SKF Lincoln KFA Series Assembly Instructions Manual
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SKF Lincoln KFA Series Assembly Instructions Manual

SKF Lincoln KFA Series Assembly Instructions Manual

Piston pump unit with reservoir for use in centralized lubrication systems
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Assembly Instructions
Piston pump unit with
reservoir KFA(S) ...
for use in centralized lubrication systems
Created on:
19.01.2023
Document no.:
951-170-246-EN
Version:
01
Read these instructions before
installation or start-up of the
product and keep them readily
available for later consultation!

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  • Page 1 Assembly Instructions Piston pump unit with reservoir KFA(S) ... for use in centralized lubrication systems Created on: 19.01.2023 Document no.: 951-170-246-EN Version: Read these instructions before installation or start-up of the product and keep them readily available for later consultation!
  • Page 2 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.
  • Page 3 Appendix to Declaration of Incorporation in accordance with 2006/42/EC, Annex II, No. 1 B Description of the essential health and safety requirements according to 2006/42/EC, Annex I, which have been applied and fulfilled: Table 1 Appendix to Declaration of Incorporation No.: Essential health and safety requirement Applicable:...

  • Page 4: Masthead

    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.

  • Page 5: Table Of Contents

    5.4 Storage temperature range ..........20 Table of contents 5.5 Storage conditions for products filled with lubricant ..20 5.5.1 Storage period up to 6 months ....... 20 Masthead ....................4 5.5.2 Storage period between 6 and 18 months ... 20 Table of contents ..................

  • Page 7: Safety Alerts, Visual Presentation, And Layout

    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.” –...

  • Page 8: Safety Instructions

    Only • If protective and safety equipment has to be dismantled, it original SKF spare parts and SKF accessories may be used. must be reassembled immediately after finishing the work, • Any unclear points regarding proper condition or correct and then checked for correct function.

  • Page 9: Foreseeable Misuse

    during transport, installation, start-up, operation, maintenance, 1.9 Painting plastic components and repair and disassembly. seals The painting of any plastic components and seals of the 1.6 Foreseeable misuse products described is prohibited. Completely mask or remove Any usage of the product other than as specified in this manual plastic components before painting the main machine.

  • Page 10: Note On China Rohs Mark

    The product should be protected as much as possible from 1.16 Note on China RoHS mark humidity, dust, and vibration, and should be installed so that it The China RoHS mark confirms that there is no is easily accessible. Ensure an adequate distance from sources danger to persons or the environment from the of heat or cold.
  • Page 11 Table 2 Residual risks Residual risk Possible in lifecycle Avoidance / Remedy Personnel slipping due to floor G H K • Exercise caution when connecting hydraulic contamination with spilled or leaked connections on the product lubricants. • Promptly apply suitable binding agents and then remove the spilled or leaked lubricant •...

  • Page 12: Lubricants

    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.

  • Page 13: Overview, Functional Description

    Fig. 2 3. Overview, functional description 3.1 Area of application and design Fig. 1 Piston pump unit with reservoir, series KFAS1 Legend to Figure 2: 1. Lubricant reservoir 2. Pump housing 3. Electrical connections 4. Mounting hole Piston pump unit with reservoir, series KFA1 5.

  • Page 14: Model Designs

    3.1.1 Model designs Table 3 Model designs Application Designation Mounted Monitoring Control manifold Fill level Cycle switch external Internal Commercial vehicles 12 V / KFA1 • 24 VDC KFA1-W • • KFAS1 • KFAS1-W • • KFAS1-W-3 (4, …9) • •...

  • Page 15: Fill Level Monitoring

    Fig. 4 Table 6 Pressure limiting valves with T connector Order No. Tube ø in mm Cracking pressure in <Co ntent> 161-210-016 300 ± 20 161-210-030 200 ± 20 161-210-031 200 ± 20 Pressure limiting valve (DBV) 161-210-032 200 ± 20 161-210-040 120 ±...

  • Page 16: Electronic Control Unit (Optional)

    • On piston pump units without control unit, the signal is issued Progressive distributor monitoring can be activated and via the corresponding connector deactivated. The monitoring of the fill level switch, if present, always remains active. 3.5 Electronic control unit (optional) In case of a fault, e.g.

