Manual: Servicing Manual Centralized Lubrication System For LIEBHERR Hydraulic Excavator R 9250

Servicing Manual
Centralized Lubrication System for LIEBHERR Hydraulic Excavator

R 9250
Manual
Manual
R9250
Änderungen vorbehalten
LINCOLN GmbH & Co. KG ∗ Postfach 1263 ∗ D-69183 Walldorf ∗ Tel +49 (6227) 33-0 ∗ Fax +49 (6227) 33-259 ∗Tx 466088
Servicing Manual
R 9250
Manual
Table of contents
A. Description of the system as a whole
1. Function of the lubrication system
2. Operation of the lubrication system
3 The lubrication system monitor
4. Inspection and maintenance
5. Exchanging / Filling the grease reservoir
6. Malfunctions and their remedy
B. Description of the components of the lubrication system
1. Description of the hydraulic pump 80l reservoir ...............................................................4.1A-68608-A05
2. Manual Flowmaster hydraulic pump.................................................................................7.5A-18100-J03
3. Manual P203.....................................................................................................................2.1A-30001-F03
4. Preliminary - Manual 15L Pump .......................................................................................
5. Circuit Board P203............................................................................................................2.6A-20003-C02
6. Description of the injectors SL1........................................................................................4.2A-68351-E05
7. Description of the injectors LM-5 ......................................................................................4.2A-18002-B05
8. Description of the progressive plunger metering devices SSV ........................................2.2A-10001-F03
9. Description of the solenoid valves ....................................................................................9.3A-68001-B00
10. Data sheet: ultrasonic-sensor...........................................................................................9.3A-70006-A00
11. Date sheet: Digital Pressure Switch .................................................................................9.3A-50012-B04
12. Data sheet: piston detector...............................................................................................9.3A-20013-A97
13. Proximity Switch................................................................................................................234-13172-6
Servicing Manual
R 9250
Manual
1 Function of the lubrication system

1.1 Description of the entire system: see the diagram under item 1.3
The lubrication points of the hydraulic excavator are supplied by two mutually independent centralized lubrication systems:
System 1 – Equipment lubrication- Slewing rim lubrication
Single-line system
Main components: Hydraulic pump "P1" 609-29333-1

Injectors LM-5, SL-1
Progressive metering devices SSV
System 2 – Gear rim lubrication
Main components: Hydraulic pump "P2" 644-46265-1-L

Progressive metering devices SSV
1.2 Sequence of a lubrication cycle
1.2.1 Systems 1
Upon expiration of the pause time the pump begins operating and supplies the lubricant to the injectors 9 (LM-5, SL-1) via the
main line. The pistons in the injectors are actuated by the lubricant under pressure and discharge a pre-dosed quantity of
lubricant to the connected lubrication points.
The pressure continues to rise in the main line until the value (220 bar) set at the pressure switch (B69) is reached. The control
unit stops the pump and, at the same time, the main line is discharged via the solenoid valve (Y79). The relieved lubricant
reaches the pump reservoir via a bypass.
The pistons in the injectors 9 (LM-5, SL-1) return to their initial position by spring force.
The pause time begins. The system is ready to carry out a new lubrication cycle.
1.2.2 System 2
After the pause time has elapsed, the pump supplies the lubricant to the connected progressive metering devices.
A progressive metering device 8 (SSV) is equipped with a proximity switch for control and monitoring.
A lubrication cycle is completed after the SSV has supplied twice, and the pump is switched off again.
Servicing Manual
R 9250
Manual
1.3 Schema
SWING GEAR
PINION GREASING
SSV8
P1 Lubrication pump -attachment B69 Pressure switch / end of lube cycle for P1
P2 Lubrication pump -swing ring teeth B51 Limit switch on progressive distributor for P2
Y79 Solenoid valve / pressure release (attachment) 8 Progressive distributor SSV
U15 Lubricating system monitor 9 Grease injector banks LM-5, SL1
1 Grease tank (80L) B50-1 “High level“ and “Low level“ sensor for P1
B50-2 “High level“ and “Low level“ sensor for P2
Servicing Manual
R 9250
Manual
2 Operation
CAUTION
• Only allow operation by properly instructed personnel
• Do not exceed permissible system pressures
• Top up lubricant or change drum in good time
When the machine is started all centralized lubrication systems are automatically pressurized.
Each pump triggers one lubrication cycle, stops only for the preadjusted pause time, ... etc.
When the excavator is delivered from the factory the time period between two lubrication cycles is 6 minutes for pump P1 and 8
minutes for pump P2. This corresponds to a grease consumption of approx. 600 g/h for P1, 20 g/h for P2.
Servicing Manual
R 9250
Manual
3 The lubrication system monitor

CAUTION
• Only allow operation by properly instructed personnel

• Do not exceed permissible system pressures
• Top up lubricant or change drum in good time
When the excavator is started the lubrication system is automatically

alive.
The lubrication pump then carries out a complete lubrication cycle, is
stopped only for the duration of the set pause time, etc....
The pause time is factory set at 2 hours.
During lubrication the diesel engine must be in operation because the

lubrication pump is driven via the compressed air of the excavator.
During a lubrication cycle, the pump function is represented by a
rotating girder on the field indicator.
The delivery of grease can be checked by ensuring that the control pin
of each injector moves back and forth.
The flashing of the pushbutton C indicates a malfunction in the

a b automatic lubrication system (lubrication cycle still not completed after
about one hour).
The fault is also indicated by means of an intermittent whistling sound at

the control unit. Possible causes of malfunction are:
• Blockage or breakage of the main line

• Fault at the pressure switch
• Lack of lubricant in the grease reservoir
• Fault in the power supply of the lubrication system
• Fault in the compressed air system
An additional lubrication cycle can be triggered at any time by pressing

c d e the key c on the control unit U15 (at least 2 sec).
On malfunction of the command unit U15, an additional lubrication cycle

can be triggered by key S84-2 of the emergency unit command E52.
Servicing Manual
R 9250
Manual
4 Inspection and maintenance
• Do not perform any repairs while system is pressurized.

• To relieve pressure open a threaded connection carefully
• Caution: Lubricant may escape while pressurized
Regular inspection and maintenance are the prerequisites for proper operation of the centralized lubrication system over a
prolonged period of time. The warranty on our product can only be valid if the prescribed maintenance intervals are adhered to.
The regular inspections and maintenance procedures are described below:
1. System as a whole
Daily: Visual check of the lubrication points for escaping lubricant

Visual check of the hose connections for leaks or wearing
Weekly: Visual check of the screwed pipe connections for leakage

Determining the time for one operating cycle. If the time determined differs from the usual operating time, the
individual components (pump station, injectors, pipes) must be checked.
Functional check of the pressure switch
2. Pump station
Weekly: Check that threaded connections and hoses are firm and tight.
Visual check of pump tube gland seal
Check function of the solenoid valve
Check electrical cable connections
Clean outside of pump station
1000 hours: Clean filter element of grease filter
3. Injectors
Daily: Check movement of control pins: During the work cycle the pins must be retracted depending on the metering
quantity; in the resting phase all the pins must be extended.
Weekly: Visual check for leaks
4. Progressive Plunger Metering Device
Weekly: Visual check for leaks
Servicing Manual
R 9250
Manual
5 Exchanging / topping up grease reservoirs
CAUTION • Lines are pressurized. Be careful when decoupling.

• Observe extreme cleanliness when exchanging or topping up the grease reservoirs.
• Contaminated lubricant causes malfunctions and premature wear of the grease pump and
other components of the system.
• Clean surroundings before exchanging or topping up
• Switch off centralized lubrication system (turn off engine)
5.1 P1 and P2: Filling of the container
Filling of the container through service-plate
∗ Remove dust protective cap at the filling coupling and the dust
protective cap at the filling nipple
∗ Couple the filling hose at item 10 (P1) resp. 11 (P2) and switch on
the filling pump
• When the reservoir is full, the ultrsonic sensor transmits an electric
signal to the control unit. Visual control is possible by screwing off
a lid
• the filling pump is switched off
∗ Disconnect the filling coupling and reinstall the dust protective
caps
Servicing Manual
R 9250
Manual
6 Malfunctions and their remedy

In the following, only malfunctions of the system as a whole are described. You will find detailed remedies for malfunctions of the
individual units in the respective User’s Information.
• Malfunction: No pressure build-up in the system
• Cause: • Remedy:
• Malfunctions of the pump • See Troubleshooting: Pump
• Leakage in the main line • Check main lines, eliminate leaks, tighten threaded
connections, replace defective hoses
• Air trapped in the main line • De-aerate the line
• Two-line metering devices leaky or worn • Replace u-cup sealing at control pin if necessary
Change complete metering device if pistons are worn
• Injectors leaky or worn • See Troubleshooting: Injectors
• Malfunction: No pressure relief or too slow pressure relief in the main line
• Cause: • Remedy:
• Pressure control device faulty • Replace pressure control device, check electric cable
• Solenoid valve faulty • Replace solenoid valve, check voltage supply
• Grease too hard or not suitable for low temperatures • Change lubricant
Servicing Manual
R 9250
Manual
Änderungen vorbehalten Seite 10 von 10

LINCOLN GmbH & Co. KG ∗ Postfach 1263 ∗ D-69183 Walldorf ∗ Tel +49 (6227) 33-0 ∗ Fax +49 (6227) 33-259
Owner’s Manual
Hydraulic Drum Pump 609-29333-1 with 80 l Container
4.1A-68608-A05
Preface to the Owner Manual
This Owner Manual is intended to familiarize the user with the If persons who are charged with work with the
pump/lubrication system and to enable him to use its various pump/lubrication system do not have a good command of the
features. English language, it is the user's responsibility to take the
The Operating Instructions contain important information for necessary action to make the Owner manual, particularly the
safe, correct and economic operation of the pump/lubrication Safety Instructions, understandable to these persons.
system. Their observance will help avoid hazards, reduce
repair costs and downtime, increase the reliability and prolong The Owner manual must be read and used by all persons who
the service life of the pump/lubrication system. are charged with work with the pump/lubrication system, e.g.
These Operating Instructions must be completed to include
the respective national regulations concerning the prevention • Operation, including adjustment, troubleshooting during
of accidents and protection of the environment. operation, elimination of production waste, maintenance,
The Owner Manual must always be available on the site where disposal of process materials
the pump/lubrication system is in operation. • Maintenance (inspection, repairs)
• Transport
Table of Contents
Item Contents Page
1 Safety Instructions 2
2 Description 3
2.1 General 3
2.2 Proper Use 3
2.3 Technical Data 3
2.4 Structure 4
2.5 Electrical Equipment 5
2.6 Mode of Operation 5
3 Erection and Assembly 5

3.1 Erection of Pump 5
3.2 Electrical Connection 5
4 Operating Instructions 6
4.1 Commissioning 6
4.2 Maintenance and Repair 7
4.3 Troubleshooting 7
5 Spare Parts Drawing 7

Spare Parts List 7
Subject to changes Page 1 of 7
LINCOLN GmbH ∗ Postfach 1263 ∗ D-69183 Walldorf ∗ Tel 06227/330 ∗ Fax 06227/33259
Owner’s Manual
4.1A-68608-A05
1 Safety Instructions
The Operating Instructions include general instructions which If necessary, this can be done by the manufacturer/supplier on
must be followed when a pump/pump unit is installed, behalf of the machine user. Furthermore, the user must
operated or serviced. Therefore, it is absolutely necessary for ensure that the contents of the Operating Instructions are fully
the fitter and the specialist/user to read the Operating understood by the personnel.
Instructions before a unit is installed and commissioned. The
Operating Instructions must always be available on the site Hazards resulting from failure to observe the safety
where the machine/system is erected. instructions
Failure to heed the safety warnings may result in damage to
All general safety instructions contained in this main chapter equipment and the environment and/or personal injury.
on safety must be observed as well as all special safety Failure to observe the safety notes may result in the loss of all
instructions given in other main chapters. claims for damage.
As an example, in the following we list some dangers which
Hazard marking in the Operating Instructions may result from failure to observe the warnings:
The notes referring to safety contained in the Operating • failure of machine/system to fulfill important functions
Instructions whose failure to observe them may result in • failure of specified methods for maintenance and repair
personal injury are marked by the following symbol • personal injury due to electrical, mechanical and chemical
influences
• danger to the environment due to leakage of harmful
materials
Safety-Conscious Working
The safety instructions given in the Operating Instructions, the
prevailing national regulations for the prevention of accidents
and any working and shop regulations and accident
Safety symbol acc. to DIN 4844-W9 prevention measures of the user must be observed.
The symbol Safety Instructions for the User/Operator

