SKF KFG User manual

EN
KFG; KFGS; KFGL; KFGC (CAN bus)
for vehicle lubrication
KFG KFGS KFGL KFGL-MonoFlex KFGC
1
2
3
max
max
1
2
3
max
max
in
ax
Use hard grease NLGI-2 only !
Assembly instructions acc. to EC Dir. 2006/42/EC
for partly completed machinery with associated operating instructions
Version 05

Notes
Masthead
These assembly instructions with associated op-
erating instructions according to EC Machinery
Directive 2006/42/EC are an integral part of
the described product and must be kept for fu-
ture use.
These assembly instructions with associated op-
erating instructions have been prepared in ac-
cordance with the established standards and
rules for technical documentation, VDI 4500
and EN 292.
© SKF Lubrication Systems Germany GmbH
This documentation is protected by copyright.
SKF Lubrication Systems Germany GmbH
reserves all rights, including those to the
photomechanical reproduction, duplication,
and distribution by means of special procedures
(e.g., data processing, data media, and data
networks) of this documentation in whole or in
part.
Subject to changes in contents and technical
information.
Service
If you have technical questions, please contact
the following addresses:
SKF Lubrication Systems Germany GmbH
Berlin Plant
Motzener Straße 35/37
12277 Berlin, Germany
Germany
Tel. [phone]
Fax [phone]
Hockenheim Plant
2. Industriestrasse 4
68766 Hockenheim
Germany
Tel. [phone]
Fax [phone] / 27-101
[e-mail]
www.skf.com/lubrication
KFG KFGS KFGL KFGC
Page 2
EN

Information concerning EC Declaration of
Conformity and EC Declaration of Incorporation 6
Explanation of symbols and signs 7
Documentation overview 8
1. Safety instructions 8
1.1 Intended use 9
1.2 Authorized personnel 9
1.3 Electric shock hazard 10
1.4 System pressure hazard 10
1.5 Compressed air hazard 10
1.6 Hydraulic pressure hazard 10
1.7 Explosion protection information 11
2. Lubricants 12
2.1 General information 12
2.2 Selection of lubricants 12
2.3 Approved lubricants 13
2.4 Lubricants and the environment 14
2.5 Lubricant hazards 14
3. Overview 15
4. Assembly 16
4.1 General information 16
4.2 Setup and attachment 16
4.2.1 Minimum clearance height
for installation 17
Assembly instructions table of contents
KFG KFGS KFGL KFGC
4.2.2 Mounting diagram 18
4.2.3 Mounting dimensions,
without control unit 19
4.2.4 Mounting dimensions,
with control unit 20
4.3 Pump elements 21
4.3.1 Pump element designs 21
4.3.2 Pump elements with
spring-return pistons 22
4.3.3 Assembly of a pump element
with spring return pistons 23
4.3.4 Pump elements with
positively driven pistons 24
4.3.3 Assembly of a pump element
with positively driven pistons 25
4.3.4 Pressure regulating valve 26
    
   
4.4.2 Filler coupling 28
4.4.3 Filling cylinder 28
4.5 Electrical power supply 29
4.5.1 General conditions for
electrical connections 29
4.6 KFG power supply and connections 30
4.6.1 KFG power supply 30
4.6.2 External control units 30
4.7 KFGS power supply and connections 31
4.7.1 KFGS power supply 31
4.7.2 Connectivity Counter operation
without system monitoring 32
4.7.3 Connectivity Counter operation
with system monitoring 32
4.7.4 Connectivity Timer operation
without system monitoring 33
4.7.5 Connectivity Timer operation
with system monitoring 33
4.8 KFGL power supply and connections 34
4.8.1 KFGL power supply 34
4.8.2 KFGL ProFlex for progressive
centralized lubrication systems 35
4.8.3 KFGL MonoFlex for single-line
lubrication systems 36
4.9 KFGC power supply and connections 37
4.9.1 Power supply 37
4.9.2 Connectivity 39
4.10 Pressure relief valve with
integrated pressure regulating valve 41
4.11 Fill level monitoring 42
4.11.1 Order code 1 (W1) 42
4.11.2 Order code 2 (W1G) 43
  
monitoring, order code 1 and 2 44
   
4.12 Lubrication line connection 45
4.13 Lubrication line arrangement 45
4.14 Progressive system ventilation 46
4.15 Single-line system ventilation 46
4.16 Note on the rating plate 46
4.17 Notes on the CE marking 47
Page 3 EN
Table of contents