  • Page 17: Parameter Memory

    3.5.8 Parameter memory All essential system parameters are stored in the control unit's non-volatile memory, ensuring that no data is lost even in the case of power failure 3.6 Piston pump units with progressive distributor installed Piston pump units of the KFA(S) series can optionally be equipped with a progressive distributor.

  • Page 18: Technical Data

    4. Technical data Table 7 Technical data Piston pump unit with Unit KFA1-(W).., KFA1-M-(W).., KFAS10-(W) KFA10-(W) reservoir KFAS1-(W).. KFAS1-M-(W).. General Delivery rate /min 1.0; 1.5; 2.0 1.0; 1.5; 2.0 1.0; 1.5; 2.0 1.0; 1.5; 2.0 at 50 Hz /min 1.2; 1.8; 2.4 at 60 Hz Operating pressure Max.
  • Page 19 Table 7 Technical data Piston pump unit with Unit KFA1-(W).., KFA1-M-(W).., KFAS10-(W) KFA10-(W) reservoir KFAS1-(W).. KFAS1-M-(W).. Control unit IG502-2-I with control unit and screen None Pause time, adjustable 0.1…99.9 / 1...999 h / pulses (timer/counter mode) (see "Mode of operation") Factory setting: tPA = 10 h Contact time (pump cycle 0.1 ...

  • Page 20: Delivery, Returns, Storage

    5.5 Storage conditions for products filled 5. Delivery, returns, storage with lubricant 5.1 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...

  • Page 21: Assembly

    6.1.1 Connection dimensions 6. Assembly Piston pump units with reservoir are designed for wall 6.1 General mounting (industrial design) or installation on a vehicle (commercial vehicle design). The piston pump unit with reservoir is mounted on a connecting flange with three NOTICE fastening points.
  • Page 22 For color coding, see Table 8 The electrical connection of the piston pump units is established via a 4-pin circular connector Table 9 Cable set Fig. 7 Order No. Length of corrugated Length of hose wires 997-000-820 10 m 12 m KFA1-W with fill level monitoring Fig.

  • Page 23: Kfas1, Kfas1-W (Commercial Vehicles)

    KFAS1-W 6.2.3 KFAS1, KFAS1-W (commercial vehicles) With internal fill level monitoring If fill level monitoring is installed, it is always active. If the fill NOTICE level falls below the "min." mark, the operational sequence is Damage from incorrect power supply stopped and a fault message appears on the screen.
  • Page 24 KFA1-M without fill level monitoring X1 Electrical connection: Plug connector acc. to DIN 175301- The piston pump unit has an X1 plug connector 803. X2 Signal output from fill level switch WS; M12x1 circular Fig. 13 connector. Fig. 12 X1 plug connector Legend to Figure 13: KFA1-M-W plug connector 1 PIN without internal connection...

  • Page 25: Kfas1-M, Kfas1-M-W, Kfas1-M-Z, Kfas1-M-W-Z (Industrial)

    KFAS1-M-Z and KFAS1-M-W-Z 6.2.5 KFAS1-M, KFAS1-M-W, KFAS1-M-Z, Fig. 16 KFAS1-M-W-Z (industrial) NOTICE Damage from incorrect power supply • Power supply 12/24 VDC • For voltage specifications, see the type plate of the piston pump unit and also section 6.3 General conditions for connections X1 Electrical connection: Plug connector acc.
  • Page 26 Fig. 17 2-wire switch as NC contact (WH) or NO-contact (BK) Fig. 18 3-wire switch Table 14 Color coding X3 PIN Color code Conductor coloring brown white blue black...

  • Page 27: Kfa10, Kfa10-W (Commercial Vehicles)

    Fig. 20 6.2.6 KFA10, KFA10-W (commercial vehicles) NOTICE Damage from incorrect power supply • Power supply 115 / 230 V AC, 50 Hz and 60• For voltage specifications, see the type plate of the piston pump unit and also section 6.3 General conditions for connections X1 Electrical connection: Plug connector acc.
  • Page 28 Table 15 Color coding X2 PIN Color code Conductor coloring brown white blue black...