• If warm or cold machine parts may involve hazards, the
customer must protect them against accidental contact.
• Do not remove protection devices for moving parts while
the machine is in operation
• Leakages of harmful materials must be disposed of so as
to jeopardize neither persons nor the environment. The
requirements of the law must be satisfied.
Safety symbol acc. to DIN 4844-W9 • Danger caused by electrical current must be excluded (for
warns of an electrical current details refer to the applicable specifications of VDE and
the local power supply companies).
If ignoring the safety note might result in machine damages

and malfunction, the word Safety Instructions for Maintenance, Inspection and
Installation Services
The user must make sure that all maintenance, inspection and
installation work is executed by authorized and qualified
experts who have thoroughly read the Operating Instructions.
On no account may work be done on the machine while the
is added. machine is in operation. Follow all instructions for shuttling
down the machine as described in the Operating Instructions.
Warnings directly fixed to the machine must always be Decontaminate pumps and pump units delivering harmful
observed and must be kept in completely legible condition.. materials.
Reassemble all safety and protection devices Immediately
after completion of the cleaning procedure.
Staff Qualification and Training Dispose of material harmful to the environment in accordance
with the applicable official regulations.
The staff responsible for operation, maintenance, inspection Before putting the pump/pump unit into operation, ensure that
and installation must be adequately qualified for these jobs. all points given in the chapter "Commissioning" are fulfilled.
The user must properly regulate the field of responsibility and
supervision of the personnel. If the personnel is not in
command of the necessary expertise, they must receive the
appropriate training and instructions.
Owner’s Manual
4.1A-68608-A05
Unauthorized Modification and Spare Parts Production Inadmissible Operating Modes

Alteration and modifications of the machine are only allowed if The operational safety of the supplied product is only granted
approved by the manufacturer. Original spare parts and if the product is operated according to the instructions given in
accessories authorized by the manufacturer ensure safe chapter 1 - General - of the Operating Instructions. The max.
operation. If other parts are used, the manufacturer may be ratings listed in the Technical Data sheet must never be
released from its liability for the resulting consequences. exceeded.
Commissioning of the product (pump/pump unit) within the
European Union is forbidden until it has been decided that the
machine in question meets the requirements of the EU
guidelines.
2 Description
2.1 General 2.3 Technical data
This Owner’s Manual refers only to the hydraulic drum pumps Supply inlet hydraulic pressure,
model 609-29333-1. maximum, PSIG (bar) 3.500 (241)©
It is intended for the installation, operation and maintenance Operating working hydraulic pressure,
personnel. PSIG (bar) 300 to 450 (20 to 32)
If you need more information than given in this manual, please Hydrauliv Inlet Flow,
contact our company and indicate the precise type GPM (l/min) Up to 7 (28)
designation (mentioned on the nameplate): Pump Ratio with manifold 9:1 at low inlet
pressure (300 to 350
LINCOLN GmbH & Co. KG psi [20 to 25 bar]) and
Postfach 1263 low Inlet flow (below 2
D-69183 Walldorf gpm [7lpm])
Tel. 49(0)6227 330 Pump ratio
Fax. 49(0)6227 33259 approaches 11.0:1
ratio at higher inlet
pressure flow
Operating Temperature, °F (°C) -20 to 150 (-29 to 65)
2.2 Appropriate use Operating Voltage, VDC 24
Hydraulic Inlet Port, In SAE4
The hydraulically operated drum pumps are designed only for Tank Return Port, In SAE6
use in centralized lubrication systems for the supply of grease. Pump Outlets, In ¼ NPTF
Do not exceed the maximum values given in the Technical Maximum Hydraulic
Data, particularly the max. input pressure for hydraulic oil (241 Fluid Temperature, °F, (°C) 250 (121)
bar) and the max. operating pressure of 32 bar. Weight, Lbs (kg) 36 (16)
Any other use not in conformity with the intended purpose will
result in the loss of claims for warranty and liability.
© Indicates change
See the enclosed Data Sheets 7.5A-18100-J03
Owner’s Manual
4.1A-68608-A05
2.4 Structure of Pump 609-29333-1
1 11
10
The Pump 609-29333-1 mainly consists of the following Parts
5
6
11
8
7
3
Item Designation Part no. Item Designation Part no.

1 Hydraulic pump 985480-E 7 Hydraulic Inlet M 16 x 1,5
2 Container 509-32232-1 8 Lubricant Outlet M 30 x 2
3 Ultrasonic Sensor 664-34009-1 9 Hydraulic Outlet M 16 x 1,5
4 Pressure gauge 0 -600 bar 234-13182-4 10 Overflow
5 Filling connection M 36 x 2 226-13690-6 11 3/2 Way Solenoid Valve 235-13175-5
6 Grease filter 235-13131-4 12 Digital Pressure Switch 234-10330-3
Owner’s Manual
4.1A-68608-A05
Pump Station Plug Occupancy
1 2 3 4
Deutsch-Plug Type DT04-4P DT04-3P DT04-4P DT04-6P
Pin-Occupancy 1, 2, 3, 4 1, 2, 3 1, 2, 3 1, 2, 3, 4
Pressure 3/2 Way Solenoid

Switch Solenoid Valve Valve Hydr.400 Ultrasonic
Designation 0-400BAR Pump Drive VP1Z Sensor
Part-No. 234-10330-3 235-13175-5

LFR-Ident 7371836 10003707
Allocation No. X732 X734 X735 X739
2.5 Electrical equipment
Electrical low level indicator: Data sheet enclosed: 9.3A-70006-A00

Pressure Switch: Date sheet enclosed: 9.3A-50012-B04
2.6 Mode of operation
See the enclosed Data Sheets 7.5A-18100-J03
3 Erection and installation

3.1 Erection of the pump
Requirements for the installation site:
• protected from dust and dirt

• safe from atmospheric influences
• free space for replacing the drum and for maintenance work
• even, stable and vibration free installation site
3.2 Electric connection
All electrical works may only be carried out by qualified personnel.
Carry out the electric connection in accordance with the terminal diagram.
Owner’s Manual
4.1A-68608-A05
4 Operating instructions
4.1 Start up
The supply lines and hoses must be cleaned with a suitable detergent and then blown with air to dry them before they can be
connected to the system. This will allow the removal of dirt, e.g. foreign bodies, moisture and metal particles which might
damage the pump or system components.
The pump has been tested with light machine oil that has been left in it to protect it against corrosion. It is recommended to
clean the pump before it is connected to the system to prevent contamination of the grease to be pumped.
Before using this equipment, make sure that all connections (particularly the hydraulic connections) are really tight.
Read and follow the hydraulic fluid manufacturer’s recommendations regarding compatibility, and use protective clothes and
equipment.
Start the pump only after it has been put into a full lubricant drum. When replacing the drum, always take care that no
dirt or other foreign bodies enter into the drum.
The drum cover must lie evenly on the drum edge.
The hydraulic oil used for the drive must be free from condensate and impurities. Filtration required: 10µm.
The pressure regulator for hydraulic oil is set at 24 bar. Do not modify this value.
All components of the lubrication system (tubes, hoses, tube fittings, etc.) must be designed for the highest system
pressure.
Owner’s Manual
4.1A-68608-A05
4.2 Maintenance and repairs
Before carrying out maintenance or repair work, switch off the pump and protect it so that it cannot be restarted
inadvertently.
Open the couplings to relieve the system from pressure.
Repair work may only be carried out by qualified personnel using original spare parts.
Check the equipment regularly and repair or replace worn or damaged parts immediately.
If overpressurizing of the equipment is believed to have occurred, contact the authorized service center immediately for
inspection of the pump.
Specialized tools and knowledge is required for repair of this pump. Contact the service center nearest you for adjustments other
than maintenance specified in this manual.
It is recommended to have the pump serviced once a year.
A list of authorized service centers is available upon request.
Damaged pumps
If a pump is damaged or badly worn or operates abnormally, it must be shut down until it is repaired. Contact the authorized
service center for repair.
Repairs
The repairs are limited to the replacement of the listed spare parts. Any other repair requires specialized knowledge and tools.
Please contact LINCOLN Walldorf to obtain the name of your nearest repair shop. When ordering spare parts, please indicate
the part number, part designation, type number and series letter.
4.2.1 Disassembly of pump
4.2.2 Assembly of pump
4.3 Troubleshooting
5 Spare parts drawing
Spare parts list
See the enclosed Data Sheet 7.5A-18100-J03
FlowMaster™ Rotary Driven Hydraulic Pump
Models: 85480 (120#), 85481 (60#),
85482 (400#), 85483 (5 Gal.),
Series “B”
Models: 85247 (120#), 85610 (400#), 8
5586 (400#), 273006 (60#)
Series “A”
U.S. Patent No. 6,102,676

Foreign Patent Pending
This pump conforms to the European Directive for Product Safety
7.5A-18100-J03 OCT - 2003 Form 403365 Section - C8 Page - 269K

Table of Contents Annual inspection by the factory authorized warranty and

Page service center nearest you is recommended.
Safety ….……………………................................................................2
Description....................................................................................2 A list of factory authorized warranty and service centers is
Appropriate Use................................................................2 available upon request.
Pump Performance and Specifications..............................3
Installing the Pump.....................................................................4 Damaged Pumps
Operation.....................................................................................5 Any pump that appears to be damaged in any way, is badly
Maintenance and Repair...........................................................5 worn or operates abnormally, shall be removed from use
Pump Dimensions.............................................................7 until repairs are made. Contact the factory authorized
Repair Parts List................................................................................9 warranty and service center nearest to you for repairs.
Trouble Shooting.........................................................................10
Description
Safety 85480 - Pump for 120 pound drum (16 gallon)
Read and carefully observe these operating instructions 85481 - Pump for 60 pound drum
before unpacking and operating the pump! The pump must 85482 - Pump for 400 pound drum (55 gallon)
be operated, maintained and repaired exclusively by per- 85483 - Pump for 5 gallon pail
sons familiar with the operating instructions. Local safety 85247 - Similar to 85480, but with a manual override
regulations regarding installation, operation and 85610 - Low Temperature Pump for 400 lb. drum (55 gallon)
maintenance must be followed. 85586 - Heavy Duty pump for 400 lb. drum
Operate this pump only after safety instructions and this