Operating instructions table of contents
KFG KFGS KFGL KFGC
1. Safety instructions 50
1.1 General information 50
1.2 Disclaimer of liability 50
2. Lubricants 50
3. Transport, delivery, and storage 51
3.1 Lubrication units 51
3.2 Electronic and electrical devices 51
3.3 General notes 51
4. Assembly 52
4.1 Information on assembly 52
4.2 Pump unit assembly procedure 52
5. Design and function 52
5.1 General information 52
5.2 Design 52
5.2.1 Pump housing 52
5.2.2 Lubricant reservoir 53
5.2.3 Fill level monitoring 53
5.2.4 KFGS and KFGL control units 53
5.3 KFG pump units 53
5.4 KFGS pump units 54
5.5 KFGL pump units 54
5.6 KFGC pump units 55
6. Functional description in
progressive systems 56
6.1 Functional description for progressive
systems with a KFG pump unit 56
6.1.1 Pump element 56
6.1.2 Pressure regulating valve 57
6.2 Progressive system with a
KFGS or KFGL pump unit 58
6.3 Progressive systems with
KFGC (CAN bus) pump unit 59
7. Functional description in
single-line systems 60
7.1 KFG-Pump unit 60
7.1.1 Pump element 60
7.1.2 Pressure relief valve 60
7.1.3 Pressure regulating valve 60
7.2 Functional description: (single-line
systems) with KFGL-Pump unit 62
7.3 Functional description in single-line
systems with a KFGC (CAN-Bus)
pump unit 64
7.3.1 Systems with 3/2 directional
solenoid valves 64
7.3.2 Multiple lubrication zones 64
8. Commissioning 65
8.1 General commissioning 65
9. KFGS control unit 66
9.1 Display and control elements
of control screen 66
9.1.1 Three-digit LED display 67
9.1.2 LED display 69
9.1.3 Pushbutton operation 70
9.2 KFGS display mode 71
9.3 KFGS programming 73
9.3.1 Start programming mode 73
9.3.2 Change lubrication interval times 73
   
9.3.4 Change operating modes 76
9.3.5 Change access code 77
9.3.6 Programming ranges 78
9.3.7 Display ranges 78
9.4 KFGS operating modes 78
9.4.1 Timer operation 78
9.4.2 Counter operation 78
9.4.3 No system monitoring 79
9.4.4 With system monitoring 79
9.5 Fill level monitoring 79
9.5.1 Monitoring via piston detector 79
Page 4
EN Table of contents

KFG KFGS KFGL KFGC
10. KFGL control unit 81
10.1 Display and control elements
of control screen 81
10.2 Display and control menu 83
10.2.1 Main menu 83
10.2.2 Info - Information mode 84
   
10.3 Programming a KFGL pump unit 88
11. KFGC control unit 89
11.1 KFGC series (CAN bus) 89
12. Shutdown/disposing 91
12.1 Temporary shutdown 91
12.2 Permanent shutdown 91
13. Maintenance and service 92
13.1 General information 93
13.2 Maintenance and repair 93
13.3 Service 93
14. Operational and pump faults 95
14.1 Operational malfunctions 95
14.1.1 General information 95
14.1.2 Malfunctions on pump units 95
14.2 Malfunctions on KFGS pump units 97
14.2.1 Display faults 97
   
14.2.3 Fault types 98
14.2.4 Recording fault times 99
14.2.5 Malfunctions on KFGS pump unit
with a progressive feeder system 99
14.3 Malfunctions on KFGL pump unit 100
14.3.1 Display faults 100
   
