Conversion ContiMaster PowerMaster III
Conversion ContiMaster PowerMaster III
951-151-006-EN
Version 02
2017/10/27
Legal disclosure
EN
Legal disclosure
Manufacturer Training courses Disclaimer
SKF Lubrication Systems Germany GmbH In order to provide a maximum of safety and The manufacturer shall not be held respon-
Manufacturer's facilities economic viability, SKF carries out detailed sible for damages caused by:
training courses. It is recommended that the ○ Non appropriate use
Head Office
training courses are attended. For more in- faulty assembly, operation, setting, main-
Walldorf Facilities
formation please contact the respective SKF tenance, repair or accidents
Heinrich-Hertz-Str. 2-8
Service address.
69190 Walldorf ○ Improper or late response to
Germany malfunctions
Phone +49 (0) 6227 33-0 Copyright
Fax: +49 (0) 6227 33-259 © Copyright SKF ○ Unauthorized modifications of the
product
All rights reserved.
Berlin Facilities ○ Intent or negligence
Motzener Straße 35/37 ○ use of non-original SKF spare parts
12277 Berlin Warranty
Germany The instructions do not contain any informa- Liability for loss or damage resulting from
Phone +49 (0)30 72002-0 tion on the warranty. This can be found in the use of our products is limited to the
Fax +49 (0)30 72002-111 our general terms and conditions. maximum purchase price. Liability for con-
[Link]/lubrication sequential damages of whatever kind is
excluded.
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@[Link]
[Link]/lubrication
951-151-006
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Table of contents
EN
Table of contents
Legal disclosure ...........................................................................................2
Explanation of symbols, signs and abbreviations ........................................4
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Explanation of symbols, signs and abbreviations
EN
Wear personal protective Wear personal protective Wear personal protective Wear personal protective
equipment (goggles) equipment (face shield) equipment (gloves) equipment (protective clothes)
Wear personal protective
General obligation
equipment (safety shoes)
Keep unauthorized persons
away.
CE marking Disposal, recycling
l
Death, serious
DANGER imminent Chronological guidelines
injury
¡
Death, serious
WARNING possible Lists
injury
CAUTION Minor injury possible Refers to other facts, causes, or consequences
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Explanation of symbols, signs and abbreviations
EN
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1. Safety instructions
EN
1. Safety instructions
1.1 General safety instructions 1.2 General behaviour when handling the ○ Precautionary operational measures and
product instructions for the respective work must
○ The owner must ensure that safety infor- be observed. Responsibilities for different
mation has been read by any persons en- ○ Keep unauthorized persons away.
activities must be clearly defined and ob-
trusted with works on the product or by ○ Wear personal protective equipment served. Uncertainty seriously endangers
those persons who supervise or instruct always. safety.
the before-mentioned group of persons.
In addition, the owner must also ensure ○ All relevant persons must be informed ○ Safety-related protective and safety
that the relevant personnel are fully fa- of the activity prior to starting any work. equipment must not be removed, modi-
miliar with and have understood the con- Observe the precautionary operational fied or affected otherwise in its function
tents of the Instructions. It is prohibited to measures and work instructions. and is to be checked at regular intervals
commission or operate the product prior ○ The product may be used only in aware- for completeness and function.
to reading the Instructions. ness of the potential dangers, in proper ○ If protective and safety equipment has to
○ These Instructions must be kept for fur- technical condition, and according to the be dismantled, it must be reassembled
ther use. information in these instructions. immediately after finishing the work, and
○ Familiarize yourself with the functions then be checked for correct function.
○ The described products were manufac-
tured according to the state of the art. and operation of the product. The speci- ○ Never use parts of the centralized lu-
Risks may, however, arise from a usage fied assembly and operating steps and brication system or of the machine as
not according to the intended purpose their sequences must be observed. standing or climbing aids.
and may result in harm to persons or ○ Any unclear points regarding proper ○ Check the parts to be mounted for ac-
damage to material assets. condition or correct assembly/ operation cordance with the intended use.
○ Any malfunctions which may affect safety must be clarified. Operation is prohibited
○ Remedy occurring faults in the frame of
must be remedied immediately. In addi- until issues have been clarified.
responsibilities. Immediately inform your
tion to these Instructions, general statu- superior in the case of faults beyond your
tory regulations for accident prevention competence.
and environmental protection must be
observed.
