SKF Electro-pneumatic Barrel Pump – EPB-Pump- STA...Barrel Pump – EPB-Pump-STA ( Original...

REPBSTA1BFI.doc 2 May 2013 Rev. 1B

SKF Elect ro- pneum at ic Barre l Pum p – EPB- Pum p-STA ( Or igina l operat ing and m aintenanc e inst ruct ions according to EU Direct ive 2 0 0 6 / 4 2 / EC)

REPBSTA1BFI.doc 2 May 2013 Rev. 1B

CONTENTS

1 EC Declarat ion of incorporat ion ........................................................................................................... 1

2 Genera l descr ipt ion ................................................................................................................................... 2

3 Design ............................................................................................................................................................. 2

4 Operat ion ...................................................................................................................................................... 5

4.1 Start -up ....................................................................................................................................................... 6

4.1.1 Start -up – in a cent ral lubricat ion system ................................................................................... 6

4.1.2 Start -up – as a feed or filler pum p ................................................................................................ 8

4.1.3................................................................................................................................................................ 8

4.2 Replacing the lubricant drum ............................................................................................................... 10

4.2.1 Lubricant drum replacem ent – in a cent ral lubricat ion system ............................................. 10

4.2.2 Lubricant drum replacem ent – as a feed or filler pum p ......................................................... 12

5 Regular inspect ions ................................................................................................................................ 13

6 Fault isola t ion ............................................................................................................................................ 13

6.1 Fault isolat ion LED signals ..................................................................................................................... 13

6.2 Troubleshoot ing table ............................................................................................................................. 14

7 Technica l data ........................................................................................................................................... 16

7.1 Designat ions ............................................................................................................................................. 19

7.2 Connect ions .............................................................................................................................................. 19

7.3 Elect r ical and pneum at ic connect ions to SKF pum ping cent res .................................................... 21

7.3.1 SKF Maxilube, delivered after 1 April 2012 ............................................................................... 21

7.3.2 SKF Maxilube/ I F-105 pum ping cent re, delivered prior to 1 April 2012............................... 23

7.3.3 SKF Maxilube hydraulic unit 24V, delivered prior to 1 April 2012 ........................................ 30

7.3.4 SG-2102 hydraulic unit .................................................................................................................. 35

8 Spare par ts ................................................................................................................................................. 39

9 Contact inform at ion ................................................................................................................................ 42

REPBSTA1BFI .doc 8 Jan 2013 Rev. 1A 1 (39)

1 EC Declarat ion of incorporat ion Origina l declarat ion of incorporat ion for par t ly com pleted m achinery ( Machinery Direct ive 2 0 0 6 / 4 2 / EC, Annex I I , par t 1 , sect ion B) Oy SKF Ab

Teollisuust ie 6 (P.O. Box 80)

FI -40951 MUURAME

Persons authorised to compile the relevant technical documentat ion: Technical Manager and Product Manager, Centralized Lubricat ion Systems, Muurame Unit .

Declares that in the case of the part ly completed machinery:

SKF Elect ro- pneum at ic Barre l Pum p SKF- EPB- PUMP- X/ X- XXX the following essent ial requirements of the Machine Direct ive 2006/ 42/ EC are applied and

fulfilled: 1.1.2. 1.1.3, 1.1.5, 1.1.6, 1.2.1, 1.2.2, 1.2.3, 1.2.4, 1.2.6, 1.3.1, 1.3.2, 1.3.4, 1.3.7, 1.5.1, 1.5.4, 1.5.6, 1.5.7, 1.5.13, 1.6.1, 1.6.2, 1.6.3, 1.6.4, 1.7.1, 1.7.2, 1.7.3, 1.7.4

the relevant technical documentat ion is compiled in accordance with part B of Annex VI I of the Machine Direct ive and that this documentat ion or parts hereof will be t ransm it ted by post or elect ronically in response to a reasoned request by the nat ional authorit ies

and that this part ly completed machinery conforms to the provisions of the following EC direct ives: EMC direct ive 2004/ 108/ EC

and furthermore declares that the following European harm onised standards have been applied: Machine direct ive 2006/ 42/ EC: EN I SO 12100-1/ A1, EN I SO 12100-2/ A1

EMC direct ive 2004/ 108/ EC: EN 61000-6-4: 2007 ( for em issions) , EN 61000-6-2: 2005 ( for im m unity)

This part ly completed machinery must not be put into service unt il the final machinery into which it is to be incorporated has been declared in conform ity with the provisions of the Machine Direct ive 2006/ 42/ EC.

Muurame 14 December 2012 Place Date

Tuomo Helm inen Local Manager


W arning Read and follow the safety precaut ions and general inst ruct ions in this m anual and also in the SKF manual “Safety and general inst ruct ions for lubricat ion system s” . Failure to follow these inst ruct ions could result in serious injury or damage to the lubricat ion system or the equipment that is lubricated.

