SKF Lincoln 254-15165-9 User manual

Version 08
22.01.2021
951-150-032-EN
Service manual
Piston detectors EN
L+
1
2/4 L-
L+
2/4
1
L-
3
L+
L-
1 (4)
4(1)
with adapters, optionally with cable break protection
Universal Piston Detector
234-13163-9
Bipolar Piston Detector
234-11454-1 Note!
For use only in combination with SKF lubrication
pumps of series KFAS/KFBS/KFGS in the com-
mercial vehicles and farm machinery.

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951-150-032-EN
Version 08
EN
EU Declaration of Conformity in accordance with Directive 2014/30/EU Annex IV
The manufacturer, SKF Lubrication Systems Germany GmbH, Walldorf Plant, Heinrich-Hertz-Str. 2-8, DE - 69190 Walldorf, hereby
declares conformity of the electrical device
Designation: Piston detector
Type: Magnetic sensor M........G
Item number: 234-13163-9 and 234-11454-1
with all relevant harmonization legislation of the European Union at the time of placing on the market.
Furthermore, the following Directives and (harmonized) standards were applied in the applicable areas:
2011/65/EU RoHS II
Walldorf, 17.12.2020
Jürgen Kreutzkämper
Manager R&D Germany
SKF Lubrication Business Unit
Standard
EN 60947-5-1:2004/AC:2005
EN 50581:2012
EU Declaration of Conformity
Stefan Schürmann
Manager PD Germany South

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951-150-032-EN
Version 08
EN
Masthead
Copyright
© Copyright SKF
All rights reserved.
Warranty
The instructions do not contain any
information on the warranty. This can
be found in our General Terms and
Conditions.
Disclaimer of liability
The manufacturer shall not be held liable for
damage resulting from:
○Improper usage, assembly, operation,
configuration, maintenance, repair, or
accidents
○Improper reaction to malfunctions
○Unauthorized modifications to the
product
○Intentional or gross negligence
○Use of non-original SKF spare parts
The maximum liability for loss or damage
resulting from the use of our products is
limited to the purchase price. Liability for
indirect damage of any kind is excluded.
Masthead
Manufacturer
SKF Lubrication Systems Germany GmbH
Address of manufacturer plants
Headquarters
Walldorf Plant
Heinrich-Hertz-Str. 2-8
69190 Walldorf
Germany
Tel: [phone]
Fax: [phone]
Berlin Plant
Motzener Strasse 35/37
12277 Berlin
Germany
Tel. [phone]
Fax [phone]
E-mail: Lubrication-german[email protected]om
www.skf.com/lubrication
Further language versions
can be found on the SKF
homepage.

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951-150-032-EN
Version 08
EN Table of contents
Explanation of symbols and signs
General warning Symbol Meaning
Wear personal protective gear (face mask) Chronological instructions
Wear personal protective gear (gloves) Bullet list items
Wear personal protective gear (protective
clothing)
Indicates the requirements that must be
met for the actions described
in the following
Pressure injection General notes
Hot surfaces
Warning level Consequence Probability
DANGER Death, serious injury Immediate
WARNING Serious injury Possible
CAUTION Minor
injury Possible
NOTE Property damage Possible

1
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951-150-032-EN
Version 08
EN
1st Safety instructions /2. Delivery and storage
Table of contents
EU Declaration of Conformity in accordance 2
Masthead 3
Explanation of symbols and signs 4
1. Safety instructions 6
2. Scope of delivery/storage 6
2.1 Storage 6
3. Overview, functional description 7
3.1 Progressive feeder overview with universal piston detector
234-13163-9 or bipolar piston detector 234-11454-1 7
3.2 Design 8
3.2.1 Function 8
3.2.2 Application in commercial vehicles or farm machinery
in combination with a KFAS/KFBS or KFGS pump 9
3.3 Information on feeder series VP; VPB; VPK; PSG1; PSG2; PSG3 9
4. Technical data 10
4.1 General technical data 10
4.2 Connection options 234-13163-9,
12-24V DC, 3-wire PNP 13
4.3 Connection options 234-13163-9,
12-24V DC, 2-wire PNP/NPN 14
4.4 Connection options 234-11454-1,
bipolar 12-24V DC, 2-wire PNP/NPN 15
5. Assembly 16
5.1 Disassembly of the old piston detector 17
5.2 Assembly of the new piston detector 18
5.3 Checking the signal 18
6. Malfunctions, causes, and remedies 19
6.1 Metering devices signal missing 19
7. Spare parts 23

