SKF KGF Series Configuration guide

1-0358-US1-3035-EN
Reservoir pump units of the
KGF series (S)(C)
for use in vehicles in automatic oil or grease lubrication systems
General Information
Pump units of the KFG, KFGS and KFGC (CAN
bus) series are electrically driven reservoir
pump units available with and without an in-
tegrated control unit. The pump provides on-
demand lubricant supply to centralized lubri-
cation systems with progressive feeders or
single-line distributors on machines, systems
and vehicles.The pump units differ in terms of
the size and type of lubricant reservoir, the
lubricant filling and their control and function
monitoring.Powerful CAN bus versions allow
one unit and a special valve to supply up to
four independent zones according to demand.
Application
Pump units of the KFG, KFGS and KFGC (CAN
bus) series are utilized in oil and grease lubri-
cation systems for on-road and off-road
vehicles.Examples include commercial vehi-
cles (on-road), construction and farm machi-
nery and forklift applications, as well as spe-
cial-purpose vehicles such as container loa-
ding devices and deep mining vehicles.
Advantages
Sturdy design with 1 to 3 pump elements•
Compact and reliable•
High-pressure technology with agitator is•
suitable for low working temperatures and
and standard greases up to NLGI Grade 2
and low working temperatures
Control unit with memory and system•
monitoring function
Optional CAN bus control for integration in•
application-specific control systems
Extensive accessories program with regard•
to system control options and application-
specific requirements

Pump units of the KFG, KFGS and KFGC (CAN bus) series for vehicle lubrication
2 1-3035-EN
Distinguishing features of
the pump units
In contrast with the KFG pump unit, which
can only be equipped with external pump
control, the KFGS pump unit contains an
internal control unit. This control unit can
configure basic settings such as timer opera-
tion (pause + run time = time-dependent) or
counter operation (pause = pulse-dependent,
run time = time-dependent). Fill level control
is also monitored by the pump control unit.
The KFGC (CAN bus) version is based on the
KFGS series. Furthermore, it is capable of
controlling up to four independent zones via
the CAN bus. The pump can optionally be
programmed, operated and its data read via
an IRDA interface.
Unit components
Item Description
1 Assembly holes
2 Lubricant reservoir
3 Pump element
4 Pressure regulating valve
5 Conical head nipple
(standard filling)
6 Electrical connection
7 General control unit
8 Pushbutton
9 Inputs and outputs (CAN bus version)
10 CAN bus plug
11 Pump bottom with control
6
:56
1
2
35
4
678
:56B
54
3
2
1
:562
20=1db
54
3
6
9
10
7
11
11
Table of Contents
Distinguishing features of the pump units 2
KFG pump unit 3
KFGS pump unit 3
KFGC (CAN bus) pump unit 3
Design 4
Pump housing 4
Assembly holes 4
Lubricant reservoir 4
Pump element 4
Pressure regulating valve 4
KFGS control unit 4
KFGC (CAN bus) 4
Functional description of progressive system
with KFG pump unit 5
Functional description of progressive system
with KFGS pump unit 5
Functional description of progressive system
with KFGC (CAN bus) pump unit 5
KFG pump unit 6
Dimensions 6
Fill level monitoring 7
Fill level switch type: W1 7
Fill level switch type: W1G 7
Function 7
Pressure regulating valves 8
Pump elements 8
General conditions for electrical connections 9
Power supply 12/24 VDC 9
KFGS pump unit 10
Dimensions 10
IG502-2-I integrated control and
monitoring unit 11
Fill level monitoring 12
Pressure regulating valves 12
Pump elements 13
General conditions for electrical connections 13
Settings for progressive lubrication 14
Connectivity for counter operation without
system monitoring 14
Connectivity for counter operation without
system monitoring 14
Connectivity for counter operation with
system monitoring 14
Connectivity for timer operation without
system monitoring 15
Connectivity for timer operation with
system monitoring 15
KFGC (CAN bus) pump unit 16
Dimensions 16
LC-CAN5000 integrated CAN bus
control unit with display 17
Connections 18
Connectivity 18
General conditions for electrical connections 18
Accessories 19
KFG - IG502-2-E electronic control unit 19
Pressure regulating valves with T connector
output for progressive systems 21
Pressure gauge 21
Connecting piece for pressure gauge 21
Pressure gauge screw connection with
gasket 21
Filling cylinder with connecting piece 22
Filling device with quick-action coupling 22
Topping-up pumps 22
Explanation of order codes 23