2 Genera l descr ipt ion SKF-EPB-PUMP-STA is an elect ro-pneumat ic barrel pump, in which the t radit ional mechanical valve cont rol has been replaced with elect ronic cont rol. The main purpose of the pump is to feed lubricant into a cent ral lubricat ion system. The pump can also be used as a separate feed or filler pum p. I n such a case, it m ust be connected to a separate 24 V power supply and a compressed air supply.

The unit is fixed on the lubricant drum and locked on the drum nut . A fully-assembled pump system consists of a pum p, a lid set and a compressed air regulator/ oiler assembly. A separate installat ion kit is needed for installing the pump in an exist ing system. The kit contains com ponents for at taching exist ing pneum at ic and elect r ic connect ions to the EPB pum p.

Note The SKF-EPB-PUMP-STA is intended for use with STA lid sets, which are suitable for greases in NLGI grades 0, 1 and 2.

3 Design

Figure 1 SKF-EPB-PUMP-STA barrel pum p

Posit ion Descr ipt ion

1 I nduct ive sensor

2 LED signal

3 Circuit board

4 Pneum at ic valve

5 I nduct ive sensor

6 M12 connector


Figure 2 MAX-LI DSET-XXX-STA-EPBP lid set

Figure 3 MAXI LUBE-SET-STA-EPBP compressed air regulator/ oiler assembly


18 Shut -off valve

19 Pressure regulator

20 Pressure gauge


7 Low level switch

8 Drum lid

9 Follower plate

10 Tank hose

11 Compressed air hose

12 M12 cable (L = 3 000 m m )

13 Pressure hose

14 Grease filter

15 Bleed screw

16 M12 Y piece

17 M12 cable (L = 600 mm)


Figure 4 STA-EPBP installat ion kit


12 M12 cable (L = 3 000 mm)

16 M12 Y piece

17 M12 cable (L = 600 mm)

21 Drum nut G2 STA

22 Air supply hose for the pum p

23 Stopper

24 Compressed air dist r ibutor

25 M12 connector (self-assembled)

26 Set screw

Stopper ( Figure 1 4 , page 2 4 )

Wire set ( Figure 1 8 , page 2 6 )

I nstallat ion kit SG-2102 ( Figure 3 0 , page 3 5 )


4 Operat ion The pump is operat ional when the power supply is connected and the green LED light is lit . The pump’s operat ion is cont rolled by an internal circuit board. Signals sent by induct ive sensors regulate the pneum at ic valve. The sensors ident ify the piston’s direct ion of movement . The lid set contains a low level alarm . The pum p m ust be connected to a com pressed air supply and a 24 VDC power supply. I f the pump is incorporated in a cent ral lubricat ion system, power is fed to the hydraulic unit through the M12 connector, either from the pump’s own cont rol unit or from an external cont rol unit .

The pump can also be used as a separate feed or filler pump. I n such a case, it must be connected to a separate compressed air supply and a 24 V power supply through the M12 connector. See sect ion 5.2: Connect ions ( page 1 9 ) .

Figure 5 Warning sym bols on SKF-EPB-PUMP-STA pum p

Wear protective eyewear

Wear hearing protection

Read operating instructions


4 .1 Star t - up

4 .1 .1 Star t - up – in a cent ra l lubr icat ion system

W arning Only professional elect r icians are allowed to make elect r ical connect ions. To m inim ise the r isk of elect r ic shock, check that the pumping cent re is turned off before m aking any connect ions. All power must be disconnected before any work involving handling any conduct ive parts or opening any part of the system or product .

W arning Make sure that there is no residual pressure in the system. Before opening the grease filter, rem ove pressure by opening the bleed screw (15) in the filter plug. Turn off the air supply by lift ing up the shut -off valve but ton (18) or set air pressure to 0 bar using the pressure regulator (19) and the pressure gauge (20) . Detach the M12 cable (12) from the pum p. I f the system is under pressure when the com ponents are being disconnected or opened, the com ponents or lubricant m ight be flung in the air causing injury to people or dam age to the environment .

Note Check that the workspace is clean. Make sure that no impurit ies enter the pump, the follower plate or the lubricant drum. I m purit ies m ay cause dam age to the lubricat ion system or the machine or device it lubricates.

Note The num bers in brackets indicate posit ion numbers in Figures 1, 2 and 3 ( pages 2 and 3 ) .

1 Check the condit ion of the lubricant drum. Damage in the drum will prevent the follower

plate (9) from lowering.

2 Rem ove the drum ’s original lid and press the follower plate closely on top of the lubricant in the drum. Ensure that air is pushed out from below the follower plate and that the follower plate’s suct ion port starts to fill with lubricant .

3 Fasten the body (10) of the low level switch to the Ø 20 mm hole on the barrel lid.

4 Fasten the lid (8) onto the lubricant drum with wing screws.

5 Place the pump through the drum lid and follower plate to the barrel. Lock the pump with the set screw in the drum nut so that the lower part of the pum p is approxim ately 2 cm above the bot tom of the drum.

