SKF KFG User manual

Assembly Instructions
KFG, KFGS, KFGL piston
pump
For automotive lubrication
Created on:
12.01.2023
Document no.:
951-170-213-EN
Version:
07
Read these instructions before
installation or start
-up of the
product and keep
them readily
available for later consultation!

2
Original EC Declaration of Incorporation in accordance with Directive 2006/42/EC,
Appendix II Part 1 B
The manufacturer hereby declares at its sole responsibility that the partly completed machinery conforms to the essential health and safety requirements
of the Machinery Directive 2006/42/EC, Annex I, marked in the Annex to the EC Declaration of Incorporation as applicable and fulfilled at the time of placing
on the market.
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 the manufacturer.
Designation:
Electrically operated pump for the supply of lubricants within a centralized lubrication system
Type:
KFG; KFGS; KFGL pump
Item number:
772-*...., 6772-*...., KFG*....
Furthermore, the following directives and standards were applied in the respective applicable areas:
2011/65/EU: RoHS II
2014/30/EU: Electromagnetic Compatibility
EN ISO 12100:2010
EN 60204-1:2018
EN 61000-6-2:2005/AC:2005
EN 61000-6-4:2007/A1:2011
EN 61131-2:2007
EN 809:1998+A1:2009/AC:2010
EN 60034-1:2010/AC:2010
EN 60947-5-1:2004/A1:2009
EN 60947-5-2:2007/A1:2012
EN IEC 63000:2018
The partly completed machinery must not be put into service until it has been established that the machinery into which it is to be incorporated is in
compliance with the provisions of the Machinery Directive 2006/42/EC and all other applicable Directives.
Walldorf, 12.01.2023
Jürgen Kreutzkämper
Stefan Schürmann
Manager, R&D
Germany
Manager, PD
Germany South
Manufacturer: SKF Lubrication Systems Germany GmbH, Heinrich-Hertz-Str. 2-8, 69190 Walldorf, Germany
Original UK Declaration of incorporation according to the Supply of Machinery (Safety)
Regulations 2008 No. 1597 Annex II
The manufacturer hereby declares under sole responsibility that the partly completed machinery complies with the essential health and safety
requirements of UK legislation Supply of Machinery (Safety) Regulations 2008 No. 1597 Annex I, marked in the Annex to the EC Declaration of
Incorporation as applicable and fulfilled at the time of placing on the market.
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.
Designation:
Electrically operated pump for the supply of lubricants within a centralized lubrication system
Type:
KFG; KFGS; KFGL pump
Item number:
772-*...., 6772-*...., KFG*....
Furthermore, the following regulations and standards were applied in the respective applicable areas:
•Electromagnetic Compatibility Ordinance 2016 No. 1091
•The Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic Equipment Regulations 2012 No. 3032
EN ISO 12100:2010
EN 60204-1:2018
EN 61000-6-2:2005/AC:2005
EN 61000-6-4:2007/A1:2011
EN 61131-2:2007
EN 809:1998+A1:2009/AC:2010
EN 60034-1:2010/AC:2010
EN 60947-5-1:2004/A1:2009
EN 60947-5-2:2007/A1:2012
EN IEC 63000:2018
The partly completed machinery must not be put into service until it has been established that the machinery into which it is to be incorporated is in
compliance with the provisions of UK legislation Supply of Machinery (Safety) Regulations 2008 No. 1597 and all other applicable Directives.
Walldorf, 12.01.2023
Jürgen Kreutzkämper
Stefan Schürmann
Manager, R&D
Germany
Manager, PD
Germany South
Manufacturer: SKF Lubrication Systems Germany GmbH, Heinrich-Hertz-Str. 2-8, 69190 Walldorf, Germany

