Lincoln SKF ContiMaster User manual

951-171-037-EN

Version 02

2017/10/27

Assembly instructions

following machinery directive 2006/42/EC

ContiMaster

Hydraulically driven barrel pump

509-33996-1

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951-171-037

Version 02

EC Declaration of incorporation following machinery directive 2006/42/EC, annex II, part 1 B

The manufacturer, SKF Lubrication Systems Germany GmbH, Walldorf Facilities, Heinrich-Hertz-Straße 2-8, D - 69190 Walldorf, hereby declares that the

partly completed machinery

Designation: Hydraulically driven barrel pump to supply lubricants

Type: ContiMaster

Part number: 509-33996-1

Year of construction: See type identification plate

complies with the following basic safety and health requirements of the EC machinery directive 2006/42/EC at the time when first being launched in the

market.

1.1.2 · 1.1.3 · 1.3.2 · 1.3.4 · 1.3.7 · 1.3.8.2 · 1.5.3 · 1.5.6· 1.5.8 · 1.6.1 · 1.7.1 · 1.7.2 · 1.7.3

The special technical documents were prepared following Annex VII part B of this directive. Upon justifiable request, these special technical documents can be

forwarded electronically to the respective national authorities. The person empowered to assemble the technical documentation on behalf of the manufacturer

is the head of standardization, See manufacturer's address.

Standard Edition

DIN EN ISO 12100 2011

DIN EN ISO 809 2012

The partly completed machinery must not be put into service until the final machinery into which it is to be incorporated has been declared in conformity with

the previsions of machinery directive 2006/42/EC and any other applicable directives.

Walldorf, 14/08/2017

Jürgen Kreutzkämper

Manager R&D Germany

SKF Lubrication Business Unit

Stefan Schürmann

Manager R&D Hockenheim/Walldorf

SKF Lubrication Business Unit

EC Declaration of incorporation

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951-171-037

Version 02

Legal disclosure

Training courses

In order to provide a maximum of safety and

economic viability, SKF carries out detailed

training courses. It is recommended that the

training courses are attended. For more in-

formation please contact the respective SKF

Service address.

Warranty

The instructions do not contain any informa-

tion on the warranty. This can be found in

our general terms and conditions.

Disclaimer

The manufacturer shall not be held respon-

sible for damages caused by:

○non appropriate use

faulty assembly, operation, setting, main-

tenance, repair or accidents

○use of inappropriate lubricants

○improper or late response to

malfunctions

○unauthorized modifications of the

product

○intent or negligence

○use of non-original SKF spare parts

Liability for loss or damage resulting from

the use of our products is limited to the

maximum purchase price. Liability for con-

sequential damages of whatever kind is

excluded.

Legal disclosure

Manufacturer

SKF Lubrication Systems Germany GmbH

Manufacturer's facilities

Head Office

Walldorf Facilities

Heinrich-Hertz-Str. 2-8

69190 Walldorf

Germany

Phone +49 (0) 6227 33-0

Fax: +49 (0) 6227 33-259

Berlin Facilities

Motzener Straße 35/37

12277 Berlin

Germany

Phone +49 (0)30 72002-0

Fax +49 (0)30 72002-111

www.skf.com/lubrication

Hockenheim Facilities

2. Industriestraße 4

68766 Hockenheim

Germany

Phone +49 (0)62 05 27-0

Fax +49 (0)62 05 27-101

E-mail: Lubrication-germany@skf.com

www.skf.com/lubrication

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951-171-037

Version 02

EN Table of contents

Table of contents

EC Declaration of incorporation following machinery

directive 2006/42/EC, ..........................................................................................2

Legal disclosure......................................................................................................3

Explanation of symbols, signs and abbreviations............................................... 6

1. Safety instructions.........................................................................8

1.1 General safety instructions....................................................................8

1.2 General behaviour when handling the product...................................8

1.3 Intended use............................................................................................ 9

1.4 Foreseeable misuse................................................................................9

1.5 Reference on Pressure Equipment Directive 2014/68/EU .............10

1.6 Modifications of the product................................................................10

1.7 Prohibition of certain activities............................................................10

1.8 Inspections prior to delivery ................................................................10

1.9 Other applicable documents................................................................10

1.10 Markings on the product......................................................................11

1.11 Notes related to the type identification plate.....................................11

1.12 Persons authorized to operate the pump ..........................................12

1.12.1 Operator.................................................................................................12

1.12.2 Specialist in mechanics ........................................................................12

1.12.3 Specialist in electrics ............................................................................12

1.13 Briefing of external technicians...........................................................12

1.14 Provision of personal protective equipment......................................12

1.15 Operation...............................................................................................12

1.16 Emergency stopping.............................................................................12

1.17 Transport, installation, maintenance, malfunctions,

repair, shutdown, disposal. ..................................................................13

