SKF ZPU 01 User manual

Assembly Instructions
Lubricant feed pump
ZPU 01 and ZPU 02
Created on:
14.12.2023
Document no.:
951
-171-016-EN
Version:
04
Read these instructions
before installation or start
-
up of the product and keep
them readily available for
consultation.

2
Original EC Declaration of Incorporation in accordance with Directive 2006/42/EC,
Appendix II Part 1 B
The manufacturer hereby declares at its sole responsibility that the partly completed machinery conforms to the essential health and safety
requirements of the Machinery Directive 2006/42/EC, Annex I, marked in the Annex to the EC Declaration of Incorporation as applicable and
fulfilled at the time of placing on the market.
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 the manufacturer.
Designation:
Electrically operated pump for the supply of lubricants within a centralized lubrication system
Type:
ZPU 01 / ZPU 02
Item number:
661-XXXXX-X, 6610-XXXXXXXX
Furthermore, the following directives and standards were applied in the respective applicable areas:
2006/42/EC: Machinery Directive
2014/30/EU: Electromagnetic Compatibility
2011/65/EU: RoHS II
EN ISO 12100:2010
EN 809:1998+A1:2009/AC:2010
EN 60204-1:2018
EN 60947-5-1:2004/A1:2009
EN IEC 60947-5-2:2020
EN IEC 63000:2018
The partly completed machinery must not be put into service until it has been established that the machinery into which it is to be
incorporated is in compliance with the provisions of the Machinery Directive 2006/42/EC and all other applicable Directives.
Walldorf, 10.05.2023
Jürgen Kreutzkämper
Stefan Schürmann
Manager, R&D
Germany
Manager, PD
Germany South
Manufacturer: SKF Lubrication Systems Germany GmbH, Heinrich-Hertz-Str. 2-8, 69190 Walldorf, Germany
Original UK Declaration of incorporation according to the Supply of Machinery (Safety)
Regulations 2008 No. 1597 Annex II
The manufacturer hereby declares under sole responsibility that the partly completed machinery complies with the essential health and
safety requirements of UK legislation Supply of Machinery (Safety) Regulations 2008 No. 1597 Annex I, marked in the Annex to the EC
Declaration of Incorporation as applicable and fulfilled at the time of placing on the market.
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:
Electrically operated pump for the supply of lubricants within a centralized lubrication system
Type:
ZPU 01 / ZPU 02
Item number:
661-XXXXX-X, 6610-XXXXXXXX
Furthermore, the following regulations and standards were applied in the respective applicable areas:
Electromagnetic Compatibility Ordinance 2016 No. 1091
The Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic Equipment Regulations 2012 No. 3032
EN ISO 12100:2010
EN 809:1998+A1:2009/AC:2010
EN 60204-1:2018
EN 60947-5-1:2004/A1:2009
EN IEC 60947-5-2:2020
EN IEC 63000:2018
The partly completed machinery must not be put into service until it has been established that the machinery into which it is to be
incorporated is in compliance with the provisions of UK legislation Supply of Machinery (Safety) Regulations 2008 No. 1597 and all other
applicable Directives.
Walldorf, 10.05.2023
Jürgen Kreutzkämper
Stefan Schürmann
Manager, R&D
Germany
Manager, PD
Germany South
Manufacturer: SKF Lubrication Systems Germany GmbH, Heinrich-Hertz-Str. 2-8, 69190 Walldorf, Germany
NOTE
The product variants without electrical components do not fall within the scope of application of the EMC Directive
(2014/30/EU) or the "Electromagnetic Compatibility Regulations 2016 No. 1091," nor the scope of the RoHS Directive
(2011/65/EU) or the "Restriction of the Use of Certain Hazardous Substances in Ele
ctrical and Electronic Equipment
Regulations 2012 No. 3032."

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.:
Essential health and safety requirement
Applicable:
Fulfilled:
1.1
Principles
1.1.2
Principles of safety integration
Yes
Yes
1.1.3
Materials and products
Yes
Not completely fulfilled
1)
1.1.5
Design of machinery to facilitate its handling
Yes
Yes
1.1.6
Ergonomics
Yes
Not completely fulfilled 2)
1.2
Control systems
1.2.1
Safety and reliability of control systems
Yes
Yes
1.2.3
Starting
Yes
Yes
1.2.6
Failure of the power supply
Yes
Yes
1.3
Protection against mechanical hazards
1.3.1
Risk of loss of stability
Yes
Yes
1.3.2
Risk of break-up during operation
Yes
Not completely fulfilled 3)
1.3.4
Risks due to surfaces, edges or angles
Yes
Yes
1.3.7
Risks related to moving parts
Yes
Yes
1.3.9
Risks of uncontrolled movements
Yes
Yes
1.5
Risks due to other hazards
1.5.1
Electricity supply
Yes
Yes
1.5.6
Fire
Yes
Yes
1.5.8
Noise
Yes
Yes
1.5.13
Emissions of hazardous materials and substances
Yes
Yes
1.5.15
Risk of slipping, tripping, or falling
Yes
Not completely fulfilled 4)
1.6
Servicing
1.6.1
Machinery maintenance
Yes
Yes
1.6.2
Access to operating positions and servicing points
Yes
Not completely fulfilled 5)
1.6.4
Operator interventions
Yes
Yes
1.7
Information
1.7.1
Information and warnings on the machinery
Yes
Yes
1.7.1.1
Information and information devices
Yes
Yes
1.7.2
Warning of residual risks
Yes
Yes
1.7.3
Marking of machinery
Yes
Yes
1.7.4
Operating instructions/assembly instructions
Yes
Yes
1.7.4.1
General principles for the drafting of operating
instructions/assembly instructions
Yes
Yes
1.7.4.2
Contents of the operating instructions/assembly instructions
Yes
Yes
1.7.4.3
Sales literature
Yes
Yes
1) The product is designed for operation with non-hazardous media. The owner-operator must check whether the lubricant used has certain
hazardous effects (such as sensitization). The installation of a drip pan could be required. Pressure-relief valves must also be used.
2) The operator must ensure that the pump is integrated into the higher-level machine in such a way that the pump can be operated and
filled ergonomically.
3) The operator must protect the lubrication system against excessive pressure. This should be done by fitting every pump element with a
pressure limiting valve with suitable opening pressure (see the “Technical data” for the pump in question).
4) Not relevant inside the incomplete machine (pump), only outside the partially completed machine. The machine's owner or operator is
responsible here.
5) The owner-operator must ensure that the pump is integrated into the main machine in such a way that it can be operated without danger.