Pump units of the KFG, KFGS and KFGC (CAN bus) series for vehicle lubrication
31-3035-EN
KFG pump unit
The KFG pump has three lubricant outlets for
connecting up to three independent zones.
A separate pump element is required for each
outlet.
Up to four pump elements with different deli-
very volumes are available so the delivery
rate can be adjusted to the requirements of
the individual zones. This provides all lubrica-
tion points with the required amount of lubri-
cant during each lubrication cycle.
The pump fill level can be monitored using
the integrated rocker switch (W1/W1G for
NLGI Grade 2 greases). The pump is available
in various voltage designs. An agitator driven
by a geared motor ensures lubricant can be
delivered at temperatures down to -25 °C de-
pending on the medium. This also applies to
KFGS and KFGC (CAN bus) pump units.
KFGS pump unit
Pump units of the KFGS series are reservoir
pump units with an integrated control unit
based on the KFG. The KFGS pump unit is
controlled by the IG502-2-I integrated control
and monitoring unit, which can operate based
on time or pulses and with or without a mon-
itoring function.
This control unit provides the following ad-
vantages:
Non-volatile memory with PIN code•
protection
Recording of remaining intervals and•
remaining lubrication times
Recording of fault notifications (diagnostics•
memory, fault memory, not deletable)
Data backup in case of voltage failure•
Connectivity for external pushbutton•
Connectivity for inductive piston detector•
Operation display system•
Fault indication system•
Interval time and contact time can be•
adjusted independently, including on moni-
tored systems
Easy electrical connection using plug con-•
nectors, all electrical options can be used
via cable harness
Interval times (timer) and pump cycle times
(contact) can be entered via a display. An in-
ductive piston detector is used to monitor the
feeding operation on progressive systems.
The KFGS pump unit is available in the same
reservoir designs, reservoir sizes and voltage
designs as the KFG series.
KFGC (CAN bus) pump unit
Pump units of the KFGC (CAN bus) series are
pump units from the KFG series with an inte-
grated CAN bus control unit.
The LC-CAN5000 control units offer the
following special features:
CAN bus interface (SAE J1939), which•
allows units to be seamlessly integrated
into the CAN bus networks.
The lubrication system can be monitored,•
operated and configured through the CAN
bus.
There is also the option of configuring and•
independently operating the pump unit via
the IRDA interface.
The control unit is still able to control up to
four independent zones and to supply them
from a single pump unit. To achieve this capa-
bility, electric switch valves which are con-
trolled based on the parameters set for each
individual lubrication zone are placed in the
main line. The control unit has up to four so-
lid-state switching outputs for this purpose.
Aside from valve control, the outputs can also
be configured as digital outputs for other pur-
poses. In addition to the above-mentioned
outputs, up to four digital inputs are available,
e.g. for monitoring piston detectors, pressure
switches or other switching contacts.

Pump units of the KFG, KFGS and KFGC (CAN bus) series for vehicle lubrication
4 1-3035-EN
KFGS control unit
Pump units of the KFGS series are equipped
with an IG502-2-I integrated control unit
with a control display. Parameters for interval
times (timer), interval pulses (counter) and
pump cycle times (contact) can be entered
through the control unit.
Design
Pump units of the KFG, KFGS and KFGC (CAN
bus) series are characterized by their compact
construction and are divided into the assem-
blies for pump housing, lubricant reservoir,
control unit and fill level monitoring. A short
description of the individual assemblies fol-
lows below.
Pressure regulating valve
To protect the components of progressive sy-
stems from overpressure damage, a pressure
regulating valve must be integrated into the
pump element. If the operating pressure ex-
ceeds the cracking pressure of the pressure
regulating valve, the valve opens and the lu-
bricant flows back (on versions with a return
line) into the lubricant reservoir. The pressure
regulating valve is installed on the pump
element.
75 0.4±
200 0.4
Ø 9.0
Assembly holes
A mounting flange with assembly holes is
present on the back of the pump housing on
all pump versions.
Pump element with pressure regulating valve
Pump element
The pump element meters the lubricant then
passes it to the downstream lubrication points
or feeders. Four different pump elements
with a delivery volume ranging from 0.8 to
2.5 cm3/min. are available to provide the
required quantity of lubricant.
Lubricant reservoir
The lubricant reservoir is available in 2 kg,
6 kg and 10 kg sizes. The reservoirs are made
of transparent plastic and have fill level mark-
ings that allow the fill level to be monitored
visually. The pump fill level can be monitored
using an integrated rocker switch or, option-
ally, a capacitive level switch attached to the
cover.
Pump housing
The pump housing contains, among other
things, the pump drive, control unit (KFGS)
and three lubricant outlets for installing a
maximum of three pump elements.
A conical head nipple can optionally be atta-
ched to the pump housing via the alternative
connections to fill the pump. A filler socket or
grease return can also be attached. A display
and control screen is mounted on the front
side of the KFGS design, while the KFGC (CAN
bus) design has a display attached. An IRDA
interface is integrated into this screen, which
can optionally be used to program the pump.
Depending on the pump version and voltage
design, the electrical connections are located
on the left front and/or the underside of the
pump housing.
Assembly holes
Pump element
Pressure regulating valve
R
A
P
R
M14 x 1,5
PA
P
A
P
M14 x 1,5
R
R
A
Pressure regulating valve with optional lubricant nipple
KFGS display and control screen
KFGC (CAN bus)
Pump units of the KFGC (CAN bus) series are
equipped with an integrated CAN bus-capable
control unit. All parameters that are relevant
to the control and monitoring function can be
integrated into higher-level control units. Pa-
rameters can be transmitted via the IRA in-
terface if a CAN bus interface is unavailable.
KFGC (CAN bus) display
Alternative
connections