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. Any
essential health and safety requirements not listed here are not relevant to this product.
Table 1
Appendix to Declaration of Incorporation
Valid for: KFG* lubricant feed pumps
No.:
Essential health and safety requirement
Applicable:
Fulfilled:
1.1.1
Definitions
Yes
Yes
1.1.2
Principles of safety integration
Yes
Yes
1.1.3
Materials and products
Yes
Partially1)
1.1.5
Design of machinery to facilitate its handling
Yes
Yes
1.1.6
Ergonomics
Yes
Partially2)
1.2
Control systems
Yes
Yes
1.2.1
Safety and reliability of control systems
Yes
Yes
1.2.3
Starting
Yes
Yes
1.2.6
Failure of the power supply
Yes
Yes
1.3
Protection against mechanical hazards
Yes
Yes
1.3.1
Risk of loss of stability
Yes
Yes
1.3.2
Risk of break-up during operation
Yes
Partially3)
1.3.4
Risks due to surfaces, edges or angles
Yes
Yes
1.3.7
Risks related to moving parts
Yes
Yes
1.3.9
Risks of uncontrolled movements
Yes
Yes
1.5
Risks due to other hazards
Yes
Yes
1.5.1
Electricity supply
Yes
Yes
1.5.6
Fire
Yes
Yes
1.5.8
Noise
Yes
Yes
1.5.11
External radiation
Yes
Yes
1.5.13
Emissions of hazardous materials and substances
Yes
Yes
1.5.15
Risk of slipping, tripping, or falling
Yes
Yes
1.6
Servicing
1.6.1
Machinery maintenance
Yes
Yes
1.6.2
Access to operating positions and servicing points
Yes
Partially4)
1.6.4
Operator interventions
Yes
Yes
1.7
Information
Yes
Yes
1.7.1
Information and warnings on the machinery
Yes
Yes
1.7.1.1
Information and information devices
Yes
Yes
1.7.2
Warning of residual risks
Yes
Yes
1.7.3
Marking of machinery
Yes
Yes
1.7.4
Operating instructions/assembly instructions
Yes
Yes
1.7.4.1
General principles for the drafting of operating instructions/assembly instructions
Yes
Yes
1.7.4.2
Contents of the operating instructions/assembly instructions
Yes
Yes
1.7.4.3
Sales literature
Yes
Yes
1) Not completely fulfilled: Hazards due to the lubricant used must be assessed by the operator on the basis of the Safety Data Sheet
(SDS) and, if necessary, protective measures must be taken.
2) Not completely fulfilled: The operator must ensure that the pump is integrated into the higher-level machine in such a way that the
pump can be operated and filled ergonomically.
3) Not completely fulfilled: The operator must protect the lubrication system against excessive pressure. For this purpose, every pump
element must be fitted with a pressure limiting valve with an opening pressure of max. 200 bar or max. 300 bar (depending on the
pump element used).
4) Not completely fulfilled: The operator must ensure that the pump is integrated into the higher-level machine in such a way that the
pump can be operated without danger.

4
Masthead
Manufacturer
SKF Lubrication Systems Germany GmbH
Email: Lubrication-[email protected]
www.skf.com/lubrication
Berlin Plant
Motzener Strasse 35/37
12277 Berlin
Germany
Tel. [phone]
Fax [phone]
Walldorf Plant
Heinrich-Hertz-Strasse 2-8
69190 Walldorf, Germany
Germany
Tel.: [phone]
Fax: [phone]
Authorized local distributors
- Great Britain -
SKF (U.K.) Limited,
2 Canada Close, Banbury, Oxfordshire,
OX16 2RT, GBR.
- North America -
SKF Lubrication Business Unit
Lincoln Industrial
5148 North Hanley Road, St. Louis,
MO. 63134 USA
- South America -
SKF Argentina Pte. Roca 4145,
CP 2001 Rosario, Santa Fe
Warranty
The instructions contain no statements regarding the warranty
or liability for defects. That information can be found in our
General Terms of Payment and Delivery.
Training
We conduct detailed training in order to enable maximum
safety and efficiency. We recommend taking advantage of this
training. For further information, contact your authorized SKF
dealer or the manufacturer.