4
Masthead
Manufacturer
SKF Lubrication Systems Germany GmbH
Email: Lubrication-germ[email protected]
www.skf.com/lubrication
Berlin Plant
Motzener Strasse 35/37
12277 Berlin
Germany
Tel. [phone]
Fax [phone]
Walldorf Plant
Heinrich-Hertz-Strasse 2-8
69190 Walldorf, Germany
Germany
Tel.: [phone]
Fax: [phone]
Authorized local distributors
- Great Britain -
SKF (U.K.) Limited,
2 Canada Close, Banbury, Oxfordshire,
OX16 2RT, GBR.
- North America -
SKF Lubrication Business Unit
Lincoln Industrial
5148 North Hanley Road, St. Louis,
MO. 63134 USA
- South America -
SKF Argentina Pte. Roca 4145,
CP 2001 Rosario, Santa Fe
Warranty
The instructions contain no statements regarding the
warranty or liability for defects. That information can be
found in our General Terms of Payment and Delivery.
Training
We conduct detailed training in order to enable maximum
safety and efficiency. We recommend taking advantage
of this training. For further information, contact your
authorized SKF dealer or the manufacturer.

5
Table of contents
Masthead .............................................................................................4
Table of contents..............................................................................5
Safety alerts, visual presentation, and layout .......................7
1 Safety instructions........................................................................8
1.1 General safety instructions................................................ 8
1.2 General electrical safety instructions ........................... 8
1.3 General behaviour when handling the product ......... 8
1.4 Intended use ........................................................................... 8
1.5 Persons authorized to use the product..........................9
1.6 Foreseeable misuse ..............................................................9
1.7 Referenced documents........................................................9
1.8 Prohibition of certain activities ........................................9
1.9 Painting plastic components and seals.........................9
1.10 Safety markings on the product .....................................9
1.11 Note on the type plate ..................................................... 10
1.12 Notes on CE marking ....................................................... 10
1.13 Note on UKCA marking ................................................... 10
1.14 Note on EAC marking....................................................... 10
1.15 Note on China RoHS mark............................................. 10
1.16 Emergency shutdown...................................................... 10
1.17 Assembly, maintenance, fault, repair ........................ 10
1.18 First start-up, daily start-up ...........................................11
1.19 Residual risks...................................................................... 12
2 Lubricants......................................................................................13
2.1 General information ........................................................... 13
2.2 Material compatibility....................................................... 13
2.3 Temperature properties ................................................... 13
2.4 Aging of lubricants............................................................. 13
2.5 Avoidance of faults and hazards .................................. 13
2.6 Solid lubricants ................................................................... 13
3 Overview, functional description..........................................14
3.1 Overview................................................................................. 14
3.2 Designs................................................................................... 14
3.2.1 Design "E" .................................................................. 14
3.2.2 Design "V" ................................................................. 14
3.2.3 Design "F" ..................................................................15
3.2.4 Fill level monitoring (XYBU) ................................15
4 Technical data .............................................................................16
4.1 Pump ZPU 01 … 02 ...............................................................16
4.2 Drive motors..........................................................................17
4.2.1 Motors 380 – 480 V AC.........................................17
4.2.2 Motors 380 – 480 V AC with gearbox .............17
4.2.3 Motors 500 V AC..................................................... 18
4.2.4 Motors 500 V AC with gearbox.......................... 18
4.3 Ultrasonic sensor 664-853xx-x......................................19
4.3.1 Switching points of ultrasonic sensor for
reservoir design XYBU..................................................... 21
4.4 Tightening torques............................................................. 21
4.5 Pump type identification code ZPU 01…02...............22
4.5.1 Basic parameters and reservoir design..........22
5 Delivery, returns, storage ........................................................23
5.1 Delivery ...................................................................................23
5.2 Return shipment .................................................................23
5.3 Storage...................................................................................23
5.4 Storage temperature range.............................................23
5.5 Storage conditions for products filled with lubricant
..........................................................................................................23
5.5.1 Storage period up to 6 months..........................23
5.5.2 Storage period between 6 and 18 months....23
5.5.3 Storage period more than 18 months .............23
5.6 Declaration of decontamination...................................23
6 Assembly.......................................................................................24
6.1 General safety instructions .............................................24
6.2 Internal transportation .....................................................24
6.3 Mechanical connection....................................................25
6.3.1 Minimum mounting dimensions........................25
6.3.2 Assembly holes .......................................................26
6.4 Electrical connection ........................................................26
6.5 Filling with lubricant.......................................................... 27
6.6 Filling via the reservoir cover.........................................27