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Version 08
EN 1st Safety instructions /2. Delivery and storage
1. Safety instructions
To convert the piston detector, consult the
documentation for the feeder
(lifecycle manual, assembly instructions) in
which the old piston detector is used. The
safety instructions in that documentation
must be observed in full.
Further:
○The operator must ensure that these
conversion instructions and the cor-
responding feeder documentation have
been read by the person who converts
the piston detector or supervises or in-
structs said person.
○Before removing the defective piston de-
tector, depressurize the affected feeder.
○The operator must also ensure that the
staff fully understands the content of the
instructions.
○Putting the products into operation or
operating them without having read the
instructions is prohibited.
2. Scope of delivery/storage
The conversion kit for the piston detectors
includes a feeder-specific adapter.
The piston detectors may be used only with
this adapter.
A stopper and a cable adapter are also en-
closed for the feeder version.
The scope of delivery also includes these
conversion instructions.
2.1 Storage
Storage conditions- See feeder documenta-
tion and:
○Store in the original product packaging.
○Store protected from nearby sources of
heat or cold.
○The permissible storage temperature
range corresponds to the operating tem-
perature range (see “Technical data”).
This service manual must be en-
closed with the
product documentation
(e.g., feeder documentation).

3
2
1
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951-150-032-EN
Version 08
EN
3. Overview, functional description
3.1 Progressive feeder overview with universal piston detector 234-13163-9 or bipolar piston detector 234-11454-1
Mounting dimensions, universal and bipolar piston detectors, Fig. 1
VPBM VPK VP SSV
PSG1 PSG2 PSG3 SSVD
/SSVL
/SSVDL
SW 12
44-0159-2507
SW 24
44-0159-2510
SW 13
419-74455-1
53,6 (53,3)
53,5 (53,5)
53,5 (53,5)
53,8 (53,5)
53,8 (53,5)
40 (39,5)
54,3 (54) 54,3 (54)
SW 12
44-0159-2508
SW 12
44-0159-2508
SW 12
44-0159-2509
SW 12
44-0159-2509
SW 13
419-74455-1
(....) = mounting dimension of previous piston detector
3. Overview, functional description

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951-150-032-EN
Version 08
EN 3. Overview, functional description
3.2 Design
The universal piston detector
234-13163-9 and the bipolar piston detec-
tor 234-11454-1 are position sensors that,
together with the respective pressure-re-
sistant adapter, are screwed into the feeder.
Through the closed adapter, the sensors
detect the feeder piston without coming into
direct contact with it.
Hydraulic pressure spikes therefore do not
act directly on the front sensor surface the
piston detectors.
There are different adapters depending on
the feeder series. These differ in terms of
thread size and clearance. They are specifi-
cally tailored to the respective feeder type
and piston type.
The piston detectors automatically detect
the clearance between the feeder piston and
the piston sensor following several feeder
strokes and adjust themselves automatically.
The universal piston detector automatically
detects the customer’s plug/cable assign-
ment, 2-wire design or 3-wire design (with
cable break protection).
The universal piston detector is not suitable
for usage in vehicles with KFGS or KFGL
lubrication pump due to an undefined pin
assignment. The bipolar piston detector is to
be used in this case.
The bipolar piston detector is available only
in a 2-wire design. The signal voltage can be
applied to either pin 1 or pin 4.
3.2.1 Function
When the piston detector is actuated (piston
stroke), a yellow LED lights up and indicates
correct functioning of the piston detector.
Subsequent replacement of the piston de-
tector during operation is possible in cases
of piston detectors with adapter which have
already been mounted if the corresponding-
ly designed adapter is also mounted. A check
of the adapter version (number of rings) is
to be carried out beforehand in accordance
with Chapter 5.1.
The piston detectors are available with a
corresponding adapter and cable harness
(cable harness only on feeder series SSV,
SSVL, SSVD,SSVDL, SSVE, SSVD-E as a re-
placement for all previous detectors of feed-
er series PSG1, PSG2, PSG3, VP, VPK, VPB,
SSV, SSV, SSVD, SSVDL, SSVE, SSVD-E.
VPB metering device, stainless
steel version
Due to the material used in the
piston (brass), the piston detectors
described here are unable to detect
the movement of the piston when
VPB metering devices in the stain-
less steel version are used. Instead
of the VPB metering device in the
stainless steel version, please use a
corresponding SSV metering device
in the stainless steel version.