  • Page 29: Kfas10, Kfas10-W (Industrial)

    Fig. 23 6.2.7 KFAS10, KFAS10-W (industrial) NOTICE Damage from incorrect power supply • Power supply 115 / 230 V AC, 50 Hz and 60• For voltage specifications, see the type plate of the piston pump unit and also section 6.3 General conditions for connections X1 Electrical connection: plug connector acc.
  • Page 30 3-wire switch Fig. 25 3-wire switch Signal distributor for 2-wire and 3-wire cycle switches Fig. 26 2-wire and 3-wire switch with signal distributor Legend to Figure 26: 1 Black nut 2 Nickel-plated nut...

  • Page 31: General Conditions For Connections

    6.3 General conditions for connections Table 17 General conditions for connections Design Rated voltage Typical power Starting current Back-up fuse consumption (load- (approx. 20 ms) / inrush dependent) current KFA1... / KFAS1... 24 V DC 0.5 A approx. 1.4 A 3.0 A Commercial vehicles 12 V DC...

  • Page 32: Lubrication Line Connection

    Legend to Figure 28: For operating pressures up to 250 bar as can occur especially in 1 Cam disc progressive centralized lubrication systems, SKF cutting-sleeve 2 Return disc screw unions conforming to DIN 2353 can be used. If using 3 Guide slot in strainer ring...
  • Page 33 NOTICE Lubricant coming out Risk of contamination of waterways and soil Centralized lubrication systems and lubrication lines must always be free of leaks. Lubricants can contaminate soil and waterways. Lubricants must be used and disposed of properly. Observe the local regulations and laws regarding the disposal of lubricants.

  • Page 34: Operation

    7. Operation NOTE Observe the instructions from the machine manufacturer 7.1 General regarding the lubricants that are to be used The piston pump unit described functions automatically. You should, however, still observe the following instructions to Fig. 30 provide for trouble-free operation: •...

  • Page 35: Bleeding The Centralized Lubrication System

    7.3 Bleeding the centralized lubrication Table 18 system Display and control elements of control screen (KFAS) Image Designation Function NOTICE Damage to the bearings requiring lubrication Three-digit LED Displays The lubricant may only be fed without bubbles. Air pockets display parameters, values, in the lubricant adversely affect the function of the piston conditions, and...

  • Page 36: Pushbutton Operation (Kfas)

    The control screen is not switched on, and any currently active display or programming mode is interrupted. At the same 7.4.1 Pushbutton operation (KFAS) time, any pending fault messages are cleared. Table 19 NOTE Pushbutton operation (KFAS) Prior to clearing pending fault messages, first read them on Button Function the control screen to ensure smooth operation by determining and rectifying the cause of the fault...

  • Page 37: Explanation Of Display Contents Of The Three-Digit Led Display (Kfas)

    7.4.2 Explanation of display contents of the three-digit LED display (KFAS) Table 20 Explanation of display contents of the three-digit LED display (KFAS) Display Explanation of Explanation Value range Factory setting characters t = timer "Pause time in timer mode" parameter. 0.1h to 99.9 h 10 h PA = PAuse...
  • Page 38 Table 20 Explanation of display contents of the three-digit LED display (KFAS) Display Explanation of Explanation Value range Factory setting characters block Block operation No signal from cycle switch. Unlike in normal mode, the control unit is still the monitoring sequence.

  • Page 39: Programming (Kfas)

    7.4.3 Programming (KFAS) 7.4.3.1 Starting programming mode (KFAS) Programming mode can only be opened if the display is off. Long-press the button (> 3 s) to switch on the screen and start the programming mode. When programming mode is activated, any currently active lubrication procedure is interrupted. After exiting programming mode, a new lubrication cycle is started with the current values and parameters if no fault message is present.
  • Page 40 Table 22 Starting programming mode (KFAS) Step Button Action Display Programming mode is active. The first adjustable parameter is displayed. Example: Pause time in timer mode The PAUSE LED flashes. Press briefly The current value for the pause time is (select the parameter) displayed.
  • Page 41 • The CS or PS LEDs will flash while you make the changes Table 23 Set monitoring functions (KFAS) Step Button Action Display Programming mode is active. The first adjustable parameter is displayed. Example: Pause time in timer mode The PAUSE LED flashes. Press repeatedly until COP is displayed.
  • Page 42 Setting a new programming code deletes the factory default programming code and activates the new value. Write down the new value and store it in a safe place. The parameters cannot be programmed if the programming code is lost or forgotten. In this case, the piston pump unit must be sent to the dealer or authorized SKF branch office.

