Central lubrication systems for commercial vehicles

Transcription

Progressive Systems for Commercial Vehicles
19430US
For grease up to NLGI grade 2
G
Y
M ANAG
EM
ENT
QUALIT
Cut wear and tear
G Reduce downtimes
G Lower maintenance costs
www.vogelag.com
Head office and factory in Berlin
Factory in Dietzenbach
Progressive Systems for Commercial Vehicles for grease up to NLGI grade 2
19430US
worldwide
ARGENTINA
AUSTRALIA
AUSTRIA
BELGIUM
BRAZIL
BULGARIA
CANADA
CZECH REPUBLIC
DENMARK
FINLAND
FRANCE
GREAT BRITAIN
HONG KONG
HUNGARY
INDONESIA
IRELAND
ITALY
JAPAN
KOREA
LUXEMBOURG
MALAYSIA
MEXICO
MOROCCO
NEW ZEALAND
NORWAY
PEOPLE'S REPUBLIC OF CHINA
POLAND
PORTUGAL
RUMANIA
SINGAPORE
SLOVAKIAN REPUBLIC
SOUTH AFRICA
SPAIN
SWEDEN
SWITZERLAND
TAIWAN
THE NETHERLANDS
TURKEY
USA
3
19430US
Table of contents
Page
Alphabetical index of subject
.................................. 5
Glossary of terms
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6/7
Systems overview
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8/9
Planning of the system
Lubricants
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10/12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Toppingup pumps for grease
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Piston pumps, group KFG, electrically operated . . . . . . . . . . . . . . . . . . . 14/15
Electronic control unit IG502E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/17
Piston pumps, group KFGS, electrically operated
Electronic control unit IG502I
Minipump unit KFA(S)
. . . . . . . . . . . . . . . . . 18
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20/21
Trailer and semitrailer lubrication
with piston pump KFG15, electrically operated
Electronic control unit IG475
. . . . . 22
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22/23
Progressive feeders, groups VPM, VPKM
Progressive feeders, group VPBM
. . . . . . . . . . . . . . . . . . . . . . . . 2427
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28/29
Piston pump with block feeder PFVPBM…, manually operated . . . . . 30
Lubricating aid (single greasefitting lubrication), premetering unit . . . . . 31
Fittings and auxiliary equipment
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3249
Notice
All products from Willy Vogel AG may be used only for their intended purpose. If operating
instructions are supplied together with the products, the provisions and information therein of
specific relevance to the equipment must be observed as well.
In particular, we call your attention to the fact that hazardous materials of any kind, especially
the materials classified as hazardous by EC Directive 67/548/EEC, Article 2, Par. 2, may only be
filled into VOGEL central lubrication systems and components and delivered and/or distributed
with the same after consultation with and written approval from Willy Vogel AG.
All products manufactured by VOGEL are not approved for use in conjunction with gases,
liquefied gases, pressurized gases in solution and fluids with a vapor pressure exceeding
normal atmospheric pressure (1013 mbars) by more than 0.5 bar at their maximum permissible
temperature.
4
19430US
Alphabetical index of subject
Page
Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Antikink coil for highpressure hose . . . . . . . . . . . . . . 45
Banjo fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Body washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Cable harness for systems
with KFG piston pumps . . . . . . . . . . . . . . . . . . . . . . . . . 37
with KFGS/KFAS piston pumps . . . . . . . . . . . . . . . . 37
Cable strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Cartridge hand pump with block feeder . . . . . . . . . . . . 30
Check valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29/32
Circular connector for cycle switches . . . . . . . . . . . . . . 38
Clips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Conical head nipple . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Control light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Control unit, IG475 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22/23
Control unit, IG502E . . . . . . . . . . . . . . . . . . . . . . . . . . 16/17
Control and monitoring unit, IG502I . . . . . . . . . . . . . . 19
Corrugated hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Coupling plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Coupling socket for toppingup port . . . . . . . . . . . . . . . 47
Coupling socket with return flow port . . . . . . . . . . . . . . 47
Crossporting bars for VPBM feeders . . . . . . . . . . . . . . 29
Crossporting bars for VPM feeders . . . . . . . . . . . . . . . . 25
Cutting sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Cycle switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27/29
Drilling template for KFG / KFA piston pump . . . . . . . . 44
Drilling template for VPBM progressive feeder . . . . . . . 44
Dust cover for stub . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Elbow bulkhead connectors . . . . . . . . . . . . . . . . . . . . . 33
Elbow connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Elbow screwin connectors . . . . . . . . . . . . . . . . . . . . . . 33
Elbows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34/36
Filler nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Filler socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Filling cylinder, complete . . . . . . . . . . . . . . . . . . . . . . . . 13
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Fittings and auxiliary equipment . . . . . . . . . . . . . . . . . . 3249
Fixing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Guard ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Hose line with cuttingsleeve screw union . . . . . . . . . . 49
Hose nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Hoses for selfinstallation . . . . . . . . . . . . . . . . . . . . . . . 41
Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Illuminated pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . 38
Indicator light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Label for toggle switch . . . . . . . . . . . . . . . . . . . . . . . . . 37
Levertype grease gun . . . . . . . . . . . . . . . . . . . . . . . . . 49
Lock washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Lubricating aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Page
Male connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Manifold block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Marking clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Minipump unit KFA(S) . . . . . . . . . . . . . . . . . . . . . . . . . 20/21
Mounting angle bracket . . . . . . . . . . . . . . . . . . . . . . . . 47
Mounting base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Mounting plate for progressive feeders . . . . . . . . . . . . 43
Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Piston pump, group PFVPBM…, manually operated 30
Piston pumps, group KFG, electrically operated . . . . . 14/15
Piston pumps, group KFGS, electrically operated . . . . 18
Plastic tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Plugin connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Premetering units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Pressure gauge adapter . . . . . . . . . . . . . . . . . . . . . . . . 45
Pressure gauge adapter with washer . . . . . . . . . . . . . . 45
Progressive feeder, group VPBM . . . . . . . . . . . . . . . . . 28/29
Progressive feeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2429
Progressive feeders, groups VPM, VPKM . . . . . . . . . . . 2427
Protective helix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Pump elements for KFG/KFGS piston pumps . . . . . . . 14
Pump fastening plate for systems
with KFG/KFGS piston pumps . . . . . . . . . . . . . . . . . 44
Reducing coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Reinforcing sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Rubber grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Screw plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Screw unions for steel and plastic tubing . . . . . . . . . . . 35
Selftapping screws . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Single greasefitting lubrication . . . . . . . . . . . . . . . . . . . 31
Socket unions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Spacer ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Spiral hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Steel tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Straight bulkhead connectors . . . . . . . . . . . . . . . . . . . . 33
Straight connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Stranded wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Stub for coupling plug . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Symbol insert for illuminated pushbutton . . . . . . . . . . . 38
Systems overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8/9
Teepieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Tapered sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Toggle switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Toppingup pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Trailer and semitrailer lubrication
with KFG15 piston pump . . . . . . . . . . . . . . . . . . . . . 22
Tube bending device . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Tube cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32/48
Tubetotube connector, detachable . . . . . . . . . . . . . . 32/36
Union nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Welding flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Welding plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5
19430US
Glossary of terms
Central lubrication system
Lubrication point
One pump supplies a large number of friction points with
lubricant via a system of lines and feeders/distributors.
Point at which lubrication is fed to the friction point.
Main line
Check valve
Line connecting the pump to the feeders.
Valve that permits flow in only one direction while blocking
flow in the opposite direction.
Metered quantity
Consistency
Amount of lubricant fed to a lubrication point by the feeder
during one application of lubricant.
See penetration.
Monitoring
Contact time
Function check with indication of malfunctions.
Operating time of pump.
NLGI grades
Control and monitoring units
See penetration.
Electronic units that control and monitor the designated
functions of the central lubrication system and indicate
malfunctions.
Outlet valve
Cycle switch
The stroke of the piston in a progressive feeder can be
checked by a cycle switch, thus making it possible to
monitor the entire feeder system.
A check valve integrated in the piston pump. It opens the
main line when the pump is in operation and closes the
main line to the pump during the suction stroke.
Penetration
Fast filler coupling
The plasticity (consistency) of a lubricating grease is des
ignated with the penetration number. The penetration
depth of a measuring cone is measured at + 25 ° C in ac
cordance with DIN standard 51 804.
The “consistency index of lubricants” is based on
NLGI grades (National Lubricating Grease Institute).
Fluid greases: NLGI grades 000, 00, 0.
Greases:
NLGI grades 1, 2
Coupling used for the fast topping up of lubricant with a
drum pump.
Pressure switch
Fittings
Device that actuates an electric switch when a specified
pressure is reached, thereby converting hydraulic infor
mation to electrical information.
Directional control valve
Valve that directs a flowing medium in various directions/
paths, e.g. 3/2way compressedair valve, pressure relief
valve.
For steel and plastic tubing, tube adapters with solderless
tube connection and cutting sleeve screw unions as per
DIN standard 2353.
Friction point
Progressive feeders (group VPM, VPKM, VPBM)
Lubricant feeders that supply lubricant to lubrication
points in progressive order.
Point at which frictional forces are effective.
Progressive systems
Indicator light
Central lubrication systems with progressive feeders.
Display lamp actuated by electric sensors (pressure,
pump operation) for function check.
Pumps
Interval time
The period between two actuations of the pump.
Lubricating cycle of progressive feeders
Period required for a complete cycle of the progressive
feeder. Each piston must have executed one double
stroke.
Positivedisplacement (piston, gear) pumps used to feed
the lubricant.
Piston pumps – manually, pneumatically,
hydraulically actuated,
electrically operated.
6
Glossary of terms
Safety valve
Valve that limits the pressure in the system to a maximum
value. The valve opens if this pressure is exceeded.
Secondary (lubrication) line
Line connecting the lubricant distributor/feeder to the
lubrication point.
Work cycle time
Period from the start of one lubrication cycle to the start of
the next.
19430US
7
19430US
8
Systems overview
Lubricant:
Grease up to NLGI grade 2
Delivery rate
Selection
criteria
Pump suitable for
Delivery rate depends on the running time and
pump elements used
farm machinery
construction machinery
special vehicles
tractive units with superstructure
trailers and semitrailers
(explosionproof and hazardousgoods types on
request)
Type of drive
electric
electric
Piston pump, group
Piston pump, group
KFG
KFGS
page 14
page 18
Operating pressure
300 bars max.
300 bars max.
Reservoir capacity
2, 6 or 10 liters
2, 6 or 10 liters
Pump
Type
designation
Technical
data
Lubricant distribution
Control system
Auxiliary
equipment
Progressive feeders VPM, VPKM, VPBM
IG502E control unit
with and without monitoring
IG475 control unit
without monitoring
steel tubing ø 6 x 1 ;
ø 10 x 1
Main line
(connection: pump – feeder)
Secondary line
(connection: feeder – lube point)
IG502I integrated control
unit with and without
monitoring
(integrated in the pump
unit)
1)
1)
plastic tubing ø 4 x 0.85
steel tubing ø 4 x 0.7
ø 6 x 1.25; ø 6 x1.5
ø 6 x 0.7; ø 6 x1
For central lubrication systems for trucks, buses or offroad equipment
with NLGI grade 000, 00, or 0 fluid grease see brochure 19420US.