6 Connect the pump to a power supply through the M12 connector (6) . See sect ions 5.2: Connect ions ( page 1 9 ) and 5.3. Elect r ical connect ions to SKF pum ping cent res ( page 2 1 ) . I f installed in other cent res, verify the connect ions from the cent re’s elect r ical drawings.

7 Connect the com pressed air hose (11) to the pressure regulator (19) and to the pum p’s inlet A.

8 Connect the low level switch cable (11) and the cables of the channel pressure cont rol units and shut -off valves to the pum ping cent re as described in the elect r ical drawings.

9 Place the rod of low level switch (12) on top of the follower plate through the hole on the lid.

1 0 Using the pressure regulator (19) and the pressure gauge (20) , set air pressure to 3.5–4.5


bar.

1 1 Connect the tank hose (10) to the pum p’s pressure connect ion (P) , and the other end of the hose to the grease filter (14) .

1 2 Turn on the pum p from the cont rol or pum ping cent re.

1 3 Bleed the tank hose of air by opening the bleed screw (15) of the grease filter.

1 4 Stop the pump from the cont rol or pumping cent re.


1 5 Move the tank hose to the pum p’s tank connect ion (T) , and the other end of the hose to the pum ping cent re’s tank connect ion (T) . Before at taching the hose, m ake sure that there is no air com ing out of the hose, only grease.

1 6 Connect the pressure hose (13) to the pum p’s pressure connect ion (P) and the other end of the hose to the grease filter (14) .

1 7 Turn on the pum p from the cont rol or pum ping cent re.

1 8 Bleed the pressure hose of air by opening the bleed screw (15) of the grease filter.

1 9 Stop the pump from the cont rol or pumping cent re.

2 0 Fill the header piping with lubricant by turning on the pump from the cont rol or pumping cent re.

2 1 After the header piping is filled and bled of air , turn off the pum p.

2 2 Check the header piping for leaks by applying pressure on it . Make sure that the pressure is suitable for the materials used in the current system and piping.

2 3 Using the pressure regulator (19) and the pressure gauge (20) , set the air pressure of the pum ping cent re to 3.5–4.5 bar. At this pressure, the pum p feeds lubricant through its pressure port P at a pressure of 220–290 bar (3200–4200 psi / 22–29 MPa) .

4 .1 .2 Star t - up – as a feed or f iller pum p

4 .1 .3

W arning Only professional elect r icians are allowed to make elect r ical connect ions. All power must be disconnected before any work involving handling any conduct ive parts or opening any part of the system or product .

W arning Make sure that there is no residual pressure in the system. Before opening the grease filter, rem ove pressure by opening the bleed screw (15) in the filter plug. Turn off the air supply by lift ing up the shut -off valve but ton (18) or set air pressure to 0 bar using the pressure regulator (19) and the pressure gauge (20) . Detach the M12 cable (12) from the pum p. I f the system is under pressure when the com ponents are being disconnected or opened, the com ponents or lubricant m ight be flung in the air causing injury to people or dam age to the environment .

Note The tank connect ion (T) and the tank hose (10) are not usually used when the pum p is used as a feed or filler pum p. I n this mode, the pump requires a separate power supply (24 VDC / m in 0.2 A, for example: SKF code 12381505) .

Note Check that the workspace is clean. Make sure that no impurit ies enter the pump, the follower plate or the lubricant drum. I m purit ies m ay cause dam age to the lubricat ion system or the machine or device it lubricates.



1 Check the condit ion of the lubricant drum. Damage in the drum will prevent the follower

plate (9) from lowering.

2 Rem ove the drum ’s original lid and press the follower plate closely on top of the lubricant in the drum. Ensure that air is pushed out from below the follower plate and that the follower plate’s suct ion port starts to fill with lubricant .

3 Fasten the body (10) of the low level switch to the Ø 20 mm hole on the barrel lid.

4 Fasten the lid (8) onto the lubricant drum with wing screws.

5 Place the pump through the drum lid and follower plate to the barrel. Lock the pump with the set screw in the drum nut so that the lower part of the pum p is approxim ately 2 cm above the bot tom of the drum.

6 Connect the pump to a power supply through the M12 connector (6) . See sect ion 5.2: Connect ions ( page 1 9 ) .

7 Connect the com pressed air hose (11) to the pressure regulator (19) and to the pum p’s inlet A.

8 Connect the low level switch cable (11) and the cables of the channel pressure cont rol units and shut -off valves to the pum ping cent re as described in the elect r ical drawings.

9 Place the rod of low level switch (12) on top of the follower plate through the hole on the lid.

1 0 Using the pressure regulator (19) and the pressure gauge (20) , set air pressure to 3.5–4.5 bar.

1 1 Connect the pressure hose (13) to the pum p’s pressure connect ion (P) and the other end of the hose to the grease filter (14) .