6.7 Filling via the fill connection (optional)...................... 27
6.7.1 Pumps with an ultrasonic sensor......................27
6.7.2 Pumps without an ultrasonic sensor...............27
6.8 Bleeding the pump.............................................................27
6.9 Connection of the lubrication line................................28
7 First start-up ................................................................................29
7.1 Inspections before first start-up ....................................29
7.2 Inspections during first start-up ...................................29
8 Operation ......................................................................................30
8.1 Operating the pump ...........................................................30
8.2 Top up lubricant..................................................................30
9 Maintenance .................................................................................31
9.1 Maintenance of the gearbox ...........................................32
9.1.1 Required oil quality.................................................32
9.2 Maintenance of the motor ...............................................32
9.2.1 Checking the bearings ..........................................32
9.2.2 Required grease quality.......................................32
9.2.3 Replacing the bearing grease ............................32
9.3 Cleaning/replacing the lubricant filter (pump design
F) ......................................................................................................33
10 Cleaning.......................................................................................34
10.1 Basics ....................................................................................34
10.2 Interior cleaning................................................................34
10.3 Exterior cleaning...............................................................34
11 Faults, causes, and remedies...............................................35
12 Repairs .........................................................................................36
12.1 Replace pump element ...................................................36
12.1.1 General notes..........................................................36
12.1.2 Pump design "E"....................................................36
12.1.3 Pump designs F and V ........................................37
12.2 Replace pressure regulating valve.............................37
12.2.1 Pump design "V"....................................................37
12.2.2 Pump design "F" ...................................................37
13 Shutdown, disposal.................................................................38
13.1 Temporary shutdown.......................................................38
13.2 Permanent shutdown, disassembly...........................38
13.3 Disposal ...............................................................................38
14 Spare parts................................................................................. 39
14.1 Motors 380 - 480 VAC.....................................................39
14.2 Motors 380 - 480 VAC with gearbox .........................39
14.3 Motors 500 VAC ................................................................39
14.4 Motors 500 VAC with gearbox .....................................39
14.5 Gearboxes ...........................................................................40
14.6 Packing ring, motor – gearbox.....................................40
14.7 Packing ring, gearbox – pump housing ....................40
14.8 Pump element for pump design E .............................. 41
14.9 Plug screw for pump design E...................................... 41

6
14.10 Pressure limiting valve for pump design E ............41
14.11 Bridge for pump design F1 (ZPU01) complete with
one pump element .....................................................................41
14.12 Bridge for pump design F2 (ZPU02) complete with
two pump elements.................................................................. 42
14.13 Bridge for pump design V1 (ZPU01) complete with
one pump element .................................................................... 42
14.14 Bridge for pump design V2 (ZPU02) complete with
two pump elements.................................................................. 42
14.15 Filter for pump design F .............................................. 43
14.16 Pressure gauge for pump designs F and V ........... 43
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

7
Safety alerts, visual
presentation, and layout
While reading these instructions, you will encounter
various symbols, illustrations, and text layouts intended
to help you navigate and understand the instructions.
Their meaning is explained below.
Safety alerts:
Activities that present specific hazards (to life and limb or
possible damage to property) are indicated by safety
alerts. Always be sure to follow the instructions given in
the safety alerts.
DANGER
These safety alerts indicate an imminent
danger. Ignoring them will result in death or
serious injury
<
WARNING
These safety alerts indicate potentially
imminent danger. Ignoring them could result
in death or serious injury
<
CAUTION
These safety alerts indicate potentially
imminent danger. Ignoring them could result
in minor injury
<
NOTICE
These safety alerts indicate a potentially
harmful situation. Ignoring them could result
in damage to property or malfunctions
Illustrations:
The illustrations used depict a specific product. For other
products, they may have the function of a diagram only.
This does not alter the basic workings and operation of
the product.
Text layout:
•First-order bulleted lists: Items on a bulleted list start
with a solid black dot and an indent.
–Second-order bulleted lists: If there is a further
listing of subitems, the second-order bulleted list is
used.
1 Legend: A legend explains the numbered contents of an
illustration, presented as a numbered list. Items in a
legend start with a number (with no dot) and an indent.
–Second-order legend: In some cases, the numbered
contents of an image represent more than just one
object. A second-order legend is then used.
1. Instruction steps: These indicate a chronological
sequence of instruction steps. The numbers of the
steps are in bold and are followed by a period. If a new
activity follows, the numbering starts again at “1.”
–Second-order instruction steps: In some cases, it is
necessary to divide up a step into a few substeps. A
sequence of second-order instruction steps is then
used.