9
2 ccm/stroke
electric
manual
manual
Piston pumps, group
Cartridge pump
Lubrication aid
KFA(S)
as lubrication aid
(single greasefitting
lubrication)
page 20
page 30
page 31
300 bars max.
400 bars max.
250 bars max.
1 liter
450 ccm
PFVPBM…
VPBM (unit with pump)
IG502I integrated
universal control unit with
and without monitoring
(integrated in the pump
unit)
Hose line
ø 6 : 982750091
ø 10 : WVN71110
Hose line
ø 4 : 734…K 1)
ø 6 : 982750091
1) Not
suitable for temperatures below – 5 °C.
VPM, VPKM, VPBM
19430US
Systems for grease up to NLGI grade 2
G Electrically driven piston pumps KFA / KFG
G Electrically driven piston pumps KFAS / KFGS with integrated control electronics
G Progressive feeders, groups VPM, VPKM, VPBM
Grease systems consists of a pump, feeders with a network of tubing and a control unit.
Progressive systems reach operating pressures of as much as 300 bars depending on the lubricant used, the ambient
temperature, size of the system and bearing back pressure. Predefined amounts of lubricant are supplied to the
lubrication points while the pump is running, the full delivery of the piston pump being apportioned via the progressive
feeders.
Several pump strokes are required to complete one full lubrication cycle, i.e. until each lubrication point has received
the amount of lubricant intended for it.
Description of units
1. Piston pump,
Group KFG / KFGS
The pumps are driven by a DC motor. The reservoir capacity
and type of filling vary.
The pumps have a maximum of 3 lubricant outlets. One pump
element is required for each outlet. The elements are
available for different delivery rates and can be exchanged at
a later date.
The grease level is checked by a visual inspection of the
reservoir.
Group KFG pumps are controlled by an IG502E control unit.
When the KFG pump is used to lubricate trailers and semi
trailers control is provided by an IG475 control unit.
Group VPM
The following metered quantities are available:
0.05; 0.14; 0.19; 0.25; 0.3; 0.35 ccm (per cycle and outlet).
Adjacent outlets can be combined externally, outlets opposite
each other can be combined internally with the help of
Ssections.
Group VPKM
The following metered quantities are available:
0.04; 0.08; 0.14; 0.18 ccm (per cycle and outlet).
In the case of this group the adjacent outlets of the finished
feeder can still be combined internally without having to
dismantle the feeder.
Group KFGS pumps are controlled by a control system
integrated in the unit (IG502I).
Group VPBM
Group KFA / KFAS
Outlet ports opposite each other can be combined internally,
adjacent/parallel outlet ports can be combined externally.
The pumps have a maximum of 2 lubricant outlets for the
connection of 2 mutually independent lube circuits. One
pump element is required for each outlet. The elements are
available for 3 different delivery rates and can be exchanged
at a later date.
Uniform metered quantity 0.13 ccm (per cycle and outlet).
Important: outlets that are not required must not be closed!
The feeders would otherwise be immobilized. The lubricant
supplied to these outlets must either be returned to the lubri
cant reservoir or directed to another lubrication point.
The lines must be connected to the feeders via connection
fittings (cuttingsleeve screw unions).
2. Progressive feeders,
groups VPM, VPKM, VPBM
Progressive feeders are used for grease up to NLGI grade 2.
Their design makes it possible to adjust the feeders to the
amount of lubricant required by the lubrication points to be
connected.
When planning a system care must be taken to see to it that
the progressive feeders apportion the entire amount of
grease delivered by the pump each running cycle. Thus, the
metered quantities only define the proportions and not the
absolute quantities.
3. Lines and fittings
In systems for grease up to NLGI grade 2 it is necessary to
lay main lines in a highpressure hose with a 6 or 10 mm
diam. connector; in special circumstances it is also possible
to use steel tubing with a diameter of 6 or 10 mm. 6 x 1.25
polyamide tubing is used for secondary lines, or also a 6 mm
highpressure hose or 6 mm steel tubing in the offroad
sector.
Main and secondary lines are supplied prefilled with grease.
10
4. Control Units
4.1 Electronic control and monitoring unit IG502E
for systems with KFG / KFA piston pumps
in conjunction with a cycle switch
With this control unit the pump’s running time is determined
by the progressive feeder’s lubrication cycle. The lubrication
cycle is monitored by a cycle switch. The interval time can be
set on the control unit.
4.2 Electronic control unit IG475
for trailer and semitrailer lubrication
with KFG piston pumps
Every time a braking pulse with a minimum interval of 5
seconds is emitted this control unit triggers lubrication for as
long as the brakes are applied, the maximum time being,
however, the preset pump running time of 2, 4 or 8 seconds.
Attention:
“General operation instructions for progressive systems”
see 951130187.
19430US
11
19430US
12
Some facts about grease …
The plasticity (consistency) of lubricating grease is designated by
its penetration number.
Penetration curve of a grease belonging to NLGI grade 2
as a function of temperature changes
350
The depth to which a measuring cone penetrates at + 25 °C is
measured in accordance with DIN 51804.
↔
340
310
In the USA, the NATIONAL LUBRICATING GREASE INSTITUTE
(NLGI) introduced penetration grades that were adopted by
DIN 51 818 for the “consistency classification of lubricating
greases”.
000
445 to 475
fluid
00
400 to 430
nearly fluid
0
355 to 385
extremely soft
1
310 to 340
very soft
2
265 to 295
soft
3
220 to 250
medium
4
175 to 205
medium hard
Grease up to NLGI grade 2 is generally used.
The feedability of fluid grease is influenced not only by its
penetration but also, among others, by its intrinsically viscous
properties.
Attention must be paid to the feedability of a fluid grease when it
is used in central lubrication systems. Pumps, tubing and feeders
must be dimensioned accordingly.
The pressures required to deliver a grease of NLGI grade 2
through tubes and feeders are much higher than those used in
systems for lubricating oils and grease of lower NLGI grades 00
and 000. Pressures of 200 bars or more can occur, depending on
the size of the system, tubing cross sections and lengths.
Greases consist of a soap skeleton in which the lubricant, oil, is
embedded as in a sponge.
There are cases in which the oil and soap skeleton are separated
in progressive systems (bleeding). The solid soap skeleton clogs
the feeder boreholes and causes the system to fail.
There can be many causes of such bleeding. The nature of the
grease, changes in pressure and temperature, filtration effects in
the case of precisely fitted pistons, etc. all have an effect.
The only remedy is to clean the feeders and, as the case may be,
change the grease. In this case it is absolutely necessary to
consult the manufacturer of the grease.
↔
250
↔
250
220
200
205
↔
Worked penetration
in 0.1 mm
295
265
§ Penetration in 0.1 mm
NLGI grade
to DIN 51 818
300
175
NLGI grade
1
NLGI grade
2
NLGI grade
3
NLGI grade
4
150
100
– 40
– 20
0
§ Temperature °C
20
25
40
60
80
100
120
Measuring point
to DIN 51 804
Lubricants
Use is made of customary greases recommended by the vehicle
and/or grease manufacturer that still display adequate priming
and flow characteristics (max. flow pressure of 700 mb) at
– 25 °C. They must not tend to bleed, since that can lead to
clogging over an extended period of operating time.
MoS2 greases (up to 5% molybdenum disulfide) can be delivered
with Vogel progressive pumps and progressive feeders.
Greases of NLGI grade 2 containing solids like graphite, copper
(e.g. tool paste) can be delivered with KFA, KFAS, KFG and
KFGS pumps. The lubricant is distributed via pump elements.
Progressive feeders must not be used in this case.
There is no problem using biodegradable grease in VOGEL
progressive systems in the conditions mentioned above.
To ensure troublefree operation of the progressive system at
all times we recommend use of NLGI grade 2 grease we have
tested (cf. brochure 18065US).
Please contact us if you have any further questions about
lubricants. Our laboratory can check the characteristics (e.g.
“bleeding”) of lubricants for use in progressive systems.
If a grease lubrication system is also supposed to work flawlessly
at temperatures down to – 25 °C, the change (reduction) in the
penetration of the grease must be taken into account.
Please note! Pay attention to cleanliness when topping up grease!
Contaminants remain suspended in grease. They can cause damage to the bearings
and immobilize system components!
Also see to it that systems are topped up only with greases with the same type of
saponification.
Sodiumsoap grease must not be used on motor vehicles (watersoluble).
Lubricating greases belonging to NLGI grade 2 are almost exclusively saponified with
lithium or calcium.
19430US
Toppingup pumps for grease of NLGI grades 1 and 2
Delivery rate ~ 40 ccm/stroke
for 25 kg drum: order No. 169000042
for 50 kg drum: order No. 169000054
Associated filler socket order No. 995000705, cf. page 47.
Filling cylinder, complete
Suitable for cartridges in accordance with DIN 1284 with an effective content of 450 ccm and 550 ccm.
cartridge tube
cap
Order No. 169000171
Fits filler nozzle 169000170
To change the filling position when the pump is hard to reach:
Filler nozzle
SW 32
cap
Adapter for filler nozzle
Order No. 853950010
washer
DIN7603A20x24AL
supplied detached
Order No. 169000170
Fits filling cylinder 169000171
SW = width across flats
Banjo fitting
Order No. 405541411
13
19430US
Piston pumps, electrically operated, group KFG
The pumps comprising the KFG group have 3 lubricant outlets for
the connection of 3 progressive feeder circuits independent of
each other. A separate pump element is required for each outlet
port.
Four pump elements with varying delivery rates are available so
that the quantity of grease can be approximately adjusted to the
needs of the individual circuits. This assures that the lubrication
points are supplied with an adequate amount of grease in the
course of every lubrication cycle.
The functioning of the pump elements is assured even at
temperatures of – 25 °C due to an agitator driven by the gear
motor.
The pumps of the KFG group differ in terms of the reservoir
capacity and type of grease filling.
The level of lubricant can be easely monitored through the
transparent reservoir.
There is an overfill release valve on the reservoir of the KFG pump
that is also used to bleed it. An IG502E control unit can be used
to control the pump (page 16/17).
Use an IG475 control unit when the pump is installed on a trailer
or semitrailer (page 22).
KFG15
See page 18 for piston pumps with integrated control unit,
group KFGS.
Order No.
Reservoir capacity
(liters)
KFG15
KFG35
2
6
via conical head nipple
with toppingup pump
6
from the top via hinged lid,
or optionally via
conical head nipple
using a toppingup pump
KFG35S3
KFG55
Grease filling
10
with toppingup pump
Prior to shipment the piston pumps are completed with the pump
elements specified in the order.
The order No. must be supplemented with the desired pump
elements. Example:
KFG15, equipped with KFG1.U 1, KFG1.U 3, KFG1.U 3
Pump elements
Order No.
Delicery rate
(ccm/min)
Number of grooves
KFG1.U1
KFG1.U2
KFG1.U3
KFG1.U4
2.5
1.8
1.3
0.8
1
2
3
4
Safety valves see page 46.