14.3.3 Fault types 100
   
14.4 Malfunctions on KFGC pump unit 101
14.4.1 Faults detected by control unit 101
14.4.2 Fault types 101
14.4.3 Read faults 101
14.4.4 Remedy faults 101
15. Technical data 102
16. Accessories 105
Page 5 EN
Table of contents

KFG KFGS KFGL KFGC
Page 6
EN
EC Declaration of Incorporation according to Machinery Directive 2006/42/EC, Annex II Part 1 B
The manufacturer SKF Lubrication Systems Germany GmbH ,Plaint Hockenheim, 2. Industriestraße 4, DE - 68766 Hockenheim hereby declares that
the partly completed machinery:
Designation: Piston pump aggregate for vehicle lubrication
Type: KFG, KFGS, KFGL, KFGC
Part no.: KFG*; KFG*F*; 772-*
Year of construction: See type identification plate
complies with the following basic requirements of the EC Machinery Directive 2006/42/EC at the time when first being launched in the market.
1.1.2 · 1.1.3 · 1.3.2 · 1.3.4 · 1.5.1 · 1.5.6· 1.5.8 · 1.5.9 · 1.6.1 · 1.7.1 · 1.7.3 · 1.7.4
The special technical documents were prepared following annex II part B of this directive. Upon justifiable request, these special technical documents can be forwarded
electronically to the respective national authorities. The person empowered to assemble the technical documentation on behalf of the manufacturer is the head of
standardization; see manufacturer‘s address.
Furthermore, the following directives and harmonized standards were applied in the respective applicable areas:
2011/65/EU RoHS II
2014/30/EU Electromagnetic compatibility | Industry
Standard Edition Standard Edition Standard Edition Standard Edition
DIN EN ISO 12100 2011 DIN EN 60947-5-1 2010 DIN EN 61000-6-2 2006 DIN EN 61000-6-4 2011
DIN EN 809 2012 DIN EN 61131-2 2008 Amendment 2011 DIN EN 60947-5-1 2010
DIN EN 60204-1 2007 Amendment 2009 DIN EN 61000-6-3 2011
Amendment 2010 DIN EN 60034-1 2015 Amendment 2012
DIN EN 50581 2013 DIN EN 61000-6-1 2007
The partly completed machinery must not be put into service until the final machinery into which it is to be incorporated has been declared in conformity with the pro-
visions of the EC Machinery Directive 2006/42/EC and any other applicable directives.
Hockenheim, 2016/04/25
Jürgen Kreutzkämper
Manager R&D Germany
SKF Lubrication Business Unit
Stefan Schürmann
Manager R&D Hockenheim/Walldorf
SKF Lubrication Business Unit

KFG KFGS KFGL KFGC
Page 7 EN
Informational symbolsIndicators used with safety instructions
and their significance
Hazard symbols
Explanation of symbols
Explanation of symbols and signs


the environment, next to all safety instructions
in these operating instructions.
Please heed these instructions and proceed
with special care in such cases. Please forward
all safety instructions to other users.
General hazard
DIN 4844-2-W000
Electrical voltage/current
Hot surface
Signal word Meaning
Danger! Danger of bodily injury
Warning! Of damage to property and
the environment
Note! Provides additional
information
Note!
Prompts an action
Used for itemizing
Refers to other facts, causes or
consequences
Provides additional information
Instructions placed directly on the machines/
grease lubrication pump units, such as:
Arrow indicators
 
must be followed and kept in fully legible
condition.
You are responsible!
Please read the assembly and operating
instructions thoroughly and follow the safety
instructions.
Danger of being drawn into machinery
DIN 4844-2-W008
DIN 4844-2-W026
BGV 8A
Slipping hazard
DIN 4844-2-W028
Warning of potentially explosive
atmosphere
DIN 4844-2-W021

