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Assembly Instructions KFG, KFGS, KFGL piston pump For automotive lubrication Created on: 12.01.2023 Document no.: 951-170-213-EN Version: Read these instructions before installation or start-up of the product and keep them readily available for later consultation!
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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.
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Description of the essential health and safety requirements according to 2006/42/EC, Annex I, which have been applied and fulfilled. Any essential health and safety requirements not listed here are not relevant to this product. Table 1 Appendix to Declaration of Incorporation Valid for: KFG* lubricant feed pumps No.: Essential health and safety requirement Applicable: Fulfilled: 1.1.1...
Training www.skf.com/lubrication We conduct detailed training in order to enable maximum safety and efficiency. We recommend taking advantage of this Berlin Plant training. For further information, contact your authorized SKF Motzener Strasse 35/37 dealer or the manufacturer. 12277 Berlin Germany Tel.
....................29 Safety alerts, visual presentation, and layout ......... 7 5.5 Lubricant level switch ............29 5.6 Type identification code for pump KFG ......30 1. Safety instructions ................8 6. Delivery, returns, storage............31 1.1 General safety instructions ............8 6.1 Delivery..................
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9.1.5 Fill level monitoring ............ 66 9.1.6 Monitoring via piston detector ......... 66 9.2 KFGL control unit ..............67 9.2.1 Display and control elements of control screen ... 67 9.2.2 Display and control menu ......... 69 9.2.3 Programming a KFGL pump unit ......71 10.
1. Instruction steps: These indicate a chronological sequence Safety alerts, visual of instruction steps. The numbers of the steps are in bold and are followed by a period. If a new activity follows, the presentation, and layout numbering starts again at “1.” –...
• Ensure proper connection of the protective conductor for modifications and changes are therefore prohibited. Only products with protection class I. Observe the specified original SKF spare parts and SKF accessories may be used. enclosure rating. • Any unclear points regarding proper condition or correct •...
1.3 General behaviour when handling the 1.5 Persons authorized to use the product product • Familiarize yourself with the functions and operation of the Operator product. The specified assembly and operating steps and their A person who is qualified by training, knowledge and experience sequences must be observed.
1.7 Referenced documents 1.10 Safety markings on the product In addition to this manual, the following documents must be observed by the respective target group: Fig. 1 • Company instructions and approval rules If applicable: Risk of dangerous electrical voltage •...
1.11 Note on the type plate 1.14 Note on Pressure Equipment Directive The type plate provides important data such as the type designation, order number, and sometimes regulatory Due to its performance characteristics, the product does not characteristics. To avoid loss of this data in case the type plate reach the limit values defined in Article 4, Paragraph 1, becomes illegible, it should be entered in the manual.
Drill required holes only on non-critical, non-load-bearing 1.21 Assembly, maintenance, fault, parts of the operator's infrastructure. Use existing holes where possible. Avoid chafe points. Immobilize any moving or detached repair parts during the work. Adhere to the specified torques. Prior to the start of this work, all relevant persons must be If guards or safety devices need to be removed, they must be notified of it.
1.23 Residual risks Table 3 Residual risks Residual risk Possible in lifecycle Avoidance / Remedy Personal injury / property damage due A B C G H K Unauthorized persons must be kept away. Nobody is to falling of hoisted parts. allowed to be present below hoisted parts.
Solid lubricants may only be used after prior consultation with make the selection in consultation with the supplier of the SKF. When solid lubricants are used in lubrication systems, the lubricant. If you have no or little experience in selecting following rules generally apply: lubricants for lubrication systems, please contact us.
20 kg sizes. These are made of transparent plastic. 3.1 General The lubricant reservoirs have fill level markings that allow the Pump units of the KFG, KFGS, and KFGL series are electrically fill level to be monitored visually. driven piston pumps with integrated reservoir and with or The pump fill level can be monitored using an integrated rocker without an integrated control unit.
Pump units of the KFG series 3.3.1 KFG pump units 3.3.3 KFGL pump units Pump units of the KFG series are reservoir pump units without Pump units of the KFGL series are reservoir pump units with an an integrated control unit.
3.4.1.2 Pressure limiting valve (DBV) 3.4 Functional description in progressive systems Fig. 5 3.4.1 KFG pump unit A general progressive metering device system consists of the following components: • Pump unit, pump element, pressure limiting valve and fill level monitoring.