KFG35
KFG35S3
Technical data
Motor
operating voltage . . . . . . . . . . . . . . . . . . . . . . 12 V DC / 24 V DC
power consumption (at +20 °C):
noload operation . . . . . . . . . . . . . . . . . . . . . . . . . 0.58 A / 0.29 A
fullload operation . . . . . . . . . . . . . . . . 2.5 A / 1.25 A at 300 bars
starting load . . . . . . . . . . . . . . . . . . . . . . . . . 9 A / 4.5 A for 10 ms
fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 A / 3 A
Unit
max. operating pressure . . . . . . . . . . . . . . . . . . . . . . . . 300 bars
permissible operating temperature . . . . . . . . . – 25 °C to + 75 °C
reservoir capacity . . . . . . . . . . . . . . . . . . . . . . . . 2, 6 or 10 liters
type of enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IP 5K6K
number of lubricant outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
If only one outlet is required, the M 20 x1.5 screw plug
must be used instead of the other pump element.
Lubricant
. . . . . . . . . . . . . . . . . . . . . grease up to NLGI grade 2
flow pressure up to 700 mbars max.
Conical head nipple DIN71412AM10x1 for topping up of grease.
Toppingup pump: standard grease gun, pneumatically operated,
with buttonhead fitting for conical head nipple conforming to DIN 71412.
14
19430US
KFG15
transparent
reservoir
conical head nipple
M10 x1 (DIN 71 412)
pump element
screw plug
1)
1
line socket
rotatable 4 x 90°
cable connection: + to 2
– to 1
) connection thread in pump housing
) return line port (normally closed)
2
See above for missing dimensions and data
KFG35
KFG35S3
Hydraulic diagram
15
19430US
Electronic control unit IG502E for systems with group KFG / KFA piston pumps
Operating and display elements
Special functions
The IG502 control units come with an operating and display panel
that can be used to check, monitor and, if necessary, readjust the
parameters as well as programmed functions.
Control units comprising the IG502 group have two electronic
counters in which times are permanently stored; they cannot be
changed by the user.
Modes of operation
These counters are used to check the operation of the central
lubrication system and are read out via the LED display.
PAUSE (pump OFF) with timer function
– programmable from 0.1 to 99.9 h
– digital display after invoking: tPA (t = timer, PA = PAUSE)
The PAUSE (the interval between two lube cycles) is determined by a
clock cycle (timer) generated by the control system and by the value (in
hours) programmed for PAUSE (tPA).
PAUSE (pump OFF) with counter function
– programmable from 1 to 999 pulses
– digital display after invoking: cPA (c = counter, PA = PAUSE)
The PAUSE (the interval between two lube cycles) is determined by the
interval between the times signals arrive at the counter input and by the
value programmed for PAUSE (cPA).
CONTACT (pump ON) with timer function
– programmable from 1 bis 99.9 minutes
– digital display after invoking: tCO (t = timer, CO = CONTACT)
The pump running time (CONTACT) is determined by a clock cycle
(timer) generated by the control system and by the value (in minutes)
programmed for CONTACT (tCO).
Monitoring functions
PS (Pressure Switch)
This monitoring function is intended for central fluidgrease
lubrication systems designed for NLGI grades 000, 00,0 in which
the pressure in the main line is monitored. Once the monitoring
parameter PS has been programmed, the pressure switch
installed in the main line is monitored for respective signals while
the pump is in operation.
CS (Cycle Switch)
This monitoring function is intended for central grease lubrication
systems with progressive feeders in which a piston's motion is
monitored with a cycle switch.
Once the monitoring parameter CS has been set, the cycle switch
installed on the progressive feeder is monitored for the respective
signal while the pump is in operation.
The respective monitoring parameter selected (PS or CS) is
displayed by the lighting of the corresponding LED in the PAUSE
(interval) mode.
Without monitoring (OFF)
The monitoring can be switched off (OFF).
The control system then works without direct monitoring of the
pressure buildup in the main line or without monitoring of the
feeder's operation. The PS or CS LEDs do not light up.
Fault displays
The red FAULT LED shows a group fault signal when it constantly
burns. The cause of the fault signal is additionally shown on the
digital display to help with troubleshooting.
The following messages are provided for:
FPS – pressure buildup fault when monitoring is effected with a
pressure switch.
FCS – cycleswitch fault when a progressive feeder is not
working or is blocked (line break).
Faulthours counter
The amount of time a farm or construction machine has been run
with a nonfunctioning central lubrication system (e.g. with no
lubricant in the reservoir) is added up by the faulthours counter.
The counter's contents are automatically updated and cannot be
cleared. The current state of the counter can be displayed by
invoking function parameter Fh on the display and operating
panel. The current value is displayed in hours.
The counter has a resolution of 0.1 hour, i.e. the smallest display
able interval amounts to 6 minutes.
Elapsedhours counter
The electronic elapsedhours counter adds up the time in which
power is applied to the control unit.
The counter's contents are automatically updated and cannot be
cleared. The current state of the counter can be displayed by
invoking function parameter Oh on the display and operating
panel. The current value is displayed in hours.
The counter has a resolution of 0.1 hour, i.e. the smallest display
able interval amounts to 6 minutes.
The units comply with the legal requirements of
EC Directives
– 72/245/EEC, version 95/54 EC
– 89/336/EEC
Application
The IG502E universal control unit is used to control and monitor
central lubrication systems on commercial vehicles. The control
unit's functions can be programmed. Its housing dimensions,
electrical connection and functions are compatible with those of
VOGEL control units in use to date.
The operating elements are protected by a foil against moisture
and dirt. The unit has a voltageindependent data memory. This is
where the configuration data and parameters are stored. As a
result, the control unit is not dependent on a constant supply of
voltage.
If an external indicator light SL has been installed in the driver's
cab, it will light up for 3 seconds after the unit is switched on.
Installation
The unit has to be installed in a closed compartment on the
vehicle where it is protected from ambient influences. It is
fastened in place with straps.
The IG502E is accommodated in an IP 20 type of enclosure.
The plug conforms to safety class IP 00.
If the control unit is installed in a hardtoreach place, it is ad
visable to additionally install an illuminated pushbutton on the
dashboard to serve as a fault display and function check.
16
19430US
Technical data
Order No.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IG502E
Associated cable harness
. . . . . . . . . order No. 997000185
control votlage ) . . . . . . . . . . . . . . . . . . . . . . . . . . 12 or 24 V DC
max. contact load, terminal M . . . . . . . . . . . . . . . . . . . . . . . . 5 A
SLoutput . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 W
type of enclosure 2) . . . . . . . . . . . . . . . . . . . . . IP 20, DIN 40 050
temperature range . . . . . . . . . . . . . . . . . . . . . . . . – 25 to +75 °C
max. fusing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 A
programmable interval times . . . . . . . . . . . . . . . . . 0.1 to 99.9 h
programmable pump running time . . . . . . . . . . . 0.1 to 99.9 min
programmable pulses . . . . . . . . . . . . . . . . . . . . . . . . . . 1 to 999
elapsedtime, fault hours memory . . . . . . . . . . . . 0 to 99999.9 h
1
1
) Please quote control voltage when ordering.
) Warranted for vertical (plugin connector pointing downward) and
horizontal installation.
2
Normal functional sequence
(time axis not to scale)
tu
ts
tp
= ignition interruption
= contact time
= interval time
30
= battery + / vehicle network
15
= operating voltage + / after ignition “ON”
31
= operating voltage –
DK/MK = pushbutton / intermediate lubrication or pulsecounter input
PS/CS = pressure switch / cycle switch
M
= pump motor
SL
= indicator light
Z
= ignition lock
F
= 5 A fuse
LED PAUSE
llights in intervals.
Wiring diagram
LED CONTACT
lights when pump running.
LED CS
lights for monitoring with cycle switch function.
LED PS
lights for monitoring with pressure switch function.
LED FAULT
lights for fault monitoring (cycle or pressure switch).
17
19430US
KFGS Piston Pumps with integrated control unit for progressive systems
The pumps comprising the KFGS Group have 3 lubricant outlets
for the connection of 3 progressive feeder circuits independent of
each other. A separate pump element is required for each outlet
port.
Four pump elements with different delivery rates are available so
that the amount of grease can be adjusted to the needs of the
individual circuits. This assures that the lubrication points are
supplied with an adequate amount of grease in the course of
every lubrication cycle.
The functioning of the pump elements is assured even at
temperatures of – 25 °C due to an agitator driven by the gear
motor.
The transparent reservoir makes it easy to check the level of
lubricant.
An overflow tube serves as overfill protection and as a vent.
As an optional feature, piston pumps comprising the KFGS series
can be equipped with a low level indicator.
Piston pump
Order No.
KFGS15
KFGS35
KFGS35S3
KFGS55
Reservoir capacity
(liters)
Grease filling
KFGS15
2
6
with toppingup pump
G
6
from the top via hinged lid,
or optionally via
conical head nipple
using a toppingup pump
with toppingup pump
G
10
The control system provides the following advantages:
G
G
G
G
G
Add W1 when ordering a pump unit with low level indicator,
example: KFGS55W1.
G
Prior to delivery the piston pumps are completed with the pump
elements specified in the order (page 14).
The following has to be appended to the pump's order number: operating
voltage, order No. for the pump elements.
Order example:
KFGS15, 24 VDC, with KFG1.U1, KFG1.U2 and KFG1.U4
Safety valve, opening pressure 300 ± 20 bars,
order No. 161210012 (page 46).
Control is provided by an integral IG502I control and monitoring
unit; it can be operated in a time or load (pulse) dependent
mode, and with or without monitoring.
Nonvolatile memory with PINcode protection
Storage of residual interval and lubricating times
Storage of fault signals (diagnosis memory)
Data save in event of a power failure
Connection for external pushbutton
Connection for inductive cycle switch
Interval and contact times can be set independent
of each other, even with monitored systems
Electrical connections easy via 7pole plug connector
Technical data
Pump
Operating voltage (please state when ordering) . . 24 V DC/ 12 V DC
Max. back pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 bars
Permissible operating temperature . . . . . . . . . – 25 °C to + 75 °C
Reservoir capacity . . . . . . . . . . . . . . . . . . . . . . . . 2, 6 or 10 liters
Type of enclosure to DIN 40 050, T9 . . . . . . . . . . . . . . . . IP 5K6K
Number of outlets ➀ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Lubricant
. . . . . . . . . . . . . . . . . . . . . Grease up to NLGI grade 2
Flow pressure up to 700 mbars max.
KFGS15 = ~281 mm
KFGS35 = ~394 mm
KFGS55 = 636 mm
KFGS35S3 = 634 mm
Cable harness order No. 997000630 page 21.
Connection for cable harness
(997000630)
KFGS35
reservoir capacity 6 liters
Filling via conical
head nipple (DIN 71412)
18
19430US
IG502I electronic control and monitoring unit integrated in KFGS and KFAS pump unit
General remarks
The IG502I control and monitoring unit is an integral component
of KFGS and KFAS pump units. Its functions are specially
designed for the control and monitoring of central lubrication
systems on commercial vehicles (traveling machinery).