8
1Safety instructions
1.1 General safety instructions
•Putting the products into operation or operating them
without having read the instructions is prohibited. The
operator must ensure that the instructions are read and
understood by all persons tasked with working on the
product or who supervise or instruct such persons.
Retain the instructions for further use.
•The product may only be used in awareness of the
potential dangers, in proper technical condition, and
according to the information in this manual.
•Any faults that could affect safety must be remedied
according to responsibility. The supervisor must be
notified immediately in case of malfunctions outside
one's individual scope of responsibility.
•Unauthorized modifications and changes can have an
unpredictable effect on safety and operation.
Unauthorized modifications and changes are therefore
prohibited. Only original SKF spare parts and SKF
accessories may be used.
•Any unclear points regarding proper condition or
correct assembly/operation must be clarified.
Operation is prohibited until issues have been clarified.
•The components used must be suitable for the
intended use and the applicable operating conditions,
e.g. max. operating pressure and ambient temperature
range, and must not be subjected to torsion, shear, or
bending.
1.2 General electrical safety
instructions
•Electrical devices must be kept in proper condition.
This must be ensured by periodic inspections in
accordance with the relevant applicable standards and
technical rules. The type, frequency, and scope of the
inspections must be determined in accordance with the
risk assessment to be carried out by the operator. Work
on electrical components may be performed only by
qualified electricians. Connect the electrical power only
in accordance with the valid terminal diagram and in
observance of the relevant regulations and the local
electrical supply conditions.
•Work on electrical components may be performed only
in a voltage-free state and using tools suitable for
electrical work. Do not touch cables or electrical
components with wet or moist hands.
•Fuses must not be bridged. Always replace defective
fuses with fuses of the same type.
•Ensure proper connection of the protective conductor
for products with protection class I. Observe the
specified enclosure rating.
•The operator must implement appropriate measures to
protect vulnerable electrical devices from the effects of
lightning during use. The electrical device is not
furnished with a grounding system for the dissipation
of the respective electric charge and does not have the
voltage strength necessary to withstand the effects of
lightning.
1.3 General behaviour when handling
the product
•Familiarize yourself with the functions and operation of
the product. The specified assembly and operating
steps and their sequences must be observed.
•Keep unauthorized persons away.
•Wear personal protective equipment always.
•Precautionary operational measures and instructions
for the respective work must be observed.
•In addition to these Instructions, general statutory
regulations for accident prevention and environmental
protection must be observed.
•Precautionary operational measures and instructions
for the respective work must be observed. Uncertainty
seriously endangers safety.
•Safety-related protective and safety equipment must
not be removed, modified or affected otherwise in its
function and is 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 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 lubrication system or
of the machine as standing or climbing aids.
1.4 Intended use
Supply of lubricants.
The product is intended solely for installation in another
machine.
Use is only permitted within the scope of commercial or
economic activity by professional users, in compliance
with the specifications, technical data, and limits
specified in this manual.

9
1.5 Persons authorized to use the
product
Operator
A person who is qualified by training, knowledge and
experience to carry out the functions and activities
related to normal operation. This includes avoiding
possible hazards that may arise during operation.
Specialist in electrics
Person with appropriate professional education,
knowledge and experience to detect and avoid the
hazards that may arise from electricity.
Specialist in mechanics
Person with appropriate professional education,
knowledge and experience to detect and avoid the
hazards that may arise during transport, installation,
start-up, operation, maintenance, repair and disassembly.
1.6 Foreseeable misuse
Any usage of the product other than as specified in this
manual is strictly prohibited. Particularly prohibited are:
•Use of non-specified consumables, contaminated
lubricants, or lubricants with air inclusions.
•Use of C3 versions in areas with aggressive, corrosive
substances (e.g., high salt load).
•Use of plastic parts in areas with high exposure to
ozone, UV light, or ionizing radiation.
•Use to supply, convey, or store hazardous substances
and mixtures as defined in the CLP Regulation (EC
1272/2008) or GHS with acute oral, dermal, or
inhalation toxicity or substances and mixtures that are
marked with hazard pictograms GHS01-GHS06 and
GHS08.
•Use to supply, convey, or store Group 1 fluids classified
as hazards as defined in the Pressure Equipment
Directive (2014/68/EU) Article 13 (1) a).
•Use to supply, convey, or store gases, liquefied gases,
dissolved gases, vapors, or fluids whose vapor pressure
exceeds normal atmospheric pressure (1013 mbar) by
more than 0.5 bar at their maximum permissible
operating temperature.
•Use in an explosion protection zone.
•Use without proper securing against excessively high
pressures, in the case of pressurized products.
•Use outside of the technical data and limits specified in
this manual.
1.7 Referenced documents
In addition to this manual, the following documents must
be observed by the respective target group:
•Company instructions and approval rules
If applicable:
•Safety data sheet of the lubricant used
•Project planning documents
•Supplementary information regarding special designs
of the pump. This you will find in the special system
documentation.
•Instructions for other components for setting up the
centralized lubrication system.
1.8 Prohibition of certain activities
•Replacement of or modifications to the pistons of the
pump elements
•Repairs or modifications to the drive.
1.9 Painting plastic components and
seals
The painting of any plastic components and seals of the
products described is prohibited. Completely mask or
remove plastic components before painting the main
machine.
1.10 Safety markings on the product
Fig. 1
Risk of dangerous electrical voltage
(on the motor terminal box)
Risk of wrapping, pinching, crushing, or
shearing when the reservoir lid is open
(only for reservoirs with filling from above)
Direction of rotation of the pump (stirring
paddle)
Possible safety markings on the product
NOTE
Further to the findings of the workplace risk
evaluation the operating company has to attach
additional markings (e. g. warnings, signs giving
orders, prohibition signs or labelling as specified by
CLP / GHS), where appropriate.