1.18 Initial commissioning / daily start-up.................................................14

1.19 Cleaning .................................................................................................14

1.20 Residual risks ........................................................................................15

2. Lubricants................................................................................... 16

2.1 General information .............................................................................16

2.2 Selection of lubricants..........................................................................16

2.3 Material compatibility...........................................................................16

2.4 Temperature characteristics................................................................16

2.5 Ageing of lubricants..............................................................................17

3. Overview, functional description ................................................ 18

4. Technical data ............................................................................. 20

4.1 Mechanics..............................................................................................20

5. Delivery, returns, and storage .................................................... 22

5.1 Delivery..................................................................................................22

5.2 Returns .................................................................................................22

5.3 Storage...................................................................................................22

6. Installation.................................................................................. 23

6.1 General information .............................................................................23

6.2 Place of installation...............................................................................23

6.3 Minimum assembly dimensions .........................................................24

6.4 Adjusting the volumetric flow rate......................................................25

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Table of contents

7. Initial start-up ............................................................................ 26

7.1 Inspections prior to initial start-up.....................................................26

7.2 Inspections during initial start-up ......................................................26

8. Operation.................................................................................... 27

9. Cleaning ...................................................................................... 28

9.1 Cleaning agents.....................................................................................28

9.2 Exterior cleaning ...................................................................................28

9.3 Interior cleaning....................................................................................28

10. Maintenance ............................................................................... 29

11. Troubleshooting.......................................................................... 30

12. Repairs........................................................................................ 31

12.1 Safety instructions................................................................................31

12.2 Tools and accessories ...........................................................................32

12.3 Replacement of the angled casings ....................................................33

12.4 Replacement of the pump tube...........................................................34

12.5 Replacement of pressure-reducing valve and flow control valve....37

12.6 Replacement of the oscillating cylinder..............................................38

13. Shutdown and disposal............................................................... 41

13.1 Temporary shutdown ...........................................................................41

13.2 Final shutdown and disassembly ........................................................41

13.3 Disposal..................................................................................................41

14. Spare parts ................................................................................. 42

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EN Explanation of symbols, signs and abbreviations

Explanation of symbols, signs and abbreviations

General warning Suspended load Risk of falling Hot surfaces

Unintentional intake Crushing hazard Pressure injection Cold surfaces

Wear personal protective

equipment (goggles)

Wear personal protective

equipment (face shield)

Wear personal protective

equipment (gloves)

Wear personal protective

equipment (protective clothes)

Wear personal protective

equipment (safety shoes) General obligation

Keep unauthorized persons

away.

CE marking Disposal, recycling

Warning level Consequence Probability Symbol Meaning

DANGER Death, serious

injury imminent lChronological guidelines

WARNING Death, serious

injury possible ¡Lists

CAUTION Minor injury possible Refers to other facts, causes, or consequences

NOTICE Property damage possible

The following abbreviations may be used within these instructions. Symbols within safety notes mark the kind and source of the hazard.

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951-171-037

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Explanation of symbols, signs and abbreviations

Abbreviations and conversion factors

re. regarding °C degrees Celsius °F degrees Fahrenheit

approx. approximately K Kelvin Oz. Ounce

i.e. that is N Newton fl. oz. fluid ounce

etc. et cetera h hour in. inch

poss. possibly s second psi pounds per square inch

if appl. if applicable d day sq.in. square inch

a.a.r. as a rule Nm Newtonmeter cu. in. Cubic inch

incl. including ml millilitre mph miles per hour

min. minimum ml /d millilitre per day rpm revolutions per minute

max. maximum cc cubic centimetre gal. gallon

min. minute mm millimetre lb. pound

etc. et cetera l litre hp horse power

e.g. for example dB (A) Sound pressure level kp kilopond

kW kilowatt > greater than fpsec feet per second

U Voltage < less than Conversion factors

R Resistance ± plus/minus Length 1 mm = 0.03937 in.

I Current Ø Diametre Area 1 cm² = 0.155 sq.in

V Volt kg Kilogram Volume 1 ml = 0.0352 fl.oz.

Wwatt rh relative humidity 1 l = 2.11416 pints (US)

AC alternating current ≈approximately Mass 1 kg = 2.205 lbs

DC: direct current = equal to 1 g = 0.03527 oz.

A ampere % per cent Density 1 kg/cc = 8.3454 lb./gal(US)

Ah Ampere hour ‰ per mille 1 kg/cc = 0.03613 lb./cu.in.