3
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951-150-032-EN
Version 08
EN
3. Overview, functional description
3.2.2 Application in commercial vehicles or farm machinery in combination
with a KFAS/KFBS or KFGS pump
If the piston detector is mounted
(in contrast with its previous
mounting position) on the opposite
side of the feeder, the feeder piston
must also be rotated.
See the respective feeder docu-
mentation for a description of
conversion.
the connection was established correctly. If
this is not the case, switch the pin assign-
ment in pin 4 (+) and pin 1 (Load) in the
power lead.
3.3 Information on feeder series
VP; VPB; VPK; PSG1; PSG2; PSG3
A detailed terminal diagram for con-
necting the bipolar piston detector
to a KFAS, KFBS or KFGS pump is
available at the links on page 1 in the
respective national languages
(attachment to the PDF).
2
3
4
5
7
6
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
YE
BK
PS
+
31 15
3
2
4
1
1
2
3
max
L+
L-
1 (4)
4 (1)
6
5
BN
KFAS
KFBS
KFGS
L+
1
2/4 L-
o 
or assignment
Socket Function Wirecolor
1 31 Brown
2 15 Red/Black
3 DK Blue
4 SL2 Pink
5 ZDS(+) Yellow
6 ZDS Black
7 SL1 Purple/Green
Connector assignment
Socket Function Wire color
1 (+) BN Brown
2 WH White
3 BL Blue
4 BK Black
Bipolar piston detector
PN: 234-11454-1
Universal piston detector
PN: 234-13163-9
Cableharness 997-000-630
or: 997-000-650
Pump cable harness, pin 5 (+), wire color yellow=>>
=>>piston detector cable harness, pin 1, wirecolor
brown
Pump cable harness, pin 6, wire color black=>>
=>> piston detector cable harness, pin 4, wirecolor black
SKF Lubrication Systems Germany GmbH
Walldorf Plant
Heinrich-Hertz-Str. 2-8
DE - 69190 Walldorf
Tel.: [phone]
Fax: [phone]
E-mail: [email protected]
www.skf.com/lubrication
951-150-035-EN Version 01
KFAS/KFBS/KFGS
vehiclelubrication
cut
Cableharness 179-990-600
Terminal diagram for system monitoring with piston detector for pumps
of series KFAS/KFBS/KFGS with control unit IG502
Bipolar piston detector 234-11454-1
is a replacement for the following piston
detectors.
Bipolar
piston detector
Replaces previous
piston detectors
234-11454-1 177-300-091
177-300-092
177-300-096
If a universal piston detector has been or-
dered accidentally instead of a bipolar piston
detector, inspect it for correct connection
before installing it in the feeder. This is done
by connecting the electrical plug connection
(plug M12x1). Then switch on the KFG pump
and hold a metallic object in front of the
face of the piston detector. If the yellow LED
lights up (actuation of the piston detector),