  • Page 43: Operation Of Kfas (Industrial And Commercial Vehicles)

    NOTICE Programming code 321 Do not enter the digits 321 as the new programming code Table 25 Change programming code (KFAS) Step Button Action Display Press longer than 3 s 000 is displayed. The three-digit LED display flashes Press either until 321 is set The key code 321 is displayed.
  • Page 44 Further information about the operating state and the set parameters can be queried in display mode: see section 7.4.4.2 Display mode (KFAS). Table 26 LED displays on the control screen during operation (KFAS) LED lights up Operating voltage is present on the piston pump unit and the control unit. The centralized lubrication system is currently in the pause time.
  • Page 45 Table 27 Display of parameters in display mode (KFAS) Step Button Display Switchover to the "contact time" parameter. Example: Contact time in timer mode Display of the remaining contact time for current lubrication cycle Example: The centralized lubrication system is currently in the pause time; the remaining contact time therefore cannot be displayed.

  • Page 46: Kfas Fault Indications

    Table 27 Display of parameters in display mode (KFAS) Step Button Display 13/14 Example: 2nd part of total value 1st part of total value Total value: 33.8 h The display clears 7.4.5 KFAS fault indications 7.4.5.1 Display of faults (KFAS) Depending on whether or not the progressive metering device monitoring is active and the piston pump unit has a lubricant level switch, the electronic control unit could display the faults listed in the following table.
  • Page 47 When this is done, all fault times counted during the entire operating time of the piston pump unit are summed. The current count can be read as described in section 7.4.4.2 Display mode (KFAS). NOTE The memory cannot be deleted...

  • Page 48: Maintenance And Repair

    Legend to Figure 33: and to prevent hazards from arising. 1 Pump element with O-ring SKF Lubrication Systems Germany GmbH shall not be held liable for damages resulting from improperly performed 2. Remove bothersome lubricant between the internal thread, assembly, maintenance or repair work on the product.
  • Page 49 Fig. 34 NOTICE Air in the unit The piston pump unit must be vented after replacement of the pump element. Sectional top view of pump housing Legend to Figure 34: 1 Cam disc 2 Return disc 3 Guide slot in strainer ring 4 Male thread 3.

  • Page 50: Cleaning

    9. Cleaning 9.1 Basics Cleaning should be carried out in accordance with the operator's own company rules, and cleaning agents and devices and the personal protective equipment to be used should likewise be selected in accordance with those rules. Only cleaning agents compatible with the materials may be used for cleaning.

  • Page 51: Faults, Causes, And Remedies

    6.2 Electrical connection 10.2 Fault analysis and rectification The following table provides an overview of possible malfunctions and their causes. Contact the Service department of SKF Lubrication Systems Germany GmbH if you cannot remedy the malfunction. Table 29...
  • Page 52 (2nd metering device) and lubrication points with higher lubrication requirements using the main metering device. In case of insufficient lubrication, reduce the pause time. In case of excessive lubrication, prolong it accordingly. Please contact SKF.

  • Page 53: Repairs

    11. Repairs < WARNING Risk of injury At a minimum, the following safety measures must be taken before any repairs: • Unauthorized persons must be kept away • Mark and secure the work area • Depressurize the product • Isolate the product, and lock and tag it out •...

  • Page 54: Appendix

    14. Appendix 14.1 China RoHS Table Table 30...
  • Page 56 ® SKF and Lincoln are registered trademarks of the SKF Group. ™ eLube is a trademark of the SKF Group. © SKF Group 2023 Reprint or reproduction of the contents of this information - even in part - is permitted only with SKF's prior written consent.

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