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1. Safety instructions
EN
1
1.3 Intended use 1.6 Markings on the product 1.8 Persons authorized to modify the
pump
Modification of PowerMaster III/ ContiMaster Existing safety-relevant markings on the
lubrication pumps to minimize leakages in product must not be removed, damaged or
the area of the oscillating cylinder. These made unrecognisable as a consequence of 1.8.1 Specialist in mechanics
service instructions are valid only for Power- the modification. Person with appropriate professional educa-
Master/ ContiMaster pumps with pump tube tion, knowledge and experience to detect
1.7 Other applicable documents and avoid the hazards that may arise during
84999. Performance data of the pump shall
not be affected by the modification. In addition to these instructions, the fol- transport, installation, start-up, operation,
lowing documents must be observed by the maintenance, repair and disassembly.
1.4 Foreseeable misuse
respective target group:
Any usage differing from the one stated ○ Operational instructions and approval
in these instructions is strictly prohibited, rules
particularly:
○ Safety data sheet of the lubricant used
○ a modification of pumps different of those
stated under Intended use. Where appropriate:
1.5 Modiications of the product
○ Project planning documents
○ Any documents of other components
Unauthorized modifications exceeding the
required to set up the centralized lubrica-
one described may result in unforeseeable
tion system
impacts on safety. Therefore, any unauthor-
ized modifications are expressly prohibited.
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2. Delivery, returns, and storage
EN
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3. Installation
EN
3. Installation
3.1 Scope of application of the activities described
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3. Installation
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3. Installation
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WARNING ○ Clean the pump. The hydraulic connec- Notes regarding a replacement of the cou-
tions, the pressure control valve and the pling and the coupling nut assy.
Risk of injury volume control valve as well as any other ○ Before replacing the coupling and/or the
Before carrying out any repair work, mounting places or assembly parts must coupling nut, check the piston rod with
take at least the following safety be free from contamination. regard to damages (e.g. scoring). If the
measures: ○ Drive the oscillating cylinder into its top piston rod is damaged, a replacement
○ Keep unauthorized persons position. should not be carried out on site, as dam- 6
age to the gaskets of the coupling nut
away. ○ Depressurize the pump and secure it cannot be excluded. Please contact our
○ Mark and secure work area. against being switched on again. Customer Service in such case.
○ Depressurize the pump. This ○ Remove the two hydraulic connections ○ After replacement there may occur a
applies to the hydraulic connec- from the oscillating cylinder. Then pro- short-term leakage on the gaskets of
tions as well as to the lubrication tect the loosened hydraulic connections the coupling nut. The leakage reduces in
line connections against being contaminated. Bind any the course of the pump operation as the
leaking hydraulic oil and dispose of in an
○ Cover wet or slippery parts ecologically sound manner.
gaskets will better fit to the piston rod
after some time. Minor light leakage of
○ Disconnect live neighbouring the gaskets even after the run-in period
units from the power supply and is normal and does not present any defect
secure them against unauthor- or damage of the pump.
ized connection.
○ The mounting sleeve is intended for sin-
gle use and must be checked for damages
prior to using it.
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3. Installation
EN
3.4.1 Disassembly
4 11
The replacement described
can be carried out only, if 4a
previously the pump was
removed from the barrel/
container.
• Remove the two angled casings (4) and Loosen screw M30x1,5 Fig. 2
keep them together with the screws (4a) Loosen the nuts of the distance rods Fig. 4
for further use.
11 1
• Turn screw M30x1,5 (10) with fork wrench
AF 32 out of coupling (11). To do so fix 10
coupling (11) with open-ring wrench AF
36.
1a 1a
• Turn coupling (11) with fork wrench AF 36
out of oscillating cylinder (1).
• Remove the four nuts (1a) of the distance
rods of the oscillating cylinder (1) from the
base plate by means of fork wrench AF 19
and eliminate them.
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3. Installation
EN
• Use suitable lifting device to lift oscillat- Remove oscillating cylinder Fig. 5 Fix the piston rod Fig. 6
ing cylinder (1) on the eyebolt (1b) and
remove it from the pump.