10
1.11 Note on the type plate
The type plate provides important data such as the type
designation, order number, and sometimes regulatory
characteristics. To avoid loss of this data in case the type
plate becomes illegible, it should be entered in the
manual.
Table
2
Table for copying out the type plate
<Content>
Model:
P-No. :
S-No. :
Fig.
2
Type plate (example)
1.12 Notes on CE marking
CE marking is effected following the
requirements of the applied directives
requiring a CE marking:
•2006/42/EC Machinery directive
•2014/30/EC Electromagnetic Compatibility
•2011/65/EU Directive on the restriction of the use of
certain hazardous substances in electrical and
electronic equipment (RoHS II)
NOTE
For product variants with electrical components
(e.g., filling level sensors), the following directives and
regulations apply (see also the original declarations of
incorporation on page 2):
•
EMC Directive (2014/30/EU) and "Electromagnetic
Compatibility Regulations 2016 No. 1091"
•
RoHS
Directive (2011/65/EU) and "Restriction of the
Use of Certain Hazardous Substances in Electrical
and Electronic Equipment Regulations 2012 No.
3032."
For this reason, these product variants bear CE,
UKCA, and China RoHS marks.
1.13 Note on UKCA marking
The UKCA conformity marking confirms the
product’s conformity with the applicable
legal provisions of Great Britain.
1.14 Note on EAC marking
The EAC conformity marking confirms the
product’s conformity with the applicable
legal provisions of the Eurasian customs
union.
1.15 Note on China RoHS mark
The China RoHS mark confirms that there is
no danger to persons or the environment
from the regulated substances contained
within for the intended period of use (year
number shown in the circle).
1.16 Emergency shutdown
This is done by a course of action to be defined by the
operator.
1.17 Assembly, maintenance, fault,
repair
Prior to the start of this work, all relevant persons must be
notified of it. At a minimum, the following safety
measures must be taken before any work is done:
•Unauthorized persons must be kept away
•Mark and secure the work area
•Cover adjacent live parts
•Dry any wet, slippery surfaces or cover them
appropriately
•Cover hot or cold surfaces appropriately
Where applicable:
•Depressurize
•Isolate, lock and tag out
•Check to ensure live voltage is no longer present
•Ground and short-circuit.
The product should be protected as much as possible
from humidity, dust, and vibration, and should be
installed so that it is easily accessible. Ensure an
adequate distance from sources of heat or cold. Any
visual monitoring devices present, such as pressure
gauges, min./max. markings, or oil level gauges must be
clearly visible. Observe the mounting position
requirements.
Drill required holes only on non-critical, non-load-
bearing parts of the operator's infrastructure. Use existing
holes where possible. Avoid chafe points. Immobilize any
moving or detached parts during the work. Adhere to the
specified torques.
If guards or safety devices need to be removed, they
must be reinstalled immediately following conclusion of
work and then checked for proper function.
Check new parts for compliance with the intended use
before using them.

11
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
•All warning labels on the product are fully present,
visible, and undamaged
•Illegible or missing warning labels are immediately
replaced.

12
1.19 Residual risks
Table
3
Residual risks
Residual risk
Possible in lifecycle
Avoidance / Remedy
Personal injury / property damage
due to falling of hoisted parts
A
B
C
G
H
K
•Unauthorized persons must be kept away.
Nobody is allowed to be present below hoisted
parts. Lift parts using suitable and tested lifting
gear.
Personal injury/property damage
due to tilting or falling product due
to non-compliance with specified
torques
B
C
D
E
F
G
•Adhere to the specified torques
•Mount the product only on components with a
sufficient load-carrying capacity.
•
If no torques are specified, use those specified for
the screw size for screws of strength class 8.8.
Personal injury / property damage
due to electric shock
B
C
D
E
F
G
H
•Inspect power cables for damage prior to initial
use and then at regular intervals.
•Before connecting the pump unit, de-energize all
relevant electrical components. Observe any
discharge times.
•Do not install the cable on moving parts or
wearing spots. If this cannot be avoided, use anti-
kink coils and/or conduits.
Personal injury / property damage
due to spilled, leaked lubricant
B
C
D
E
F
G
H
K
•Be careful when filling the reservoir and then
connecting or disconnecting the lubricant lines.
•Use only hydraulic screw unions and lubrication
lines suitable for the specified pressure.
•Do not install lubrication lines on moving parts or
chafe points. If this cannot be avoided, use
flexible hose lines or anti-kink coils and/or
conduits.
•Promptly apply suitable binding agents and then
remove the spilled or leaked lubricant.
•Follow operational instructions for handling the
lubricants and contaminated parts.
Injury from contact with the stirring
paddle when filling the pump
C
D
F
• Preferably fill via the fill connection. Fill from the
top, only when the paddle is motionless, and with
the pump de-energized. Do not reach into the
reservoir while filling.
Objects falling into the motor vent
C
D
E
F
•If the motor is installed vertically and there is a
risk of objects (such as stones, metal chips, etc.)
falling into the motor vent, a suitable canopy
must be fitted.
Injury from hot/faulty motor
E
F
G
•Switch off the pump. Let parts cool off; remedy
the cause.
Lifecycle phases: A = Transport, B = Assembly, C = First start-up, D = Operation, E = Cleaning, F = Maintenance, G = Malfunction, repair, H =
Shutdown, K = Disposal