General Description
service manual are fully understood.
The Lincoln Industrial rotary Hydraulic Pump is a fully
hydraulically operated grease pump. Grease output is
proportional to the hydraulic input flow. The pump is primari-
ly designed for centralized lubrication systems such as the
Single Line parallel, Single Line Progressive and Two Line
Indicates a potentially hazardous situation which, if not
systems. An integrated pump control manifold is incorporat-
avoided, could result in death or serious injury.
ed with the motor to control input flow and pressure. A 24
volt DC solenoid valve is also incorporated as a method to
turn the pump on and off. A 24 volt DC solenoid valve with a
manual override is standard on model 85247 and is an
Indicates a potentially hazardous situation which, if not
option on other models.
avoided, may result in minor or moderate injury.
The pump is driven by the rotary motion of the hydraulic
Safety Instructions motor. Rotary motion is converted to reciprocating motion
This equipment generates very high grease pressure. through an eccentric crank mechanism. The reciprocating
Extreme caution should be used when operating this action causes the pump cylinder to move up and down. The
equipment as material leaks from loose or ruptured unit is a positive displacement double acting pump as
components can inject fluid through the skin and into the grease output occurs during both the up and down stroke.
body causing serious bodily injury. Adequate protection is
recommended to prevent splashing of material onto the During the down stroke, the pump cylinder is extended into
skin or into the eyes. the grease. Through the combination of shovel action and
vacuum generated in the pump cylinder chamber, the grease
is forced into the pump cylinder. Simultaneously, grease is
discharged through the outlet of the pump. The volume of
grease during intake is twice the amount of grease output
If any fluid appears to penetrate the skin, get emergency during one cycle. During the upstroke, the inlet check
medical care immediately. Do not treat as a simple cut. closes, and one half of the grease taken in during the
Tell attending physical exactly what fluid was injected. previous stroke is transferred through the outlet check and
discharged to the outlet port. Typical output of the pump is
Inspection shown on page 4.
If overpressurizing of the equipment is believed to have
occurred, contact the factory authorized warranty and service Appropriate Use
center nearest you for inspection of the pump. • All pump models are exclusively designed to pump and
dispense lubricants using hydraulic power.
Specialized equipment and knowledge is required for repair • The maximum specification ratings should not be
of this pump. Contact the factory authorized warranty and exceeded.
service center nearest you for repair or adjustments other • Any other use not in accordance with instructions will
than maintenance specified in this manual. result in loss of claims for warranty and liability.
Page Number - 2 7.5A-18100-J03 Form 403365

Hydraulic Motor
(Item 42)
Hydraulic Material
Fluid Return Outlet
to Tank
Hydraulic
Fluid Inlet
Flow Control
Valve (Item 39)
Solenoid Valve
(Items 34*© & 35)
Pressure Gauge
Pressure Reducing
Vent (Item 32)
Valve (Item 38)
Valve
Illustration 1
Pump Performance and Specification

Supply inlet hydraulic pressure, Operating Temperature, ºF (ºC)- -20 to +150 (-29© to 65)**
maximum, PSIG (bar) - 3,500 (241) Operating Voltage, VDC - 24
Operating working hydraulic Hydraulic Inlet Port, In - SAE 4
pressure , PSIG (bar) - 300 to 450 (20 to 32). Tank Return Port, In - SAE 6
Hydraulic Inlet Flow, Pump Outlets, In - 1/4 NPTF
GPM (l/min) - Up to 7 (28) Maximum Hydraulic
Pump Ratio with manifold - 9:1 at low inlet pressure Fluid Temperature, ºF, (ºC) - 250 (121)
(300 to 350 psi [20 to 25 Weight, Lbs (Kg) - 36 (16)
bar]) and low inlet flow
(below 2 gpm [7 lpm])
Pump ratio approaches
11.0:1 ratio at higher
inlet pressure and flow. Do not exceed 3,500 PSIG (241 bar) maximum supply inlet
hydraulic pressure. Exceeding the rated pressure may result
in damage to system components and personal injury.
HYDRAULIC PUMP PERFORMANCE SPECIFICATIONS

Test conducted with Alvania NLGI # 2 Grade Grease
Grease Output 1,000 psi Backpressure
Cubic inches/min. (cm³/min.) (70 bar)
Hydraulic Flow Input
Temperature F 1 gpm 2 gpm 3 gpm 4 gpm 5 gpm 6 gpm 7gpm
(Temperature C) (4 l/min) (8 l/min) (11 l/min) (15 l/min) (19 l/min) (23 l/min) (26 l/min)
80 7 14 21 28 34 40 45
(27) (115) (229) (344) (459) (557) (656) (737)
40 7 14 21 28 33 38 41
(4) (115) (229) (344) (459) (541) (623) (642)
20 6 13 17 22 28 32 36
(-7) (98) (213) (279) (361) (459) (594) (590)
0 6 11 15 19 23 27 30
(-18) (98) (180) (245) (310) (376) (442) (491)
-10 5 7 8 9 10 12 13
(-23) (82) (115) (131) (148) (164) (197) (213)
-20 4 6 8 10 12 14 15
(-29) (66) (98) (131) (164) (197) (229) (245)
*Solenoid valve with manual override standard on Model 85247,

optional on other models.
** 85610 Operating Temperature, ° F(°C) is -70 to 150 (-57 to 65)
Form 403365 7.5A-18100-J03 Page Number - 3

Grease Output vs. Hydraulic Input Grease Output vs Hydraulic Input

800 50 80º F
30º C
Grease Output (cm³ /min.)
Grease Output (inches³/min.)

45
700
40 20º F
600 0º C
35
500 -10º C 0º F
30
400 25
300 -30º C 20
-20º F
15
200
10
100 5
0 0
1 2 3 4 5 6 7
4 8 12 16 20 24 28
Hydraulic Flow Input (g/m)
Hydraulic Flow Input (l/m)
24VDC Connections Installing the Pump

No Connection to Typical installation is shown only as a guide for selecting
Center Lug and installing system components. Contact your Lincoln
Solenoid Valve Industrial representative for assistance in designing a
Illustration 2 system to suit your specific needs.
F
E The pump was tested in light weight oil which was left in to
protect the pump from corrosion. Flush the pump before
D G connecting it to the system to prevent contamination of the
H grease with residual oil.
C
J
B The pump has flow and pressure controls integrated into
the manifold (37). A normally closed ON/OFF Solenoid Valve
(35) is also integrated into the manifold and will start or
A
stop the pump operation.
K L 1. Mount the pump securely on the drum cover so that it

cannot move or vibrate during operation.
2. Attach hydraulic supply line to the Inlet and return line to
the Tank ports.
3. Connect material supply line to the pump outlet. Plug
the unused outlet on opposite side of the pump.
4. Install high pressure shut-off valve in the material supply
line. (Required)
5. Connect 24 VDC power supply to the solenoid valve (35).
See Illustration #1. Use connector plug (36) supplied
with the pump.
NOTE: To install the pump Model 85481 as a replacement

pump for 84961 used on Model 84944, use adapter/spacer
A - Pump Outlet Plug
kit p/n 272013 with bolts p/n 50014, included in the pump
B - Hydraulic Supply Line
package (see illustration #4).
C - Hydraulic Return to Tank
line (3/4” ID min.)
D - Supply Line Shut-off Valve
E - 24 VDC from Controller
F - Return Line Shut-off Valve
(3/4” ID min.)
G - Vent Valve Port with Restrictor
H- Outlet Shut-off Valve
J - Material Supply Line
K - Follower Plate (85492 for 120 lb. drum only)
L - Drum Cover (83115 for 400 lbs., 84616 for 120 lbs.)

Do not exceed maximum operating temperature of the

hydraulic fluid (250º F/121º C) . Never allow the pump to run
dry of lubricant. A dry pump quickly speeds up, creating fric-
tion heat, which can damage the seals. Monitor the supply
lubricant level and refill when necessary.
Setting the Pump Manifold Pressure and

Flow Controls
Illustration 4 The pressure must first be adjusted to insure the desired flow
* Included in Spacer Kit 272013 setting is achieved.
Pressure Control Valve Adjustment

- Loosen the lock nut on the Pressure control by turning the
nut COUNTERCLOCKWISE.
- Turn the valve stem COUNTERCLOCKWISE until it no
Mount the pump securely on the drum cover. Failure to do
longer turns. The valve stem will unscrew until it reaches
so could result in personal injury and equipment damage.
the stop. It will not come off. This is the minimum pressure
setting, which is about 170 psi (12 bar).
- With the pump stalled against pressure, turn the Pressure
Control Valve stem CLOCKWISE until the desired pressure
is attained on the manifold Pressure Gage. (Do not exceed
Do not exceed 450 PSIG (32 bar) working hydraulic
450 PSI.
pressure. Use high pressure components to reduce risk of
- Tighten the lock nut by turning CLOCKWISE.
serious injury including fluid injection and splashing in the
eyes or on the skin. All accessories connected to the pump
outlet must have at least 5,000 PSIG (350 bar) minimum Flow Control Valve Adjustment
hydraulic pressure. All accessories connected to the pump - Loosen the lock nut on the Flow Control Valve by turning the
inlet must have at least 3,500 PSIG (241 bar) minimum nut COUNTERCLOCKWISE.
working pressure. - Adjust the flow by turning the valve stem CLOCKWISE to
reduce the flow and COUNTERCLOCKWISE to increase it.
The Flow Control Valve can be turned in until the valve is
Operation completely closed, and out a maximum of 2 1/2 turns. The
All pumps are factory set at 350 PSIG (24 bar) working inlet valve stem will not come out when fully open (unscrewed)
hydraulic pressure with a flow rate of 2.5 GPM (9.5 l/min). as there is a stop at this position.
Do not change the settings for the pump until after the - After adjusting the flow to the desired setting, tighten the
start up procedure. lock nut by turning it CLOCKWISE.
1. Shut off the material supply line valve. Maintenance and Repair
2. Turn on the hydraulic pressure.
Relieve pressure from the pump and supply lines before
3. Energize the solenoid On/Off valve.
servicing or repairing the pump, to reduce the risk of an
4. Prime the pump by slowly opening the shut-off lubricant
injury from injection, splashing fluid or moving parts.
supply line valve. Make sure that all air has been
expelled from the pump and even lubricant flow is
achieved.
5. Adjust the pump pressure and flow to the desired
application requirements. See Pressure and Flow
Always use Lincoln Industrial parts for service and repair.
Control Valve Adjustment for instructions to adjust
pressure and flow, Do not exceed pump operating
pressure of 450 PSIG (32 bar). Crank Case Oil
6. Always use the lowest pump output pressure and Check the oil after every 100 hours of operation. The crank-
hydraulic fluid flow to obtain the desired results. This case should be filled to the center of the drain plug located on
will reduce the pump wear. the back of the crankcase. Change the oil after every 500
hours of operation. Use SAE 10W30 motor oil in all units
except 85610. In 85610, use Mobil Arrow HFA Low Temp oil for
use at -70°F ambient temperatures.

Disassembly Procedure (See illustration #6) Pump Assembly Procedure
Tools Required: 1. When the pump is dissembled, it is recommended to