The control unit can be programmed by the customer to suit the
vehicle's or machine's operating conditions and can be set for
the following modes of operation:
switch is monitored for the emittance of a signal. When the cycle
switch signal arrives at the control unit, the monitoring program is
immediately ended and operation with the normal sequence of
functions is continued. When the monitoring program elapses, a
fault signal is admitted at the end and the functional sequence
stopped.
No intermediate lubrication can be triggered while the monitoring
program is running.
1. TIMER without monitoring
Memory (EEPROM)
2. TIMER with monitoring
The control system comes with a nonvolatile memory
(EEPROM), so a constant supply of power is not required for the
storage of residual times and fault signals. When the power is
switched off (ignition), the current value is stored and is available
for the further sequence of functions after the power returns.
3. COUNTER without monitoring
4. COUNTER with monitoring
Interval (tPA) in the "TIMER" mode
The interval (pause between two lubrications) in the TIMER mode
is determined by a clock cycle generated by the control system
and by the value programmed as tPA. It can be set for a value
between 0.1 and 99.9 h.
Interval (cPA) in the "COUNTER" mode
The interval (pause between two lubrication routines) in the
COUNTER mode is determined by the interval between pulses
arriving at input "DK" (signal change from 0 V to 24 V) and by the
value programmed as cPA. It can be set for a value from 1 to 999
pulses. In this mode terminal "DK" leading out of the unit is used
as a counter input in order to trigger lubrication after a defined
number of pulses. In this case, there is no possibility to press an
external pushbutton to trigger intermediate lubrication.
Monitoring and fault displays
Function monitoring with cycle switch
Central lubrication systems can be monitored with cycle
switches. For this to be done, the unit has to be set
(programmed) under "COP" for "CS" monitoring (cycle switch).
The signal emitted by the switch during the lubrication routine is
then monitored.
If no signal is emitted during both the lubrication routine and the
monitoring program automatically started thereafter, a fault signal
is emitted at the end of the monitoring program (terminal "SL2" is
constantly on) and the functional sequence is interrupted. The
"FCS" error code (Fault Cycle Switch) can be invoked by pressing
a button on the control panel.
Setting of the interval and pump running times as well as
desired monitoring function
Monitoring of filling level
The operations required to set the control unit for the values and
functions in line with the vehicles' use can be found in the
operating instructions included with the pump unit.
KFGS and KFAS pump units with the identifier "W1" in the order
number come from the factory with integrated fillinglevel
monitoring that is always active and does not have to be
programmed
Function (standard "TIMER" function without monitoring)
The lubrication periods are repeated on a cyclic basis at the rate
of the selected interval (tPA or cPA). The pump running time
during a lubrication routine corresponds to the time in minutes
set on the control panel as tCO (contact time).
The intervals as well as the pump running times are executed
only when the power is on (terminals 15 and 31 connected to 12
VDC or 24 VDC, depending on the unit). If the power is switched
off (interruption of the voltage to terminal 15), the currently
running residual time is stored and continued after the power is
switched on again.
If the monitoring function "CS" is programmed (only for central
lubrication systems with cycle switches), the cycle switch
mounted on a progressive feeder is queried for the emittance of a
signal while the pump is running. At least one signal change
(either ON>OFF or OFF>ON) is expected from the control routine
at terminal ZDS in the cable harness in order for a new interval to
start at the end of the pump's running time and for the sequence
of functions to continue normally. If this signal fails to materialize
during the preset pump running time (tCO), a monitoring program
(block mode) is started at the end of that period. In this program
routine the pump unit is additionally switched on at specially
defined intervals up to a maximum of two times and the cycle
When the minimal filling level is reached, a fault display is shown
(terminal "SL2" is constantly on) and the functional sequence is
interrupted. The "FLL" fault code (Fault LowLevel) can be
invoked by pressing a button on the control panel.
Clearing a fault message
No signal change at ZDS input this fault signal can be cleared
while the power is on by pressing pushbutton DK.
Filling level fault this fault signal can be cleared when the power
is on after the reservoir has been filled by pressing pushbutton
DK.
Elapsedhours counter
The control unit comes with a builtin elapsedhours counter
which adds up the time in which power is applied to the control
unit. The memory cannot be changed. The stored values can be
called up on the control panel and viewed.
Faulthours memory
The control unit comes with a faulthours memory that adds up
the time in which the control unit was operated with a pending
fault signal. The memory cannot be changed. The stored values
can be called up on the control panel and viewed.
19
19430US
KFA/KFAS MiniPump Units with integral control system
Pumps belonging to the KFA(S) series come with a maximum of 2
outlet ports for the connection of 2 independent lube circuits. A
separate pump element is required for each outlet.
Three pump elements with different delivery rates are available so
that the volume of grease can be adjusted to the needs of the
individual circuits. That makes sure every lube point is supplied
with an adequate amount of grease in each lubrication cycle.
Piston pump
Order No.
Reservoir capacity
(liters)
Grease filling
KFA1
1
KFAS1 (incl. control system) 1
via toppingup pump
A “W” has to be appended to the order No. for pump units with filling
level monitoring, order example: KFAS1W.
Pump elements
Order No.
Delivery rate 1)
(ccm/min)
KFA1.U1
KFA1.U2
KFA1.U3
2.0
1.5
1.0
KFAS1
The following has to be appended to the pump's order number:
operating voltage, order No. for the pump elements.
Order example:
Control is provided by an integral IG502I control and monitoring
unit; it can be operated in a time or load (pulse) dependent
mode, and with or without monitoring (page 19).
The control system provides the following advantages:
KFAS1, 12 V DC with KFA1.U2, KFA1.U3
1
) The indicated rates refer to the delivery of NLGI grade 2 grease at an
operating temperature of 20°C and a back pressure of 50 bars.
Temperatures and pressures that deviate from these figures lead to
different delivery rates. The indicated values must be taken as a basis in
the design of a central lubrication system.
G
G
G
G
G
G
G
Technical Data
G
Unit
operating voltage
Cable harness please order separately (page 21 and 37).
. . . . . . . . . . . . . . . . . . . . . . 12 V DC / 24 V DC
(please indicate when ordering)
Mode/ON time
Nonvolatile memory with PINcode protection
Storage of residual interval and lubricating cycle
Storage of fault signals (diagnosis memory)
Data save in event of a power failure
Connection for external pushbutton
Connection for inductive cycle switch
Interval and contact times can be set independent
of each other, even with monitored systems
Electrical connections easy via 7pole plug connector
. . . . . . . . . . . . . . . . . . . . . . . . S3/20% 50 min.
Pay attention to interval and contact time when setting!
Max. runtime 10 min., interval time = 4 x runtime
max. back pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 bars
permissible operating temperature . . . . . . . . . – 25 °C to + 75 °C
reservoir capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 liter
DIN 40050 enclosure, T9 . . . . . . . . . . . . . . . . . . . . . . . . IP 6K9K
max. number of outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
weight (filled with grease) . . . . . . . . . . . . . . . . . . . approx. 3.8 kg
lubricant . . . . . . . . . . . . . . . . . . . . . . grease up to NLGI grade 2
flow pressure up to max. 700 mbars
Compliant with the legal requirements of EC directives:
– 72/245/EEC, version 95/54 EC
– 89/336/EEC
Safety valves page 46.
20
19430US
KFA1
without integral control sytsem
transparent
reservoir
4pole circular connector
Connection for
cable harness
Conical head nipple
M10 x1 (DIN 71 412)
KFAS1
with integral control system
See above for missing dimensions and data.
Conical head nipple
M10 x1 (DIN 71 412)
Operating and
display panel
7pole circular connector
Connection for
cable harness
Pin allocation
KFA1
KFAS1, KFAS1W
Cable harness 997000820 (not included in delivery)
Cable harness 997000630 (not included in delivery)
Pin allocation
Pin allocation
Pin No. Function
Core color
Pin No. Function
Core color
1
2
red/black
brown
1
2
3
4
5
6
7
brown
red/black
blue
pink
black
black
purple/green
15
31
plus potential
minus potential
minus potential
31
15
plus potential
DK manual lubrication
SL2 indicator light, ext
ZDS+ cycle switch, +output
ZDS cycle switch, input
SL1 status display light
21
Progressivanlagen für Nutzfahrzeuge für Fett bis NLGIKlasse 2
19430
Trailer and semitrailer lubrication with KFG15 piston pump, electrically operated
The system of feeders and lines is planned and installed in the
same way as with tractor trucks.
This pump has a maximum of 3 lubrication outlets for the
connection of 3 separate progressive feeders, so that in many
cases there is no need to combine a master feeder with second
ary feeders.
Five pump elements with varying outputs are available so that
the quantity of grease can be approximately adjusted to the
needs of the individual circuits. This makes it possible to supply
every lubrication point with grease in one lubrication cycle.
See page 14 for pump elements.
Due to a builtin agitator driven by a gear motor the pump
elements are supplied with an adequate amount of grease even
at temperatures of – 25 °C.
KFG15 piston pump
electrically operated
The grease is filled via a conical head nipple by means of a
standard toppingup pump. There is an overfill release valve on
the reservoir that is also used to bleed the same.
An IG475 control unit is used to control this system.
IG475 electronic control unit
The electronic control unit is used to control the central
lubrication system on commercialvehicle trailers and semi
trailers.
It is accommodated in a 120 x 122 mm plastic housing. The lines
for connection to the power supply (stop light power supply) and
pump motor are introduced into the housing via two cable glands
and plugged into the respective tab connectors.
IG475
electronic control unit
Wiring diagram
Electrical connections
All electrical connections are made with internally fitted
tab connectors (6.3 mm).
ground:
+ stop light:
+ motor:
– motor:
terminal 31
terminal 54
terminal 2
terminal 1
el. supply
of vehicle
stop light
switch
stop light
22
Progressivanlagen für Nutzfahrzeuge für Fett bis NLGIKlasse 2
Functional sequence
19430
Circuit board
The operating voltage is tapped from the stop light signal. This
means voltage is fed to the control unit via the stop light switch
only when the brakes are applied. The pump unit is only switched
on after a fixed delay time t V in order to keep the making current
as small as possible when the brakes are applied. This assures
that the making current of the stop lights has already decayed
when the pump motor starts.
The preset lubricating time t S begins when the pump unit is
switched on. But the pump unit only runs as long as the brakes
are applied and the lubricating time has not yet expired. If the
braking is briefly interrupted during the lubricating time (for less
than the recovery time t W [5 sec.]), the remaining lubricating time
in the memory runs down when the brakes are applied again and
after expiration of the delay time t V. The recovery time already
expired is cleared.
If braking is interrupted longer than the recovery time, renewed
braking triggers new lubrication at the end of the delay time. Any
remaining lubricating times in the memory are cleared.
The automatic time function is deactivated when switch S1 is set
to position D. The pump unit is switched on when the operating
voltage is applied and after the delay time t V expires. It remains
on as long as the operating voltage is applied. This position can
be used, for example, to fill the lines when the central lubrication
system is started up the first time.
plugin jumpers
2s
lubricating time
2 sec., 4 sec., 8 sec.
4s
••
8s
••
switch
Z D
automatic
time function = Z
continuous
operation
=D
54 (+)
31 (–)
S1
II I I I
312
tab connector
terminals
2 (+)
1 (–)
Preselection of pump running time
The pump running time can be set for 2, 4 or 8 seconds on the
circuit board with a plugin jumper. The time is set for 2 seconds
at the factory.