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Example of progressive system with KFG pump unit Fig. 6 Progressive system with KFG pump unit 1 KFG pump unit 5 Lubrication lines 2 Lubricant level switch 6 Main metering device 3 Pump element with pressure limiting valve 7 Secondary metering device...
3.4.2 Progressive system with a KFGS or KFGL pump unit The general functional description for progressive systems with a KFG pump unit also applies for the design with KFGS and KFGL pump control. The control unit integrated into the pump housing allows the following additional configuration, monitoring and connectivity options: •...
3.5.1.3 Pressure limiting valve 3.5 Functional description in single-line Fig. 8 systems 3.5.1 KFG-Pump unit with grease follower plate technology A general single-line system consists of the following components: • Pump unit with pump element, pressure limiting valve, pressure relief valve and fill level monitoring •...
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Example of a single-line system with KFG pump unit Fig. 9 Single-line system with KFG pump unit 1 KFG pump unit 4 Main lubrication line 2 Pump element with pressure 5 Single-line metering device relief valve with integrated 6 Pressure gauge for...
Fig. 10 unit The general functional description for single-line systems with a KFG pump unit also applies for the design with KFGL pump control. The LC502 control unit integrated into the pump housing allows the following additional configuration, monitoring and connectivity options: •...
4. Accessories Accessories are used to extend, supplement the functional range or to assemble the product. Table 4 Accessories Designation Data Item number M12x1 plug, 4-pin, with 5 m cable 4x 0.25 mm , enclosure rating IP 67 (mounted) 179-990-719 Double-pin plug (T-connector) Double-pin plug (two-way distributor, for connecting to the M12x1 plug 179-990-700...
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Electronic control unit ST-102 for cab installation for single-line, dual-line, ST-102 for commercial vehicles and progressive systems Cable set for IG502-2-E For systems with piston pumps from the KFG series 997-000-185 NOTE The operating instructions/functional description of the corresponding control unit must be observed.
5. Technical data 5.1 General technical data Table 6 Technical data of the pump Parameter Values 12/24 VDC Maximum back pressure 300 bar Ambient temperature • with spring-return pump elements: -25 °C to +70 °C • with positively actuated pump elements: -30 °C to +70 °C Pump elements Max.
NOTE Protective measures that must be taken for operation according to the intended use in machinery for KFG, KFGS, KFGL... 24 VDC: • Protective Extra Low Voltage (PELV) Table 7 Reservoir size Weight (empty) Weight (filled) 2 kg reservoir 6 kg Approx.
5.3 Pressure limiting valve Fig. 12 Pressure limiting valve with emergency lubrication nipple Pressure limiting valve with T connector Pressure limiting valves 1 Emergency lubrication nipple (optional) P Pipe thread for pump element A Connection for pipe Ø R Grease discharge at overpressure Table 10 Pressure limiting valve without emergency lubrication nipple Tube ø...
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Table 12 Pressure limiting valve with T connector Tube ø [mm] Opening pressure [bar] Item number 161-210-038 161-210-032 161-210-039 161-210-031 161-210-016 161-210-030 Table 13 Pressure limiting valve with pressure gauge (not shown) Tube ø [mm] Opening pressure [bar] Item number 161-210-046 161-210-047 161-210-048...
– – 6 to 12 mA consumption Voltage drop – – ≤ 1,8 V at 200 mA Connection for KFG 7-pin circular connector 7-pin circular connector without control unit Connection for KFG Internal connection Internal connection with control unit Only for pumps without integrated control...
5.6 Type identification code for pump KFG O rd e r co d e Pum p unit Voltage key Pum p pau se tim e Con trol unit Reservoir capacity Pum p run tim e Ran ge of application Fitting, pressure regu latin g or relief valve...
6.5 Storage conditions for products filled 6. Delivery, returns, storage with lubricant 6.1 Delivery For products filled with lubricant, the permitted storage temperature range is: After receipt of the shipment, it must be inspected for any minimum + 5 °C [+41 °F] shipping damage and for completeness according to the maximum...
Table 16 local regulations for assembly and accident prevention. Minimum clearance height [mm] Size Without control unit With control unit < (KFG) (KFGL/KFGS) NOTICE Electrical interference fields <Co ntent> 2 kg On the pump units' electrical connections, ensure 6 kg...
7.2.2 Setup and attachment The pump unit should be installed in a place protected from contamination, water splashes, and vibrations. Any assembly holes must be made according to the diagram on the following page. Design specifications and conditions of the manufacturer and the object must be observed when installing the pump unit.