- Hex Bit Socket Wrenches (3/8” square drive) with 3/8” hex, replace all seals and gaskets, which are included in the
5/32” hex, 1/4” hex. 270663 repair kit.
- 3/8” O.D. Steel Rod 2. In the process of disassembly, examine the following
- 12” Crescent Wrench components and replace if excessive wear is indicated:
- Spanner Wrench (for 3/8” diameter tube, 1/8” pin) Ball Bearing (8), Crank Eccentric (7), Crankrod (5), Wrist
- 1/2” to 3/8” square drive adapter Pin Bushings (13), Plunger Tube (11), Pump Plunger and
- Torque wrench (1/2” square drive, 0 - 50 ft-lb capacity) Upper Check Parts (20, 19 and 18), Pump Cylinder (24),
- Torque wrench (3/8” square drive, 0 - 120 in-lb capacity) Check Seat Housing and Lower Check Ball (28 and 26),
- 1/4” nut driver upper Bronze Bushing (51), Housing Tube (55), Shovel
- Screwdriver (flat blade, 1/8” blade width) Plug (56), and Reciprocating Tube (21).
1. Remove the four Socket Head Screws (33) and separate 3. Assembly Procedure is the reverse of the Disassembly
Manifold from the Hydraulic Motor (42). Procedure except for the following:
2. Remove Pipe Plug (45) and drain the crankcase oil from 4. Install parts (22) through (28) into the Reciprocating Tube
the Pump Housing (46). (21) after the plunger assembly (9 through 20) is installed.
3. Remove six self-threading Screws (29) and remove the 5. Install the Pump Subassembly (1 through 28) into the
Housing Cover (30) and the Cover Gasket (31). Pump Housing (46) before tightening the Housing Tube
4. Remove Retaining Ring (57) and pull the Shovel Plug (55) to the Pump Housing (46). Be sure the Reciprocating
(56) from the Housing Tube (55). Tube (21) is inserted through both bushings before
5. Remove two Socket Head Screws (44) and separate the tightening the Housing Tube (55).
Hydraulic Motor (42) from the Pump Housing (46). 6. Use loctite 242 (or similar product) medium strength thread
6. Remove two Outlet Pin Nuts (50) from the Pump Housing lock on all torqued threaded connections. Extreme care
(46). must be exercised to prevent excess compound from
7. Remove the Pump Subassembly (1 through 28) from flowing into critical areas such as clearance fits and ball
the Pump Housing (46). Pushing the subassembly up check. Allow a minimum of 30 minutes cure time before
with a wooden or plastic rod 3/4 O.D. against the Check operating the pump.
Seat Housing (28) is helpful. 7. Torque Specifications:
8. Remove the Housing Tube (55) from the Pump Housing A. Plunger Tube (11) to Outlet Pin (9) - 100 to 110 In.-Lbs.
(46) by inserting a 3/4 rod through the inlet holes at the B. Button Head Screws (12) to Wrist Pin Anchor (14) 110
bottom of the Housing Tube (55) and unscrewing it. to 125 In.-Lbs©.
9. Remove the Bronze Bearing (51), the O-Ring (52), and C. Plunger Tube (11) to Plunger Link Rod (17) - 100 to 110
the Backup Washer (53) from the Housing Tube (55). In.-Lbs.
10. Remove the Crankrod Assembly (1 through 8) from the D. Plunger Link Rod (17) to Pump Plunger (20) - 100 to
pump by unscrewing the Button Head Screws (12) and 110 In.-Lbs.
then pulling out the Wrist Pin Bushings (13). E. Flat Head Screws (1) to Counter Weight (2) - 100 - 110
11. Remove the Check Seat Housing (28) from the In.-Lbs.
Reciprocating Tube (21). There is a 3/8 Allen Head F. Wrist Pin Anchor (14) to Reciprocating Tube (21) - 20 to
socket in the throat of the Check Seat Housing (28) to 25 Ft.-Lbs.
facilitate removal. G. Check Seat Housing (28) to Reciprocating Tube (21) -
12. Unscrew the Wrist Pin Anchor (14) from the 20 to 25 Ft.-Lbs.
Reciprocating Tube (21) and pull the Plunger Assembly H. Outlet Pin Nut (50) to Pump Housing (46) - 30 to 35 Ft.-
(9 through 20) from the tube. Lbs.
13. Using a 1/2” wooden or plastic rod, push the Cup Seal I. Housing Tube (55) to Pump Housing (46) - 20 to 25 Ft.-
(22) and the Pump Cylinder (24) from the Reciprocating Lbs.
Tube (21). J. Socket Head Screw (44) to Pump Housing (46) - 50 to 55
14. Remove the Pump Plunger (20) from the Plunger Link Ft. Lbs (be sure to use 271501 lock washers).
Rod (17). A spanner wrench, which uses the holes in K. Pressure Reducing Valve (38) to Manifold (37) - 20-25 Ft.
the Pump Plunger, is required. Lbs.
15. Unscrew the Plunger Link Rod (17) from the Plunger L. Flow Control Valve (39) to Manifold (37) - 20 -25 Ft. Lbs.
Tube (11) and slide off the Cup Seal (16), the Backup M. Solenoid Valve (34) to Manifold (37) - 15 -20 Ft. Lbs.
Washer (15) and the Wrist Pin Anchor (14). N. Socket Head Screws (33) to Manifold (37) - 20 - 25 Ft.
16. Unscrew the Plunger Tube (11) from the Outlet Pin (9). Lbs.
17. To dismantle the Crankrod Assembly (1 through 8),
remove Flat Head Screws (1) and the Counter Weights
(2).
18. Remove the Retaining Rings (6) and press the Crank
Eccentric (7) out of the Ball Bearing (8). Be sure to
support the Ball Bearing (8) on the inner race. © Indicates change

8. For Models 85480, 85481, 85482, 85483 and 85247, fill

crankcase with SAE 10W30 motor oil up to pipe plug (45)
before fastening housing cover (30) and housing gasket
(31). If pump will be used in very cold environments, use
Mobil Arrow HFA Low Temperature Oil. This oil stays fluid
even at -70°F.
For Model 85610, fill crankcase with lightweight Mobil

Arrow HFA Hydraulic Oil up to pipe plug (45) before
fastening housing cover (30) and housing gasket (31).
9. On 85586, replace inlet strainer (63).

11.46 9.08
(291) (231)
4.61
(117)
8
3.125
(79)
5.025
Fill with SAE 2 (128)
10W30 Motor Oil
for Pumps 85480,
85481, 85482,
85483 and
85247. Fill with 3
light weight Mobil
Arrow HFA 1
Hydraulic Oil for
Pump 85610.
1. 1/4 NPTF Pump Outlets

2. SAE 4 Inlet Port
3. SAE 6 Tank Port
A 4. 1/4 NPTF Orifice fitting for
Vent Valve Port
5. Solenoid Valve
6. Pressure Reducing Valve
7. Flow Control Valve
8. Pressure Gauge
ø 1.25
(32)
5
MODEL DIM "A" in (mm) DIM "B" in (mm)
85480 27.50 (699) 38.56 (980)
85481 19.00 (483) 30.06 (764) 4
85482 34.00 (864) 44.94 (1142)
85483 13.69 (348) 24.75(629)
85247© 27.50 (699) 38.56 (980) 2.25
(57)
85586© 34.18 (868) 45.12 (1146) 7
85610© 34.00 (864) 45.06 (1145)
1/4-20 THD 2.25

(57)

2
1
4
29 5
* Not used on Model 273006 62 6
7
32*© 30 8
6
31 4
34 33
2 9
58
35 1 10
11
36 60
12 & 12L©
37 59
13
38 45
14
61 39 46 15
40 47 16
41 48
42 49 17
43
50
44 51
52
53
18
54
19
20
55
21
56
57
22
63 23
64 24
25
26
27
28
© Indicates change

REPAIR PARTS
Item No. Qty Description All Models Item No. Qty Description All Models
1 2 Flat Head Screw 34 1 Solenoid Valve
(1/4 x 1-3/4) 270635 Cartridge (Note #2) 270690
2 2 Counter Weight 272197 or 1 Solenoid Valve Cartridge 272112
4 2 Retaining Ring 270609 with Manual Override Knob 271918
5 1 Crankrod 270665 35 1 Solenoid Valve
6 2 Retaining Ring 270608 Coil (24 VDC) 270691
7 1 Crank Eccentric 270666 36 1 Solenoid Connector 242209
8 1 Ball Bearing 270607 37 1 Manifold 270771
9 1 Outlet Pin 270670 38 1 Pressure Reducing
10 1 O-Ring (Nitrile) * Valve (Note #3) 270692
11 1 Plunger Tube 270667 39 1 Flow Control Valve
12 2 Button Head Screw (Note #4) 270693
(1/4 x 1/2) 252877© 40 2 O-Ring (Viton) *
12L© 2 Lockwasher 66170 41 1 Motor Gasket *
13 2 Wrist Pin Bushing 270668 42 1 Hydraulic Motor
14 1 Wrist Pin Anchor 270669 (Note #1) 270676
15 1 Backup Washer * 43 2 Washer 271501
16 1 Cup Seal 44 2 Socket Head
(Polyurethane) * Screw (1/2 x 1-1/4) 270658
17 1 Plunger Link Rod See Chart Below 45 1 Pipe Plug (3/8 NPTF) 67417
18 1 Spring 270616 46 1 Pump Housing 270673
19 1 Ball 66010 47 2 Backup Ring (Polyurethane) *
20 1 Pump Plunger 270671 48 2 O-Ring (Polyurethane) *
21 1 Reciprocating Tube See Chart Below 49 2 O-Ring (Nitrile) *
22 1 Cup Seal 50 2 Outlet Pin Nut 270619
(Polyurethane) * 51 1 Bronze Bearing 270674
23 1 O-Ring 52 1 O-Ring (Polyurethane) *
(Polyurethane) * 53 1 Backup Washer *
24 1 Pump Cylinder 270672 54 1 O-Ring (Nitrile) *
25 1 Ball Cage 270675 55 1 Housing Tube See Chart Below
26 1 Ball 66001 56 1 Shovel Plug 270707
27 1 O-Ring (Nitrile) * 57 1 Retaining Ring 270705
28 1 Check Seat 270664 58 1 Seal Kit (Nitrile) 270687
29 6 Self-Threading 59 1 Seal Kit (Nitrile) 270688
Screw (8 x 1/2) 270633 60 1 Seal Kit (Nitrile) 270689
30 1 Housing Cover 270629 61 1 Orifice Fitting 270735
31 1 Cover Gasket 62 6 Gasket 252986
(Nitrile) * 63 1 Inlet Strainer 272180***
32 1 Pressure Gauge 270768 64© 1 Cable Assembly (273006 only) 272992
33 4 Socket Head Soft parts Kit 270663
Screw (5/16 x 1-1/4) 270680
© Indicates change
Repair Parts List
(Non-common items)
Item Qty. Description Model Model Model Model Model Model
No. 85480 85481 85482 85483 85586**** 85610**
17 1 Plunger Link Rod 270648 270614 270645 270641 270645 270645
21 1 Reciprocating Tube 270649 270617 270646 270642 272176 270646
55 1 Housing Tube 270659 270660 270661 270662 270661 270661
25 1 Ball Cage 270675 270675 270675 270675 272179 270675
38 1 Pressure Reducing Valve 270692 270692 270692 270692 272177 270692
39 1 Flow Control Valve 270693 270693 270693 270693 272178 270693
* Included in 270663 Soft Parts Kit. are made more robustly for longer life.
** This Model is similar to 85482, except that the crankcase 1. Includes Gasket (Item 41) and O-Rings (Item 40).
is filled with Mobil Arrow HFA Low Temperature Oil. 2. Includes Seal Kit (Item 58).
*** The inlet strainer fits on all FlowMaster models. 3. Includes Seal Kit (Item 59).
**** This model is similar to 85482, several internal parts 4. Includes Seal Kit (Item 60).

Troubleshooting
Condition Possible Cause Corrective Action
Pump does not run. No pressure on gauge (32):
- Closed Supply line shut off valve. Open shut-off valve.
- No power to solenoid valve (34). Correct electrical fault.
- Faulty Solenoid (35). Replace solenoid (35).
- Pressure Reducing Valve (38) is Reset Pressure Reducing Valve (38).
set too low.
- Insufficient Hydraulic Fluid supply. Check hydraulic supply for proper
pressure and flow.
Pressure is shown on gauge (32):
- Closed Fluid outlet line. Check outlet line and clear
obstructions.
- Flow Control valve is fully closed. Readjust valve to 3/4 turn open.
- Pump is stalled due to grease Check vent valve in system.
backpressure.
Pump is seized or damaged. Dismantle the pump and repair
defective or seized component. See
disassembly and assembly
procedure.
Pump speeds up or runs erratically. Low level of grease or reservoir Refill reservoir.
is empty
Follower plate is stuck and separated Check follower plate and container
from grease. for damage.
Pump piston or checks are worn. Disassemble the pump and repair.
Pump runs, but output is low. Insufficient hydraulic fluid supply. Check hydraulic supply and adjust
flow using valve (39).
Inlet pressure too low. Increase pressure using valve (38).
Faulty inlet (25, 26, 27) or discharge Replace faulty components.
check valve (18, 19, 20).
Weepage from housing cover 30. Cup seal (16) or O-Ring (48) wore out. Check the seals and replace if
necessary.
Pump becomes noisy. No crank case oil. Add crank case oil. Remove Pipe
Plug (45) from Pump Housing (46).
Oil level should be at the bottom of
the Pipe Plug opening. For Models
85480, 85481, 85482, 85483 and
85247Add 10W30 motor oil until
the crankcase is full.
For Model 85610, add light weight
Mobil Arrow HFA Hydraulic Oil until
the crankcase is full.
Worn wrist pin bushing (13). Check the bushings and replace if
necessary.
Pump does not build pressure. Foreign material holding lower Dismantle & clear check. Consider
check open. installing inlet screen 272180
before returning pump to service.