5
Table of contents
Masthead ...............................................................................................4
Table of contents..................................................................................5
Safety alerts, visual presentation, and layout.................................7
1. Safety instructions...........................................................................8
1.1 General safety instructions......................................................8
1.2 General electrical safety instructions.....................................8
1.3 General behaviour when handling the product ...................9
1.4 Intended use...............................................................................9
1.5 Persons authorized to use the product.................................9
1.6 Foreseeable misuse ..................................................................9
1.7 Referenced documents ......................................................... 10
1.8 Prohibition of certain activities ............................................ 10
1.9 Painting plastic components and seals .............................. 10
1.10 Safety markings on the product ....................................... 10
1.11 Note on the type plate ........................................................11
1.12 Notes on CE marking .......................................................... 11
1.13 Note on Low Voltage Directive.......................................... 11
1.14 Note on Pressure Equipment Directive........................... 11
1.15 Note on UKCA marking.......................................................11
1.16 Note on UL mark .................................................................11
1.17 Note on ECE mark ...............................................................11
1.18 Note on EAC marking.......................................................... 11
1.19 Note on China RoHS mark................................................. 11
1.20 Emergency shutdown ......................................................... 11
1.21 Assembly, maintenance, fault, repair............................... 12
1.22 First start-up, daily start-up.............................................. 12
1.23 Residual risks........................................................................ 13
2. Lubricants ...................................................................................... 14
2.1 General information............................................................... 14
2.2 Material compatibility ............................................................ 14
2.3 Temperature properties........................................................14
2.4 Aging of lubricants .................................................................14
2.5 Avoidance of faults and hazards.......................................... 14
2.6 Solid lubricants ....................................................................... 14
3. Overview, functional description................................................ 15
3.1 General..................................................................................... 15
3.2 Design.......................................................................................15
3.2.1 Pump housing............................................................. 15
3.2.2 Lubricant reservoir .................................................... 15
3.2.3 Fill level monitoring ................................................... 15
3.2.4 KFGS and KFGL control units .................................. 15
3.3 Overview ..................................................................................16
3.3.1 KFG pump units.......................................................... 16
3.3.2 KFGS pump units....................................................... 16
3.3.3 KFGL pump units ....................................................... 16
3.4 Functional description in progressive systems................. 17
3.4.1 KFG pump unit............................................................ 17
3.4.2 Progressive system with a KFGS or KFGL pump
unit ..........................................................................................19
3.5 Functional description in single-line systems................... 20
3.5.1 KFG-Pump unit with grease follower plate
technology.............................................................................. 20
3.5.2 Single-line system with a KFGL pump unit .......... 22
4. Accessories..................................................................................... 23
5. Technical data ............................................................................... 25
5.1 General technical data...........................................................25
5.2 Nominal delivery rates ..........................................................26
5.3 Pressure limiting valve..........................................................27
5.4 Pressure relief valve with integrated pressure limiting
valve .................................................................................................29
5.5 Lubricant level switch............................................................29
5.6 Type identification code for pump KFG..............................30
6. Delivery, returns, storage............................................................ 31
6.1 Delivery.....................................................................................31
6.2 Return shipment.....................................................................31
6.3 Storage..................................................................................... 31
6.4 Storage temperature range .................................................31
6.5 Storage conditions for products filled with lubricant....... 31
6.5.1 Storage period up to 6 months...............................31
6.5.2 Storage period between 6 and 18 months........... 31
6.5.3 Storage period more than 18 months................... 31
7. Assembly ........................................................................................ 32
7.1 General safety instructions................................................... 32
7.2 Mechanical connection ..........................................................32
7.2.1 Minimum mounting dimensions .............................32
7.2.2 Setup and attachment ..............................................33
7.2.3 Mounting diagram......................................................34
7.2.4 KFG dimensions.......................................................... 35
7.2.5 KFGL/KFGS dimensions ............................................35
7.3 Pump elements of the KFG series.......................................36
7.3.1 Pump element designs .............................................37
7.3.2 Installing a pump element with spring-return
piston ......................................................................................37
7.3.3 Assembly of a pump element with positively driven
pistons.....................................................................................38
7.3.4 Pressure limiting valve (DBV) ..................................39
7.4 Filling with lubricant...............................................................39
7.4.1 Filling via fill connection............................................39
7.4.2 Filler coupling..............................................................40
7.4.3 Filling cylinder.............................................................40
7.5 Power supply...........................................................................41
7.5.1 General conditions for electrical connections ....... 41
7.5.2 KFG power supply...................................................... 42
7.5.3 KFGS/KFGL power supply.........................................42
7.6 Control port assignments ..................................................... 43
7.6.1 KFG series (external control)....................................43
7.6.2 KFGS series (integrated control) .............................43
7.6.3 KFGL series .................................................................47
7.6.4 Pressure relief valve with integrated pressure
limiting valve.......................................................................... 49
7.6.5 Fill level monitoring ...................................................49
7.7 Pump unit fill level control.................................................... 51
7.8 Connection of the lubrication line........................................52
8. First start-up................................................................................. 53
8.1 Inspections before first start-up..........................................53
8.2 Inspections during first start-up..........................................53
8.3 Progressive system ventilation............................................ 54
8.4 Single-line system ventilation..............................................54
9. Operation........................................................................................ 55
9.1 KFGS control unit ................................................................... 55
9.1.1 Display and control elements of control screen... 55
9.1.2 KFGS display mode....................................................58
9.1.3 KFGS programming mode........................................60
9.1.4 KFGS operating modes .............................................65

6
9.1.5 Fill level monitoring....................................................66
9.1.6 Monitoring via piston detector .................................66
9.2 KFGL control unit....................................................................67
9.2.1 Display and control elements of control screen ...67
9.2.2 Display and control menu.........................................69
9.2.3 Programming a KFGL pump unit ............................71
10. Maintenance and repair ............................................................72
10.1 General...................................................................................72
10.2 Service....................................................................................72
10.3 Maintenance schedule.........................................................73
11. Cleaning........................................................................................74
11.1 Basics......................................................................................74
11.2 Interior cleaning....................................................................74
11.3 Exterior cleaning...................................................................74
12. Faults, causes, and remedies ...................................................74
12.1 Malfunctions on pump units...............................................75
12.2 Malfunctions on KFGS pump unit .....................................76
12.2.1 Displaying fault notifications..................................76
12.2.2 Deleting fault notifications......................................76
12.2.3 Fault types.................................................................76
12.2.4 Recording fault times ..............................................76
12.2.5 Faults in a progressive system..............................76
12.3 Malfunctions on KFGL pump unit......................................77
12.3.1 Displaying fault notifications..................................77
12.3.2 Deleting fault notifications......................................78
13. Repairs..........................................................................................78
14. Shutdown, disposal ....................................................................79
14.1 Temporary shutdown..........................................................79
14.2 Permanent shutdown, disassembly..................................79
14.3 Disposal..................................................................................79
15. Spare parts ..................................................................................80
16. Appendix.......................................................................................84
16.1 China RoHS Table ................................................................84