A switch marked S1 on the circuit board is used to switch over
from automatic to continuous lubrication. Position D is for
continuous operation and position Z for automatic lubrication.
Technical data
Order No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IG475
control voltage 1) . . . . . . . . . . . . . . . . . 24 or 12 V DC
breaking capacity
. . . . . . . . output + motor (terminal 2) at 24 V DC: 10 A
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . at 12 V DC: 15 A
operate delay . . . . . . . . . . . . . . . . . . 0.75 sec. ± 30 %
lubricating time . . . . . . . . . . . . . 2 sec., 4 sec., 8 sec.
recovery time . . . . . . . . . . . . . . . . . . . . 5 sec. ± 10 %
rated consumption without motor . .at 12 V DC: ≈ 2 W
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .at 24 V DC: ≈1.5 W
type of enclosure . . . . . . . . . . . . . . . . . . . . . . . . IP 65
operating temperature . . . . . . . . . . . . . – 25 to + 75 °C
Functional sequence diagrams
Switch S1 set to Z
operating voltage
brake switch +54
lubricating time
switching relay
The recovery time t w is initiated after every downward edge of the
battery voltage
1
) Please state control voltage when ordering.
Switch S1 set to D
t V: operate delay of lubricating time
t A: time in which battery voltage is not applied
t W: recovery time
for clearing of stored lubricating time
t S: preselected lubricating time
t 1 and t 2 = t S
t3 = < tS
operating voltage
brake switch +54
lubricating time
switching relay
23
19430US
Progressive feeders, groups VPM, VPKM
In the case of systems for NLGI grade 2 grease the lubricant is
distributed by way of progressive feeders.
Progressive feeders are available for use on commercial vehicles
in three groups that differ not only in size but also in design.
A sectiontype progressive feeder consists of at least three
sections to a maximum of ten. In each feeder section there is one
piston for the apportioning and delivery of the lubricant. The
piston diameter and piston path determine the delivery rate per
stroke. Each piston has two tasks, first delivering and second
controlling, i.e. it can deliver its lubricant only after the preceding
one has discharged its lubricant. This makes it relatively simple to
monitor lubricant delivery. It is sufficient to monitor only the
motion of the piston in one single section to be sure that the
progressive feeder is still working.
The lubricant quantity supplied by the pump is apportioned In the
progressive feeder to the individual lubrication points in keeping
with the metered quantity of the individual sections.
The delivery rate in ccm and length of the cycle (pump running
time) determine the absolute quantity fed to the individual lubri
cation points. The pistons of the progressive feeders execute one
or more strokes in this connection.
Important!
Progressivefeeder outlets that are not required must not be
plugged. Instead, these outlets must either be combined with an
adjacent outlet, i.e. fed to a lubrication point, or connected to the
pump via a return line.
When monitored systems are involved, one feeder section must
be provided with a cycle switch. In the case of sectiontype
feeders this cycle switch has to installed on a PS section or
ordered together with the progressive feeder, cf. page 27.
Later installation of a cycle switch is possible only on PS
sections.
Function
lubricant
inlet
¬
Fig. 1
In Fig. 1 piston side 4 is pressurized by the pump, piston side 1
has delivered lubricant to outlet 1a. The connection between the
main line and piston side 5 has become free due to the stroke of
piston 1/4.
lubricant
inlet
¬
Fig. 2
In Fig. 2 piston side 5 is pressurized and piston side 2 delivers the
lubricant via outlet 2a. Piston side 6 is the next to be pressurized,
etc.
24
19430US
Progressive feeders, group VPM
In the case of this group the feeder sections have two outlets on
each side, one each on the side and one on top, but only one
may be used. The second outlet must always be kept closed.
These feeders are supplied with a builtin check valve.
A later combination of two outlets is only possible with a
crossporting bar that is screwed into the upper alternative outlets.
Any odd number of outlets can be achieved with the help of
Ssections without additional crossporting bars.
Operating pressure: 10 bars min. / 250 bars max.
Screw plug incl Oring 466431001
If “outlet on top”,
screw top plug in on the side
lubricant
outlets
lubricant
inlet
¬
end section
inlet section
feeder sections
Straight connectors
Order No.
Number of
feeder sections
Number of
possible outlets
L1 1)
L2
VPM3
VPM4
VPM5
VPM6
VPM7
VPM8
VPM9
VPM10
3
4
5
6
7
8
9
10
6
8
10
12
14
16
18
20
84
104
124
144
164
184
204
224
98
118
138
158
178
198
218
238
Apportionment
for inlet M14x1.5: for 6 mm diam. tube, order No. 406413
for 10 mm diam. tube, order No. 410403
for outlets M10x1: for 4 mm diam. tube, order No. 404006K
or corresponding plugin connectors
1
) The spacing between holes for attachment of the feeders can deviate
from the indicated dimensions due to the individual tolerances of the
feeder sections.
It is therefore advisable to drill the attachment holes on the mounting
surface.
Selection of feeder sections for the desired lubricant quantity
Amount per cycle
and outlet (ccm)
Number of
outlets
Designation
of sections
0.05
0.14
0.19
0.25
0.3
0.35
0.1
0.28
0.38
0.5
0.6
0.7
2
2
2
2
2
2
1
1
1
1
1
1
1T
2T
3T
4T
5T
6T
1S *
2S *
3S *
4S *
5S *
6S *
All PS sections can be outfitted with a cycle switch.
*) The two outlets of one feeder section are combined here.
Crossporting bar
The crossporting bar is used to combine the lubricant outputs of
two adjacent feeder sections via the alternative outlets on top of
the feeder.
Crossporting bar
Order No. VPC
Model: complete with banjo bolts and washers.
25
19430US
Progressive feeders, group VPKM
This group has only one outlet on each side of the section and is
not equipped with builtin check valves.
Adjacent outlets on one side can be combined by screwing out
the plugs installed as a standard feature (see page 27 for exam
ples).
Operating pressure: 5 bars min. / 250 bars max.
lubricant outlets
lubricant
inlet
¬
end section
inlet section
feeder sections
Order No.
2
VPKM3 )
VPKM4
VPKM5
VPKM6
VPKM7
VPKM8
VPKM9
VPKM10
Number of
feeder sections
Number of
possible outlets
l 1 1)
l2
3
4
5
6
7
8
9
10
6
8
10
12
14
16
18
20
66.5
82.5
98.5
114.5
130.5
146.5
162.5
178.5
79.5
95.5
111.5
127.5
143.5
159.5
175.5
191.5
Apportionment
Selection of feeder sections for the desired lubricant quantity.
Amount per cycle
and outlet (ccm)
Number of
outlets
Designation
of sections
0.04
0.08
0.14
0.18
0.08
0.16
0.28
0.36
2
2
2
2
1
1
1
1
05 T
1T
2T
3T
05 S
1S
2S
3S
The order No. of the feeder must be supplemented with the
section designations.
Example of an order for 1 respective 1T, 2T and 3T section
starting from the inlet section:
VPKM31T2T3T
Ssections only have to be used in this group when an odd number of
outlets are called for.
Straight connectors
for inlet M10x1:
for outlets M10x1: for 4 mm diam. tube, order No. 404006K
1
) The spacing between holes for attachment of the feeders can deviate
from the indicated dimensions due to the individual tolerances of the
feeder sections.
It is therefore advisable to drill the attachment holes on the mounting
surface.
2
) This progressive feeder must in principle be used only with check
valves.
26
19430US
Progressive feeders, group VPKM
Examples showing the combination of several adjacent outlets.
quantity 5 and 6
combined
inlet
section
quantity 9 and 10
combined
quantity 3, 7 and 8
combined
end section
lubricant
inlet
screw plug incl. Oring 466431001
plug VPKM.U4
(hexagon socket SW 3)
quantity 2 and 4
combined
Two adjacent outlets are combined from the end section in
the direction of the inlet section, namely by screwing the
VPKM.U4 plug out of the respective outlet closest to the end
section and closing the outlet hole with a screw plug 1). The
lubricant quantity of both outlets is then discharged from the
adjacent outlet in the direction of the inlet section. Please note!
The feeder section behind the inlet section must not be
closed!
Important!
Always see to it that the VPKM.U4 plug is removed before the
screw plug is screwed in, as otherwise the feeder will be
blocked.
quantity 2 and 6
combined
The outlets of one whole side of a feeder can be combined in this
way provided there is no Ssection between them. The Ssection
terminates a group. A new group can then be formed again
behind the Ssection.
If it later turns out that the lubricant quantities of two adjacent
outlets have to be split up again, e.g. because a lubrication point
has been added, this is possible without further ado. In that case,
it is only necessary to screw in a VPKM.U4 plug again and
connect the hitherto closed outlet to the new lubrication point.
) Screw plug incl. Oring, order No. 466431001
1
Groups VPM, VPKM
Technical data for cycle switch
Progressive feeder with cycle switch
Max. operating pressure . . . . . . . . . . . . . . . . . . . . . . . . 350 bars
Operating voltage . . . . . . . . . . . . . . . . . . . . . . . . . 10 to 36 V DC
Permissible current loading . . . . . . . . . . . . . . . . . . 100 mA max.
Residual current/power consumption . . . . . . . . . . . . . . ≤ 0.8 mA
Type of enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IP 67
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NC contact
When a cycle switch is screwed into the piston bore of the
progressive feeder it is possible to check the piston's motion and
thus monitor the feeder's functioning.
In this case a proximity switch is screwed directly into the
pressure chamber of the piston bore, where it is actuated by the
correspondingly shaped piston in the PS section. Another
advantage of this setup is the fact that there is no need to seal
moving parts. The switch is screwed into the rear piston bore on
the right, as viewed from the inlet.
Order example for a feeder belonging to the VPKM group:
VPKM305T3S2TPS installed with 177300092, on the
right.
Please note:
cycle switches can be installed only on PS sections at a later date.
When retrofitting a cycle switch, always use the special associated feeder
section! All feeder sections are available with cycle switches.
LED
For associated circular connector see page 38.
Order No.
Group
d1
L
L1
L2
SW
Cable with screwed plug, length 5 m, order No. 169990600
length 10 m, order No. 169990603
177300091
177300092
VPM
VPKM
M12x1
M10x1
61
59.5
38
36
7.5
6
17
14
27
19430US
28
Progressive feeder, group VPBM
Features:
G
Blocktype design, smallest feeder group, used mainly for
greaselubricated machines and equipment.
G
Uniform metering: 0.13 ccm.
G
Two outlets opposite each other can be connected at a
later date by screwing out the plug in the outlet on the right
(outlet ports on top as viewed from the lubricant inlet) and
closing one of the two outlets.
G
Two or more adjacent outlets are combined with external
crossporting bars.
G
Without builtin check valves.
G
Without alternative outlets.