Lincoln Industrial Lincoln GmbH Lincoln Industrial © Copyright 2003

One Lincoln Way 69190 Walldorf 25 International Business Park Printed in USA
St. Louis, MO 63120-1578 Heinrich-Hertz Strasse 2-8 #01-68 German Centre
(+1) 314 679 4200 (+49) 6227 33-0 Singapore 609916 Web site:
(+65) 562-7960 www.lincolnindustrial.com

Owner Manual
Technical Description
2.1A-30001-F03
QUICKLUB®
Pump Model 203
10011327
Subject to change without notice
Page 1 from 32
LINCOLN GmbH & Co. KG • Postfach 1263 • D-69183 Walldorf • Tel +49 (6227) 33-0 • Fax +49 (6227) 33-259
Owner Manual
2.1A-30001-F03
All rights reserved.

Any duplication of this Owner Manual, in its entirety or in part,
by whatever means is prohibited without the prior consent in
writing of Lincoln GmbH & CO. KG.
Subject to modifications without prior notification.
© 2002 by
LINCOLN GmbH & Co. KG
Postfach 12 63
D-69183 Walldorf
Phone: +49 (6227) 33-0

Fax: +49 (6227) 33-259
Page 2 from 32
Owner Manual
2.1A-30001-F03
Fields of Applications of the QUICKLUB Progressive Central Lubrication Pumps
Industry - Machines - Commercial Vehicles -

Pump Type
Building Machinery - Agricultural Machines
Pump QUICKLUB 203
2) 2) 3) 1) 3)
Reservoir 2 l -2XN ,2XNFL , 2YN , 2XNBO , 2YNBO
1) 3)
4 l -4XNBO , 4YNBO
8 l - 8XNBO , 8YNBO3)
1)
1)
Filling from the top or bottom
2)
Filling only from the bottom
3)
Filling only from the top
4 l, 8 l with lockable reservoir lid (option)
Low-level control (option)for all reservoir sizes
available, on request
Control Without control unit for 12/24 VDC or 120, 230 VAC
Integrated control units (V10-V13) 4) for 12/24 VDC
4)
Integrated control units (V10-V13) for 120, 230
VAC
Integrated control unit with metering device monitor-
4)
ing (M 00 - 23)
External control units
- PSG 01 (Commercial vehicles)
- PSG 02 (Industry)
4)
Control H
4)
Control V10 - ADR
Control H - ADR4)
4)
See the respective model designation on the pump nameplate e.g. P203 - 2XN - 1K6 - 24 - 1A1.10 - V10
Page 3 from 32
Owner Manual
2.1A-30001-F03
Table of Contents
Page Page
Fields of applications of QUICKLUB progressive Setting for the lubricant output on an adjustable
central lubrication pumps ................................................ 3 pump element .................................................................... 15
Introduction ...................................................................... 5 Retrofit adjustment of max. lubricant output ................. 16
Safety instructions ........................................................... 6 Adjusting of small lubricant output................................ 17
Installation ....................................................................... 8 Pressure relief valve .......................................................... 17
Specifications for the installation of electric equippment ... 8 Return line connection ...................................................... 18
Pump installations – Areas of risk...................................... 9 Control unit ........................................................................ 18
Pump types ..................................................................... 10 Low-level control (optional) ............................................... 19
Identificatiom Code - Pump Models 203........................ 11 Low-level for grease ..................................................... 19
Description....................................................................... 12 Low-level for oil ............................................................ 20
Electric connections ......................................................... 12 Measures for contact protection .................................. 20
The QUICKLUB 203 central lubrication pump ................... 13 Maintenance, repair and tests........................................ 21
Low-level control (optional) ......................................... 13 Maintenance ..................................................................... 21
Mode of operation ........................................................... 14 Pump filling.................................................................. 21
Pump elements with fixed Lubricant output ...................... 14 Repair ........ ....................................................................... 21
Suction phase ............................................................. 14 Tests ................................................................................. 22
Delivery phase ............................................................ 14 Operational test/To trigger an additional
Check valve ................................................................. 15 lubrication.................................................................... 22
Arrangement of the pump elements............................. 15 To check the pressure relief valve............................... 22
Troubleshooting.............................................................. 23
Technical data ................................................................. 24
Torques ............................................................................ 24
Weights ............................................................................ 24
Connection diagram Pump without control unit................ 25
Dimensions ...................................................................... 26
Lubricants ....................................................................... 32
Further information can be found in the following manuals:
Technical Description for ‘‘Electronic Control Units” of the pump model 203
Technical Description Progressive Metering Devices for Grease and Oil, model SSV
Printed Circuit Board 236-13862-1 - Model V10-V13
Printed Circuit Board 236-13857-1 - Model H
Printed Circuit Board 236-13870-1 - Model M 00 - M 15
Printed Circuit Board 236-13870-1 - Models M 16 - M 23
Control unit 236-13860-2 Model PSG02
Installation Instructions
Parts Catalog Pump 103 and 203
Page 4 from 32
Owner Manual
2.1A-30001-F03
Introduction
Explanation of Symbols Used

The following description standards are used in this manual: Furthermore, you will find the following text symbols in this
Safety Instructions manual:
Structure of safety instructions: Listing
Pictogram - Subpoint
Signal word Procedural instruction
Danger text
- Danger note
User's Responsibility
- How to avoid danger To ensure the safe operation of the unit, the user is responsi-
The following pictograms are used in this manual and are ble for the following:
combined with the corresponding signal words: 1. The pump / system shall be operated only for the in-
tended use (see next chapter "Safety Instructions") and
its design shall neither be modified nor transformed.
2. The pump / system shall be operated only if it is in a
proper functioning condition and if it is operated in accor-
dance with the maintenance requirements.
3. The operating personnel must be familiar with this Owner
1013A94 4273a00 6001a02 Manual and the safety instructions mentioned within and
- ATTENTION - ATTENTION - NOTE observe these carefully.
The correct installation and connection of tubes and hoses, if
- CAUTION - CAUTION - IMPORTANT
not specified by Lincoln GmbH & Co. KG, is the user's re-
- WARNING - WARNING sponsibility. Lincoln GmbH & Co. KG will gladly assist you
The signal words give the seriousness of danger if the follow- with any questions pertaining to the installation.
ing text will be not observed:
Environmental Protection
ATTENTION refers to faults or damages on
machines. Waste (e.g. used oil, detergents, lubricants) must be dis-
CAUTION refers to bad damages and possi- posed of in accordance with relevant environmental regula-
ble injuries. tions.
WARNING refers to possible dangerous inju-
ries. Service
NOTE refers to improvements in handling
of systems. The personnel responsible for the handling of the pump /
IMPORTANT refers to considerable disadvan- system must be suitably qualified. If required, Lincoln GmbH
tages in handling of systems. & Co. KG offers you full service in the form of advice, on-site
installation assistance, training, etc. We will be pleased to
Example: inform you about our possibilities to support you purposefully.
In the event of inquiries pertaining to maintenance, repairs
and spare parts, we require model specific data to enable us
ATTENTION!
to clearly identify the components of your pump / system.
When making use of other than the origi- Therefore, always indicate the part, model and series number
nal spare parts, serious damage may of your pump / system.
affect your device.
Therefore, for the operation of your device
always use original spare parts made by
1013A94
Lincoln GmbH & Co. KG.
Page 5 from 32
Owner Manual
2.1A-30001-F03
Safety Instructions
Appropriate Use Operation, Maintenance and Repair

Use the 203 pump only for dispensing lubricants in cen- Repair should only be performed by authorized and in-
tralized lubrication systems.The pump is designed for instructed personnel who are familiar with the regulations.
termittent operation. Lincoln QUICKLUB central lubrication pumps must only be
operated with a fitted safety valve.
General Safety Instructions Lincoln QUICKLUB central lubrication pumps must be
regularly refilled with clean lubricant.
Lincoln-QUICKLUB - centralized lubrication systems
- are state of the art;
CAUTION!
- can be assembled for safe operation.
High Voltage!
Incorrect use may result in bearing damage caused by In the case of pumps which are filled
poor or over-lubrication. from the reservoir cover, switch off
Unauthorized modifications or changes to an installed the power supply before filling in the
system are not admissible. Any modification must be 4273a00 lubricant..
subject to prior consultation with the manufacturer of the ATTENTION!
lubrication system.
Risk of bursting if the reservoir is
overfilled!
Regulations for Prevention of Accidents When filling the reservoir by means of
pumps with a large delivery volume
Adhere to the regulations for prevention of accidents which
1013A94 do not exceed the max. filling mark.
are effective in the country where the system is to be used.
Lincoln QUICKLUB centralized lubrication systems oper-

ate automatically. However, a regular check (about every
two weeks) should be made to ensure that lubricant is
actually reaching all the lubrication points.
Defective printed circuit boards shall be suitably packed
and returned to the factory.
Dispose of used or contaminated lubricants in accordance
with the legislation concerning the environment.
The manufacturer of the centralized lubrication system will
not accept any liability
- for damages due to the use of greases which are not or
only conditionally pumpable in centralized lubrication
systems
- for damage caused by insufficient lubricant and irregular
pump refilling;
- for damage caused by the use of contaminated lubri-
cants
- for damage caused by an environmentally incompatible
disposal of used or contaminated lubricants.
Page 6 from 32
Owner Manual
2.1A-30001-F03
Safety Instructions, continuation
Installation
Any safety equipment already fitted to the vehicle or the 1. The ADR QUICKLUB central lubrication pump complies
machine: with the design regulations of annex B of the act governing
- should not be modified or made ineffective; the road haulage of hazardous materials valid for Europe
(ADR1)) and that valid for the Federal Republic of Ger-
- should only be removed for the purpose of fitting the 2)
many (GGVS )
system;
2. Moreover, the pump and its electrical equipment comply
- must be replaced afterwards. with the regulations of annex B.2 (ADR / GGVS regula-
Keep QUICKLUB centralized lubrication systems away tions for electrical equipment) according to Rn 220000 in
from sources of heat. Adhere to the operating temperature. conjunction with the transport units mentioned in Rn
10251.
Use only original LINCOLN spare parts (see Parts Catalog)
or parts approved by LINCOLN. 3. The ADR central lubrication pump is in conformity with the
protection class IP 54.
Adhere to:
- the installation instructions of the vehicle or machine CAUTION!
manufacturer as regards all drilling and welding proce-
dures. It is not allowed to use the pump in other
potentially explosive fields.
- the specified minimum distances between the bore holes
and the upper/lower rim of the frame or between two
bore holes.
6001a02
The manufacturer of the centralized lubrication system will 4. Install the ADR QUICKLUB 203 pump, the metering
not accept any liability for: devices, lines and tube fittings as well as the electrical
- damage caused by unauthorized modification of the connection parts in accordance with the Installation In-
system components; structions. Use only original LINCOLN parts.
- damage caused by the use of unapproved spare parts. 5. After completion of the proper installation and commis-
sioning, the installation of the system must be certi-
IMPORTANT fied by means of a stamp and signature of the spe-
cialized workshop or expert. For this purpose, use the
Only for use in commercial vehicles. form attached to the Operating Instructions (pump 203).
6. If the pump and the installation do not comply with the
6001a02
construction regulations of ADR and GGVS, the type ap-
proval is no longer valid.
7. The Operating Instructions along with the certificate duly
filled in must be added to the vehicle papers. It is to be
submitted at the inspection in accordance with § 6, clause
4 GGVS.
Page 7 from 32
Owner Manual
2.1A-30001-F03
Installation
Specifications for the installation of electric equipment for ADR-application in

comercial vehicles
Lines
- must be fixed by means of clamps or strips to prevent
them from rubbing, sagging or getting loose,
- must be protected from shocks, stone impact and heat,
- other than in a fixed installation, must be sufficiently
flexible in spite of their covering.
The electric circuits can optionally be interrupted by single-
or double -pole disconnecting switches.
In case of single-pole disconnecting switches, the negative
conductor must be able to be interrupted.
For avoidance of short-circuits, please note the following:
current return lines must be insulated
4244a99
they must be connected to the vehicle frame (MASS 31)
Fig. 1 Measures of protection for electric lines
below the driver’s cab.
1- Conductor insulation 3- Frame
2- Conductor 4- Coating housings and connectors must be of protection class IP 54
according to DIN 40050
plastic tubes must be of polyamide, tube coverings must be
of polyurethane according to DIN VDE 0250 (only use
original Lincoln ADR tubes).
Mounting of the Pump – Areas of Risk