7
Safety alerts, visual
presentation, and layout
While reading these instructions, you will encounter various
symbols, illustrations, and text layouts intended to help you
navigate and understand the instructions. Their meaning is
explained below.
Safety alerts:
Activities that present specific hazards (to life and limb or
possible damage to property) are indicated by safety alerts.
Always be sure to follow the instructions given in the safety
alerts.
<
DANGER
These safety alerts indicate an imminent danger.
Ignoring them will result in death or serious injury
<
WARNING
These safety alerts indicate potentially imminent
danger. Ignoring them could result in death or
serious injury
<
CAUTION
These safety alerts indicate potentially imminent
danger. Ignoring them could result in minor injury
<
NOTICE
These safety alerts indicate a potentially harmful
situation. Ignoring them could result in damage to
property or
malfunctions
Illustrations:
The illustrations used depict a specific product. For other
products, they may have the function of a diagram only. This
does not alter the basic workings and operation of the product.
Text layout:
•First-order bulleted lists: Items on a bulleted list start with
a solid black dot and an indent.
–Second-order bulleted lists: If there is a further listing of
subitems, the second-order bulleted list is used.
1 Legend: A legend explains the numbered contents of an
illustration, presented as a numbered list. Items in a legend
start with a number (with no dot) and an indent.
–Second-order legend: In some cases, the numbered
contents of an image represent more than just one object.
A second-order legend is then used.
1.Instruction steps: These indicate a chronological sequence
of instruction steps. The numbers of the steps are in bold and
are followed by a period. If a new activity follows, the
numbering starts again at “1.”
–Second-order instruction steps: In some cases, it is
necessary to divide up a step into a few substeps. A
sequence of second-order instruction steps is then used.

8
1. Safety instructions
1.1 General safety instructions
•Putting the products into operation or operating them without
having read the instructions is prohibited. The operator must
ensure that the instructions are read and understood by all
persons tasked with working on the product or who supervise
or instruct such persons. Retain the instructions for further
use.
•The product may only be used in awareness of the potential
dangers, in proper technical condition, and according to the
information in this manual.
•Any faults that could affect safety must be remedied
according to responsibility. The supervisor must be notified
immediately in case of malfunctions outside one's individual
scope of responsibility.
•Unauthorized modifications and changes can have an
unpredictable effect on safety and operation. Unauthorized
modifications and changes are therefore prohibited. Only
original SKF spare parts and SKF accessories may be used.
•Any unclear points regarding proper condition or correct
assembly/operation must be clarified. Operation is prohibited
until issues have been clarified.
•The components used must be suitable for the intended use
and the applicable operating conditions, e.g. max. operating
pressure and ambient temperature range, and must not be
subjected to torsion, shear, or bending.
1.2 General electrical safety instructions
•Electrical devices must be kept in proper condition. This must
be ensured by periodic inspections in accordance with the
relevant applicable standards and technical rules. The type,
frequency, and scope of the inspections must be determined
in accordance with the risk assessment to be carried out by
the operator. Work on electrical components may be
performed only by qualified electricians. Connect the electrical
power only in accordance with the valid terminal diagram and
in observance of the relevant regulations and the local
electrical supply conditions.
•Work on electrical components may be performed only in a
voltage-free state and using tools suitable for electrical work.
Do not touch cables or electrical components with wet or
moist hands.
•Fuses must not be bridged. Always replace defective fuses
with fuses of the same type.
•Ensure proper connection of the protective conductor for
products with protection class I. Observe the specified
enclosure rating.
•The operator must implement appropriate measures to
protect vulnerable electrical devices from the effects of
lightning during use. The electrical device is not furnished
with a grounding system for the dissipation of the respective
electric charge and does not have the voltage strength
necessary to withstand the effects of lightning.

9
1.3 General behaviour when handling the
product
•Familiarize yourself with the functions and operation of the
product. The specified assembly and operating steps and their
sequences must be observed.
•Keep unauthorized persons away.
•Wear personal protective equipment always.
•Precautionary operational measures and instructions for the
respective work must be observed.
•In addition to these Instructions, general statutory regulations
for accident prevention and environmental protection must be
observed.
•Precautionary operational measures and instructions for the
respective work must be observed. Uncertainty seriously
endangers safety.
•Safety-related protective and safety equipment must not be
removed, modified or affected otherwise in its function and is
to be checked at regular intervals for completeness and
function.
•If protective and safety equipment has to be dismantled, it
must be reassembled immediately after finishing the work,
and then checked for correct function.
•Remedy occurring faults in the frame of responsibilities.
Immediately inform your superior in the case of faults beyond
your competence.
•Never use parts of the centralized lubrication system or of the
machine as standing or climbing aids.
1.4 Intended use
Supply of lubricants.
The product is intended solely for installation in another
machine.
Use is only permitted within the scope of commercial or
economic activity by professional users, in compliance with the
specifications, technical data, and limits specified in this manual.
1.5 Persons authorized to use the
product
Operator
A person who is qualified by training, knowledge and experience
to carry out the functions and activities related to normal
operation. This includes avoiding possible hazards that may
arise during operation.
Specialist in electrics
Person with appropriate professional education, knowledge and
experience to detect and avoid the hazards that may arise from
electricity.
Specialist in mechanics
Person with appropriate professional education, knowledge and
experience to detect and avoid the hazards that may arise
during transport, installation, start-up, operation, maintenance,
repair and disassembly.
1.6 Foreseeable misuse
Any usage of the product other than as specified in this manual
is strictly prohibited. Particularly prohibited are:
•Use of non-specified consumables, contaminated lubricants,
or lubricants with air inclusions.
•Use of C3 versions in areas with aggressive, corrosive
substances (e.g., high salt load).
•Use of plastic parts in areas with high exposure to ozone, UV
light, or ionizing radiation.
•Use to supply, convey, or store hazardous substances and
mixtures as defined in the CLP Regulation (EC 1272/2008) or
GHS with acute oral, dermal, or inhalation toxicity or
substances and mixtures that are marked with hazard
pictograms GHS01-GHS06 and GHS08.
•Use to supply, convey, or store Group 1 fluids classified as
hazards as defined in the Pressure Equipment Directive
(2014/68/EU) Article 13 (1) a).
•Use to supply, convey, or store gases, liquefied gases,
dissolved gases, vapors, or fluids whose vapor pressure
exceeds normal atmospheric pressure (1013 mbar) by more
than 0.5 bar at their maximum permissible operating
temperature.
•Use in an explosion protection zone.
•Use without proper securing against excessively high
pressures, in the case of pressurized products.
•Use outside of the technical data and limits specified in this
manual.