Pump units of the KFG, KFGS and KFGC (CAN bus) series for vehicle lubrication
51-3035-EN
Functional description of progressive
system with KFG pump unit
A general progressive feeder system con-•
sists of the following components: Pump
unit with pump element and pressure
regulating valve
Lubricant lines•
Progressive feeders•
When the pump motor is turned on, the pi-
ston pump delivers lubricant from the lubri-
cant reservoir to the lubricant outlet. The
pump element attached to the outlet delivers
the lubricant further, into the downstream
main line. The lubricant flows through the
main line to the progressive feeder. There, the
lubricant is distributed according to the volu-
me required by the lubrication point being
supplied. In progressive systems with a master
feeder and secondary feeder, the lubricant co-
ming from the pump unit is delivered to the
master feeder. The master feeder distri-
butes the lubricant to the secondary feeders
according to their individual volume require-
ments. From there, the lubricant flows to the
lubrication points.
Example of progressive system with KFG pump unit
3
2
7
6 6
5
4
4
4
1
Progressive system with KFG pump unit
1 KFG unit
2 Electrical pump connection
3 Pump element with
pressure regulating valve
4 Lubricant line
5 Master feeder
6 Secondary feeder
7 Lubrication points
Functional description of progressive
system with KFGS pump unit
The general functional description for progres-
sive systems with a KFG pump unit also ap-
plies for the design with KFGS pump control.
The control unit integrated into the pump
housing allows the following additional con-
figuration, monitoring and connectivity op-
tions:
Interval time and contact time can be•
adjusted independently, including on moni-
tored systems
Recording of remaining intervals and•
remaining lubrication times
Data backup in case of voltage failure•
Non-volatile memory with PIN code•
protection
Connectivity for inductive piston detector•
to monitor the feeder functionConnectivity
for external pushbutton Internal fill level
monitoring (W1 control); lubrication cycle
is halted and a fault signal is sent if the fill
level falls below minimum
KFGS progressive system with piston detector
1 KFGS unit
2 Power supply
3 Fault indicator light
4 Pump element with
pressure regulating valve
5 Lubricant line
6 Master feeder
7 Piston detector
8 Secondary feeder
9 Lubrication points
Example of progressive system with KFGS pump unit
2
3
4
7
9
8 8
6
5
5
5
1
Functional description of progressive
system with KFGC (CAN bus)
pump unit
The general functional description for pro-
gressive systems with a KFGS pump unit also
applies for the design with CAN bus pump
control. The integrated LC-CAN5000 control
unit permits the lubrication zone of a pro-
gressive feeder system to be distributed into
individual lubrication zones for which individ-
ual parameters (e.g. contact and interval
times) can be set. Up to four lubrication sec-
tions can be installed in total. To distribute the
lubricant, a corresponding number of electric
switch valves is installed in the lubricant line
leading from the pump element. A valve is
opened as soon as the control unit starts a
pump cycle period for the corresponding lu-
brication segment. The pump can only pro-
vide one lubrication segment with adequate
lubrication, so it must be ensured that only
one valve is opened during operation. This is
handled by the internal control unit in auto-
matic and semiautomatic operation.
A 5/4 directional solenoid valve can optionally
be used in place of single valves.
20=1dbB049 ("(
Progressive system with KFGC (CAN bus) pump unit

Pump units of the KFG series for vehicle lubrication
6 1-3035-EN
KFG pump unit
Dimensions
Delivery data
Pump element Delivery rate Maximum flow pressure Max. permis. pressure
at pump element
[cm3/min.] [mbar with NLGI 2] [bar]
KFG1.U1 2.5 700 300
KFG1.U2 1.8 700 300
KFG1.U3 1.3 700 300
KFG1.U4 0.8 700 300
KFG pump unit, reservoir sizes 2 kg, 6 kg and 10 kg
Max
max
951110 190
Min
Max
200
266.5
13
27 Ø9 75
229 (Reservoir size 2 kg )
343.5 (Reservoir size 6 kg )
585 (Reservoir size 10 kg )
8.5
206 (2 kg)
227 (6 kg)
217.5 (10 kg)
in
305
184
78.5
with pressure relief valve
with W1 or W1G
2 kg 6 kg 10 kg

Pump units of the KFG series for vehicle lubrication
71-3035-EN
Fill level monitoring
Fill level switch type: W1
Designed as rocker switch,
for NLGI Grade 2 greases
Functional description
The W1/W1G fill level switches described below are designed as rocker switches and are inte-
grated in the bottom of the reservoir. A magnetic rocker mounted on the agitator is turned
downward by the grease resistance when the reservoir is full and the agitator rotates. On the
W1 version, a pulse is created at each revolution; in contrast, versions with signal smoothing
(W1G) keep a constant signal. When the minimum fill level is reached, the resistance the
grease exerts on the rocker subsides. The rocker turns back and the pulse (W1) or signal (W1G)
sequence is interrupted.
Technical data for W1G fill level control
Fill level monitoring
Function .......................floating contact
Form of contact ..........changeover
Switching capacity ......max. 60 W
Switching voltage .......max. 30 VDC
Plug-in connection .....DIN EN 60947/IEC 947
Connection diagram ...round plugs
(seven pin) 1)
1) connectoin socket - see Accessoories page 13
Fill level switch type: W1G
Designed as rocker switch with signal
smoothing, floating signal contact,
for NLGI Grade 2 greases
Floating signal from fill level monitoring•
Fill level information can also be queried•
during the interval time.
Reverse voltage protection in pump feed•
line planned.
Optional time-out periods.•
The individual functions can be pro-•
grammed according to the customer's
requirements.
Technical data for W1 fill level control
Fill level monitoring
Function ............................mechanical, via
floating reed
contact
Form of contact ...............NO-contact
Switching capacity, max... 0.6 W
Switching voltage, max....24 VDC
Switched current, max. ..25 mA, only ohm
load 1)
Plug-in connection ..........DIN EN 60947/IEC 947
Connection diagram ........round plugs
(seven pin) 2)
1) No inductive load, no lamp load (signal lamp)
2) connectoin socket - see Accessoories page 13
Contact W1 closed,
go position Contact W1 open
W1 block diagram
Function
Reservoir filled
Reservoir empty
Signal
2
4
5
3
1
67
W1 connector pin assignment (pump unit)
PIN Description
1 = 31 - Supply voltage
potential (0V, GND)
2 = 15 + Supply voltage potential
3 = not assigned
4 = not assigned
5 = + Potential
6 = Signal (pulses)
7 = not assigned
2
4
5
3
1
67
W1G connector pin assignment (pump unit)
PIN Description
1 = 31 - Supply voltage
potential (0V, GND)
2 = 15 + supply voltage
potential
3 = nc (pin 5 and pin 3 closed,
reservoir empty
4 = no (pin 5 and pin 4 closed,
 reservoirlled)
5 = COM (+ potential)
6/7 = not assigned