VPBM3
shown with
outlet ports on top
operating pressure: 5 bars min. / 400 bars max.
lubricant
inlet
¬
lubricant
outlets
Straight
connectors
for inlet M10x1:
for outlets M10x1:
for 4 mm diam. tube, order No. 404006K
plug VPKM . U4
Function diagram
screw plug incl. Oring
466431001
Number of
outlet pairs (pistons)
Number of
maximum outlets
L
(mm)
VPBM3 1)
VPBM4
VPBM5
VPBM6
VPBM7
VPBM8
VPBM9
VPBM10
3
4
5
6
7
8
9
10
6
8
10
12
14
16
18
20
60
75
90
105
120
135
150
165
¬
Order No.
lubricant
inlet
1
) This progressive feeder must in principle be used only with check
valve VPKMRVS4.
plug VPKM . U4
19430US
Prosgressive feeder, group VPBM
Cycle switch for VPBM
in order to monitor the stroke of the piston.
This switch can be screwed into any cylinder bore since it is
actuated directly by the piston.
The cycle switch can be ordered separately for later
installation or complete with feeder.
Cycle switch: Order No. 177300096
177300096
Progressive feeder with cycle switch:
Order example: VPBM3 mounted with 177300096, right
The cycle switch is then installed in the rear, righthand bore of
the feeder as viewed from the inlet.
For the associated circular connector see page 38.
See page 27 for technical data.
LED
Cable with screwed plug, length 5 m, order No. 169990600
length 10 m, order No. 169990603
VPBMC3
Crossporting bars for the connection of adjacent outlets
Number of
outlets to be
connected
Order No.
of complete crossporting
bar including banjo bolts and
adapter for 6 mm diam. tube
and check valve
Order No.
of complete crossporting
bar including banjo bolts and
adapter for 6 mm diam. tube
2
3
4
VPBMC2
VPBMC3
VPBMC4
VPBMC
–
–
VPBMC
Check valve
for direct installation in a feeder outlet.
Order No. VPKMRVS4
VPKMRVS4
6 mm diam tube connector
direction of flow
¬
29
19430US
Piston pump with block feeder PFVPBM., manually operated
The piston pumps with a block feeder are used on farm machinery,
small stackers and construction machinery as well as motor
vehicle superstructures.
Pay attention to cleanliness when changing cartridges, and
proceed as follows:
1. Open the toggletype fastener
The piston pump has 6 to 12 lubricant outlets depending on the
block feeder. 2 ccm of lubricant are delivered to the feeder with
every stroke of the lever.
2. Unscrew the gun tube
Also available without block feeder with only one M1 0 x 1 outlet
on the front (order No. 169000146).
5. Screw in the gun tube
The level of the lubricant in the cartridge can be checked by
pulling out the cartridge until distinct resistance is felt. When the
cartridge is full the piston rod can be pulled out approx. 415 mm.
7. Loosen the lock, push in the piston rod up to the stop
3. Pull piston rod out to the stop
4. Change the cartridge
6. Close the toggletype fastener
8. Actuate the vent valve until grease emerges
piston rod
~ 400 when pump actuated
Vogel order No. of the cartridge: FK042
when cartridge replaced
end of gun tube
lock
vent valve
marked with
order No.
Technical data
Order No.
with block
feeder 1)
Number of
outlets
Dimensions (mm)
L1
L2
PFVPBM32
PFVPBM42
PFVPBM52
PFVPBM62
169000146
VPBM3
VPBM4
VPBM5
VPBM6
–
6
8
10
12
1
60
75
90
105
–
1
) cf. page 28
461
476
491
506
396
lubricant . . . . . . . . . . . . . . . . . . . . . . grease up to NLGI grade 2
reservoir capacity . . . . . . . . . . . . . . . 450 ccm in 400 g cartridge
G or W DIN 1284
temperature range . . . . . . . . . . . . . . . . . . . . . . . . – 25 to + 80 °C
mounting position . . . . . . . . . . . . . . . . . . . . . . . . . . any position
delivery rate . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ccm per stroke
max. back pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400 bars
30
19430US
Lubricating aid (single greasefitting lubrication)
a) with premetering unit
b) without premetering unit
Central lubrication system with premetering unit
(central single greasefitting lubrication
All the lubrication points of the chassis (with the exception
of those on the cardan shaft) can be combined by means
of progressive feeders to form a system with a single
grease fitting. The lubricating times are kept to a mini
mum, and no lubrication point can be forgotten.
a) We recommend that the system be operated with a
premetering unit.
The quantity of lubricant delivered by a standard grease
gun in the shop is fed to the progressive feeders after
being limited to either 20 or 40 ccm by the premetering
unit. From there it goes to the lubrication points. Keep
the grease gun pressed to the nipple until the function
display on the premetering unit has reached its full
throw. The function display slowly returns to its initial
position after the grease gun is removed, and a small
amount of grease emerges from the nipple of the
premetering unit (discharge volume).
master feeder
lubrication points
Please note: The lubrication nipple on the premetering
unit does not contain a check valve to ensure renewed
charging of the unit.
tube connector
with lubrication nipple
b) The same system with progressive feeders, but without
a premetering unit to limit the volume, and thus
indirectly the pressure, can be reliably operated only if it
is ensured
1. that the pump pressure does not exceed 100 bars
or
2. that flexible highpressure hoses are used for non
stationary lubrication points.
pin for
function display
nipple for
grease gun
premetering unit
b) or a)
drum pump
with grease gun
Operate the drum pump or grease gun until grease can
be seen to emerge at the friction points. Locate the
lubrication nipple at an easily accessible place.
The grease fed to the individual lubrication points is not
metered out, but only portioned out; i.e. the total
amount of lubricant fed to all the lubrication points is up
to the operator. Only the proportional distribution of this
quantity is determined by the choice of the metered
feeder quantities.
Premetering unit
The systems described in point a) have the following
advantages:
1. The pump, lubricant reservoir and control unit can be
dispensed with on the vehicle.
2. Metered apportionment of lubricant; thus savings on
grease.
Any grease gun, even one producing a pressure of 400
bars, can be used without risk. Furthermore, the use of
flexible highpressure hoses will only be necessary in
exceptional cases.
If changes in trucking operations or the shop staff make it
appear advisable, both systems – with or without a pre
metering unit – can easily be supplemented by a pump,
reservoir and control unit of the vehicle's own. The feeders
and tubing, i.e. the entire system, remain unchanged.
Please note! Clean lubrication nipple!
Use clean grease gun!
Fouling risk!
indicator pin
beneath
protective cover
adapter for
10 mm diam. tube
lubrication nipple
acc. to DIN 71 412
Order No.
Output in ccm
Operating pressure in bars
VF20
VF40
20
40
100 350
31
19430US
Fittings and auxiliary equipment (see brochure 10103US for further fittings and accessories)
Plugin connectors, detachable
Adapters
tube diam. A
Order No.
G
D
L
6
451006468VS
M 6 tap.
5.5
30
6
451006498VS
M 8x1 tap.
5.5
29.5
6
451006518VS
M 10x1 tap. 5.5
27
6
406423WVS
R 1/8 tap.
6.5
28.5
D
Banjo fittings
tube diam. A
Order No.
G
øB
L1
L2
SW 1
6
455529068VS
M 8x1 tap.
12.5
6
26
20
10
10
6
455531068VS
M 10x1 tap. 12.5
6
26
20.5
10
12
tube diam. A
Order No.
G
D
L1
L2
SW
6
453006468VS
M 6 tap.
12.5
6
26
15
10
6
506508VS
M 8x1 tap.
12.5
6.5
26
14
10
6
506510VS
M 10x1 tap. 12.5
6
26
14
10
6
506511VS
R 1/8 tap.
8.5
26
16.5
10
Elbows
12.5
Tubetotube connector, detachable
f. tube diam. 6
tap.
tube diam. 6
f. tube diam. 6
Check valve
øB
tube diam.
Order No.
Opening pressure [bars]
tube diam.
Order No.
6
VPKMRVVS
3 +2
6
406426VS
Tube cutter
with clawgroove cutting fixture for plugin connectors
f. steel tubing ø
Order No.
4
169000322
6
169000323
(drawing)
SW 2
32
19430US
Progressive feeder systems for greases of NLGI grades 1 and 2
require fittings for higher pressures.
Straight bulkhead connectors
The cutting sleeve screw unions conform to the Lseries, with the
exception of the small and compact fittings marked with an
asterisk. The LLseries applies in that case
max. wall thickness
16 mm
Male connectors
D (outer tube diam.)
Order No.
d1
Order Nor.
d1
6
6
6
6
6
6
6
6
6
10
10
10
406443 *
406433
406423 *
VPKMRVS4 1)
406403
406413
406423W *
406446
406513W
410443
410403
410403W
M 6 tap.
M 8x1 tap.
M 10x1 tap.
M 10x1 tap.
M 10x1
M 14x1.5
R 1/8 tap.
M 6 tap. short
R 1/4 tap.
M 10x1 tap.
M 14x1.5
G 1/4 A
6
10
406416
410416
M12x1.5
M16x1.5
Elbow bulkhead connectors
max. wall thickness
16 mm
1
) with check valve
Elbow screwin connectors
Order No.
d1
6
6
6
6
6
10
406445 *
406435 *
406425 *
406455W *
406415W
410405
M 6 tap.
M 8x1 tap.
M 10x1 tap.
R 1/8 tap.
R 1/4 tap.
M 14x1.5 tap.
Order No.
d1
6
10
406409
410409
M 12x1.5
M 16x1.5
Teepieces
Straight connectors
Order No.
6
6
10
406426 *
406406
410410
Steel parts, galvanized surface
*) especially small and compact
Order No.
6
10
406407
410407
adjustable
6
6
10
443406061
443406351
443410101
L series
S series
33
19430US
Elbow connectors
Elbows
for outer tube diam.
Oder No.
Order No.
d
10
410404
406145K
406045K
M 8x1 tap.
M 10x1 tap.
Material: steel, galvanized surface
Elbow Connectors, adjustable
for outer tube diam. d 1 Order No.
d
sw
6
10
M 12x1.5
M 16x1.5
14
19
443306341
443310372
Order No.
d
406089K
406090K
M 8x1 tap.
M 10x1 tap.
Cutting sleeves
Order No.
6
6
10
406301
406331 *)
410301
Banjo fittings, freely movable
washer
*) For the “especially small” fittings
marked thus * on page 33.
banjo union
banjo bolt
Plug
D (outer tube diam.) Order No.
6
10
d1
430706001 M 12x1.5
430710001 M 16x1.5
for outer tube diam.
Order No.
d1
4
4
405549049
405551049
M 8x1 tap.
M 10x1 tap.
Swing angle: 360°
Frequency: approx. 1 movement/min at max. swing angle
1
) Port tapped for solderless tube connection
Union nuts
D (outer tube diam.) Order No.
6
6
10
d1
406302
M 12x1.5
406332 *) M 10x1
410302
M 16x1.5
*) For the “especially small” fittings
marked thus * on page 33.
34
19430US
Screw unions for steel and plastic tubing
(use reinforcing socket for plastic tubing)
socket union
tapered sleeve
tapped port
reinforcing socket
(for plastic tubing)
Reinforcing
socket
for plastic tubing
Tapered
sleeves
Socket unions
for outer
tube diam.
Order No.
Order No.
Order No.
d1
4
6x1.25
404603
406613
404611
406611
404612MS
406612MS
M 8x1
M 10x1
Assembly
Slide socket union and tapered sleeve onto end of the tube.