7.3 Pump elements of the KFG series Pump units of the KFG series are generally delivered with pump elements installed. KFG pump units can be equipped with up to three pump Perform the following to later add or replace a pump element: elements.
2. Undo and remove the plug screw (if there was no pump element installed at the position previously). Pump units of the KFG series are generally delivered with pump 3. If there is a pump element already installed at the position: elements installed.
7.3.3 Assembly of a pump element with positively driven pistons Fig. 20 Installing a positively driven pump element 1 Pump element 4 Guide of the eccentric ring 2 Pressure limiting valve 5 Housing bore 3 Lubrication line 6 Piston 10. Insert the piston in the bore of the pump element, leaving 1.
7.3.4 Pressure limiting valve (DBV) 7.4 Filling with lubricant Fig. 21 7.4.1 Filling via fill connection < NOTICE Contamination of the lubrication system Only fill using clean lubricant and an appropriate filling device. Contaminated lubricants can result in severe system malfunction.
7.4.2 Filler coupling 7.4.3 Filling cylinder Fig. 23 Fig. 24 Filling via filler cylinder (optional) 1 Plug screw M20 × 1.5 3 Filler cylinder Filler coupling (optional) 2 Fill connection 4 Caps 1 Filler neck 2 Coupling socket Optionally, the pump unit can be filled through one of the lubricant outlets using a filler cylinder.
1 Operating voltage specification on type plate The pump units of the KFG series are available in the voltage designs 12 VDC and 24 VDC. The electrical voltage is connected through a 4-pin cable socket according to DIN/EN 175301-803 or a 7-pin circular connector according to DIN 72585.
3-7 See the following connectivity sections through a 7-pin bayonet connector: see section 7.6.5.3 Electrical connection of KFG low-level signal on page 50. The The electrical connection is established via a 7-pin plug-in low-level signal must be processed by a system provided by the connection on the underside of the pump unit.
Fig. 28 7.6 Control port assignments The following sections present the connectivity most often applied with pump series KFG, KFGS, and KFGL. 7.6.1 KFG series (external control) The external control units listed in the section External control units and cable sets, Page 24are intended to be used for...
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Timer operation without system monitoring Timer operation with system monitoring Fig. 29 Fig. 30 Programming: tPA, tCO, COP = OFF Programming: tPA, tCO, COP = CS Connector pin assignment Connector pin assignment Table 23 Table 24 Connector pin assignment in timer operation Connector pin assignment in timer operation Code Assignment Code Assignment...
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Fig. 31 Counter operation without system monitoring Fig. 32 Plug-and-socket connection according to ISO 15170-1 Table 25 Connector pin assignment Color code Conductor coloring <Co ntent> Brown RD-BK Red-black Programming: cPA, tCO, COP = OFF Blue Connector pin assignment Pink Table 26 Yellow Black...
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Counter operation with system monitoring Fig. 33 Programming: cPA, tCO, COP = CS Connector pin assignment Table 27 Connector pin assignment in counter operation Code Assignment <Co ntent> – Supply voltage potential (0 V, GND) + Supply voltage potential "ignition ON" Pushbutton = 1.
7.6.3 KFGL series With integrated LC502 control unit The KFGL pump unit is available in the voltage version 12/24 VDC. The KFGL pump unit can be fitted with multiple fill level indicators, with the fill level indicator for Minimum being connected to the internal pump control unit. The other fill level indicators are connected to control devices supplied by the customer.
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7.6.3.2 KFGL ProFlex for progressive centralized lubrication systems Fig. 35 KFGL pump unit, ProFlex programming Table 29 Pin assignment, ProFlex programming 12/24 VDC Plug Assignment Power OV (-) 12/24 VDC (+) Fault Fault notification (-) Fault notification (+) In 3 External DK (+) External DK (-) Out 1...
• Type identification code 2 (previously W1G control) with signal smoothing, for grease of NLGI Grade 2 Table 30 With the pump model KFG (without control unit) with fill level Connector pin assignment monitoring, the signals are processed by a system provided by Assignment the customer.
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The connection is established via a 7-pin circular connector on the bottom of the pump unit. 7.6.5.3 Electrical connection of KFG low-level signal The standard version of the KFG pump units does not include fill level monitoring. If KFG pump units have fill level monitoring, its signals must be connected and processed externally (using a system provided by the customer).