Pump units of the KFG series for vehicle lubrication
8 1-3035-EN
Pressure regulating valves
for progressive systems
R
A
P
R
M14 x 1,5
PA
P
A
P
M14 x 1,5
R
R
A
Technical data
Cracking pressure ...... 200 -/ 300 ± 20 bar
Nominal tube sizes Ø. 6 mm, 8 mm, 10 mm
Note
The pressure regulating valve is optionally
available with a lubricant nipple with T con-
nector output (see accessories on page 21).
Spare parts
Pressure regulating valve
without lubricant nipple
Tube Ø Cracking pressure Order No.
[mm] [bar]
6 300 161-210-012
6 200 161-210-032
8 300 161-210-018
8 200 161-210-031
10 300 161-210-016
10 200 161-210-030
Pressure regulating valve
with lubricant nipple
6 300 161-210-014
8 300 161-210-025
Connections for pressure regulating valve
AConnection to main lubricant line
PPipe thread for pump element
R Grease emitted at overpressure
Spare parts
Delivery rate 1) Number of Order No.
[cm3/min.] grooves
2.5 1 KFG1.U1
1.8 2 KFG1.U2
1.3 3 KFG1.U3
0.8 4 KFG1.U4
Pump elements
1) The values given here apply for a temperature of 20 °C
, back pressure of 50 bar and greases of NLGI Grade 2.
For progressive systems, pump elements ≤ 2.5 cm3/
min. are recommended.
Technical data
Delivery rate:
0.8, 1.3, 1.8, 2.5 cm3/min. 1)
Max. permiss. operating pressure:
0.8, 1.3, 1.8, 2.5 cm3/min. ................ 300 bar

Pump units of the KFG series for vehicle lubrication
91-3035-EN
General conditions for electrical connections
Power supply 12/24 VDC
L+
1
KFG...DC
2 3
X1
+
M
-
KFG...AC
X1 1 2 3
M
DC
AC
2)
1)
C6A
F
L1 N PE
90 - 264 V AC
47 - 440 Hz
6.5.2 Baureihe KFG
6.5.2 Baureihe KFG
L-
4 AT
2
3
1
31 15 (Fahrzeug)
M L+ (Industrie)
1
KFG...DC
F
2 3
X1
1)
2) 2)
+
M
-
KFG...AC
X1 1 2 3
M
DC
AC
2)
1)
C6A
F
L1 N PE
90 - 264 V AC
47 - 440 Hz
General conditions for electrical connections
Nominal Power Power Pump Max.
voltage consumption consumption starting current pre-connected fuse
[load-dependent] [max.] [~20 ms]
24 VDC 1) 1.25 A 2) < 2.5 A 4.5 A 4 A 3) 4)
12 VDC 1) 2.4 A 2) < 5 A 9 A 6 A 3) 4)
1) Protective measures that must be applied for designat-
ed usage: "Functional Extra Low Voltage", "Protective
Extra Low Voltage“ (PELV) Standards: EN 60204 Part
1: IEC 60204-1: DIN VDE 0100 Part 410 / IEC 364-
4-41: HD384.4.41
2) Typical value at ambient temperature = 25 °C and
operating pressure = 150 bar
3) Fuse in accordance with DIN 72581 T.3
4) Conductor: cross-section 1.5 mm2, length ≤ 12 m
Cable socket in accordance
with DIN EN 175 301-803
Connector pin assignment for 12/24 VDC
Pin Description
1 - (mass) = M - (31) potential
(0 V, GND)
2 +(current) = L+ Supply voltage
potential (15)
(Main machine switch ON)

Pump units of the KFGS series for vehicle lubrication
10 1-3035-EN
KFGS pump unit
with integrated control
Dimensions
KFGS pump unit, reservoir sizes 2 kg, 6 kg and 10 kg
Delivery data
Pump element Delivery rate Maximum flow pressure Max. permis. pressure
at pump element
[cm3/min.] [mbar with NLGI 2] [bar]
KFG1.U1 2.5 700 300
KFG1.U2 1.8 700 300
KFG1.U3 1.3 700 300
KFG1.U4 0.8 700 300
Z
ax
n
ax
n
636 (Reservoir size 10 Kg )
200
266.5
13
393.5 (Reservoir size 6 Kg )
281 (Reservoir size 2 Kg )
78.5 Ø9
75
8.5
227 ( 6 Kg )
206 ( 2 Kg )
217.5 ( 10 Kg )
305
235.5
with pressure relief valve
with pump element
and W1 control
2 kg 6 kg 10 kg