13
2Lubricants
2.1 General information
Lubricants are selected specifically for the relevant
application. The manufacturer or operator of the machine
should ideally make the selection in consultation with the
supplier of the lubricant. If you have no or little
experience in selecting lubricants for lubrication systems,
please contact us. We would be happy to assist you in
selecting suitable lubricants and components to build a
lubrication system optimized for your particular
application. Consider the following points when
selecting/using lubricants. This will spare you potential
downtime and damage to the machine or lubrication
system.
2.2 Material compatibility
The lubricants must generally be compatible with the
following materials:
•Plastics: ABS, CR, FPM, NBR, NR, PA, PET, PMMA, POM,
PP, PS, PTFE, PU, PUR
•Metals: steel, gray cast iron, brass, copper, aluminum.
2.3 Temperature properties
The lubricant used must be suitable for the specific
ambient temperature of the product. The viscosity
approved for proper functioning must neither be
exceeded at low temperatures nor fall too low at high
temperatures. For the approved viscosity, see the
“Technical data” chapter.
2.4 Aging of lubricants
Based on past experience with the lubricant used, checks
should be conducted at regular intervals defined by the
operator, to determine whether the lubricant needs to be
replaced due to aging processes (oil separation). In case
of doubt regarding the continued suitability of the
lubricant, it must be replaced before the system is started
up again. If you do not yet have any experience with the
lubricant used, we recommend conducting a check after
just one week.
2.5 Avoidance of faults and hazards
To avoid faults and hazards, please observe the following:
•When handling lubricants, observe the relevant safety
data sheet (SDS) and any hazard labeling on the
packaging.
•Due to the large number of additives, some lubricants
that meet the pumpability requirements specified in
the manual are not suitable for use in centralized
lubrication systems.
•Whenever possible, always use SKF lubrication
greases. They are ideal for use in lubrication systems.
•Do not mix lubricants. This can have unpredictable
effects on the properties and usability of the lubricant.
•Use lubricants containing solid lubricants only after
technical consultation with SKF.
•The lubricant’s ignition temperature has to be at least
50 kelvin above the maximum surface temperature of
the components.
2.6 Solid lubricants
Solid lubricants may only be used after prior consultation
with SKF. When solid lubricants are used in lubrication
systems, the following rules generally apply:
Graphite:
•Maximum graphite content 8%
•Maximum grain size 25 µm (preferably in lamellar form).
MoS2:
•Maximum MoS2 content 5%
•Maximum grain size 15 µm.
Copper:
•Lubricants containing copper are known to lead to
coatings forming on pistons, bore holes, and mating
surfaces. This can result in blockages in the centralized
lubrication system.
Calcium carbonate:
•Lubricants containing calcium carbonate are known to
lead to very heavy wear on pistons, bore holes, and
mating surfaces.
Calcium hydroxide:
•Lubricants containing calcium hydroxide are known to
harden considerably over time, which can lead to
failure of the centralized lubrication system.
PTFE, zinc, and aluminum:
•For these solid lubricants, it is not yet possible to
define any limit values for use in lubrication systems on
the basis of existing knowledge and practical
experience.

14
3Overview, functional description
3.1 Overview
Fig. 3
Overview
1 Reservoir with stirring
paddle
2
Pump element
3
Pump housing
4 Gearbox
5 Motor
6
Fill connection (optional)
7
Return connection
(optional)
Pumps of the type ZPU 01/ ZPU 02 are comprised
essentially of the following main components:
Reservoir with stirring paddle
The reservoir contains the lubricant and possibly a sensor
for sending a low-level signal.
The stirring paddle turns while the pump is running,
homogenizing the lubricant and removing air from it.
The lower part of the stirring paddle presses the lubricant
toward the pump elements, thus improving its
pumpability.
Pump element
This feeds the lubricant into the lubricant line.
Gearbox
The gearbox reduces the speed of the motor to the speed
required for the eccentric shaft of the pump.
Motor
The motor drives the pump and is connected to the
gearbox.
Fill connection (optional)
The optional fill connection can be used to fill the pump
with lubricant.
Return connection (optional)
The optional return connection (3/8″) can be used if the
pump is used in a dual-line system (in the standard
design, it is closed off with a plug screw).
3.2 Designs
3.2.1 Design "E"
Fig.
4
Overview of design E
1 One or two pump elements
The “E” design contains one or two pump elements that
are installed directly in the pump housing.
ZPU 01 / ZPU 02 pumps of the “E” design are mainly used
for progressive lubrication systems with one or two
lubrication circuits.
NOTE
“E” design pumps must be safeguarded by the owner-
operator with suitable pressure limiting valves to
prevent excessive pressure.
3.2.2 Design "V"
Fig.
5
Overview of design “V“
1 Bridge
2 Pressure limiting valve
3 Pressure gauge
The “V” design includes a bridge to merge the lubricant
flow, a pressure limiting valve, and a pressure gauge.
ZPU 01 / ZPU 02 pumps of the V design are mainly used
for progressive lubrication systems with one lubrication
circuit.
3
1
2
4
5
67
1
3
1
2