1 2 Turn on the pum p by turning on the power.

1 3 Bleed the pressure hose of air by opening the bleed screw (15) of the grease filter.

1 4 Stop the pum p by turning off the power.

1 5 Using the pressure regulator (19) and the pressure gauge (20) , set the pump’s air pressure to 3.5–4.5 bar.


4 .2 Replacing the lubr icant drum

4 .2 .1 Lubr icant drum replacem ent – in a cent ra l l ubr icat ion system

NOTE Ensure that the system is not under pressure when the drum is being replaced. Before opening the grease filter, rem ove pressure from the system by opening the bleed screw in the filter plug ( Figure 2 , pos. 1 5 ) . I f the system is under pressure when the components are being disconnected or opened, the components or lubricant m ight be flung in the air causing injury to people or damage to the environment .

Note Check that the workspace is clean. When changing the lubricant drum, make sure that no impurit ies enter the pum p, the follower plate or the drum. I mpurit ies may cause damage to the lubricat ion system or the machine or device it lubricates.


1 Turn off the power from the cont rol or pum ping cent re.

2 Turn off the air supply by lift ing up the shut -off valve but ton (18) or set air pressure to 0 bar using the pressure regulator (19) and the pressure gauge (20) .

3 Detach the M12 cable (12) from the pump.

4 Lift the pump out of the lubricant drum and place it on the pum p bracket or on a clean plast ic base. Be careful not to dam age the suct ion port at the bot tom of the pump.

5 Lift the rod of the low level switch (7) from the barrel.

6 Rem ove the lid (8) from the top of the drum .

7 Use the handles to lift the follower plate out of the barrel.

8 Replace the old lubricant drum with a new one.

9 Place the follower plate in the drum, closely on top of the lubricant . Ensure that air is pushed out from below the follower plate and that the follower plate’s suct ion port starts to fill with lubricant .

1 0 Fasten the lid onto the lubricant drum with wing screws.

1 1 Place the pump through the drum lid and follower plate to the barrel. Lock the pump with the set screw in the drum nut so that the lower part of the pum p is approxim ately 2 cm above the bot tom of the drum.

1 2 Place the rod of low level switch (13) on top of the follower plate through the hole on the lid.

1 3 Remove pressure from the grease filter (14) by opening the bleed screw (15) in the filter plug.

1 4 Clean the grease filter and the filter cart r idge, replace as necessary.

1 5 Turn on the air supply by pressing down the shut -off valve but ton (18) or set air pressure to 3.5–4.5 bar using the pressure regulator (19) and the pressure gauge (20) .

1 6 Connect the M12 cable to the pump.

1 7 Turn on the power from the cont rol or pumping cent re. I f a low level warning appears, reset it .


1 8 Make a test run.


4 .2 .2 Lubr icant drum replacem ent – as a feed or f iller pum p

NOTE Make sure that the pump does not start when the drum is being replaced. Rem ove pressure from the system . I f the system is under pressure when the com ponents are being disconnected or opened, the com ponents or lubricant m ight be flung in the air causing injury to people or dam age to the environment .

Note Check that the workspace is clean. When changing the lubricant drum, make sure that no impurit ies enter the pum p, the follower plate or the drum. I mpurit ies may cause damage to the lubricat ion system or the machine or device it lubricates.



2 Detach the M12 cable (12) from the pump.

3 Lift the pump out of the lubricant drum and place it on the pum p bracket or on a clean plast ic base. Be careful not to dam age the suct ion port at the bot tom of the pump.

4 Lift the rod of the low level switch (7) from the barrel.

5 Rem ove the lid (8) from the top of the drum .

6 Use the handles to lift the follower plate out of the barrel.

7 Replace the old lubricant drum with a new one.

8 Place the follower plate in the drum, closely on top of the lubricant . Ensure that air is pushed out from below the follower plate and that the follower plate’s suct ion port starts to fill with lubricant .

9 Fasten the lid onto the lubricant drum with wing screws.

1 0 Place the pump through the drum lid and follower plate to the barrel. Lock the pump with the set screw in the drum nut so that the lower part of the pum p is approxim ately 2 cm above the bot tom of the drum.

1 1 Place the rod of low level switch (7) on top of the follower plate through the hole on the lid.

1 2 Remove pressure from the grease filter (14) by opening the bleed screw (15) in the filter plug.

1 3 Clean the grease filter and the filter cart r idge, replace as necessary.

1 4 Turn on the air supply by pressing down the shut -off valve but ton (18) or set air pressure to 3.5–4.5 bar using the pressure regulator (19) and the pressure gauge (20) .

1 5 Connect the M12 cable to the pump.

1 6 Make a test run.


5 Regular inspect ions Monthly inspect ions

cont rol of the air regulator/ oiler assembly and water removal

cont rol of the operat ion of the pump

When the barrel is replaced:

Clean the grease filter and the filter cart r idge, replace as necessary.