EN 4. Technical data
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951-150-032-EN
Version 08
4. Technical data
4.1 General technical data
General data Designation Dimension drawing
Field of application Lubricant feeders
Ambient temperature [°C] -40 ....+85
Principle of operation Piston detector/position sensor
Material Active area stainless steel (1.4404); housing stainless
steel (1.4016), plug: PEI
Mounting type Mountable flush in associated adapter
Tightening torque [Nm] 7 ±0.5
Circuit state display LED Yellow/lights up on damping
Electrical connection M12x1 plug-in connection, gold-plated contact
Sensing range Bipolar piston detector
Sensing distance [mm] 2.2 condition on delivery
Effective sensing distance (Sr) [mm] 2.2 ±10%
Hysteresis [% of Sr] ≤ 10
Accuracy/deviations
Switching point [% of Sr] ±10%
Reproducibility [% of Sr] ±10%
Permiss. operating pressure
with associated adapter [bar]
Identical to permiss. operating pressure of the
feeder in which the sensor with adapter is installed
(see feeder documentation)
8,5
15
M10x0,8
52
SW10
M12x1
8
8,7
3
LED
L+
L-
1 (4)
4(1)
4
1
3
22-wire DC PNP/NPN

EN
4. Technical data
4
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951-150-032-EN
Version 08
Electrical data Universal piston detector Bipolar piston detector Universal piston detector
Design 3-wire DC PNP
2-wire DC PNP/NPN 2-wire DC PNP/NPN
Operating voltage [V] 10-36 DC, supply class 2 per cULus
Max. harmonics [V] - 10% of max. permissible operating voltage
Power consumption [mA] < 5 only in 3-wire operation
Safety class III
Polarity reversal protection Yes Reversible
Output function NO-contact
Voltage drop [V] 3.5 4.5
Minimum load current [mA] 5
Residual current [mA] < 0.8
Current-carrying capacity [mA] 100
Short-circuit-proof Yes
Overload-proof Yes
Switching frequency [Hz] 10, with damping surface Ø 4mm to 7 Hz
Protection class [IP] IP65 / IP68 / IP69K; with cable box screwed
on properly
Immunity to magnetic fields [mT] - 0,5 bis +0,5
L+
2/4
1
L-
3
4
1
3
2
Connector pin assignment with cable break
protection 3-wire DC PNP
Universal piston detector
L+
1
2/4 L-
4
1
3
2
Connector pin assignment without cable
break protection 2-wire DC PNP/NPN

EN 4. Technical data
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951-150-032-EN
Version 08
Electrical data Universal piston detector Bipolar piston detector
234-13163-9 234-11454-1
Visual differentiations of the piston detectors
Both of the current piston detectors are equipped with the
“SKF Lubrication Systems Germany GmbH” lettering as well
as with the code “AB.”
In addition to this code, the bipolar piston detector also has
a thick black circumferential marking ring ( ).
Visual differentiations of the adapters for: Marking Part number
Progressive metering devices of the series VP and PSG2 44-0159-2509
Progressive metering devices of the series VPK andPSG1 44-0159-2508
Progressive metering devices of the seriesVPB 44-0159-2507
Progressive metering devices of the series PSG3 44-0159-2510
Progressive metering devices of the series SSV, SSVL, SSVD,
SSVDL, SSVC, SLC, VSG, VSL 419-74455-1
AB AB
rings 2
rings 2 M12x1
M10x1
M10x1
rings 3
rings 2 M11x1
rings 2

EN
4. Technical data
4
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951-150-032-EN
Version 08
4.2 Connection options 234-13163-9, 12-24V DC, 3-wire PNP
Adernfarben / Core colors br = brown = braun / ws = white = weiß / sw = schwarz = black / bl = blau = blue
1
2
3
4
12
3 4
+ 12-24 V DC
br
ws
sw
bl
0 V DC (ground)
Load
1
2
3
4
12
3 4
+ 12-24 V DC
br
ws
sw
bl
0 V DC (ground)
Load