According to paragraph 9.7.8 of the ADR directive, vehicles
with hazardous goods type FL are divided into zones, ac-
cording to the EX prescriptions, see Fig. 26.
These are the correspondences:
- tank inside zone 0,
- fitting cabinet zone 1
- shut-off devices zone 1
- venting devices zone 1
Zone 2 is located around zones 0 and 1.
The installation of the centralized lubrication system is
allowed outside of zones 0, 1 and 2, only, whereby the
extension is not determined in the ADR directive.
Page 8 from 32
Owner Manual
2.1A-30001-F03
Installation, continuation
Mounting of the Pump – Areas of Risk, continuation

4332a01
Fig. 2 Areas of risk on vehicles with hazardous goods
Page 9 from 32
Owner Manual
2.1A-30001-F03
Pump Types
1173a95
Fig. 3 The different types of pump 203

Pumps 203 Control unit models 203
The 203 pumps differ from each other only in the design and The following control units can be used for the 203 pumps:
reservoir size as well as in the type of the electric connection (refer to the respective Technical Description)
(different plugs with or without electric cable).
Reservoir sizes: a) external control units
2 l transparent plastic reservoir PSG 01
4 l transparent plastic reservoir PSG 02 (Industry)
8 l transparent plastic reservoir b) integrated control units
1)
Electric connection with adjustable pause and operating times, V10-V13
For the industrial applications, the pumps are only with adjustable pause and operating times, V10-V131) for
equipped with plugs. alternate current 120, 230 VAC, separate owner manual
The pumps model 203 used in commercial vehicles are with metering device monitoring (microprocessor control),
1)
equipped with a 10 m electric cable. M 00 - M 23
c) integrated control unit (trailers)
All other data such as: with fixed time of availability (6 hours) and adjustable
motor voltage operating time, H
1)
version of the control unit 1)

Refer to the designation on the pump nameplate.
remote control for triggering an additional lubrication Example: P203 -2XNBO - 1 K6 - 24 - 2A1.10 - V10
cycle (2A1) Also refer to the designation code on page 6.
design and number of pump elements
design and number of safety valves
filling type
use of return line connections
low - level control (option)
can be learnt from the pump type designation code.
Page 10 from 32
Owner Manual
2.1A-30001-F03
Identification Code - Pump Models 203
Examples of model designations
NOTE P203 - 2 - X - N - 1 - K6 - 24 - 1A - 1. - 01 - V10
P203 - 4 - X - L - 1 - K7 - 24 - 2A - 1. - 10 - V12
6001a02 Any pumps combinations other the above
P203 - 2 - X - N - 1 - K6 - 12 - 1A - 8. - 00
standard pumps can be composed and or-
P203 - 2 - X - N - 1 - K6 - 24 - 2A - 1. - 11 - V10- ADR
dered in accordance with the valid model
P203 - 2 - Y - N - BO - 2 - K5 - 24 - 1A - 1. - 01
identification code.
P203 - 4 - X - L - BO - 1 - K6 - 24 - 2A - 4. - 12 - M00
Basic pump model for grease or oil

with 1-3 outlets and 12 VDC or 24 VDC motor
Reservoir design
2 = 2 l transparent plastic reservoir
X = Reservoire for grease

Y = Reservoire for oil
N = Standard design
L = Low - level control
without designation = Standard reservoire (2 Litre)

BO = Filling from top
FL = Flat-type reservoire (2 Litre)
Pump elements
1-3 = Number of the use elements
K 5 = Piston diameter = 5 mm
KR = Pump element, adjustable, piston-Ø = 7 mm
C7 = Piston diameter = 7 mm 3)
Motor
12 V DC oder 24 VDC (DC motor)
AC = 94 - 265 VAC (47 - 63 Hz) with 24 VDC direct current motor5)
(see documentation P203 with power supply unit for 94 - 265 VAC)
Number of electric connecting possibilities (on pump housing only)

- 1A = 1. connection for power supply, on the left
- 2A = 1A (on the left)
and
2. connection (2 A - on the right) for illuminated pushbutton
(external additional lubrication, not possible with variant AC) and/ or
external low-level control
(with or without control p.c.b. V10-V13, possible with variant AC)****
or second connection (2 A – on the right) for piston detector (for M00-M23 control
p.c.b.) also see table on page 10
Type of connection
- 1 = cube-type plug, acc. to DIN 43650, type of construction A 1)
- 4 = AMP - flanged plug (microprocessor M00 - M23)
- 8 = PG - cable gland
- 9 = AMP- plug, wire to wire
Connection outside the pump
- 00 = without socket-outlet, without cable
- 01 = with socket-outlet, without cable l5)
- 10 = with 10 m cable
- 11 = with 10 m ADR cable
- 12 = with 10 m cable, 4 - wire (microprocessor M00 - M07)
- 13 = with 10 m cable, 5 - wire (microprocessor M08 - M23)
Control p. c. b. s. 12V / 24 V
V10 -V13 -with adjustable pause and operating time
V10 -V13 - ADR with adjustable pause and operating time 2)
M 00 ...M 23* - with microprocessor control (various
1)
adjustments - see combinations of the jumper - positions)
H - for trailer or semitrailers
H - ADR for trailers and semitrailers 2)
No designation: Pump without control p. c. b.

1)
Not in conjunction with Hirschmann plugs (type of connection 1)
2)
For transport of hazard materials
3)
C 7 = Designation of pump elements for supplying of paste for chisel (C = chisel), C 5 or C 6 on reques
4)
Low-level control for oil; connection of the low-level control is not provided (only 1A; 2A only for illuminated push-button).
5)
Pump with supply voltage 230 VAC only available with connection type 01, with or without control panel V 10 - V 13
Page 11 from 32
Description: Electric connections for pump 203

for example P203-2XN-1K6-24-... . ..-V10
Printed circuit boards
Connecting plug, on the left Connecting plug, on the right
V10-V13, V20-V23, H
Page 12 from 32
possible connections Power supply Illuminated push button External Lamp
Owner Manual
Trigger additional
Activity/display Operating time Low-level control
lubrication
Pump
without p. c. b. VDC 1A1.01/1A1.10 ----- ----- 2A1.01/2A1.10
without p. c. b. VAC 1A1.01 ----- ----- 2A1.01
with p. c. b. V...
1A1.01/1A1.10 2A1.01/2A1.10 2A1.01/2A1.10 2A1.01/2A1.10
for grease, VDC
with p. c. b. V...
1A1.01 -----1) -----1) 2A1.01
for grease, VAC
with p. c. b. V...
1A1.01/1A1.10 2A1.01/2A1.10 2A1.01/2A1.10 2A1.01/2A1.10
for oil, VDC
with p. c. b. V... separate plug on
1A1.01 -----1) -----1)
for oil, VAC lid of reservoir
with p. c. b. H
1A1.10 -----1) -----1) -----
for grease, VDC
Printed circuit boards Connecting plug,
Connecting plug, on the left
M00-M23 on the right
possible connections Power supply Illuminated push button Piston detector
Trigger additional Fault/low-level control/

Activity/display Operating time
lubrication readiness for service
Pump
with p. c. b. M00-M07 for
2A4/9.12 2A4/9.12 2A4/9.12 2A4/9.12 1 or 2 piston detector(s)
grease or oil, VDC
with p. c. b. M08-M23 for
2A4/9.13 2A4/9.13 2A4/9.13 2A4/9.13 1 or 2 piston detector(s)
grease or oil, VDC
1)
- 1A1.01-cube-type plug, left without cable - 2A4.12-AMP-plug, 4-wires possible on the control p.c.b. only
- 1A1.10-cube-type plug, left with cable - 2A4.13-AMP-plug, 5-wires
- 2A1.01-cube-type, right without cable - 2A9.12-AMP-plug, wire to wire, 4-wires - 1A8.00-PG- cable gland without cable
- 2A1.10-cube-type, right with cable - 2A9.13-AMP-plug, wire to wire, 5-wires - 1A8.XX-PG- -cable gland with cable (option,OEM)
2.1A-30001-F03
Owner Manual
2.1A-30001-F03
Description, continuation
The QUICKLUB 203 central lubrication

pump
is a compact multiline pump consisting of the following

components:
- Housing with integrated motor
- Reservoir with stirring paddle
- Printed circuit board
- Pump element
- Pressure relief valve
- Filling nipple
- Electrical connection parts
can drive up to 3 pump elements

operates according to lubrication cycles (pause and oper-
ating times)
can be equipped with a low-level control
00002618b can supply up to 300 lubrication points depending on the
Fig. 4 Pump components line lengths
1- Reservoir 5- Plug 2A1 is designed for the automatic lubrication of the connected
2- Pump element 6- Filling nipple, pump lubrication points
3- Safety valve 7- Printed circuit board
4- Filling nipple, system 8- Plug 1A1
is designed for the delivery of greases up to NLGI 2 at
Emergency lubrication 9- Return line connection temperatures from - 25° C to 70° C or of mineral oils of at
possible least 40 mm²/s (cST)
can be used at low temperatures down to - 40° C.
During the operating time the pump dispenses lubricant to the
connected lubrication points via one or several metering de-
vices.
Low-level control (optional)
The pump model 203 can be equipped with a low-level

control.
The following versions are available:
- Low-level control in conjunction with printed circuit
boards
1)
V10-V13
- Low-level control in conjunction with printed circuit board
1)
M00-M23
- Low-level control for pumps without printed circuit
board.
When the reservoir is empty, the signal lamp flashes, thus
indicating the low level. Refer to the chapter Low-level
control, page 19.
1)
The designation indicates the version of the printed circuit
board. It is part of the pump type designation code mentioned on
the nameplate of each pump. Example: P203 - 2XN - 1K6 - 24 -

1A1.10 - V10
1006a93
Fig. 5 QUICKLUB central lubrication pump, 2 l reservoir
Page 13 from 32
Owner Manual
2.1A-30001-F03
Mode of Operation
Pump elements with fixed lubricant output

The electric motor drives the eccentric 1 (Fig. 5, 6).
During the operating time:
- piston 2 sucks in lubricant from the reservoir. Refer to Fig.
5.
- piston 2 dispenses the lubricant to the connected lubri-
cation points via the metering device. Refer to Fig. 6.
The following designs are available:
- Piston diameter, K5 ............................................. 5 mm
- Lubricant output................................approx. 2 cm³/min
- Piston diameter K6 (standard) ............................. 6 mm
20002068
- Lubricant output............................approx.. 2.8 cm³/min
Fig. 6 Pump element - Piston diameter, C7, K7....................................... 7 mm
1- Piston 2- Return spring
3- Check valve - Lubricant output ...............................approx. 4 cm³/min
NOTE
Pump elements with piston diameter C 7

must be used for supplying of chisel paste.
6001a02
The design and the mode of operation are
the same as those of the pump elements
with piston diameter K 7.
1003a95
Fig. 7 The pump element sucks in lubricant