• Pull the piston rod (14) upwards by 1b
hand so that the fixing insert (18) can be 1
mounted.
• Fix the piston rod in the pump tube by 18
means of the fixing insert (18) as shown.
Otherwise during the replacement of the
coupling nut the piston rod might glide 6
into the pump tube.
• Use fork wrench AF 19/32” to loosen and
remove the connecting screw (12) from
the piston rod. When doing so fix piston
rod (14) with fork wrench AF 7/8“ against
torsion.
• Remove screw M 30x1,5 (10) from the
piston rod.
• Remove coupling nut (13) by means of Remove connecting screw Fig. 7
fork wrench AF 2 1/4“. 12
14
10
13
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3. Installation
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3. Installation
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3. Installation
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3.6 Replacement of the pump tube Remove casing Fig. 17 Loosen the nuts of the distance rods Fig. 20
• Remove the two angled casings (4) and
keep them together with the screws (4a) 1
for further use.
4
• Turn screw M30x1,5 (10) with fork
wrench AF 32 out of coupling (11). To do
4a
so fix coupling (11) with fork wrench AF 1a 1a
36.
• Turn coupling (11) with fork wrench AF
36 out of oscillating cylinder (1). 6
Loosen screw M30x1,5 Fig. 18 Remove oscillating cylinder Fig. 21
• Remove the four nuts (1a) of the distance
rods of the oscillating cylinder (1) from
the base plate and eliminate them. 11 1b
• Use suitable lifting device to lift oscillat- 10
ing cylinder (1) on the eyebolt (1b) and 1
remove it from the pump.
11
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3. Installation
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• Use fork wrench AF 19/32” to loosen and Remove connecting screw Fig. 22 Pump tube Fig. 24
remove the connecting screw (12) from
the piston rod. When doing so fix piston 12
rod with fork wrench AF 7/8“. 14 Loctite 274
• Remove old pump tube. 10
Fix the piston rod. Otherwise 13
the piston rod might glide into
the pump tube.
• Remove the closure cap (6a) from the 5
new pump tube (5).
Remove oscillating cylinder Fig. 23
• Use fork wrench AF 19/32” to screw con-
necting screw (12) onto the piston rod of
the new pump tube. When doing so, use 1c
fork wrench AF 7/8” to fix piston rod.
1
Tightening torque 95 Nm ± 5 Nm
6a
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3. Installation
EN
• Lift the oscillating cylinder (1) over the Mount parts Fig. 25 Mount coupling Fig. 26
pump again and use fork wrench AF 19
to mount it to the base plate of the new
pump tube with the four nuts (1a). 1
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3. Installation
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3. Installation
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3.8 Replacement of the oscillating
cylinder
Remove casings Fig. 29 Loosen the nuts of the distance rods Fig. 32
• Remove the two angled casings (4) and
keep them together with the screws (4a) 1
for further use.
• Turn screw M30x1,5 (10) with fork 4
wrench AF 32 out of coupling (11). To do
so fix coupling (11) with fork wrench AF 4a
36. 1a 1a
• Turn coupling (11) with fork wrench AF
36 out of oscillating cylinder (1).
6
• Remove the four nuts (1a) of the distance Loosen screw M30x1,5 Fig. 30 Remove oscillating cylinder Fig. 33
rods of the oscillating cylinder (1) from
the base plate and keep them for further
use. 11
1b
• Use suitable lifting device to lift oscillat- 10
1
ing cylinder (1) on the eyebolt (1b) and
remove it from the pump.
• Use fork wrench AF 19 to turn the 4 dis-
tance rods out of the oscillating cylinder,
coat them with Loctite 274 and turn
them into the new oscillating cylinder.
Remove coupling Fig. 31
Tightening torque 40 Nm ± 4.0 Nm
11
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3. Installation
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3. Installation
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4a
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4. Spare parts and accessories
EN
4. Spare parts
The spare parts may be used exclusively for replacement of identical defective parts. Modifications with spare parts on existing products are
not allowed.
14.2 a
14.2 b
14.2
14.2 c
14.2 d
14.3 a
14.5 14.3 b
14.4 14.3 c
14.6
14.3 d
14.7
14.3 e
14.3
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4. Spare parts and accessories
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14
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Version 02
2017/10/27