Hz Frequency [Hertz] ≥greater than Force 1 N = 0.10197 kp

nc normally closed contact ≤less than Pressure 1 bar = 14.5 psi

no normally open contact mm2square millimetre Temperature °C = (°F-32) x 5/9

N/A Not released rpm revolutions per minute Output 1 kW = 1.34109 hp

Acceleration 1 m/s² = 3.28084 ft./s²

Speed 1 m/s = 3.28084 fpsec.

1 m/s = 2.23694 mph

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EN 1. Safety instructions

1. Safety instructions

1.1 General safety instructions

○The owner must ensure that safety infor-

mation has been read by any persons en-

trusted with works on the product or by

those persons who supervise or instruct

the before-mentioned group of persons.

In addition, the owner must also ensure

that the relevant personnel are fully fa-

miliar with and have understood the con-

tents of the Instructions. It is prohibited to

commission or operate the product prior

to reading the Instructions.

○These Instructions must be kept for fur-

ther use.

○The described products were manufac-

tured according to the state of the art.

Risks may, however, arise from a usage

not according to the intended purpose

and may result in harm to persons or

damage to material assets.

○Any malfunctions which may affect safety

must be remedied immediately. In addi-

tion to these Instructions, general statu-

tory regulations for accident prevention

and environmental protection must be

observed.

1.2 General behaviour when handling the

product

○Keep unauthorized persons away.

○Wear personal protective equipment

always.

○All relevant persons must be informed

of the activity prior to starting any work.

Observe the precautionary operational

measures and work instructions.

○The product may be used only in aware-

ness of the potential dangers, in proper

technical condition, and according to the

information in these instructions.

○Familiarize yourself with the functions

and operation of the product. The speci-

fied assembly and operating steps and

their sequences must be observed.

○Any unclear points regarding proper

condition or correct assembly/ operation

must be clarified. Operation is prohibited

until issues have been clarified.

○Precautionary operational measures and

instructions for the respective work must

be observed.

○Responsibilities for different activities

must be clearly defined and observed.

Uncertainty seriously endangers safety.

○Safety-related protective and safety

equipment must not be removed, modi-

fied 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 be checked for correct function.

○Never use parts of the centralized lu-

brication system or of the machine as

standing or climbing aids.

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1. Safety instructions

○Remedy occurring faults in the frame of

responsibilities. Immediately inform your

superior in the case of faults beyond your

competence.

1.3 Intended use

Supply of lubricants within a centralized lu-

brication system following the specifications,

technical data and limits stated in these

Instructions:

Usage is allowed exclusively for professional

users in the frame of commercial and eco-

nomic activities.

1.4 Foreseeable misuse

Any usage differing from the one stated in

these Instructions is strictly prohibited, par-

ticularly a usage:

○outside the indicated temperature range

○with non-specified means of operation

○without pressure-reducing valve and

flow-control valve

○in areas with aggressive or corrosive ma-

terials (e.g. high ozone pollution)

○in areas with harmful radiation (e. g. ion-

ising radiation)

○to supply, transport, or store hazardous

substances and mixtures in accordance

with annex I part 2-5 of the CLP regula-

tion (EG 1272/2008) and marked with

GHS01 - GHS06 and GHS08 hazard

pictograms.

○to feed, forward, or store gases, liquefied

gases, dissolved gases, vapours, or fluids

whose vapour pressure exceeds normal

atmospheric pressure (1013 mbar) by

more than 0.5 bar at the maximum per-

missible operating temperature.

○in an explosion protection zone

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951-171-037

Version 02

EN 1. Safety instructions

1.5 Reference on Pressure Equipment

Directive

2014/68/EU

Because of its performance data the product

does not achieve the limit values defined in

Article 4 (1) (a) (i) and is therefore excluded

from the scope of application of Pressure

Equipment Directive 2014/68/EU following

Article 4 (3).

1.6 Modications of the product

Unauthorized conversions or modifica-

tions may result in unforeseeable impacts

on safety. Therefore, any unauthorized

conversions or modifications are expressly

prohibited.

1.7 Prohibition of certain activities

Due to potential sources of faults that may

not be visible or due to legal regulations

the following activities may be carried out

by manufacturer specialists or authorized

persons only:

○Repairs or changes to the drive exceeding

replacement in case of defects

1.8 Inspections prior to delivery

The following inspections were carried out

prior to delivery:

○Safety and functional tests

1.9 Other applicable documents

In addition to these instructions, the fol-

lowing documents must be observed by the

respective target group:

○Operational instructions and approval

rules

○Safety data sheet of the lubricant used

Where appropriate:

○Project planning documents

○Additional information on special ver-

sions of the pump. You will find these in

the special system documentation.

○Any documents of other components

required to set up the centralized lubrica-

tion system

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