15
3.2.3 Design "F"
Fig.
6
Overview of design “F“
1 Bridge
2 Pressure gauge
3 Filter block
4
Pressure limiting valve
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)
Low-level and full signals using a digital ultrasonic
sensor (optional)
Ultrasonic sensor for monitoring the fill level in the
reservoir. Two LEDs are used to display the respective fill
level. (See the "Technical data" of the ultrasonic sensor).
The switching points are set at the factory according to
the reservoir size.
2
1
34

16
4Technical data
4.1 Pump ZPU 01 … 02
Table
4
Technical data of the pump
Parameter
ZPU 01
ZPU 02
Number of pump elements
1
2
Delivery rate
•With transmission ratio 1:490 (M490):
160 cm3/h
320 cm3/h
•With transmission ratio 1:100 (M100):
800 cm3/h
1600 cm3/h
•With transmission ratio 1:049 (M049):
1600 cm
3
/h
3200 cm
3
/h
Operating pressure
•With transmission ratios 1:100 and
1:490:
Max. 350 bar [5076.3 psi]
Max. 350 bar [5076.3 psi]
•With transmission ratio 1:049:
Max. 400 bar [5801.5 psi]
Max. 400 bar [5801.5 psi]
Operating temperature
1)
-25 to +70 °C [-13 to +158 °F]
Permissible drive speed 2)
(for pumps without motor and gearbox)
Lubrication oil: 2.5 to 30 rpm
Lubrication grease: 2.5 to 35 rpm
Weight of the empty pump
Approx. 19 kg
Approx. 19 kg
Filling the pump
•Via the reservoir cover
•
Via button-head lubricating nipple (optional)
•Via fill connection (optional)
Via t he res er vo ir
cover
Enclosure rating
IP55
Via t he res er vo ir
cover
Lubricant
Mineral oils (base oils) or environmentally friendly oils from ISO VG 46 to
greases of NLGI Grade 2: dynamic viscosity (oils) ≥ 50 mm
2
/s
Reservoir capacity
10 or 30 liters [2.64 or 7.93 gal.]
Drive motor
See section Drive motors, Page 17
Sound pressure level
< 70 db(A)
Mounting position
Upright, i.e., with the reservoir upward. Deviation ±5°
1) The specified operating temperature range of the pump requires that the lubricant used be suitable for the actual
operating temperature present. Using a lubricant that is unsuitable for the actual operating temperature may result in
damage or pump failure at low temperatures due to excessive lubricant viscosity.
2) Compliance with the specified speeds must be ensured by selecting a suitable motor and gearbox.
NOTE
In the case of drive motors with a power supply frequency of 60 Hz, the speed and thus also the delivery rate are 20%
higher.
In the case of lubricating greases of Grade NLGI
2 or NLGI 3 and very low temperatures, the actual delivery rate can be
below the calculated theoretical rate.

17
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
S1
S1
Voltage
[V]
230 / 400
265 / 460
230 / 400
265 / 460
Circuit
/
/
/
/
Frequency f
[Hz]
50
60
50
60
Rated capacity P
[kW]
0.18
0.21
0.25
0.29
Rated speed n
[rpm]
1380
1656
1334
1600
Rated current IN
[A]
1.22
0.7
2.5
1.4
Starting current
2.5 x I
N
2.5 x I
N
Power factor cos φ
0.69
0.55
Efficiency η
[%]
62
62
Type
B14
B14
Frame size
63
63
Enclosure rating
IP55
IP55
Insulation class
F
F
Flange
[mm / in]
∅ 90 [3.5]
∅ 90 [3.5]
Shaft extension
[mm / in]
∅ 11 × 23 [0.4 × 0.9]
∅ 11 × 23 [0.4 × 0.9]
4.2.2 Motors 380 – 480 V AC with gearbox
Table
6
Technical data
Parameter
Gearbox M100
Gearbox M049
Gearbox M490
Item number
245-13915-1
245-13916-1
245-13918-1
Manufacturer, model
See the name plate on the motor or ask us
Operating mode
S1
S1
S1
Voltage
[V]
230 / 400
265 / 460
220 / 420
250 / 480
230 / 400
265 / 460
Circuit
/
/
/
/
/
/
Frequency f
[Hz]
50
60
50
60
50
60
Rated capacity P
[kW]
0.18
0.21
0.25
0.29
0.18
0.21
Rated speed n
[rpm]
1360
1630
1500
1800
1380
1656
Rated current I
N
[A]
1.2
0.7
2.07 / 1.2
2.07 / 1.2
1.22
0.7
Starting current
2,5 x IN
3,6 x IN
2,6 x IN
Power factor cos φ
0.7
0.77
0.68
Efficiency η
[%]
54
65
54.3
Type
B14
B14
B14
Frame size
63
63
63
Enclosure rating
IP55
IP55
IP55
Insulation class
F
F
F
Flange
[mm / in]
∅ 90 [3.5]
∅ 90 [3.5]
∅ 90 [3.5]
Shaft extension
[mm / in]
∅ 11 × 23 [0.4 × 0.9]
∅ 11 × 23 [0.4 × 0.9]
∅ 11 × 23 [0.4 × 0.9]
Ratio
[i]
1:100
1:49
1:490