Pump units of the KFGS series for vehicle lubrication
111-3035-EN
The KFGS pump unit is controlled by the
IG502-2-I integrated control and monitoring
unit.
IG502-2-I integrated control
and monitoring unit
Setting interval and pump cycle times
and desired monitoring function
See the operating instructions included with
the pump unit for information on how to con-
figure the control unit for application-specific
values and functions.
Function:
(Standard "TIMER" function
without monitoring)
The lubrication intervals are repeated cycli-
cally according to the set interval (tPA or cPA).
The pump cycle time during a lubrication pro-
cedure corresponds to the time configured on
the control panel as tCO (contact time) in
minutes.Interval and pump cycle times ad-
vance only in the presence of supply voltage
(attach connection 15 and 31 to 12 V DC or
24 V DC depending on unit). When the supply
voltage is turned off (power supply is inter-
rupted), the current interval time is saved and
continued once the supply voltage is turned
on again. When the monitoring function CS is
programmed (only for centralized lubrication
systems with cycle switch), the piston detector
mounted on a progressive feeder is queried
for a signal during the pump cycle time. If this
signal is absent during the preselected pump
cycle time (tCO), a monitoring program (block
operation) is started after the cycle time fin-
ishes. During this program sequence, the
pump unit is turned on up to two times at
specially defined intervals and the piston de-
tector is monitored for a signal. If the piston
detector signal reaches the control unit, the
monitoring program ends immediately and
operation continues as normal. If the moni-
toring program completes its sequence, a
fault signal is sent on completion and the op-
erational sequence is halted. While the moni-
toring program is ongoing, no interim lubrica-
tions can be triggered.
Storage (EEPROM)
The control unit has non-volatile memory
(EEPROM), so continuous power supply is not
required to store intervals and fault notifica-
tions. When the supply voltage is turned off,
the current value is saved and will be avail-
able for continued operation once the supply
voltage is re-established.
Monitoring and fault indications
Function monitoring with piston detector or
pressure switch Progressive systems can be
monitored by a piston detector and single-line
systems can be monitored by a pressure
switch. To do this, monitoring under COP
must be configured as CS (cycle switch, piston
detector) or PS (pressure switch) when the
device is configured (programmed). The signal
from the switch is then monitored during lu-
brication. If the signal is not sent during the
lubrication procedure and the monitoring
program it automatically triggers does not
start, a fault signal is sent (connection SL2 is
constantly switched on) after the monitoring
program ends, and the operational sequence
is interrupted. When monitoring is performed
by a pressure switch (PS), any fault signal is
sent directly after conclusion of the monitor-
ing time. In contrast with the CS setting, there
is no monitoring program (block operation) in
this case. The error codes FCS (Fault Cycle
Switch) and FLL (Fault Low Level) can be
viewed by pressing a key on the control panel.
General
The IG502-I control and monitoring device is
an integral component of the KFGS pump
unit. Its functions are specially designed to
control and monitor centralized lubrication
systems. The customer can program the
control unit to adapt it to the particular ope-
rating conditions of the machine/system.
Pause (tPA) in "TIMER" mode
The interval (time period between two lubri-
cations) in the TIMER mode is determined
based on a time interval generated by the
control unit and the value programmed as
the tPA. Its value can be set from 0.1 h to
99.9 h.
Pause (cPA) in "COUNTER" mode
The interval (time period between two lubri-
cations) in "COUNTER" mode is determined
based on the time between pulses received
at connection DK (signal change from 0 V to
24 V) and by the value programmed as the
cPA. Its value can be set from 1 to 999 puls-
es. In this mode, the DK connection (pin 3,
blue cable core) leading from the unit is used
as a clock pulse input to trigger lubrications
after a specified number of pulses. In this
case, an external pushbutton cannot be
used to trigger interim lubrications.
Display

Pump units of the KFGS series for vehicle lubrication
12 1-3035-EN
Fill level monitoring
Fill level switch type: W1
Designed as energized rocker switch,
for NLGI Grade 2 greases
Contact W1 closed, go position
Contact W1 open
Functional description
The W1 fill level switch described below is de-
signed as a rocker switch and is integrated in
the bottom of the reservoir. A magnetic rocker
mounted on the agitator is turned downward
by the grease resistance when the reservoir is
full and the agitator rotates. A pulse is created
at each revolution of the agitator. When the
minimum fill level is reached, the resistance
the grease exerts on the rocker subsides. The
rocker turns back and the pulses are inter-
rupted.
In contrast to the KFG pump unit, on which
the fill level signal is evaluated externally, the
internal pump control unit on the KFGS pump
unit evaluates the fill level of the W1 control.
A fault indicator light can optionally be con-
nected through the 7-pin plug on the bottom
of the pump
(see connectivity on page 14/15).
Pressure regulating valves
for progressive systems
R
A
P
R
M14 x 1,5
PA
P
A
P
M14 x 1,5
R
R
A
Spare parts
Pressure regulating valve
without lubricant nipple
Tube Ø Cracking pressure Order No.
[mm] [bar]
6 300 161-210-012
6 200 161-210-032
8 300 161-210-018
8 200 161-210-031
10 300 161-210-016
10 200 161-210-030
Pressure regulating valve
with lubricant nipple
6 300 161-210-014
8 300 161-210-025
Note
The pressure regulating valve is optionally avail-
able with a lubricant nipple with T connector
output (see accessories on page 21).
Technical data
Cracking pressure....... 200 -/ 300 ± 20 bar
Nominal tube sizes Ø. 6 mm, 8 mm, 10 mm
Connections for pressure regulating valve
AConnection to main lubricant line
PPipe thread for pump element
R Grease emitted at overpressure