7.7 Pump unit fill level control Table 32 Visual Connector pin assignment for type identification code The transparent lubricant reservoir allows for visual fill level 2 (W1G) control. This must be performed on a regular basis for safety Assignment reasons. <Co ntent>...
7.8 Connection of the lubrication line < CAUTION Risk of slipping Exercise caution when handling lubricants. Immediately remove and bind any leaked lubricants. NOTICE Damage to the higher-level machine caused by faulty planning of the centralized lubrication system All parts for the construction of the centralized lubrication system must be designed for the maximum operating pressure that occurs, the permissible ambient temperature range, the...
8. First start-up In order to warrant safety and function, a person assigned by the operator must carry out the following inspections. Immediately eliminate detected deficiencies. Deficiencies may be remedied by an authorized and qualified specialist only. 8.1 Inspections before first start-up Table 33 Checklist: Inspections before first start-up Inspections to be performed...
8.3 Progressive system ventilation 8.4 Single-line system ventilation 1. Fill pump with lubricant. 1. Fill pump with lubricant. NOTE NOTE The initial filling (basic filling) of the pump is done at the The initial filling (basic filling) of the pump is done at the factory.
9. Operation 9.1 KFGS control unit 9.1.1 Display and control elements of control screen Fig. 40 KFGS control screen The display and control unit is protected from water splashes and mechanical damage by a transparent plastic cover. The cover must be removed to program the unit and then remounted afterwards.
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9.1.1.1 LED indications The LED display is off in normal mode. It can be activated by briefly pressing one of the two pushbuttons . Current values and pre-set parameters are displayed. The display also serves to guide and prompt the operator while programming operating parameters. Table 36 Display and control elements of the KFGS control screen Display...
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9.1.1.2 LED display Table 37 LED indications LED lights up = display mode LED flashes = programming mode Operating voltage is present on pump unit and Value for PAUSE can be changed. control unit, system is currently in operating status PAUSE. Operating voltage is present on pump unit and Value for CONTACT can be changed.
9.1.2 KFGS display mode Display mode can be identified by the lit-up LED displays. The display does not flash. It is used to query the current settings and operating parameters. Always start the display mode by briefly pressing one of the two keys Table 39 Display mode Step...
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Table 39 (continued) Display mode Step Button Display Description Monitoring switched Monitoring via piston Not permitted on progressive systems. detector 10. / 11. Example: 1st part of 2nd part of total value total value Total value: 00533.8 h Note this down! Maximum value: 99999.9 h Display fault hours 13.
9.1.3 KFGS programming mode The working/pause times can be reprogrammed to adapt the lubrication intervals and the resulting lubricant quantities to specific requirements. 9.1.3.1 Start programming mode 1. Press and hold the key for more than 2 s. 2. The 3-digit LED display starts flashing. 3.
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Programming mode – Change lubrication interval times Step Button Display Description Pump cycle time 4.0 min (factory setting) For the permissible setting range for KFG(S), see section Technical data, Page 25 Press briefly (display in minutes) Set new value Example: 3 min Confirm new value —...
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9.1.3.3 Configure system monitoring System monitoring can be changed to activate or deactivate the monitoring functions for lubrication. When system monitoring is active, you can select monitoring via piston detector or monitoring via pressure switch. Table 41 Programming mode – Configure system monitoring Step Button Display...
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9.1.3.4 Change operating modes A change of operation mode means changing to timer operation, counter operation or special applications. Table 42 Programming mode – Configure system monitoring Step Button Display Description The display flashes. Enter the code (000 factory setting) Press for more than 2 s...
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Write down the new value and store it in a safe place. The parameters cannot be programmed if the code is lost or forgotten. In this case, the pump unit must be sent to the dealer or authorized SKF branch office.
0.1 min to 99.9 min Set tPA and tCO in programming mode. Pulses 1 to 999 For the permissible setting range for KFG(S), see section 9.1.4.2 Counter operation General technical data, Page 25. Pause time: dependent on the number of pulses, pump run time: time-dependent.
9.1.5 Fill level monitoring 9.1.6 Monitoring via piston detector NOTE NOTE If fill level monitoring is installed, it is always active. Only possible for centralized lubrication systems with progressive metering devices. For greases up to NLGI Grade If the level in the lubricant reservoir falls below the minimum fill level, the lubricant cycle is stopped and a fault notification is issued on the control screen.