1004a95
Fig. 8 The pump element dispenses lubricant

1- Eccentric 2- Piston 3- Spring 4- Check valve
Page 14 from 32
Owner Manual
2.1A-30001-F03
Mode of Operation, continuation
Check valve
The check valve:
- closes the pressure line during suction stroke
- prevents the lubricant from flowing back to the housing or
reservoir
1 - Reservoir with stirring paddle
2 - Pump
3 - Check valve, spring-loaded
4 - Pressure relief valve
R - Return line
p - Pressure line
1164b95
Fig. 9 Hydraulic diagram of the pump
Arrangement of the pump elements
If several pump elements are to be installed, the installation

arrangement shown in Fig. 8 must be adhered to.
If there is only one pump element , it can be installed in any
position. Standard position is no. 3.
If there are two elements, install one in position 3 and the
other in position 1.
1163a95
Fig. 10 Arrangement of the pump elements
Pump element with adjustable lubricant output

The mode of operation (suction and supply phase) is the
same as that of the pump elements with an invariable lu-
bricant output.
The lubricant outputs are adjustable from 0.04 to
0.18m3/stroke, or 0.7 to 3cm3/min.
The pump elements are factory-adjusted to the maximum
lubricant output; the adjusting dimensions “S” should be
29 ± 0.1 mm.
4158a99
Fig. 11 Adjustable pumpelement
Page 15 from 32
Owner Manual
2.1A-30001-F03
4159a98
Fig. 12 Sectional view: adjustable element

1- adjusting sindle SW 16 3- pump element body 6- control piston
(with over flats) 4- gasket 7- delivery piston
2- counternut SW 24 5- pump cylinder S- dimension
Setting of adjustable pump elements

Unsrew the coupling nut for fixing the safety valve.
Loosen counter nut (2, Fig. 10) while holding in position
pump element body (3) by means of a seconf wrench.
Change the position of the adjusting spindel (1) by means
of a wrench.
The dimension “S” (see Fig. 10) for the desired lubricant
output can be ascertained by using the delivery diagram
shown in Fig. 11.
Retrofit adjustment of max. lubricant output
NOTE
In order to ensure that the lubricant output

setting will be as excat as possible, first
6001a02
the actual dimensions “S” of the max.
4179a99 lubricant output must be ascertained as
follows. The measured difference from
Fig. 13 Supply diagram
3
the nominal value 29 must be considered
A- Lubricant output cm /min for all other settings values (e.g. ± 0.1).
B- Lubricant output cm3/stroke
S- Dimension Unsrew the adjusting spindle (1, Fig 10) from the pump
element body (3) until “S” is approx. 30 mm.
Srew counter nut (2) onto stop collar of the adjusting

spindle (1)
Screw adjusting spindle (1) with counter nut (2) into pump
element body (3) until stop.
1)
All indications of positions refer to Fig. 10.
Page 16 from 32
Owner Manual
2.1A-30001-F03
Adjusting of small lubricant outputs

Before the pump element can be adjusted to a small lu- NOTE
bricant output, the dimension “S” for max lubrcant output
must be ascertained, and the difference from the nominal At maximum steeing “S” is 29 ±0.1 mm.
value 29 must be tranferred to any desired settings be-
tween 25.5 ... 28,.5.
6001a02
Dimension “S” must be adjusted to the desired value in
accordance with the delivery diagramm (Fig. 11).
Pressure Relief Valve
IMPORTANT
Each pump element must be secured with

a pressure limiting valve.
6001a02
The pressure relief valve

- limits the pressure build-up in the system
- opens at an overpressure of 250 or 350 bar depending
on the safety valve design.
If lubricant is leaking at the pressure relief valve, this indi-
cates that the system is malfunctioning.
10022618a
Fig. 14 Pressure relief valve NOTE
Between a malfunction (blockage) and

the following fault indication (lubricant
6001a02
leakage; monitoring intermittent LED
display on the control p.c.b. M00-M15)
there may be a longer time delay
The duration of the delay depends on the

type and length of the lines, the type of
lubricant, the ambient temperature and
other influences.
Despite existing fault monitoring devices a regular visual
and function control must be carried out on the lubrication
system.
Pressure relief valve with grease return (optional)

If the system is blocked, grease will leak from the pressure
relief valve. This grease quantity is returned to the reser-
voir.
00002626a
Fig. 15 Pressure relief valve with grease return
Page 17 from 32
Owner Manual
2.1A-30001-F03
Pressure relief valve with grease return

In the case of a blockage in the system, the grease pushes
out the red pin at the pressure relief valve, thus indicating
that there is a fault.
00002629a
Fig. 16 Fault indication in the case of a blockage
Return Line Connection

The lubricant quantities which cannot be dispensed by the
metering device must be returned to the pump via the re-
turn line connection (Fig. 15).
10032618
Fig. 17 Return line connection
Control Unit
NOTE
The present Technical Description de-

scribes the ”Pump model 203 without
6001a02
control unit”. Information concerning the
design and operation of the individual
control units can be found in the respec-
tive Technical Descriptions.
If the pump is to be equipped with a control unit, it is pos-

sible to use an integrated printed circuit board or an ex-

ternal control unit.
00002616
Fig. 18 Printed circuit board integrated in the housing
Page 18 from 32
Owner Manual
2.1A-30001-F03
Low-Level Control (optional)
Low-level control for grease

When the reservoir is filled
The stirring paddle rotates clockwise during the operating
time.
Due to the rotating motion of the stirring paddle in the
lubricant the pivoting guiding plate with the round solenoid,
item 11), is pressed backwards. The solenoid moves toward
the center of rotation of the stirring paddle. The electro-
1)
magnetic switch item 2 cannot be activated.
Control cam item 31) guides the round solenoid with the
pivoting guiding plate automatically outwards, in the direc-
tion of the reservoir wall. After the lubricant has left the
control cam, it flows against the guiding plate, thus dis-
placing the solenoid again onto the center of rotation of the
stirring paddle.
1)
All indications of positions refer to Fig. 17
00002444
When the reservoir is empty
Fig. 19 Switching parts of the low-level control
1- Guiding plate with round 2- Electromagnetic switch (at During the rotating motion of the stirring paddle there is no
solenoid stirring paddle) backpressure from the lubricant. The guiding plate with the
3- Control cam round solenoid no longer moves towards the center of ro-
tation of the stirring paddle. After control cam 3 has been
overtravelled, the solenoid remains in the outer position
NOTE
and overruns electromagnetic switch 2. The solenoid ac-
The above mentioned switching parts tivates the electromagnetic switch contact-free, thus
must not be used with fluid grease. In this triggering a low-level signal.
6001a02
case, use a float magnetic switch, see The flashing frequency in the case of printed circuit boards
below low-level control for oil. 236-13856-1 (F) and 236-13862-1 (V00-V03) and in the
case of pumps without control units depends on the motor
speed.
NOTE
The flashing frequency in the case of printed circuit board
The flashing signal starts only after the 236-13870-1 (only M 00 - M 15) is:
solenoid has activated the electromag- 0.5 second ”ON” - 0.5 second ”OFF”
6001a02
netic switch 6 times contact-free. M16 - M 23
The external relay drops out and the LED is extinguished once
the operating time has expired. The pump stops operating and
no longer restarts automatically.
Magnetic switch
The electromagnetic switch is activated contact-free and
with-out wear by the magnetic field of the magnetic fitted to the
stirring paddle.
NOTE
The life of the magnetic circuit breaker

strongly depends on the conditions under
6001a02
which it is loaded. Since the data relative
to the maximum switching capacity refer
to strictly resistive loads, which cannot be
always guaranteed in practice, it is nec-
essary to take the corresponding contact
protection measures in the case of devi-

ating loads.
4237a03
Fig. 20 Connection diagram

Technical data:
Maximum switching capacity: 60 VA
Maximum switching voltage: 230 V
Current switched: 3 A
Page 19 from 32
Owner Manual
2.1A-30001-F03
Low-Level Control (optional), continuation
Low-level control for Oil

Float magnetic switch
The electromagnetic switch is activated contact-free and
with-out wear by the magnetic field of the solenoid fitted to the
float.
NOTE
The life of the magnetic circuit breaker

strongly depends on the conditions under
6001a02
which it is loaded. Since the data relative
to the maximum switching capacity refer
to strictly resistive loads, which cannot be
always guaranteed in practice, it is nec-
1202a99
essary to take the corresponding contact
protection measures in the case of devi-
Fig. 21 Connection diagram ating loads.
Technical data:
Maximum switching capacity: 60 VA
Maximum switching voltage: 230 V
Current switched: 3 A
1201a95
Fig. 22 Contact protection measures

1- Electromagnetic switch
2- RC element
3- Diode
4- Load
Page 20 from 32
Owner Manual
2.1A-30001-F03
Maintenance, Repair and Tests
Maintenance
The maintenance is essentially limited to refilling the res- NOTE
ervoir with clean lubricant in good time. However, check
regularly whether the lubricant is really dispensed to all the Whenever work is done on the centralized
lubrication points. lubrication system, particular attention
Also check the main lines and lubricant feed lines for 6001a02
should be paid to absolute cleanliness.
damage and replace them, if necessary. Dirt in the system will cause problems.
For cleaning the system use benzine or petroleum. Do not
use tri-, perchloroethylene or similar solvents.
Also do not use polar organic solvents such as alcohol,
methylacohol, acetone or similar
Pump Filling
2 l, 4 l, 8 l - reservoirs
Fill the reservoir up to the ”Max.” mark via the filling nipple, if
any, or via the upper filling opening.
It is possible to use greases up to penetration class NLGI 2 or
mineral oils of at least 40 mm²/s (cST).
IMPORTANT
The grease or oil must be free from im-

purities and must not be liable to change
6001a02
its consistency in the course of time.
CAUTION!
If the pump is filled via the upper filling

opening, switch off the power supply
before starting filling.
1011a93
4273a00
Fig. 23 Fill pump reservoir
CAUTION!
Risk of bursting if the reservoir is

overfilled.
When filling the reservoir by means of

1013A94
pumps with a large delivery volume do
not exceed the max. filling mark.
NOTE
If the reservoir has been completely

emptied, the pump may require until 10
6001a02
minutes before it operates with its full
output.
Repair
Pump
Use only original Lincoln spare parts for repair on the
pumps.
The pump should be returned to the factory for warranty

work or major repairs.
Defective printed circuit boards should be suitably packed
and returned to the factory.
Page 21 from 32
Owner Manual
2.1A-30001-F03
Maintenance, Repair and Tests, continuation
Replace pump element

Remove the pressure relief valve from the pump element
Unscrew the pump element. Take care that the piston, the
pull-back spring and the washer are not left lying in the
grease, otherwise the reservoir must be disassembled in
order to remove these pieces
IMPORTANT
Do not leave the piston, spring and

washer in the housing because they may
6001a02
block the motor.
Install a new pump element and a new sealing ring.
NOTE
Pump element with adjustable lubricant

output is set to the same output as the old
6001a02
pump element.
5026a96
Fig. 24 Replacing the pump elememt
Tests
Operational Test / Triggering an Additional Lubrication
Cycle
To check the pump operation it is possible to perform an
additional test. Refer to the Technical Description of the
respective printed circuit board.
To Check the Safety Valve
1st option
Connect the pressure gauge (0-600 bar; 0-8708 psi) to the
safety valve (Fig. 23).
Trigger an additional lubrication cycle.
2nd option
Connect the manual pump of the pressure and checking
set 604-36879-1 to the safety valve and check the opening
pressure by means of the manual pump.
The safety valve should open at a pressure of 250 or 350
bar depending on its design.
IMPORTANT
Do not connect the pressure gauge di-

rectly to the pump element. High pressure
6001a02
may exceed the above mentioned range,
causing the motor to stall. The motor is
designed in such a way that it can stall for
about 30 minutes without being damaged.
1- Hose line, min.length 1m