Pump units of the KFGS series for vehicle lubrication
131-3035-EN
Spare parts
Delivery rate 1) Number of Order No.
[cm3/min.] grooves
2.5 1 KFG1.U1
1.8 2 KFG1.U2
1.3 3 KFG1.U3
0.8 4 KFG1.U4
Pump elements
Technical data
Delivery rate:
0.8, 1.3, 1.8, 2.5 cm3/min. 1)
Max. permiss. operating pressure:
0.8, 1.3, 1.8, 2.5 cm3/min. ................ 300 bar
7-pin cable socket for 12 and
24 VDC power supply
General conditions for electrical connections
1) The values given here apply for a temperature of 20 °C,
back pressure of 50 bar and greases of NLGI Grade 2.
For progressive systems, pump elements ≤ 2.5 cm3/min.
are recommended.
2
4
5
3
1
67
Connector pin assignment
Pin Color code Conductor coloring
1..............BN.....................brown
2..............RD-BK..............red-black
3..............BU.....................blue
4..............PK .....................pink
5..............BK .....................black
6..............BK .....................black
7..............VT-GN ..............purple-green
Note
The connector pin assignment depends on
the specific operating mode. The pins should
therefore be assigned according to the fol-
lowing examples.
Accessories
Description Order No.
Cable harness, 12 m long,
in corrugated pipe,
with pump-side socket 997-000-760
Cable harness,
three-core, 8 m long,
in corrugated pipe,
with pump-side socket 997-000-630
General conditions for electrical connections
Nominal Power Power Pump Max.
voltage consumption consumption starting current pre-connected fuse
[load-dependent] [max.] [~20 ms]
24 VDC 1) 1.25 A 2) < 2.5 A 4.5 A 4 A 3) 4)
12 VDC 1) 2.4 A 2) < 5 A 9 A 6 A 3) 4)
1) Protective measures that must be applied for designat-
ed usage: "Functional Extra Low Voltage", "Protective
Extra Low Voltage“ (PELV) Standards: EN 60204 Part
1: IEC 60204-1: DIN VDE 0100 Part 410 / IEC 364-
4-41: HD384.4.41
2) Typical value at ambient temperature = 25 °C and
operating pressure = 150 bar
3) Fuse in accordance with DIN 72581 T.3
4) Conductor: cross-section 1.5 mm2, length ≤ 12 m

Pump units of the KFGS series for vehicle lubrication
14 1-3035-EN
Connectivity for counter operation
without system monitoring
1
BN
KFGS...
F
2 3 4 5 6 7
X1
RD-BK
BU
31 15 54 (Example: of a stop light switch)
(Observe the starting current of the pump!)
Interval depends on number of pulses
Pump cycle time depends on time
Connector pin assignment
PIN Code Assignment
1 31 - Supply voltage potential
(0 V, GND)
2 15 + Supply voltage potential
3 + Potential of stop light
switch signal
Settings for progressive lubrication
Control using pulses
(Counter mode = pulse-dependent lubrication)
Connectivity for counter operation
without system monitoring
Connector pin assignment in counter operation
PIN Code Assignment
1 31 - Supply voltage potential (0 V, GND)
2 15 + Supply voltage potential "ignition ON"
3 DK Pushbutton"1stInterimlubrication","2ndDeletefaultnotication"
4 SL2 Indicator light "fault"
5 ZS piston detector "+"
6 ZS Piston detector "signal"
Connectivity for counter operation
with system monitoring
31 15
1
BN
KFGS...
F
2 3 4 5 6 7
X1
RD-BK
BU
PK
DK SL2
2,4 W
31 15
1
BN
KFGS...
F
2 3 4 5 6 7
X1
RD-BK
BU
PK
DK SL2
2,4 W
BK
BK
ZS
Both the number of pulses that determine the
interval time and the pump cycle time can be
configured.
The fill level monitoring unit is internally con-
nected to the integrated pump control unit. A
fault signal can be sent to the vehicle control/
electronics system via indicator light SL2.
The duration of the interval time is deter-
mined by a pulse generator that sends pulses
to the control unit based on how long the ve-
hicle has been in use. The control unit counts
the pulses that are received and starts the
pump after the preset number of pulses. The
pump cycle time is defined by a time value.

Pump units of the KFGS series for vehicle lubrication
151-3035-EN
Accessories
Description Order No.
Cable harness, in corrugated pipe,
with pump-side socket
8 m length 997-000-760
12 m length 997-000-630
16 m length 997-000-650
Connectivity for timer operation
without system monitoring
Connector pin assignment in timer operation
PIN Code Assignment
1 31 - Supply voltage potential (0 V, GND)
2 15 + Supply voltage potential "ignition ON"
3  DK Pushbutton"1stInterimlubrication","2ndDeletefaultnotication"
4 SL2 Indicator light "fault"
5 PS Pressure switch "+"
6 PS Pressure switch "signal"
7 SL1 Indicator light "pump ON"
Connectivity for timer operation with
system monitoring
1
BN
KFGS...
F
2 3 4 5 6 7
X1
RD-BK
BU
PK
VT-GN
DK SL2
2,4 W
31 15
SL1
2,4 W
1
BN
KFGS...
F
2 3 4 5 6 7
X1
RD-BK
BU
PK
VT-GN
DK SL2
2,4 W
SL1
2,4 W
BK
BK
PS +
31 15
In timer mode, the interval time is determined
by a time value. It is configured by entering a
time value in minutes and/or hours.
The pump cycle time is configured using a
time value in hours, minutes and seconds.
The fill level monitoring unit (W1 control) is in-
ternally connected to the integrated pump
control unit. A fault signal can be sent to the
vehicle control/electronics system via indicator
light SL2.