10
1.7 Referenced documents
In addition to this manual, the following documents must be
observed by the respective target group:
•Company instructions and approval rules
If applicable:
•Safety data sheet of the lubricant used
•Project planning documents
•Supplementary information regarding special designs of the
pump. This you will find in the special system documentation.
•Instructions for other components for setting up the
centralized lubrication system.
1.8 Prohibition of certain activities
•Replacement of or modifications to the pistons of the pump
elements
•Repairs or modifications to the drive
•Alterations to the control circuit board beyond adjustment of
lubrication times and interval times or replacement in case of
defect
1.9 Painting plastic components and
seals
The painting of any plastic components and seals of the
products described is prohibited. Completely mask or remove
plastic components before painting the main machine.
1.10 Safety markings on the product
Fig. 1
Risk of dangerous electrical voltage
(for VAC pumps only)
Risk of wrapping, pinching, crushing, or
shearing when the reservoir lid is open
(only for reservoirs with filling from above)
Risk of injury from spring tension
(only for pumps with a follower plate)
Direction of rotation of the pump (stirring
paddle)
Read the instructions
(before initial filling of a pump with double-lip
follower plate delivered without lubricant)
Possible safety markings on the product
NOTE
Further to the findings of the workplace risk evaluation the
operating company has to attach additional markings (e. g.
warnings, signs
giving orders, prohibition signs or labelling
as specified by CLP / GHS), where appropriate.

11
1.11 Note on the type plate
The type plate provides important data such as the type
designation, order number, and sometimes regulatory
characteristics. To avoid loss of this data in case the type plate
becomes illegible, it should be entered in the manual.
Fig. 2
Type plate
1 Order number (type
identification code)
2 Type designation
3 Customer item number
4
Power supply
Table 2
Table for copying out the type plate
<Conte nt>
Type designation:
Order number:
Item number:
1.12 Notes on CE marking
CE marking is effected following the requirements
of the applied directives requiring a CE marking:
•2014/30/EC Electromagnetic Compatibility
•2011/65/EU Directive on the restriction of the use of certain
hazardous substances in electrical and electronic equipment
(RoHS II)
1.13 Note on Low Voltage Directive
The protection objectives of the Low Voltage Directive
2014/35/EU are met in accordance with Annex I, No. 1.5.1 of
the Machinery Directive 2006/42/EC.
1.14 Note on Pressure Equipment
Directive
Due to its performance characteristics, the product does not
reach the limit values defined in Article 4, Paragraph 1,
Subparagraph (a) (ii) and is excluded from the scope of Pressure
Equipment Directive 2014/68/EU in accordance with Article 1,
Paragraph 2 Subparagraph (f).
1.15 Note on UKCA marking
The UKCA conformity marking confirms the
product’s conformity with the applicable legal
provisions of Great Britain.
1.16 Note on UL mark
The UL Mark certifies that the product has UL
certification of compliance with U.S. and Canadian
safety regulations.
1.17 Note on ECE mark
The ECE test mark (E1) confirms that an ECE
type approval (components requiring approval on
motor vehicles) has been granted for a product
which bears this mark on its type plate.
1.18 Note on EAC marking
The EAC conformity marking confirms the
product’s conformity with the applicable legal
provisions of the Eurasian customs union.
1.19 Note on China RoHS mark
The China RoHS mark confirms that there is no
danger to persons or the environment from the
regulated substances contained within for the
intended period of use (year number shown in the
circle).
1.20 Emergency shutdown
This is done by a course of action to be defined by the operator.