9.2 KFGL control unit 9.2.1 Display and control elements of control screen Fig. 43 KFGS control screen The display and control unit is protected from water splashes and mechanical damage by a transparent plastic cover. The cover must be removed to program the unit and then remounted afterwards. Table 46 Display and control elements of the KFGS control screen Image...
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9.2.1.1 Operator keys Table 47 Functions of the operator keys Button Function Menu selection (navigation) Go to the selected menu based on direction of arrow. Editing numerical values (up/down arrow key) The numerical value is incremented/decremented based on direction of arrow. •...
Service menu Password-protected menu level enabled Not all possible options are displayed in the settings. Only only for SKF service personnel settings that are available and permitted for the selected device type (ProFlex or MonoFlex) and the current device settings are shown.
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3. Entering the password (if Change is selected): Table 49 Use the keys to enter the password and then Info menu confirm your entry using the key Parameter Description – You can use the key to cancel your entry and go back to <Co ntent>...
Fig. 48 "Config." menu Table 50 "Config." menu Menu/parameter Description <Co ntent> System Submenus in the "Config." menu Settings For detailed information, see the Inlets separate operating instructions for the Outlets control unit. Default Reset New Pwd 1. Use the keys to select the desired menu.
The centralized lubrication system is pressurized abroad. A list with current addresses is available on the Internet during operation. Depressurize the centralized lubrication system before starting maintenance www.skf.com/lubrication work NOTE Only original spare parts from SKF Lubrication Systems Germany GmbH may be used.
10.3 Maintenance schedule Careful and regular maintenance is required in order to detect and remedy possible faults in time. The operator must always determine the specific intervals according to the operating conditions, review them regularly, and adjust them where necessary. If necessary, copy the table for regular maintenance activities.
11. Cleaning 12. Faults, causes, and remedies < WARNING Risk of fatal electric shock The operator/operating personnel must perform visual fill level control of the lubricant reservoir at regular intervals. Cleaning work may only be performed on The control intervals depend on the amount of lubricant products that have been de-energized first.
12.1 Malfunctions on pump units Table 52 Pump malfunctions Fault Possible cause Remedy Stirring paddle in the lubricant reservoir • Mechanical damage, e.g., motor defective. • Replace pump. does not rotate during the activated pump • Carry out start-up and functional test. run time.
12.2 Malfunctions on KFGS pump unit NOTE The time during which the control unit and pump unit have been operated without lubrication is stored as fault hours NOTICE Fh in the EPROM and cannot be deleted. Damage to components The lubrication points may not be supplied with adequate lubrication because a malfunction has affected the proper 12.2.3 Fault types functioning of the lubrication system.
12.3 Malfunctions on KFGL pump unit NOTE A total of three lubrication cycles are performed with query NOTICE to the piston detector. Damage to components The lubrication points may not be supplied with adequate lubrication because a malfunction has Fig. 50 affected the proper functioning of the lubrication system.
13. Repairs NOTE The operating instructions for the LC502 control unit are < supplied together with these assembly instructions. WARNING • Document No. 951-180-004-EN: Pump units in Risk of injury MonoFlex design (single-line centralized lubrication At a minimum, the following safety system) measures must be taken before any •...
14. Shutdown, disposal 14.1 Temporary shutdown Temporary shutdowns should be done by a course of action to be defined by the operator. 14.2 Permanent shutdown, disassembly Permanent shutdown and disassembly of the product must be planned properly by the operator and conducted in compliance with all applicable laws and regulations.
15. Spare parts Spare parts may be used exclusively for replacement of identical defective parts. Modifications with spare parts on existing products are not allowed. Fig. 53 Exploded-view and spare parts drawings...
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Fig. 54 SKF MonoFlex design A SKF MonoFlex design B SKF MonoFlex design C with three pump elements with two pump elements with two pump elements Exploded-view and spare parts drawings Table 56 Wearing parts Item number Type identification Description code KFG1.U0...
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161-210-065 200 bar, straight connector ø 10 mm 161-210-062 200 bar, straight connector ø 12 mm 161-210-061 200 bar, SKF plug connector ø 8 mm 161-210-036 300 bar, female thread G1/4 161-210-012 300 bar, straight connector ø 6 mm 161-210-024 300 bar, straight connector ø...
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KFG DBV on the housing cover 30 bar G1/4 kit (rotary application) 24-9909-0243 – KFG fastening kit (for reservoir capacities from 8 kg to 20 kg only) 24-9909-0246 – KFG Sensor/Actuator Box kit, 230 V (+486) Industry or rotary application 24-9909-0254 –...
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