6 Fault isola t ion

6 .1 Fault isola t ion LED signals Fault isolat ion is an autom at ic funct ion. During start -up, r ight after the first com pleted st roke, the system checks that the piston works correct ly:

Both induct ive sensors confirm movement within 5 s green light is lit .

Only one of the sensors sends a confirm at ion yellow light is lit . Change the induct ive sensors.

Neither of the induct ive sensors sends a confirm at ion red light starts blinking. First , check the pressure of the com pressed air supply. I f the fault is not cleared, change the induct ive sensors.


6 .2 Troubleshoot ing table Operat ion disturbance Cause of operat ion

disturbance Solut ion

The pump does not start . Compressed air supply is closed. Pressure of the com pressed air feed is not sufficient . Supply voltage is switched off.

Turn on the air supply by pressing down the shut -off valve but ton (18) ( Figure 6 , pos. e) or set air pressure to 3.5–4.5 bar using the pressure regulator (19) and the pressure gauge (20) . Check that the pressure at the compressed air regulator of the pum ping cent re is 3,5-4,5 bar. Check the compressed air supply piping for leaks. Check that the pump LED light is lit . Check that the supply voltage is switched on. Check that the M12 cable is connected. Check the condit ion of the M12 cable.

The pum p starts but the pressure does not r ise.

Pressure of the com pressed air feed is not sufficient .

Check that the pressure at the compressed air regulator of the pum ping cent re is 3,5-4,5 bar. Check the compressed air supply piping for leaks.

NOTE Before checking the following disturbances, turn off the power from the cont rol and pumping cent re. Turn off the air supply by lift ing up the shut -off valve but ton ( Figure 6 , pos. e) or set air pressure to 0 bar using the pressure regulator (19) and the pressure gauge (20) . Before opening the grease filter, remove pressure from the system by opening the bleed screw in the filter plug ( Figure 7 , pos. 1 5 ) . I f the system is under pressure when the components are being disconnected or opened, the components or lubricant m ight be flung in the air causing injury to people or dam age to the environm ent .

Operat ion disturbance Cause of operat ion disturbance

Solut ion

The pum p starts but the pressure does not r ise.

The grease filter has clogged. There is air in the suct ion piping.

Clean or replace the filter cart r idge of the grease filter. Bleed the pump of air by opening the bleed screw of the grease filter( Figure 7 , pos. 1 5 ) or the pump’s pressure connect ion (P) . Ensure that only grease (no


There are impurit ies in the suct ion head or the suct ion port of the pum p.

air) is com ing out of the bleed screw or the pressure connect ion. Contact Oy SKF Ab.

Figure 6 Shut-off valve but ton (e)

Figure 7 Grease filter (14) , bleed screw (15)


7 Technica l data Table 1 SKF-EPB-PUMP-STA, technical data

Value Unit Descr ipt ion

0…+ 50 32…120

° C ° F

Operat ing temperature range

300 4,350 30

bar psi MPa

Maximum pressure

1: 65 bar Pressure rat io

20…32 V DC Operat ing voltage

1.5 W Power consumpt ion

850 g/ m in Max. pum p output ( Figure 9 , page 1 8 )

5.5 gram s/ st roke

Pum p output per st roke

3.5–4.5 bar Compressed air supply

300 l/ m in Max. air consum pt ion ( Figure 9 , page 1 8 )

10,000 cSt Maximum viscosity

0–2 NLGI Lubricant grade

18 50 180

kg Lubricant drum capacity, 1/ 8 pum p Lubricant drum capacity, 1/ 4 pum p Lubricant drum capacity, 1/ 1 pum p

6.3 7.6 8.8

kg Weight , 1/ 8 pum p Weight , 1/ 4 pum p Weight , 1/ 1 pum p

650 × 130 × 130 920 × 130 × 130 1020 × 130 × 130

mm (H × L × W)

Dim ensions, 1/ 8 pum p Dim ensions, 1/ 4 pum p Dim ensions, 1/ 1 pum p

Alum inium, plast ic and steel

Body m aterial

50 mm Pump hose diameter

I P65 Protect ion class

80 dB Max. noise level

Table 2 Low level switch, technical data

Value Unit Descr ipt ion

2 wire sensor, NO Type

10…36 VDC Operat ing voltage

< 4.6 VDC Voltage drop

4…150 m A Current load

< 0.5 m A Leak current


Figure 8 Dim ensions, pum p with drum STA (1/ 1, 1/ 4, 1/ 8)


Figure 9 Pum p output curve

Unit Descr ipt ion

bar Lubricant counter pressure

g/ m in Pum p output

l/ m in Pum p air consum pt ion

Exam ple: I n indicat ion (1) , the compressed air input is 6 bar, and the counter pressure ( I ndicat ion 2) is 285 bar, which gives a lubricant output of 330 g/ m in ( I ndicat ion 3) . To determ ine the air consum pt ion, follow the 6 bar dashed line to I ndicat ion 4 and draw a horizontal line to the air consum pt ion scale ( I ndicat ion 5; 180 l/ m in) .


