,52005016
Fig. 3
Bracket support GSJ1096
16

Fig. 4
Pump element
Pumping element GS100...
1 – Flow rate set screw
2 – Outlet port
3 – Fixing screw on pump housing + seal
4 – Piston pump with heel
Pump element
The pump element type GS100.8._ is made
of two different pistons: the valve piston and
the pumping piston. The pump piston is buil-
ding up the pressure inside the pump ele-
ment. It is actuated (to-and-fro movement)
by the eccentric as the heel of the piston is
inserted into the groove of the eccentric.
The pumping element has a check valve at
the outlet connection.
1 2 3 4
Pump element
Order No. Tube Flow rate
– mm cm3/stroke
GS100.8.6 Ø6 0 à 0,15
GS100.8.6 Ø8 0 à 0,15
17

Mounting the pump
elements
It is possible to mount up to 6 pump ele-
ments on the GSJB unit.
There are six outlet ports radially placed
around the GSJB pump unit housing. The
pump element can be mounted in one of
these ports. It is directly connected to the ec-
centric by the groove.
• Screw off the closing plug (initial moun-
ting) or the pumping element (replacing).
• Remove bothersome lubricant between
the fixing thread and the groove.
• Pull out the piston of the new pump ele-
ment as far as possible.
• Insert the pump element with a light
upward inclination until the eccentric
(† fig. 5). The seal has to be between the
pump element and the pump housing.
• Set the pumping element horizontally
such as the piston heel is coming into the
eccentric groove (†fig. 6).
• Screw in the pump element.
!Mount and dismount pump ele-
ments only when the unit is dis-
connected from power supply. Failure to
comply with this requirement may lead
to bodily injury or damage of the unit.
Fig. 5
Fig. 6
18

Level monitoring
The transparent reservoir of the GSJB unit
enables to visually monitor the level. The le-
vel should be checked at regular intervals for
safety reasons.
GSJB units can also be fitted with a mini-
mal level switch.
The type of minimal level switch depends
on the lubricant.
Fluid greases NLGI grades
000 to 1
The level switch is an inductive proximity
switch for greases and fluid greases. It is in-
tegrated to the cover of the reservoir.
• For 2 kg reservoir, connection with 3 leads
cable.
• For 6 kg reservoir, connection with 4 leads
cable.
Level-switch, 2 kg reservoir
3-wire cable
PNP
BU
BK
BN
-
+
Level-switch, 6 kg reservoir
Round connector 4 poles
PNP2/unusedWHBKBU4/NO3/-0V1/+24VDCBN!This level switch is not for greases
NLGI grade 2.
19

Greases NLGI grade 2
The level switch used here is designed as
rocker switch and is integrated in the bottom
of the reservoir. A magnetic rocker mounted
on the agitator is turned downward by the
grease resistance when the reservoir is full.
Every time the agitator rotates a pulse is ge-
nerated. When the minimum fill level is
reached, the resistance the grease exerts on
the rocker subsides and the rocker turns
back. Therefore the pulse sequence is
interrupted.
REEDNCS4314
1 (+)4 (signal)
Level switch
!This level switch is for greases
NLGI grade 2.
20