In the case of plastic tubing, first insert the reinforcing
socket. Insert end of tube into tapped port up to the stop.
First tighten the socket union fingertight and then turn it
another 11/2 turns.
Material: brass
Adapters with respective washers
1)
for outer
tube diam.
Adapter
Order No.
d1
d2
l1
l2
sw **)
Washer
Order No.
4
4
4
4
4
6
6
6
8
8
8
404044 *)
404004
404005
404006
404164
406004
406166
406054
408004
408005
301020
M 8x1
M 8x1
M 8x1
M 10x1
M 14x1.5
M 10x1
M 16x1.5
G 1/4 A
M 10x1
M 16x1.5
G 1/4 A
M 8x1
M 8x1
M 8x1
M 8x1
M 8x1
M 10x1
M 10x1
M 10x1
M 14x1.5
M 14x1.5
M 14x1.5
46
24
32
18
18
18
19
20
28
22
23
6
14
22
7.5
9
7.5
9
10
7.5
9
10
11
11
11
14
17
14
19
17
17
19
17
DIN7603A8x11.5CU
DIN7603A8x11.5CU
DIN7603A8x11.5CU
504019
DIN7603A14x18CU
504019
DIN7603A16x20CU
508108
504019
DIN7603A16x20CU
508108
Material
Adapters:
steel, galvanized surface
Washers: copper
Please note!
Order washers separately!
1
) Ports tapped for solderless tube
connection
*) extra long
**) sw = width across flats
Adapters with tapered thread for screwing into lubrication ports without sealing face
1)
2)
for outer
tube diam. Order No.
d1
d2
L1
L2
sw**)
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4.5
4.5
6
6
M 6 tap.
M 6 tap.
M 6x0.75 tap.
M 7 tap.
M 8x1 tap.
M 8x1 tap.
M 10x1 tap.
M 10x1 tap.
*)
*)
R 1/8 tap.
1/8 NPTF
R 1/4 tap.
1/428 UNF
1/4 BSF
3/16 BSF
M 10x1 tap.
R 1/8 tap.
M 10x1 tap.
M 10x1 tap.
M 8x11)
M 8x11)
M 8x11)
M 8x11)
M 8x11)
M 8x11)
M 8x11)
M 8x1
M 8x11)
M 8x11)
M 8x11)
M 8x1
M 8x11)
M 8x1
M 8x1
M 8x1
M 10x1
M 10x1
M 10x11)
M 10x1
19
20
20
20
17
62.5
16
25
18
46
16
20
14
20
20
18
18
18
23
40
5
6
6
6
7.4
7.4
7.4
7.4
5.2
5.2
6
6.7
9
5.6
5
5
7
6
7.4
8
11
11
11
11
11
11
11
11
11
11
11
11
14
11
11
11
13
13
14
14
404662K
404663K
404673K
404047K
404003K
404045
404006K
401004512
404050
853460000
404040K
404040KUS
404054K
404072
401004903
401004904
406004KS2
456004KS2
406004K
406035K
Adapters with tapered threads are
used without washers, since
tapered threads are selfsealing.
Therefore, the ports do not have to
be provided with sealing faces.
Material:
steel, galvanized surface
1
) Ports tapped for solderless tube
connection
2
) Tapered thread according to DIN 158,
tapered, short, or as per DIN 2999
*) Selfforming thread for 7.6 mm diam.
borehole
**) sw = width across flats
35
19430US
Elbows with tapered threads
Connectors
for screwing into lubrication ports without sealing face.
Elbows with tapered threads are used without washers, since
tapered threads are selfsealing. Therefore, the ports do not have
to be provided with sealing faces.
for outer
tube diam.Order No.
4
4
d1
404008
M 14x1.5
404009 2) M 14x1.5
d 2 1)
d 3 1)
L1
L2
sw
M 8x1
M 8x1
M 8x1 27
M 8x1 38
19
30
17
17
Material; steel, galvanized surface
1
) Ports tapped for solderless tube connection
) especially long connector for double chassis
2
for outer
tube diam.
Order No.
d1
4
4
4
504200K
504201K
504202K
M 6 tap.
M 8x1 tap.
M 10x1 tap.
Material: brass
for outer
tube diam.
Order No.
4
504103
Material: brass
tap. 2)
for outer
tube diam.
Order No.
4
504211K
Material: brass
for outer
tube diam.
Order No.
6
DAR506
Material: aluminum
Double connector
Selfforming thread for
7.6 mm diam. borehole
for outer
tube diam.
Order No.
4
504050
1
) Ports tapped for solderless tube connection
) Tapered thread to DIN 158, short
2
for outer
tube diam.
Order No.
4
DAR524
36
19430US
Cable harness
Toggle switch
Connection
terminals for
the control unit
IG502E
for systems with group
KFG piston pumps
Switching capacity . . . . 2 A / 250 V AC/DC
Type of switch . . . . . . . . . oneway switch
housing for
A.M.P. tabs
flat tab
receptacles
(supplied detached)
indicator light
pink, 2.5 m
(if needed)
pushbutton or
machine contact
blue, 2 m
terminal connector
(supplied detached)
Order No. 177100057
Material: thermosetting plastic, black
Label for toggle switch
ignition
red/black, 2 m
ground brown, 2 m
Order No. 951210222
motor
blacklilac/brown, 9 m
doublesheathed
Material: aluminum
cycle switch
grey and black, 5 m
(cable is part of the cycle switch)
Rubber grommet
Order No. 997000185
Cable harness
Order No. 898210119
for systems with group
KFGS/KFAS piston pumps
Order No.
997000630
997000650
997000760
Cable
length (m)
12
16
8
7 conductors
3 conductors
Material: soft PVC, black
Stranded wire
Order No. 981900031
Please indicate length when ordering.
Description:
Outer ø:
6.1+ 0.2 mm
Cable code: LIYYÖ 2 x 1.5 mm 2
Sheath:
black RAL 9005
full encapsulation,
oilproof
Core insulation: 1 brown
1 blacklilac
heavily powdered
Core material: bare copper
Core structure: 30 x 0.25
37
19430US
Illuminated pushbutton
round
Indicator light fitted with filament lamp
Tab 6.3x0.8
P 3
▼
Tab connector
2.8 x 0.8 mm
Installed diam.
20.3 mm
N 4
Order No.
Pushbutton
Voltage
Power
177100062
177100065
green
yellow
max. 24 V
2W
12 or 24 V
2W
Order No.
Face
Voltage
Power
P66.60GRUEN
P66.60ROT
P66.60GELB
green
red
yellow
12 or 24 V
2W
12 or 24 V
2W
Filament lamp (please order separately)
179100043
Spare filament lamp
P66.62
Please indicate 12 V or 24 V voltage when ordering.
Please indicate 12 V or 24 V voltage when ordering.
cornered
Installation opening
▼
P 3
Nameplate
N 4
Order No.
Voltage
Order No.
177100063
177100064
24 V
12 V
760048
951120025
(for indicator light P66.60)
(for illuminated pushbutton 177100062/065)
Material: PVC and thermoplastic, acid and baseresistant, 0.5 mm thick
Control light
Circular connector, 4pole type
for illuminated pushbutton, cornered
for cycle switches
P
M12x1
Max. operating voltage . . . . . . . . . . 0 to 30 V AC/DC
Max. operating current . . . . . . . . . . 3 A
Temperature range . . . . . . . . . . . . . . – 40 to + 85 °C
19.5
54
36
19.5
Order No.
Pushbutton
179100078+924 green
179100088+912 yellow
29
M12x1
N
without cable
Voltage
24 V
12 V
Order No.
Version
179990371
179990372
straight
angled
Max. operating voltage . . . . . . . . . . 10 to 30 V AC/DC
Max. operating current . . . . . . . . . . 4 A
Temperature range . . . . . . . . . . . . . . – 25 to + 90 °C
M12x1
15
27
Order No.
Pushbutton
Voltage
951110991
951110992
yellow
green
24 V
12 V
"L"
"L"
for illuminated pushbutton 177100063 / 064 and
control light 179100078 /088
M12x1
42
Central lubrication
31
45
°
Symbol insert
15
with 4core cable, 5 m long
Order No.
Version
179990600
179990601
straight
angled
38
19430US
Fixing bolts
Lock washers
Hexagonal head bolts
Order No.
l
b
k
sw
e
DIN933M6x208.8
DIN933M6x258.8
DIN931M6x308.8
DIN933M6x358.8
DIN931M6x408.8
DIN933M6x458.8
DIN931M6x558.8
DIN933M8x258.8
DIN933M8x358.8
20
25
30
35
40
45
55
25
35
20
25
18
35
18
45
18
25
35
4
4
4
4
4
4
4
5.5
5.5
10
10
10
10
10
10
10
13
13
11.1
11.1
11.1
11.1
11.1
11.1
11.1
14.4
14.4
Order No.
for bolt
d1
d2
s
h
650060
650080
650140
650160
650200
M6
M8
M 14
M 16
M 20
6.4
8.4
15
17
21
10
13
22
24
30
0.7
0.8
1.2
1.3
1.5
0.9
1.2
1.8
1.9
2.2
Order No.
d1
d2
s
821400006
821400010
6.6
8.4
28
30
2
1.5
Material: spring steel
Body washers
Selftapping screws
Order No.
l
d1
d2
DIN7981B4.2x9.5
DIN7981BZ4.8x9.5
DIN7981BZ4.8x13
9.5
9.5
13
4.2
4.8
4.8
8.2
9.5
9.5
Nuts
Screw plugs
and respective flat washers
Order No.
d1
m
sw
e
DIN934M68
DIN934M88
DIN936M14x1.55
DIN936M16x1.55
DIN936M20x1.55
M6
M8
M 14x1.5
M 16x1.5
M 20x1.5
5
6.5
8
8
9
10
13
22
24
30
11.5
14.4
25.4
27.7
34.6
Screw plugs
Order No.
d1
Flat washers
Order No.
404011
406011
408011
M 8x1
M 10x1.5
M 14x1.5
DIN7603A8x11.5CU
504019
DIN7603A14x18CU
Material: copper
Please note!
Order flat washers
separately!
39
19430US
Tubing
Steel tubing, galvanized
Order No.
da
s
di
minimum bending radius r
bent with
bent with
mandrel
grooved disk
WVRO4x0.7VERZI
WVRO6 x0.7VERZI
WVRO6x1VERZI
WVRO10x1VERZI
4
6
6
10
0.7
0.7
1.0
1.0
2.6
4.6
4.0
8.0
6
22
22
71
–
16
16
27
6
2.0
2.0
22
16
Diesel injection pipe
DIN73000A26ST30AL
Plastic tubing, WVN715, unplasticized/semirigid
Order No.
Code
WVN715RO4x0.85+A89
WVN715RO6x1.25+A89
WVN715RO6x1.5 +A89
as per DIN 73 378
da
s
di
minimum bending radius r
4
6
6
0.85
1.25
1.5
2.3
3.5
3.0
38
63
63
color: black
The plastic tubing can also be supplied filled with NLGI grade 2, code AF 5.
The respective code and tubing length must be added to the order No.
Please note!
see screw unions
with reinforcing sockets
for plastic tubing.