12
1.21 Assembly, maintenance, fault,
repair
Prior to the start of this work, all relevant persons must be
notified of it. At a minimum, the following safety measures must
be taken before any work is done:
•Unauthorized persons must be kept away
•Mark and secure the work area
•Cover adjacent live parts
•Dry any wet, slippery surfaces or cover them appropriately
•Cover hot or cold surfaces appropriately
Where applicable:
•Depressurize
•Isolate, lock and tag out
•Check to ensure live voltage is no longer present
•Ground and short-circuit
The product should be protected as much as possible from
humidity, dust, and vibration, and should be installed so that it
is easily accessible. Ensure an adequate distance from sources
of heat or cold. Any visual monitoring devices present, such as
pressure gauges, min./max. markings, or oil level gauges must
be clearly visible. Observe the mounting position requirements.
Drill required holes only on non-critical, non-load-bearing
parts of the operator's infrastructure. Use existing holes where
possible. Avoid chafe points. Immobilize any moving or detached
parts during the work. Adhere to the specified torques.
If guards or safety devices need to be removed, they must be
reinstalled immediately following conclusion of work and then
checked for proper function.
Check new parts for compliance with the intended use before
using them.
Avoid mixing up or incorrectly assembling disassembled parts.
Label parts. Clean any dirty parts.
1.22 First start-up, daily start-up
Ensure that:
•All safety devices are fully present and functional
•All connections are properly connected
•All parts are correctly installed
•All warning labels on the product are fully present, visible, and
undamaged
•Illegible or missing warning labels are immediately replaced

13
1.23 Residual risks
Table 3
Residual risks
Residual risk
Possible in lifecycle
Avoidance / Remedy
Personal injury / property damage due
to falling of hoisted parts.
A
B
C
G
H
K
Unauthorized persons must be kept away. Nobody is
allowed to be present below hoisted parts. Lift parts
using suitable lifting gear.
Personal injury / property damage due
to tilting or falling product due to non-
compliance with specified torques.
B
C
G
Adhere to the specified torques. Mount the product
only on components with a sufficient load-carrying
capacity. If no torques are specified, use those specified
for the screw size for screws of strength class 8.8.
Personal injury, property damage due
to spilled, leaked lubricant.
B
C
D
F
G
H
K
Be careful when connecting or disconnecting the
lubricant lines. Use only hydraulic screw unions and
lubrication lines suitable for the specified pressure. Do
not mount lubrication lines on moving parts or chafe
points. If this cannot be avoided, use anti-kink coils
and/or conduits.
Fire hazard or damage to the pump
from operation with damaged electrical
components, such as power leads and
plugs.
B
C
D
E
F
G
H
Inspect electrical components for damage prior to
initial use and then at regular intervals. Do not install
cables on moving parts or chafe points. If this cannot
be avoided, use anti-kink coils and/or conduits.
Lifecycle phases: A = Transport, B = Assembly, C = First start-up, D = Operation, E = Cleaning, F = Maintenance, G = Malfunction, repair, H
= Shutdown, K = Disposal

14
2. Lubricants
2.1 General information
Lubricants are selected specifically for the relevant application.
The manufacturer or operator of the machine should ideally
make the selection in consultation with the supplier of the
lubricant. If you have no or little experience in selecting
lubricants for lubrication systems, please contact us. We would
be happy to assist you in selecting suitable lubricants and
components to build a lubrication system optimized for your
particular application. Consider the following points when
selecting/using lubricants. This will spare you potential
downtime and damage to the machine or lubrication system.
2.2 Material compatibility
The lubricants must generally be compatible with the following
materials:
•Plastics: ABS, CR, FPM, NBR, NR, PA, PET, PMMA, POM, PP,
PS, PTFE, PU, PUR
•Metals: steel, gray cast iron, brass, copper, aluminum
2.3 Temperature properties
The lubricant used must be suitable for the specific ambient
temperature of the product. The viscosity approved for proper
functioning must neither be exceeded at low temperatures nor
fall too low at high temperatures. For the approved viscosity,
see the “Technical data” chapter.
2.4 Aging of lubricants
Based on past experience with the lubricant used, checks should
be conducted at regular intervals defined by the operator, to
determine whether the lubricant needs to be replaced due to
aging processes (oil separation). In case of doubt regarding the
continued suitability of the lubricant, it must be replaced before
the system is started up again. If you do not yet have any
experience with the lubricant used, we recommend conducting
a check after just one week.
2.5 Avoidance of faults and hazards
To avoid faults and hazards, please observe the following:
•When handling lubricants, observe the relevant safety data
sheet (SDS) and any hazard labeling on the packaging.
•Due to the large number of additives, some lubricants that
meet the pumpability requirements specified in the manual
are not suitable for use in centralized lubrication systems.
•Whenever possible, always use SKF lubrication greases. They
are ideal for use in lubrication systems.
•Do not mix lubricants. This can have unpredictable effects on
the properties and usability of the lubricant.
•Use lubricants containing solid lubricants only after technical
consultation with SKF.
• The lubricant’s ignition temperature has to be at least
50 kelvin above the maximum surface temperature of the
components.
2.6 Solid lubricants
Solid lubricants may only be used after prior consultation with
SKF. When solid lubricants are used in lubrication systems, the
following rules generally apply:
Graphite:
•Maximum graphite content 8%
•Maximum grain size 25 µm (preferably in lamellar form)
MoS2:
•Maximum MoS2 content 5%
•Maximum grain size 15 µm
Copper:
•Lubricants containing copper are known to lead to coatings
forming on pistons, bore holes, and mating surfaces. This can
result in blockages in the centralized lubrication system.
Calcium carbonate:
•Lubricants containing calcium carbonate are known to lead to
very heavy wear on pistons, bore holes, and mating surfaces.
Calcium hydroxide:
•Lubricants containing calcium hydroxide are known to harden
considerably over time, which can lead to failure of the
centralized lubrication system.
PTFE, zinc, and aluminum:
•For these solid lubricants, it is not yet possible to define any
limit values for use in lubrication systems on the basis of
existing knowledge and practical experience.