EN 4. Technical data
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951-150-032-EN
Version 08
4.3 Connection options 234-13163-9, 12-24V DC, 2-wire PNP/NPN
Adernfarben / Core colors br = brown = braun / ws = white = weiß / sw = schwarz = black / bl = blau = blue
1
2
3
4
12
3 4
+ 12-24 V DC
br
ws
sw
bl
0 V DC (ground)
load
1
2
3
4
12
3 4
+ 12-24 V DC
br
ws
sw
bl
0 V DC (ground)
load
1
2
3
4
12
3 4
+ 12-24 V DC
br
ws
sw
bl
0 V DC (ground)
load
1
2
3
4
12
3 4
+ 12-24 V DC
br
ws
sw
bl 0 V DC (ground)
load
NPN
PNP
NPN
PNP

EN
4. Technical data
4
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951-150-032-EN
Version 08
4.4 Connection options 234-11454-1, bipolar 12-24V DC, 2-wire PNP/NPN
Adernfarben / Core colors br = brown = braun / ws = white = weiß / sw = schwarz = black / bl = blau = blue
1
2
3
4
12
3 4
+ 12-24 V DC
br
ws
sw
bl 0 V DC (ground)
load
1
2
3
4
12
3 4
+ 12-24 V DC
br
ws
sw
bl
0 V DC (ground)
load
1
2
3
4
12
3 4
+ 12-24 V DC
br
ws
sw
bl
0 V DC (ground)
load 1
2
3
4
12
3 4
+ 12-24 V DC
br
ws
sw
bl
0 V DC (ground)
load

EN 5. Assembly
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951-150-032-EN
Version 08
Assembly drawing, Fig. 2
5. Assembly
5.1 Disassembly of the old piston detector (VPB/VPK/PSG1/VP/PSG2/PSG3/SSV/SSVL/SSVD/SSVDL)
5.2 Assembly of the new piston detector (VPB/VPK/PSG1/VP/PSG2/PSG3)
5.2 Assembly of the new piston detector (SSV/SSVL/SSVD/SSVDL)
4 3 2 1
4 3 2 1
VPB
VPK
PSG1
VP
PSG2
PSG3
SSV,SSV-L,
SSVD,SSVDL,
SSVC, SLC,
VSG,VSL
SSV D
444
5 6 6
3
2
8
77
8
29
1
1
Visual differentiation
In contrast to the universal piston detector,
the bipolar piston detector is equipped with
a thick black marking ring
( ).

EN
5. Assembly
5
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951-150-032-EN
Version 08
CAUTION
Pressure hazard
Before beginning conversion work,
depressurize the system in which
the feeder with the piston detector
to be replaced is installed and de-
pressurize the feeder itself.
see Figures 1 to 3
5.1 Disassembly of the old piston detector
• Loosen and unscrew the defective piston
detector (3) from the metering device (4).
• nachfolgend überprüfen ob bereits ein
Adapter (7) montiert ist
Afterwards, check whether an adapter (7) is
already mounted.
• If present, remove old packing ring (5)
from the metering device (4) (VP; VPB;
VPK; PSG1; PSG2; SSV/SSVL/SSVD/
SSVDL)
Procedure for metering devices with mount-
ed adapter (7):
The adapters (7) have different wall
thicknesses suitable for the piston de-
tectors/metering devices. The code of
the adapter in accordance with Figure
3 is therefore to be checked prior to the
assembly of the piston detector.
• Depressurize the lubrication system and
the metering device
• If possible, place a drip pan for the dis-
charging lubricant below the correspond-
ing metering device.
• Place individual parts of the new piston
detector replacement kit (1) ready to
hand on a clean storage surface.
• Disconnect the electrical connection
cable (2) from the old/defective piston
detector.
• The old adapter (7) is to be discon-
nected from the metering device (4) if the
adapter code (rings) of the adapter that
is already mounted does not match the
code in Figure 3.
Adapter code, Fig. 3
rings 2 VP and PSG2
rings 3 VPK and PSG1
rings 2 VPB
SSV/SSVL/SSVD/
SSVDL/SSVC/SLC/
VSG/VSL
PSG3
rings 2
rings 2