Documentation overview
KFG KFGS KFGL KFGC
Description/
Document number
LC502 control unit for ProFlex
progressive centralized lubrication systems
951-180-005-EN
LC502 control unit for MonoFlex
single-line lubrication systems
951-180-004-EN
KFG; KFGS; KFGC (CAN bus) for
vehicle lubrication
951-170-204-EN
CAN bus control system description
951-130-502-EN
Page 8
EN Assembly instructions
The operator of the described prod-
uct must ensure that the assembly
instructions are read and understood by
all persons tasked with the assembly,
operation, maintenance, and repair of
the product. The assembly instructions
must be kept readily available.
Note that the assembly instructions
form part of the product and must
accompany the product if sold to a new
owner.
1. Safety instructions
In addition to the assembly instructions,
general statutory regulations and other
regulations for accident prevention
and environmental protection must be
observed and applied.
The described product is manufactured in ac-
cordance with the generally accepted rules and
standards of industry practice and with occu-
pational safety and accident prevention regula-
tions. Risks may, however, arise from its usage
and may result in physical harm to persons or
damage to other material assets. Therefore the
product may only be used in proper technical
condition and in observance of the assembly
instructions. In particular, any malfunctions
which may affect safety must be remedied
immediately.

KFG KFGS KFGL KFGC
Page 9 EN
1.1 Intended use
Pump units of SKF's KFG, KFGS, KFGL and
KFGC series are used to supply centralized lu-
brication systems in vehicles, systems and ma-
chines. They deliver oils and greases (up to
NLGI Grade 2).
The use of synthetic oils requires prior approval
from SKF Lubrication Systems Germany GmbH.
Any other usage is deemed non-compliant
with the intended use.
Hazardous materials of any kind, especially the
materials classified as hazardous by CLP
Regulation EC 1272/2008 may only be used to
fill SKF centralized lubrication systems and
components and deliv-ered and/or distributed
with the same after consulting with and re-
ceiving written approval from SKF.
The product described here is neither designed
nor approved for use in conjunction with gas-
es, liquefied gases, pressurized gases in solu-
tion, vapors and such fluids whose vapor pres-
sure exceeds normal atmospheric pressure
(1013 mbar) by more than 0.5 bar at their
Assembly instructions
maximum permissible temperature.
Unless specially indicated otherwise, products
from SKF Lubrication Systems Germany GmbH
are not approved for use in potentially explosive
areas as defined in the ATEX Directive
2014/34/EC.
1.2 Authorized personnel
Only qualified technical personnel may install,
operate, maintain, and repair the products de-
scribed in the assembly instructions. Qualified
technical personnel are persons who have
been trained, assigned and instructed by the
operator of the final product into which the de-
scribed product is incorporated. Such persons
are familiar with the relevant standards, rules,
accident prevention regulations, and assembly
conditions as a result of their training, experi-
ence, and instruction. They are authorized to
identify and perform necessary actions while
avoiding any risks which may arise.
The definition of qualified personnel and the
prohibition against employing non-qualified
personnel are laid down in DIN VDE 0105 and
IEC 364.

KFG KFGS KFGL KFGC
Page 10
EN
Dangerous contact voltages may occur
on the unit if the protective earth
conductor is not connected or is inter-
rupted.
1.4 System pressure hazard
Lubrication systems are pressurized
during operation. Centralized lubrication
systems must therefore be depressurized
before starting assembly, maintenance
-
tions or system repairs.
1.5 Compressed air hazard
The described product is pressurized
during operation. The product must
therefore be depressurized before
starting assembly, maintenance or repair

system repairs.
Depending on the model design, the product
may be able to be operated with compressed air.
1.6 Hydraulic pressure hazard
The described product is pressurized
during operation. The product must
therefore be depressurized before
starting assembly, maintenance or repair

system repairs.
Depending on the model design, the product
may be able to be operated hydraulically.
1.3 Electric shock hazard
Electrical connections for the described product
may only be established by qualified and
trained personnel authorized to do so by the
operator, and in observance of the local condi-
tions for connections and local regulations
(e.g., DIN, VDE). Significant bodily injury and
property damage may result from improperly
connected products.
Danger!
Work on products that have not been
de-energized may result in bodily injury.
Assembly, maintenance and repair work
may only be performed on products

technical personnel. Supply voltage
must be switched off before opening
any of the product's components.
The protective earth conductor (PE)
must always be connected. Always
ensure adequate, standard conductor
diameter and secure contact.
Assembly instructions