Pump units of the KFGC (CAN bus) series for vehicle lubrication
16 1-3035-EN
KFGC (CAN bus) pump unit
with integrated control
Dimensions
KFGC (CAN bus) pump unit, reservoir sizes 2 kg, 6 kg and 10 kg
266.5
200 13
78.5
Ø9
75
281 ( Reservoir size 2 Kg )
393.5 ( Reservoir size 6 Kg )
636 (Reservoir size 10 Kg )
8.5
206 ( 2 Kg )
227 ( 6 Kg )
217.5 ( 10 Kg )
Delivery data
Pump element Delivery rate Maximum flow pressure Max. permis. pressure
at pump element
[cm3/min.] [mbar with NLGI 2] [bar]
KFG1.U1 2.5 700 300
KFG1.U2 1.8 700 300
KFG1.U3 1.3 700 300
KFG1.U4 0.8 700 300
2 kg 6 kg 10 kg

Pump units of the KFGC (CAN bus) series for vehicle lubrication
171-3035-EN
Pump units of the KFGC (CAN bus) series are
reservoir pump units (piston pumps) with an
integrated control unit for on-demand lubri-
cant supply to centralized lubrication systems
with progressive feeders or to single-line sys-
tems. A special feature of pump units of the
KFGC (CAN bus) series is the integrated
LC-CAN5000 control unit, which is distin-
guished by the following characteristics:
CAN bus interface (SAE J1939), which•
allows units to be integrated into the
CAN bus networks of machines and sys-
tems. The lubrication system is monitored,
operated and configured through the
CAN bus by the vehicle electronic control
system.
There is also the option of configuring and•
operating the pump unit without a CAN bus
connection.
The control unit is able to control and•
monitor up to four independent zones and
to supply them from a single pump unit.
Electric switch valves which are controlled•
based on the parameters set for each
individual lubrication zone are placed in
the main line. The control unit has up to
four solid-state switching outputs for this
purpose.
Aside from valve control, the outputs can•
also be configured as digital outputs for
other purposes.
In addition to the outputs, up to four digital•
inputs are available, e.g. for monitoring
piston detectors, pressure switches or oth-
er switching contacts.A detailed description
of the electrical connections can be found
in the operating instructions for the KFG
series of pumps.
The control unit's comprehensive monitoring
functions allow potential faults to be detected
early. This includes, among other things,
monitoring the fill level in the lubricant reser-
voir, monitoring the signal lines on attached
components for line breakage, and monitor-
ing the switching outputs for short circuits.
Important system events such as a low fill
level in the lubricant reservoir are saved by
the control unit and given a time stamp. This
allows the causes of operational faults to be
determined more easily.
The flexible parameters and configuration
options allow custom lubrication concepts
to be implemented for each individual lu-
brication zone in the system. The control
unit can store up to 16 sets of parameters.
Each set of parameters contains all the in-
formation required to control and monitor
the lubrication process. This means that
different lubrication scenarios can be pre-
pared and saved then called on when
needed.
The CAN bus control unit is available in
12/24 V DC designs.
LC-CAN5000 integrated CAN bus
control unit with display

Pump units of the KFGC (CAN bus) series for vehicle lubrication
18 1-3035-EN
Connections
2
4
5
3
1
67
Power supply
through 7-pin
round plug
CAN bus connection,
plug type DEUTSCH
DT04-3P-L012
A
B
C
34
1 2
Connection for reversing valve/piston detector
(max. 6 connections)
Connectivity
Example of connecting four reversing valves and four piston detectors on devices with the
maximum equipment level (6x M12x1 round plug-in connections) for operating a progressive
feeder system, distributed in four lubrication zones
V
3V2V1
1 1 1
1
1 1
2
2 2
2
2 2 3 3 3
3
3 3 4 4 4
4
4 4
1 2 3 4 1
2 2 1 2 1 2 1 1
2
3 4 1 2
3
4 1 2 3 4
A B C
1 2 345 6 7
X1
BN
RD-BK
BU PK
BK BK
VT-GN
CAN-BUS
M12x1
1x21M1x21M
M12x1
1x21M1x21M
M12x1
1x21M1x21M
M12x1
F1
S1
M L
+
31 30
15
CS4 (MC) V4
SL2
RD CS1
CS1
CS2
CS2
CS3
CS3
V1 V2 V3
+++++++ + + –– – – –
A
B
C
CS.. = Piston detector V.. = Reversing valves
2
4
5
3
1
67
34
1 2
Assignment of
round 7-pin plug
Assignment of
M12x1 4-pin round plug
Legend for connection illustration with maximum equipment level
S1 – CS4 Piston detector 1 - 4 V1 – V4 Valves 1 – 4
MC Machine contact SL2 Indicator light "fault" (can alter-
nately be operated in place of
valve 4 (V4))
L+ + potential of
supply voltage
F1 Fuse S1 Ignition switch
Assignment of
CAN bus plug
General conditions for electrical connections
The general conditions for electrical connections are identical with those of the KFG and KFGS
series. The data listed below are specific to CAN bus units.
KFGC (CAN bus), general conditions for electrical connections
Switching outputs: Type: Solid-state output, short-circuit-proof and overload-proof
Max. current-carrying capacity: - with simultaneous operation of 4 outputs 1.0 A
- with simultaneous operation of 2 outputs 1.25 A
- with operation of 1 output 1.5 A
Modes of operation: - Single operation
- Parallel connection of multiple outputs while simultaneously
increasing output current
Signal inputs: Type: digital solid-state input, short-circuit-proof
Connectivity: - Switching contact, no detection of wire breakage
- Dual wire sensors (e.g. piston detector), detection of wire breakage