15
3. Overview, functional
description
3.1 General
Pump units of the KFG, KFGS, and KFGL series are electrically
driven piston pumps with integrated reservoir and with or
without an integrated control unit.
so the pump is always able to supply demand-based lubrication
to centralized lubrication systems with progressive metering
devices and to single-line systems.
The pump units differ in terms of the size and type of lubricant
reservoir, the lubricant filling and their control and function
monitoring.
3.2 Design
Pump units of the KFG, KFGS and KFGL series are characterized
by their compact construction and are divided into the
assemblies for pump housing, lubricant reservoir, control unit,
and fill level monitoring.
A short description of the individual assemblies follows below.
3.2.1 Pump housing
The pump housing contains, among other things, the pump
drive, control unit (KFGS, KFGL) and three lubricant outlets for
installing a maximum of three pump elements. One pressure
limiting valve can be attached to each pump element.
When used in single-line systems (MonoFlex), a pressure relief
valve with an integrated pressure limiting valve is attached to
the pump element (max. 2 lubrication zones per pump with
KFGL).
An optional fill connection can be installed on the pump housing
using the alternative connections, to allow filling of the pump
when used at low temperatures. A grease return can also be
attached.
In the case of the KFGS and KFGL designs, a control screen is
mounted on the front side.
3.2.2 Lubricant reservoir
The lubricant reservoir is available in 2 kg, 6 kg, 8 kg, 10 kg, 15
kg and 20 kg sizes. These are made of transparent plastic.
The lubricant reservoirs have fill level markings that allow the
fill level to be monitored visually.
The pump fill level can be monitored using an integrated rocker
switch.
3.2.3 Fill level monitoring
For monitoring of the minimum pump fill level, there are two
lubricant level switches to choose from:
•Mechanical lubricant level switch W1 (type identification code
1)
•Mechanical lubricant level switch W1G with signal smoothing
and dry contact (type identification code 2, only for versions
without control unit).
The lubricant level switches are suitable for lubricants up to
NLGI Grade 2.
The output signal only communicates the following:
•Reservoir full (filled)
•Reservoir empty
3.2.4 KFGS and KFGL control units
Pump units of the KFGS series are equipped with an IG502-2-I
integrated control unit with a control display.
Parameters for pause times (timer), pause pulses (counter) and
pump cycle times (contact) can be entered through the control
unit.
The KFGL's control unit, model LC502, allows up to three
lubrication zones to be lubricated independently. Sectional
lubrication is available for differing lubricant requirements; the
lubrication lines can be controlled and monitored individually.

16
3.3 Overview
Fig. 3
Pump units of the KFG series
3.3.1 KFG pump units
Pump units of the KFG series are reservoir pump units without
an integrated control unit.
With the KFG pump unit, the fill level monitoring signals are
processed by a system provided by the customer.
The pump is available in various voltage designs.
On pumps for single-line systems, an electrical pressure relief
valve is additionally installed on the pump housing, which
ensures that pressure is relieved as required after the feeding
operation.
3.3.2 KFGS pump units
Pump units of the KFGS series are reservoir pump units with an
IG502-2-I integrated control unit with a control display.
Parameters for pause times (timer), pause pulses (counter) and
pump cycle times (contact) can be entered through the control
unit.
An piston detector is used to monitor the feeding operation on
progressive systems.
Fill level monitoring of the pump units is done with the lubricant
level switches: see section Fill level monitoring, Page 49.
Monitoring signals for the minimum fill level are processed by
the integrated KFGS control.
3.3.3 KFGL pump units
Pump units of the KFGL series are reservoir pump units with an
LC502 integrated control unit with a control display.
The control unit is pre-programmed with standard settings and
easy to operate The control unit can be used to set the pump
run time in two ways:
•based on pump speed.
•based on time or machine cycles (load-dependent).
Sectional lubrication is available for differing lubricant
requirements; the lubrication lines can be controlled and
monitored individually. The LC502 also offers a wide range of
options for monitoring functions and processes, with up to three
lubrication zones able to be monitored independently.
The LC502 is fitted with integrated temperature overload
protection and continuous system monitoring with fault
detection and fault analysis.
A piston detector is used to monitor the feeding operation on
progressive systems; a pressure switch is used for single-line
systems.
Fill level monitoring of the pump units is done with the lubricant
level switches: see section Fill level monitoring, Page 49.
Monitoring signals for the minimum fill level are processed by
the integrated KFGL control.