7 .1 Designat ions Table 3 SKF-EPB-PUMP-STA, designat ions

SKF- EPB- PUMP- A- B Abbrevia t ion Descr ipt ion

SKF-EPB-PUMP: SKF-EPB-PUMP SKF Elect ro-pneumat ic Barrel Pump

A: 1/ 8 Lubricant drum capacity: 18 kg

1/ 4 Lubricant drum capacity: 50 kg

1/ 1 Lubricant drum capacity: 180 kg

B: STA The unit is fixed on the lubricant drum.

Exam ple:

Lubricant barrel size 1/ 1 = 180 kg

The pum p is fixed on the lubricant barrel

SKF Elect ro-pneumat ic Barrel Pum p

SKF EPB-PUMP-1/ 1-STA

7 .2 Connect ions

Figure 1 0 Connect ions

Hydraulic connect ions (P, T) :

P = pressure, lubricant out let , pipe connector Ø 12 m m

T = tank, lubricant input , pipe connector Ø 12 mm

Air inlet (A)

Push- fit connector 8 mm, 1/ 4 woven nylon hose

Elect r ical connect ions (P/ C)

M12 connector (socket )


Figure 1 1 The pum p’s M12 connector

M1 2 pin

M1 2 cable w ire colours Descr ipt ion

1 brown low level switch (+ )

2 white pum p cont rol 0 VDC

3 blue pum p cont rol 24VDC

4 black low level switch ( - )

5 grey cont rol (opt ional)


7 .3 Elect r ica l and pneum at ic connect ions to SKF pum ping cent res

7 .3 .1 SKF Maxilube, de livered after 1 Apr il 2 0 1 2 1 Connect the M12 cable (3,000 mm) delivered with the replacem ent kit to the pump’s P/ C

socket and Maxilube’s D socket .

2 Cut the low level switch cable to about 1,000 mm.

3 Remove the jacket of the low level switch cable to a 30 mm distance from the cut . Repeat for the t ips of individual wires (bk, wh) to a 10 m m distance. Using ferrules on the t ips is recom m ended.

4 Detach parts Y1, Y2 and Y3 of the M12 connector.

5 Push the low level switch cable through Y1 and Y2 and press the cable jacket to the connector by screwing Y1 and Y2 together.

6 At tach the wire t ips with screws to part Y3 of the M12 connector (see Table 4 and Figure 12) .

7 Screw Y3 and Y2 together.

Figure 1 2 M12 connector of the low level switch

Table 4 Connect ions of the M12 connector of the low level switch

M1 2 connector

M1 2 w ire colours

Descr ipt ion

1 white (wh) low level switch

(+ ) NO

2 do not connect N/ A N/ A


4 black (bk) low level ( - ) NO


switch


8 Connect the M12 cable (L = 600 mm) to the M12 connector of the pum p and the other end to the M12 Y piece (16) (see Figure 13) .

9 Connect the M12 cable (12) leading to the hydraulic unit to the M12 Y piece (16) .

1 0 Connect the M12 connector (25) of the low level switch to the M12 Y piece (16) .

1 1 Turn on the air supply by pressing down the shut -off valve but ton (18) .

1 2 Turn on the power from the cont rol and pumping cent re.


7 .3 .2 SKF Maxilube/ I F- 1 0 5 pum ping cent re, de liver ed pr ior to 1 Apr il 2 0 1 2

W arning Only professional elect r icians are allowed to make elect r ical connect ions. To m inim ise the r isk of elect r ic shock, all power must be disconnected before any work involving handling any conduct ive parts or opening any part of the system or product .

Note A separate installat ion kit is needed for installing the pump in an exist ing system ( Figure 4 , page 4 ) (SKF code 12381354)

1 Turn off the power from the cont rol and pumping cent re.

2 Turn off the air supply by lift ing up the shut -off valve but ton (18) .


3 Remove the old pump and at tach the plug delivered with the installat ion kit to SKF Maxilube pum ping cent re’s com pressed air inlet (Figure 14, connect ion A2) .

Figure 1 4 Compressed air inlet A2

4 Connect the com pressed air dist r ibutor ( f) delivered with the installat ion kit to the air regulator/ oiler assembly’s output port (e) , see Figure 15.

5 Connect the following com ponents to the com pressed air dist r ibutor: SKF Maxilube pum ping cent re’s air supply hose to port (h) and the EPB pum p’s air supply hose to port ( i) , see Figure 15.

Figure 1 5 Compressed air connect ions

6 Open the metal cover (a) of the SKF Maxilube pum ping cent re and unscrew the nut (b) below it , see Figure 16. Then lift off the lid (c) and the shell (d) of the pump.