18
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
S1
S1
Voltage
[V]
290 / 500
290 / 500
Circuit
/
/
Frequency f
[Hz]
50
50
Rated capacity P
[kW]
0.18
0.25
Rated speed n
[rpm]
1360
1400
Rated current I
N
[A]
1.0 / 0.6
2.0 / 1.2
Starting current
2,5 x IN
2,5 x IN
Power factor cos φ
0.69
0.55
Efficiency η
[%]
62
62
Type
B14
B14
Frame size
63
63
Enclosure rating
IP55
IP55
Insulation class
F
F
Flange
[mm / in]
∅ 90 [3.5]
∅ 90 [3.5]
Shaft extension
[mm / in]
∅ 11 × 23 [0.4 × 0.9]
∅ 11 × 23 [0.4 × 0.9]
4.2.4 Motors 500 V AC with gearbox
Table
8
Technical data
Parameter
Gearbox M100
Gearbox M049
Gearbox M490
Item number
245-13921-1
245-13922-1
245-13923-1
Manufacturer, model
See the name plate on the motor or ask us
Operating mode
S1
S1
S1
Voltage
[V]
290 / 500
290 / 500
290 / 500
Circuit
/ / /
Frequency f
[Hz]
50
50
50
Rated capacity P
[kW]
0.18
0.25
0.18
Rated speed n
[rpm]
1360
1360
1360
Rated current I
N
[A]
1.0 / 0.6
1.1 / 0.64
1.0 / 0.6
Starting current
2,5 x I
N
2,5 x I
N
2,5 x I
N
Power factor cos φ
0.68
0.69
0.68
Efficiency η
[%]
54
38
54
Type
B14
B14
B14
Frame size
63
63
63
Enclosure rating
IP55
IP55
IP55
Insulation class
F
F
F
Flange
[mm / in]
∅ 90 [3.5]
∅ 90 [3.5]
∅ 90 [3.5]
Shaft extension
[mm / in]
∅ 11 × 23 [0.4 × 0.9]
∅ 11 × 23 [0.4 × 0.9]
∅ 11 × 23 [0.4 × 0.9]
Ratio
[i]
1:100
1:49
1:490

19
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.
The light gray areas (B) represent the range in which
a large reflector (such as the lubricant surface) is still
detected provided that it is optimally al
igned to the
sensor.
No evaluation is possible outside the light
gray area.
Operating voltage U
B
9-30 VDC (reverse polarity resistant)
Residual ripple
± 10%
No-load power consumption
≤ 60mA
Connection type
M12 connector, 5-pin
Response delay
272 ms
Readiness delay
< 300 ms
Enclosure rating per EN 60529
IP65 / IP67 (depending on the cable box used)
Operating temperature range
- 40 °C to + 70 °C
Switching points
Full signal D1; low-level signal D2 according to the reservoir size; pre-empty signal
D3 programmable upon customer request, preset to 10
mm above the low-level
signal (use is optional)
Conformity with standards
DIN EN IEC 60947-5-2
Display elements
LED green/LED orange
Switching output set/not set
Housing material
PBT, polyester, ultrasonic transducer: PUR, epoxy resin with glass contents
Switching output
3x pnp; UB-2V; lmax = 3 x 200 mA; NO contact, short-circuit proof
NOTE
The specified enclosure rating is contingent on the use of connection sockets and cables suitable for that enclosure
rating. If connection sockets and cables with a lower protection rating are used, the lowest of those protection ratings
will apply.

20
Table
10
Electrical connection
Cable colors in accordance with IEC
60757
1
+ U
B
Brown (BN)
3
- U
B
Blue (BU)
4
D2
Black (BK)
2
D1
White (WH)
5
D3 / Com
Gray (GY)
Table
11
Display of the circuit states
Parameter
Switching points
Display of the LEDs
D1
D2
D3
D1 (up
to
10/21)
D1
(from
10/21
)
D2 (up
to
10/21)
D2
(from
10/21
)
--
Full signal (high level)
A
A
B
Orange
Green
Orange
Green
C
Between full signal and
pre-empty signal
B
A
B
Green
Orange
Orange
Green
C
Pre-empty signal
B
A
A
Green
Orange
Orange
Green
D
Low-level signal
B
B
B
Green
Orange
Green
Orange
C
A = switched, B = not switched, C = steady, D = flashing
Dimensions:
Fig.
7
Dimensions
62
M12x1
47
Ø 5,3
Ø 8,1
47
7,5
26,5
31 31
11,3
27