17
3.4 Functional description in progressive
systems
3.4.1 KFG pump unit
A general progressive metering device system consists of the
following components:
•Pump unit, pump element, pressure limiting valve and fill
level monitoring.
•Lubrication lines, consisting of main and possibly branch lines.
as well as lubrication point lines.
•Progressive metering devices.
When the pump is switched on, it supplies lubricant from the
lubricant 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
metering device. There, the lubricant is distributed according to
the volume required by the lubrication point being supplied.
In progressive systems with a main metering device and
secondary metering device, the lubricant coming from the pump
unit is delivered to the main metering device. The main
metering device distributes the lubricant to the secondary
metering devices according to their individual volume
requirements. From there, the lubricant flows to the lubrication
points.
3.4.1.1 Pump element
Fig. 4
Layout of pump elements
The pump element delivers the lubricant then passes it to the
downstream progressive metering device. Pump elements
which differ in terms of lubricant discharge are available,
depending on the quantity of lubricant required (see section
Nominal delivery rates, Page 26).
3.4.1.2 Pressure limiting valve (DBV)
Fig. 5
Pressure limiting valve
A pressure limiting valve must be installed on the pump
element on progressive systems to prevent excessive operating
pressure in the lubrication system.
If the operating pressure exceeds the opening pressure of the
pressure limiting valve (see section Pressure limiting valve,
Page 27), the valve opens and the lubricant flows back (on
versions with a return line) into the lubricant reservoir.
A further option are pressure limiting valves with an emergency
lubricant nipple (Fig. 5/1). These can be actuated manually to
provide the lubrication system with adequate lubricant in case
of power failure or a defective pump.

18
Example of progressive system with KFG pump unit
Fig. 6
Progressive system with KFG pump unit
1 KFG pump unit
2
Lubricant level switch
3
Pump element with pressure limiting valve
4 Electrical pump connection
5 Lubrication lines
6
Main metering device
7
Secondary metering device
8 Lubrication points

19
3.4.2 Progressive system with a KFGS or KFGL pump unit
The general functional description for progressive systems with a KFG pump unit also applies for the design with KFGS and KFGL pump
control.
The control unit integrated into the pump housing allows the following additional configuration, monitoring and connectivity options:
•Pause time and pump run time can be adjusted independently, including on monitored systems
•Recording of remaining intervals and remaining lubrication times
•Data backup in case of voltage failure
•Non-volatile memory with PIN code protection
•Option of connecting a magnetic piston detector (standard) or inductive piston detector, to monitor the functioning of metering devices
•Connectivity for external pushbutton
•Internal fill level monitoring, lubrication cycle stop and fault notification remain on control display in case the level falls below minimum
•Fault memory
Example of progressive system with KFGS/KFGL pump unit
Fig. 7
progressive system with KFGS/KFGL pump unit
1 KFGS/KFGL pump unit
2 Power supply
3 Fault indicator light
4 Lubricant level switch
5 Pump element with pressure limiting valve
6 Lubrication lines
7
Piston detector
8
Main metering device
9
Secondary metering device
10 Lubrication points

20
3.5 Functional description in single-line
systems
3.5.1 KFG-Pump unit with grease follower
plate technology
A general single-line system consists of the following
components:
•Pump unit with pump element, pressure limiting valve,
pressure relief valve and fill level monitoring
•Main lubrication line
•Single-line metering devices.
When the pump is switched on, it supplies lubricant from the
lubricant reservoir to the lubricant outlet.
The connected pump element meters the lubricant and supplies
it to the main line through the pressure-relief valve attached to
the pump unit.
The lubricant flows through the main line to the single-line
metering devices, where it is metered and passed to the
lubrication points. This is performed during or after the pump
cycle time, depending on the type of metering devices used
(prelubrication or relubrication metering devices).
The pressure relief valve switches after pressure build-up is
complete. After the main line has been relieved, the pump unit
is now prepared for another lubrication cycle.
3.5.1.1 Pump element
The pump element delivers the lubricant according to the
capacity of the connected single-line metering devices. There
are both prelubrication metering devices and relubrication
metering devices.
3.5.1.2 Pressure-relief valve
In order to allow another lubrication cycle after metering is
complete, the main line must first be relieved of pressure, which
also relieves the downstream single-line metering devices. The
main line and single-line metering devices relieve into the
lubricant reservoir.
3.5.1.3 Pressure limiting valve
Fig. 8
Pressure relief valve/pressure limiting valve
A pressure limiting valve can be installed single-line systems to
prevent excessive operating pressure in the lubrication system.
If the operating pressure exceeds the opening pressure of the
pressure limiting valve (see section Pressure relief valve with
integrated pressure limiting valve, Page 29), the valve opens.
The lubricant escapes through the valve or flows back into the
lubricant reservoir. This protects the pump unit against
overload.