EN 5. Assembly
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951-150-032-EN
Version 08
• Tighten the piston detector (8) with a
torque of 7±0.5 Nm.
• Connect electrical connection cable
(provided by customer) (2) to the piston
detector (8).
In case of different cable connection:
• Remove old connection cable (2).
• In place of the previous connection cable,
connect the supplied adapter cable (9) to
the piston detector (8) and the customer-
provided port
• Attach the adapter cable (9) in a stress-
free position.
• Clean the work area/feeder of lubricant
contamination.
• Remove the drip pan.
5.3 Checking the signal
See Figure 2
• On the subsequent metering device
strokes, the signal from the piston detec-
tor must be received by the customer’s
monitoring equipment.
• Check the metering stroke signal from
the piston detector on the yellow piston
detector LED (flashing) or at the cus-
tomer’s signal connection
5.2 Assembly of the new piston detector
see Figures 1 and 3
• Apply grease to the new sealing ring (6)
and place it on the new adapter (7).
• Apply the adapter (7) to the feeder (4)
and tighten with the following torque:
Adapter torques
VP/PSG2 SW 13 = 20+1Nm
VPK/PSG1 SW 12 = 15+1Nm
PSG3 SW 24 = 70±4Nm
SSV/SSVC/SSVD/SSVE SW 13 = 15±1Nm
SSVL/SSVDL SW 13 = 15±1Nm
SSVD/SSVD-E SW 13 = 15±1Nm
SLC1/SLC2 SW 13 = 15±1Nm
VSG, VSL SW 13 = 15+1Nm
VPB SW 12 = 15+1Nm
• Apply new piston detector (8) to the
adapter (7) and tighten gently.
Avoid uncontrolled tightening of
the piston detector, as this could
cause damage.
Maintain tightening torque of
70.5 Nm.

EN
6. Malfunctions, causes, and remedies
6
5
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951-150-032-EN
Version 08
6. Malfunctions, causes, and remedies
Malfunctions table
Malfunction Possible cause Remedy
None
Feeder signal
○Mechanical blockage of the metering device • Eliminate the blockage, check the metering device
○Socket not connected or connected
incorrectly
• Check plug contacts
• Install socket correctly
○Signal line is broken • Check signal line
○Piston detected is not installed correctly • Check engagement depth of adapter and piston detector, tighten if
necessary
○Piston detector overtightened • Disconnect piston detector, perform functional test, replace piston detector
if damaged
○Wrong adapter used • Use only the adapter appropriate for the respective feeder
○Universal piston detector ordered instead of a bipolar
piston detector; only when connecting to KFG pumps
in vehicle lubrication applications
• Swap the pigtails, see Chapter 3.3
6.1 Metering devices signal missing

EN 6. Malfunctions, causes, and remedies
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951-150-032-EN
Version 08
Failure table
If, after working through the fault causes (previous page), there is still a malfunction in the metering device signal
(continuous signal or missing signal), proceed as follows:
Malfunction Possible cause Remedy
Continuous signal ○Positive magnetic field beyond the permissible im-
munity margin (more than >0,5 mT)
Requirements:
The metering device must be functioning correctly, and the piston
detector must be connected correctly.
• Check for any excessive magnetic fields in the assembly area of the
metering device. Proceed as follows:
• Install the metering device with piston detector at a different
installation location and carry out a functional test of the piston
detector installed in the metering device..
• If the fault (continuous signal or missing signal) no longer occurs,
suitable measures should be taken to prevent the excessive magnetic
field. Contact SKF Service for assistance.
• If the fault (missing signal) continues to occur, return the entire me-
tering device to SKF Service/your dealer -see the manufacturer’s
address on page 3).
Missing signal ○Negative magnetic field beyond the permissible im-
munity margin (less than <-0,5 mT)