Order example:
Plastic tubing WVN715RO4x0.85, black color, 5 m long:
Order No.
WVN715RO4x0.85+A89x5m
Plastic tubing WVN715RO4x0.85, black color, filled with grease, 8 m long:
Order No.
WVN715RO4x0.85+AF5x8m
Hoses
socket union
double tapered sleeve
For secondary lines
(connection: feeder lubrication point)
L +5
Order No.
220
260
300
340
734220K
734260K
734300K
734340K
External
tube diam.
Hose diam.
d3
4
8.8
M 8 x1
Complete with socket unions and double tapered sleeves
Material
hose
oilproof internal and external rubber with braided layer of rayon.
tube ends: steel tubing, ends permanently joined to the hose.
Please note! These hoses must not be used as main lines.
Sleeves
Corrugated hose
Order No.
982760070
982760120
982760130
982760160
rated width
4
8
10
12
Material: polyamide 6, black color
da x s
di
7 x 1.25
11.7 x 1.6
12.9 x 1.5
15.7 x 1.7
4
8.4
10
12.3
L
up to max. of 50 m *)
*) please indicate when ordering
for corrugated hose 982760130
(rated width 10)
Order No.
2hole:
898210047
3hole:
898210075
4hole:
898210063
40
19430US
Hoses for selfinstallation
for main lines (connection: pump – feeder)
and secondary lines (connection: feeder – lubrication point)
*) Take length of engaged thread into account twice when determining the length of the hose.
Designation
➀
Order No.
Highpressure hose, max. length supplied 50 m
L (mm)
a (mm)
b (mm)
2
13
13
2
21
47
36
21
982750091
982750091+AF2
filled with NLGI grade 2 grease
982750092+AF2
steelsheathed
(associated clip, order No. 941514101)
➁
➂
Sleeve
853540010
Tube stub, straight
853370002
853380002
853390002
853370002VS
853380002VS
853380003
853390003
853390004
853380003VS
with claw groove for plugin connector

Tube stub, 90° angle
with claw groove for plugin connector
Technical data
Materials:
Hose:
rupture pressure .............. 800 bars
min. bending radius ........ 35 mm
hose : inner lining ..............
inner layer ...............
outer cover .............
sleeve, tube stub: ..............
20
30
66
20
30
unplasticized polyester
braided synthetic fibers
weatherproof polyurethane
steel, galvanized
for main lines (connection: pump – feeder)
*) Take length of engaged thread into account twice when determining the length of the hose.
Designation
➀
Order No.
Highpressure (max. length supplied 100 m)
Highpressure (max. length supplied. 50 m)
WVN71110
WVN71110+AF2
filled with NLGI grade 2 grease
➁
➂
Sleeve
Tube stub
406810002
406710002
Technical data
Materials:
Hose:
rupture pressure .............. 315 bars
min. bending radius ........ 55 mm
hose : inner lining ..............
inner layer ...............
outer cover .............
sleeve: ...............................
tube stub: ..........................
Perbunan
diagonally woven synthetic fibers
weatherproof neoprene
aluminum alloy
steel, galvanized
41
19430US
Clips
Spacer ring
lubrication
lines
separating cut
brake
hose
spacer ring
for outer tube diam. D
Order No.
L
number of tubes
4
4
6
8
604001A
604002A
606010A
608001A
9
9
10
12
1
2
1
1
corrugated
tube
Order No. 898210061
Material: mild steel, galvanized surface
Material: CR (chloroprene rubber)
Cable strap
rubber profile
Order No.
4
6
6
8
9
9
10
12
13
15
17
17
18
20
22
25
27
941204104
941206104
941206108
941208104
941209104
941209105
941210104
941212104
941213104
941215104
941217104
941217105
941218101
941220104
941222100
941225104
941227104
d
5.2
5.2
6.4
6.4
5.2
6.4
6.4
6.4
6.4
6.4
5.2
6.4
6.4
6.4
6.4
6.4
10.2
cable
strap
b
L
15
15
18.5
18.5
15
18.5
18.5
18.5
18.5
18.5
15
18.5
18.5
18.5
18.5
18.5
31
10
11
14.2
15.2
12.5
15.7
16.2
17.2
17.7
18.7
16.5
19.7
20.1
21.2
22.2
23.7
31
Order No.
l
b
898610000
898710000
898710001
197
302
360
4.9
4.9
7.5
Material: polyamide
For automatic pincers:
Order No. 898510002
Material: polyamide
Mounting base
selfstick
foil
rubber profile
Order No.
l
l1
9
17
941309204
941317204
12.5
16.5
9
17
Order No. 179990186
42
19430US
Guard ring
Mounting plate
for VPM, VPKM, VPBM feeders
Order No. 871770006
Material: steel
Order No.
a
d
d1
h
821730010
821750010
821950010
20
10
13
60
60
90
50
50
78
20
40
40
Material. Steel
Welding flange for connection of grease nipple
Welding plates
for VPKM feeders
8 mm thick
Order No. 871530010
Material: steel
tap.
Conical head nipple with valve
Order No. 996001890
associated cap, order No. 898210050
Manifold block
Order No.
L
L1
L2
Number of
threaded holes
871340006
871340008
871360006
871360008
871380006
871390020
871390023
30
30
50
50
70
210
270
–
–
20
20
40
20
20
19.5
19.5
39.5
39.5
59.5
199.5
200
1
1
2
2
3
10
13
nipple port
(drawing)
nipple port
Order No.
L1
L
871990083
871990084
871990073
871990086
871990087
871990088
871990089
871990065
66.5
82.5
98.5
114
130.5
146.5
162.5
178.5
85
100
177
135
150
165
182
199
without ø 20 hole
43
19430US
Drilling template for piston pumps
Pump fastening plate
for systems with group KFG/KFGS piston pumps
square tube
3 holes imprinted
only
type KFG
Order No.
Order No. 951130115
KFG1.U16
KFG1.U17
Material: selfstick paper
without square tube
(drawing)
3 holes imprinted
only
type KFA
Order No. 951130148
Order No. 881290430
Material selfstick paper
Drilling template
for progressive feeder, type VPBM
2 holes with 7 mm
diam. imprinted only
Order No. 951130145
Material: selfstick paper
44
19430US
Protective helix
Antikink coil for highpressure hose
Max. length of 25 m, please indicate when ordering
Order No.
Segment width
a
Wall thickness
s
Inside
diam. d i
982760061
982760121
982760141
982760171
9
10
16
22
1
1.5
1.5
2
4
9
11.5
13
Material: polyethylene, black color
Order No.
804920010
804920011
982760132
982760220
L
85
200
5000
2000
d
10.6
10.6
10.6
20
Material: stainless steel
Spiral hose
Pressure gauge
Order No.
d1
a
Wall thickness
Bundling range
982760102
982760172
982760222
982760272
10.4
17.4
22.7
28
10
14
17
20
0.8
0.8
0.9
1.0
6–9
10 – 16
17 – 21
21 – 28
Order No.
Indicating ranges
169125000
0 to 250 bars
0 to 3600 psi
0 to 400 bars
169140001
Mounting position: standing upright.
Please order washer 248610.02
separately.
Marking clip
for secondary lines
marking
Adapter for pressure gauge
Order No.
Marking
808110010
808110011
808110012
808110013
808110014
808110015
808110016
808110017
808110018
808110019
0
1
2
3
4
5
6
7
8
9
808220010
808220011
808220012
808220013
808220014
808220015
808220016
808220017
808220018
808220019
0
1
2
3
4
5
6
7
8
9
External
line diam.
d
5.9 8.5
7.5
appropriate clip
installation rod
order No. 808110020
Order No.
d1
301134
301034
M10x1
M14x1.5
Adapter for pressure gauge with washer
Order No. 248610.01
Order No. 441110163
8.6 11.1
10,5
appropriate clip
installation rod
order No. 808220020
Material: nylon, heatrestistant, selfextinguishing
yellow color
45
19430US
Safety valve
Safety valve
f. tube ø 8
without lubricant nipple
Order No.
Opening pressure (bars)
161210008
300 ± 20
Order No.
tube diam.
161210012
161210016
161210018
6
10
8
300 ± 20
f. tube ø 6
Safety valve with switch
(Fig.)
f. tube ø 6
with lubricant nipple
blue
blue
brown
brown
black
black
Rated operating voltage: 1A (220 V AC);
Operating temperature range: – 30 to + 80 °C
Order No.
tube diam.
Order No.
161210 014
6
300 ± 20
169200130
250 ± 20
46
19430US
Filler socket
Coupling plug
Order No. 995000705
Respective coupling socket order No. 995001500
Order No. 995001621
Stub for coupling plug
Coupling socket for toppingup port
Order No. 995001622
Order No. 995001500
Respective plug order No. 833370001
Mounting angle bracket for coupling socket
Hose nozzle
Order No.
d
857760007
857870002
13
16
Order No. 881430000
Material: brass
Dust cover for stub
Coupling socket with return flow port
Main line port
10 deep
Return flow port
Order No. 995001620
Order No. 995001623
47
19430US
Brush
Brush
4 brushes
bundle 4 mm in diam.
Order No. 992000289
soft Perlon
Screen filter
for systems with NLGI grade 000 to 2 grease
Order No. 992000171
Cleaning tips:
To clean the screen filter first unscrew the size 13 hexagon nut.
The filter element can then be pulled – without having to loosen
the tubing.
horsehair
Tube cutter
approx. 40 mm of free space
for changing of filter element
Order No. 169000301
Spare cutting wheel
Order No. 844300001
Order No.
Max. operating
pressure
(bars)
Mash opening
width
(mm)
Screen area
(ccm)
213870
213870F
60
60
0.063
0.160
21
20
Mounting position preferably as shown
Tube bending device
This device can be used to bend tubes with a 6, 8 and 10 mm outside diameter. A special grooved disk is available for every
tube diameter. Thinwalled steel tubes with a 10 mm outside diam. may be slightly flattened at the outer bend, but that is not
essential with regard to strength or reduction of cross section..
Inner bending radius tube 6 mm outside tube diam.: 16 mm
tube 8 mm outside tube diam.: 22 mm
tube 10 mm outside tube diam.: 27 mm
back stop
bending lever
back stop
Tapped holes for
displaceable back
stops in accordance
with tube diameter.
Order No. 248803.20
There is a special grooved disk available for the bending tube with 12 mm o.d., order No. 248803.17
48
19430US
Levertype grease gun
for checking of feeders
in the installed system
Pressure gauge
400 bars
Order No. 169000143
f. tube ø 6
Reducing coupling
with cuttingsleeve screw unions
with cuttingsleeve screw union
f. tube ø 6
f. tube ø 6
Hose line, 2 m long
Order No. 441006347
Reducing coupling
f. tube ø 6
Order No. 167002001
Order No. 444510062
f. tube ø 10
f. tube ø 6
with cuttingsleeve screw union
49
Notes
19430US
50
V000 09/2002
Subject to change without notice!
Willy Vogel AG
Motzener Strasse 35/37
12277 Berlin, Germany
P.O. Box 97 04 44 · 12704 Berlin
Phone
Fax
Email
Internet
(++49) 307 20 020
(++49) 307 20 02111
[email protected]
www.vogelag.com