Figure 1 6 Accessing the inner parts of the pum ping cent re

7 Detach connectors ( j ) and (k) from the circuit board, see Figure 17. Pull the low level switch’s M12 connector out of socket D at the bot tom of SKF Maxilube pum ping cent re, and pull out the detached wire set .

Figure 1 7 Wire set rem oval

8 Detach solenoid valve plugs MV1, MV2 and MV3, see Figure 17. Pull out the detached wire set .

9 Connect solenoid valve plugs MV1, MV2 and MV3 of the wire set (Figure 18, delivered with


the installat ion kit ) in the order shown in Figure 19.

Note The plugs m ust be placed in the correct sockets. Each plug’s cable shell is marked with the corresponding MV m arking. Check also that the gaskets under the plugs are in the correct posit ion. Change the gaskets as necessary.

Figure 1 8 Wire set

Figure 1 9 Solenoid valve connect ions


1 0 Connect the wire set ’s header plug to socket ( I ) as shown in Figure 20.

1 1 First , detach the wire set ’s connector (n) . Then, plug the wir ing set ’s M12 connector (m ) in socket D at the bot tom of SKF Maxilube pum ping cent re.

1 2 When the wire set has been at tached, reconnect the connector (n) .

Figure 2 0 Connect ing the wire set


1 3 Cut the low level switch cable to about 1,000 mm.

1 4 Remove the jacket of the low level switch cable to a 30 mm distance from the cut . Repeat for the t ips of individual wires (bk, wh) to a 10 m m distance. Using ferrules on the t ips is recom m ended.

1 5 Detach parts Y1, Y2 and Y3 of the M12 connector.

1 6 Push the low level switch cable through Y1 and Y2 and press the cable jacket to the connector by screwing Y1 and Y2 together.

1 7 At tach the wire t ips with screws to part Y3 of the M12 connector (see Table 5 and Figure 21) .

1 8 Screw Y3 and Y2 together.



M1 2 connector

M1 2 w ire colours

Descr ipt ion


(+ ) NO



4 black (bk) low level switch ( - ) NO


1 9 Connect the M12 cable (L = 600 mm) to the M12 connector of the pum p and the other end to the M12 Y piece (16) (see Figure 22) .

2 0 Connect the M12 cable (12) leading to the hydraulic unit to the M12 Y piece (16) .





2 4 Connect the M12 cable (3,000 mm) delivered with the installat ion kit to the pum p’s P/ C socket and Maxilube’s D socket .

2 5 Mount the hydraulic unit ’s shell (d) , lid (c) , nut (b) and m etal cover (a) in their or iginal posit ions (see Figure 15) .




7 .3 .3 SKF Maxilube hydraulic unit 2 4 V, delivered pr ior to 1 Apr il 2 0 1 2

W arning Do not m ake the connect ion if the operat ing voltage of the hydraulic unit is 115 VAC or 230 VAC. The operat ing voltage of the hydraulic part m ust always be checked on the hydraulic part type plate before start ing to m ake the connect ion.




2 Turn off the air supply by lift ing up the shut -off valve but ton (18) .

3 Remove the old pump and at tach the plug delivered with the installat ion kit to SKF Maxilube pum ping cent re’s com pressed air inlet (Figure 23, connect ion A2) .

Figure 2 3 Compressed air inlet A2


4 Connect the com pressed air dist r ibutor ( f) delivered with the installat ion kit to the air regulator/ oiler assembly’s output port (e) , see Figure 24.

5 Connect the following com ponents to the com pressed air dist r ibutor: SKF Maxilube pum ping cent re’s air supply hose to port (h) and the EPB pum p’s air supply hose to port ( i) , see Figure 24.


6 Open the metal cover (a) of the SKF Maxilube pum ping cent re and unscrew the nut (b) below it , see Figure 25. Then lift off the lid (c) and the shell (d) of the pump.

Figure 2 5 Accessing the hydraulic unit

7 Detach the wires of the low level switch, i.e. o: white and p: black, see Figure 26. Remove the cable of the low level switch from the hydraulic unit . Wires q (brown) and r (blue) will rem ain connected in parallel with new wires.


Figure 2 6 The connector st r ip of SKF Maxilube’s hydraulic unit before new connect ions

8 Connect the M12 cable (3,000 mm) delivered with the installat ion kit to the pum p’s P/ C socket

9 Cut off the plug on the other end of the M12 cable. Pass the cable through the low level switch’s cable ent ry at the bot tom of the hydraulic unit .

1 0 Rem ove the jacket to a 60 m m distance from the cut . Repeat for the t ips of individual wires to a 10 mm distance. Using ferrules on the t ips is recommended.

1 1 Connect the free wires of the M12 cable to the hydraulic unit ’s connector st r ip in the order indicated in Table 6.