Pump units of the KFG, KFGS and KFGC (CAN bus) series for vehicle lubrication
191-3035-EN
Accessories
KFG - IG502-2-E electronic control unit
Technical data
Control voltage 1)...................................................... 12 or 24 V DC
Max. contact rating, connection M...........................10 A
SL output.....................................................................4 W
Protection class 2).......................................................IP 40, DIN 40050
Temperature range.....................................................-25 to +75 °C
Fusing max. .................................................................5 A
Programmable interval times................................... 0.1 to 99.9 h
Programmable pump cycle time .............................. 0.1 to 99.9 min.
Programmable pulses................................................1 to 999
Operation and fault hours memory......................... 0 to 99999.9 h
Technical description.................................................see following page
1) Specify control voltage when ordering.
2) Ensured both in vertical (connector pointing downward) and horizontal installation.
Normal operational sequence
(Time axis not to scale)
Legend for operational sequence
tu = Ignition cut-off ts = Contact time
tp = Interval time 30 = Battery + / vehicle electrical system
15 = Operating voltage + / "ON" after ignition 31 = Operating voltage –
DK/MK = Pushbutton / interim lubrication or pulse counter input
PS/CS = Pressure switch / cycle switch M = Pump motor
SL = Signal lamp Z = Ignition lock
F = Fuse 5 A
KFG control unit and cable set
Description Order No.
Electronic control unit IG502-2-E
Cable set 997-000-185
Cable set for IG502-2-E control unit
Contact assignments
on connector plug
of IG502-2-E
control unit
RD/BK = Ignition, terminal 15
BN = Mass
PK = Indicator lamp, 2.5 m (optional)
BU = Pushbutton/machine contact
Note
Tab connectors
are loose.
IG502-E
103±1.2

Pump units of the KFG, KFGS and KFGC (CAN bus) series for vehicle lubrication
20 1-3035-EN
IG502-2-E electronic control unit
Control and display elements
IG502 control units have a control and display
panel that allows set parameters and the pro-
grammed functions to be checked, monitored
and readjusted as necessary.
Modes of operation
PAUSE (pump OFF) with timer function pro-
grammable from 0.1 to 99.9 h – Digital dis-
play by selecting:
tPA (t = Timer, PA = PAUSE)The PAUSE
(time period between two lubrication cycles)
is determined based on a time interval gen-
erated by the control unit and the value (in
hours) programmed as the PAUSE (tPA).
PAUSE (pump OFF)
with counter function
– programmable from 1 to 999 pulses
– Digital display by selecting:
cPA (c = Counter, PA = PAUSE)
The PAUSE (time period between two lubri-
cation cycles) is determined based on the
time between signals received by the clock
pulse unit and the value programmed as the
PAUSE (cPA)
CONTACT (pump ON))
with timer function
– Programmable from 1 to 99.9 minute(s)
– Digital display by selecting:
tCO (t = Timer, CO = CONTACT)
The pump cycle time (CONTACT) is deter-
mined based on the time interval generated
by the control unit (timer) and the value pro-
grammed (in minutes) for CONTACT (tCO).
Monitoring functions
CS (Cycle Switch)
This monitoring function is designed for cen-
tralized grease lubrication systems with pro-
gressive feeders whose piston movement is
monitored by a cycle switch.
If the monitoring parameter CS is pro-
grammed, the cycle switch mounted on the
progressive feeder monitors for the relevant
signal during pump operation. The selected
monitoring parameter (PS or CS) is shown by
the corresponding LED in PAUSE mode.
Without monitoring (OFF)
Monitoring can also be switched off (OFF).
The PS or CS LEDs do not light up.
Fault notifications
A centralized fault is indicated by the red LED
labeled "FAULT" lighting up and remaining
constant. The cause of the fault notification is
also shown on the digital display to assist in
fault-finding.
The following notifications are provided:
FPS – Pressure build-up fault on pressure
switch monitoring.
FCS – Cycle switch fault in case of blocked
or non-functional progressive feeder
(line break).
Special functions
The IG502 series of control units possess two
electronic counters which store times perma-
nently and in a way that users cannot alter.
These counters provide operational control of
the centralized lubrication system and are
shown on the LED display.
Fault-hours counter
The fault-hours counter adds up the time
of long-term faults. The counter's record is
automatically updated and cannot be deleted.
The current counter reading can be shown on
the display and control panel by calling up the
function parameter Fh. The current value is
shown in hours. The counter increments in
0.1 hour steps, i.e. the smallest interval it can
display is 6 minutes.
Operational hours counter
The electronic operational hours counter adds
up the time during which the operating volt-
age is applied to the control unit.
The counter's record is automatically updated
and cannot be deleted. The current counter
reading can be shown on the display and con-
trol panel by calling up the function parame-
ter Oh. The current value is shown in hours.
The counter increments in 0.1 hour steps,
i.e. the smallest interval it can display is
6 minutes. The units meet the statutory re-
quirements of EG Directives
– 72/245/EEC as amended by 95/54 EC
– 89/336/EEC
Application
The IG502-2-E universal control unit is used
to control and monitor centralized lubrication
systems on commercial vehicles. The control
unit's functions can be programmed. Its hous-
ing dimensions, electrical connection and
functions are compatible to previous VOGEL
control units. The control elements have a
film that protects them from humidity and
contamination. The unit possesses non-vola-
tile data memory which is used to store con-
figuration data and parameters. This allows
the control unit to function without a continu-
ous power supply. If an external SL signal
lamp has been installed in the vehicle cab, it
will light up 3 seconds after the unit is
switched on.
Assembly
The unit is to be installed inside a closed area
in the vehicle where it is protected from envi-
ronmental influences. It is fastened using as-
sembly brackets. The IG502-2-E is contained
in a housing that meets protection class
IP 20. The plug meets safety class IP 00.
If the control unit is installed in a location that
is difficult to access, we recommend also us-
ing an illuminated pushbotton on the dash-
board for fault notification and function con-
trol.