Table 6 Strip connector diagram for SKF Maxilube’s hydraulic unit

Figure 2 7 The connector st r ip of SKF Maxilube’s hydraulic unit with completed connect ions

Maxilube st r ip connector

M1 2 w ire colours

Descr ipt ion

1 brown low level switch (+ )

5 white pum p cont rol 0 VDC

4 blue pum p cont rol 24VDC

2 black low level switch ( - )

do not connect grey cont rol (opt ional)










M1 2 connector

M1 2 w ire colours

Descr ipt ion


(+ ) NO











2 3 Mount the hydraulic unit ’s shell (d) , lid (c) , nut (b) and m etal cover (a) in their or iginal posit ions (see Figure 24) .




7 .3 .4 SG- 2 1 0 2 hydraulic unit





3 Connect the com pressed air dist r ibutor delivered with the installat ion kit to the output port of the air regulator/ oiler assem bly. I f necessary, use fit t ing (Figure 30, pos. s) .

4 Connect the com pressed air hose to port (u) as shown in Figure 30. Connect the other end of the com pressed air hose to the air input port of SG-2102 hydraulic unit .

5 Connect EPB pum p’s com pressed air supply hose to port (v) , see Figure 30.

6 Plug unused ports ( t ) with stoppers delivered with the installat ion kit .


7 Cut off the plug on the other end of the M12 cable. Pass the cable into SG-2102 hydraulic unit .

8 Rem ove the jacket to a 60 m m distance from the cut . Repeat for the t ips of individual wires to a 10 mm distance. Using ferrules on the t ips is recommended.

9 Connect the free wires of the M12 cable to the SG-2102 hydraulic unit ’s connector st r ip. The correct order is indicated in Table 8.


Table 8 Hydraulic unit SG-2102 – st r ip connector connect ion diagram

SG- 2 1 0 2 st r ip connector

M1 2 w ire colours

Descr ipt ion

10 brown (br) low level switch (+ )

2 white (wh) pump cont rol 0 VDC

3 blue (bl) pum p cont rol 24VDC

11 black (bk) low level switch ( - )

do not connect grey

cont rol (opt ional)









Table 9 M12 connector (connect ions)

M1 2 connector

M1 2 w ire colours

Descr ipt ion


(+ ) NO












8 Spare par ts Table 1 0 Spare parts for SKF-EPB-PUMP-STA. See Figure 33.

Posit ion Descr ipt ion Order code

1 I nduct ive sensor M8x1 L225 12381066

2 Signal light , 3 colour LED 12502334

3 Circuit board 12501370

4 Pneum at ic valve 12602120

5 I nduct ive sensor M8x1 L100 12381068

6 M12 connector 12502338

Figure 3 3 Spare parts for SKF-EPB-PUMP-STA


Table 1 1 Spare parts for MAX-LI DSET-XXX-STA-EPBP lid sets. See Figure 34.


7 Low level switch M12 STA 12381040

8 Drum lid 1/ 1 (180 kg) Drum lid 1/ 4 (50 kg)

12603700 12603750

9 Follower plate 1/ 1 (180 kg) Follower plate 1/ 4 (50 kg)

12603925 12603920

10 Hose assembly 12651232

11 Compressed air hose 12389728

12 M12 cable (L = 3 000 mm) 12502336

13 Hose assembly 12651232

14 Grease filter (com plete) 12386250

14 Grease filter cart r idge 12606550

15 Grease filter bleed screw 12407848

16 M12 Y piece 12502333

17 M12 cable (L = 600 mm) 12502337

Figure 3 4 Spare parts for the MAX-LI DSET-XXX-STA-EPBP lid set


Table 1 2 Spare parts for air regulator/ oiler assemblies See Figure 35.


18 Shut -off valve 12381392

19 Pressure regulator 12381394

20 Pressure gauge 12381396

Figure 3 5 Air regulator/ oiler assem bly MAXI LUBE-SET-STA-EPBP


Figure 3 6 Order codes

I tem Order code

Prodm ast code

Pum ps

SKF-EPB-PUMP-1/ 1-STA 12381540 VGBN 12381540

SKF-EPB-PUMP-1/ 4-STA 12381550 VGBN 12381550

I nsta lla t ion k it ( conta ins com ponents for a t taching ex ist ing pneum at ic and e lect r ic connect ions to the EPB pum p)

I NSTALLATION KI T STA-EPBP 12381353 VGBV 12381353

Lid sets

MAX-LI DSET-1/ 1-STA-EPBP 12381345 VGBV 12381345

MAX-LI DSET-1/ 4-STA-EPBP 12381335 VGBV 12381335

Com pressed a ir regula to r / oiler assem bly

MAXI LUBE-SET-STA-EPBP 12382678 VGBV 12382678

Pow er supply

EPBP-UNI POWER 24V 0.63A 100-240VAC 12381505 VGBV 12381505

9 Contact inform at ion Oy SKF Ab

P.O. Box 80 (Teollisuust ie 6)

FI -40951 MUURAME

FI NLAND

Tel. + 358 (0) 207 400 800

Fax + 358 (0) 207 400 899

www.skf.com

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