2- T-piece
3- Pressure gauge
1005a93
4- Relief cock
Fig. 25 To check the safety valve
Page 22 from 32
Owner Manual
2.1A-30001-F03
Troubleshooting
NOTE
The pump operation can be checked from the outside by observing whether the stirring paddle is rotating (e.g.
by triggering an additional lubrication).
For troubleshooting in the case of pumps with integrated control units, please refer to the respective Technical
6001a02
Description of the printed circuit board.
Fault: The pump motor does not run
Cause : Remedy:
Power supply interrupted Check the power supply and fuses. If necessary rectify the
fault and/or replace the fuses.
Check the line leading from the fuses to the pump plug.
Electric motor defective Check the power supply to the motor. If necessary, replace
the motor.
Fault: The pump does not deliver the lubricant
Cause : Remedy:
NOTE
If a lubricant low-level is available, the low
level is indicated by the flashing light of the
signal lamp in the case of pumps without
6001a02 printed circuit board. The flashing fre-
quency depends on the speed of the motor.
Reservoir empty Fill up the reservoir with clean grease or oil. Allow pump to
run (trigger an additional lube cycle) until the lubricant is-
sues from all the lubrication points.
NOTE
Depending on the ambient temperature
and/or sort of lubricant it may take 10 min-
utes of operation before the pump elements
6001a02 reach their full lubricant output.
Air bubbles in the lubricant Trigger an additional lubrication cycle. Loosen the outlet
fitting or the main line at the safety valve. The lubricant
must issue without air bubbles.
NOTE
When push-in type fittings are used, the
high-pressure plastic hose which is under
pressure cannet be easily disconnected
6001a02 from the safety valve. For this purpose,
loosen the safety valve. For this purpose,
filling nipple on the safety valve in order to
relieve the high-pressure hose.
Unsuitable lubricant has been used Renew the lubricant. See the Lubricant List.
Suction hole of the pump element clogged Remove the pump element. Check the suction hole for
foreign particles. If there are any, remove them.
Pump piston worn Replace the pump element.
Check valve in the pump element defective or clogged. Replace the pump element.
Page 23 from 32
Owner Manual
2.1A-30001-F03
Technical Data
Pump
1)
Torsion torques
Admissible operating temperature ..............-25° C to 70° C
Number of outlets.......................................................1,2 or 3 Install pump .................................................................18 Nm
Reservoir capacity ................................................. 2 l, 4 l, 8 l Electric motor on housing ............................................12 Nm
Refilling .................via hydraulic lubrication fitting or from top Pump element in housing ............................................25 Nm
Lubricant ....................................greases up to NLGI grade 2 Closure plug in housing ...............................................12 Nm
& mineral oils of at least 40mm²/s (cST) at 40° C Return line connector in housing ..........................10 - 12 Nm
Class of protection ................. IP6K 9K acc. to DIN 40050 T9
1)
NOTE Weights
The pump is designed for the above The weights below include the following ‘‘individual
mentioned temperature range. The lu- weights”:
bricants used must still be pumpable at - Pump kit with one pump element, safety valve, grease
6001a02 the temperatures mentioned above. In filling (0.75 kg, 1.5 kg)
case of doubt, consult the lubricant - Packing (cardboard box)
manufacturer. - Attaching parts
Motor: - Operating Instructions
DC gear motor (interference-suppressed)
- Operating voltage. ................................12VDC or 24VDC 2 l reservoir, standard design (0.75 kg)
- Max. current input - Pump 203 without connection cable .......................5.4 kg
12V .......................................................................... 6.5 A - Pump 203, version E 1............................................6.5 kg
24V ............................................................................. 3 A - Pump 203, version E 2............................................7.1 kg
Speed ............................................................ approx.17 rpm
Pump element with fixed lubricant output 4 l reservoir, standard design (1.5 kg)
Piston diameter, K5.......................................................5 mm
- Lubricant output................................... approx. 2 cm³/min - Pump 203 without connection cable .......................8.3 kg
Piston diameter, (standard) K6 .....................................6 mm - Pump 203, version E 1............................................9.3 kg
- Pump 203, version E 2............................................9.9 kg
- Lubricant output................................. approx. 2.8cm³/min
Piston diameter, K7, C7 ................................................7 mm
- Lubricant output................................... approx. 4 cm³/min 8 l reservoir, standard design (1.5 kg)
Max. operating pressure. ...........................................350 bar - Pump 203 without connection cable .......................8.6 kg
Connection thread......................................................... G 1/4 - Pump 203, version 1A1...........................................9.6 kg
- suitable for tube DIA................................................6 mm - Pump 203, version 2A1.........................................10.2 kg
2)
suitable for chisel paste; contact the manufacturer of the lubrication
system In the case of pump versions deviating from those mentioned,
Pump element with adjustable lubricant output add the weights of the following components to the mentioned
KR ............................................... 0.04 to 0.18 cm³/stroke weights:
.......................................................... 0.7 to 3 cm³/min - Per pump element................................................ +0.2 kg
Connection thread.................................................... G 1/4 in. - Per safety valve ................................................... +0.1 kg
- suitable for tube DIA................................................6 mm - 10 m monitoring cable, 5-wire
- suitable for tube DIA................................................8 mm (microprocessor) E 4............................................ +1.1 kg
- 10 m monitoring cable, 4-wire
IMPORTANT (microprocessor) E 4............................................ +0.4 kg
The lubricant output listed refers to - Connection cable with piston detector ....................0.1 kg
grease of NLGI grade 2 measured at - Reservoir version ”Filling from top” (only 2 l) 3) ... +0.15 kg
20°C, backpressure 100 bar, nominal - 2 l flat-type reservoir ............................................ +0.5 kg
6001a02 voltage 12/24 V. Any differing pressures
or temperatures result in different lubri- 3)
cant outputs. Any system design must be NOTE
based on the above values.compte.
The 4l and 8l reservoirs have the standard
Safety valve design ”filling from top”.
SVETVT-350-G 1/4A-D6....................................624-28894-1 6001a02
SVETVT-350-G 1/4A-D8....................................624-28774-1
Page 24 from 32
Owner Manual
2.1A-30001-F03
Technical Data, continuation
Connection Diagram - Pump without Control Unit
1165a95
Fig. 26 Schéma Connection diagram QUICKLUB 203 without control unit, Connection via cube-type-in connectors DIN 43650-A
A- Pump housing F- Low-level control
B- Connector 1 Switching capacity max. 60 W/VA
C- Line socket 1 with connection cable, 3-wire Switching voltage max. 230 VAC
D- Connector 2 1) Switched current max. 3 A
E- Line socket 2 1) M- Electric motor
1)
Only with low-level control available
NOTE
All the other connection diagrams can be found in the respective Technical Description ”Electronic Control
Units for Central Lubrication Pump Model 203”.
6001a02
Page 25 from 32
Owner Manual
2.1A-30001-F03
Dimensions - 2 l Reservoir
1166a95
Fig. 27 Dimensions - 2 l Reservoir
Page 26 from 32
Owner Manual
2.1A-30001-F03
Dimensions - 2 l Reservoir with Filling from Top

1167a95
Fig. 28 Dimensions - 2 l Reservoir with Filling from Top
Page 27 from 32
Owner Manual
2.1A-30001-F03
Dimensions - 2 l Flat-Type Reservoir

1168a95
Fig. 29 Dimensions - 2 l Flat-Type Reservoir
Page 28 from 32
Owner Manual
2.1A-30001-F03
1169a95
Page 29 from 32
Owner Manual
2.1A-30001-F03
1170a95
Page 30 from 32
Owner Manual
2.1A-30001-F03
Attaching Boreholes of the 2 l, 4 l, 8 l Pump
1171b03
Fig. 32 Attaching Boreholes of the 2 l, 4 l, 8 l Pump
NOTE
Thighten pump models with 2 L- Flat, 4 L - and 8 L reservoir with three fastening screws ( see pt. 9,5).
6001a02
Page 31 from 32
Owner Manual
2.1A-30001-F03
Lubricants
The pump QUICKLUB 203 can dispense commercial greases
up to NLGI grade 2 or mineral oils of at least 40 mm²/s (cSt) IMPORTANT
at 40° C.
IMPORTANT The manufacturer of the centralized
lubrication system will not accept any
Absolute cleanliness is essential when liability for damages due to the use of
6001a02 greases which are not or only condition-
handling lubricants. Impurities will remain
suspended in the lubricant and cannot ally pumpable in centralized lubrication
6001a02 settle. This will result in damage to the systems, for damage caused by insuffi-
lubrication system and thus to the bear- cient lubricant and irregular pump refilling.
ings. In case of doubt ask the manufacturer of
the central lubrication system.
Lubricating greases for QUICKLUB systems
Manufacturer Designation Base soap Min. delivery temperature
AGIP F1 Grease 24 Ca
ARAL Graisse multi-usages ZS 1/2 Ca/Li -20° C
AUTOL Top 2000 Ca -10° C
AUTOL Top 8000 W Ca -20° C
BP Graisse lubrifiante Ca
BP C1 Graisse lubrifiante Ca -20° C
CASTROL CLS - Grease Li/Ca -20° C
ESSO Cazar K2 Ca
ESSO Graisse haute pression Ca
FIAT LUBRIFICANTI Comar 2 Li -25° C
FINA CERAN LT Ca -20° C
FINA CERAN WR2 Ca
FUCHS FN 745 Ca -25° C
FUCHS Renocal FN3 Ca -20° C

FUCHS Renolit HLT 2 Li -25° C
KLÜBER Centoplex 2EP Li
MOBIL Mobilgrease 28 Li -30° C
epaissant(s) organiques
MOLYKOTE TTF 52 -30° C
(epaissant)
OPTIMOL Longtime PD 2 Li -20° C
OPTIMOL OLIT CLS Li/Ca -15° C
SHELL Retinax C Ca
WESTFALEN Gresalit ZSA 2 Li -15° C
ZELLER & GMELIN ZG 450 Li
Bio-degradable greases
Manufacturer Designation Base soap Min. delivery temperature
ARAL BAB EP 2 Li/Ca
AUTOL Top Bio 2000 Ca -25° C

AVIA Biogrease 1 Li up to 0 ° C
DEA Dolon E 2 Li -15° C
FUCHS Plantogel S2 Li/Ca
KLÜBER Klüberbio M32-82 Ca -20° C
Page 32 from 32
Preliminary - Manual
Electric Pump 644-46265-1-L with 15L Reservoir
P203-15XYB -1K6-24-2A8.XX-M05(O.FETT)LFR
Änderungen vorbehalten Seite 1
LINCOLN GmbH & Co. KG ∗ Postfach 1263 ∗ D-69183 Walldorf ∗ Tel 06227/330∗ Fax 06227/33259
Preliminary - Manual
Electric Pump 644-46265-1-L with 15L Reservoir
The Pump P203-15XYB -1K6-24-2A8.XX-M05(O.FETT)LFR with 15L Reservoir and Overflow nozzle,
lubricates the swing gear pinion.
2 1
6
3
7
8
The Pump 644-46265-1-L mainly consists of the following parts:

Pos. Benennung Part-No. Pos. Benennung Part-No.
1 15L Reservoir - 7 Connection Piston Plug: DT06-2S 664-36884-3
Detector
2 High and Low Level 8 Connection Power Plug: DT04-4P 664-36884-4
234-13172-6
Supply
3 Befüllanschluss M 26X1,5
4 Overflow nozzle -
6 Pump Housing
See the enclosed Data Sheets
Pump 203: 2.1G-30001-G05
Circuit Board: 2.6G-20003-D01
Proximity Switch: 234-13172-6
Änderungen vorbehalten Seite 2
LINCOLN GmbH & Co. KG ∗ Postfach 1263 ∗ D-69183 Walldorf ∗ Tel 06227/330∗ Fax 06227/33259
Owner Manual
2.6A-20003-C02
Printed Circuit Board 236-13870-1

for Metering Device Control
(microprocessor control)
Models : M 00 - M 15
Applications for Commercial Vehicles or Industrial Applications

with Flashing Fault Indication
10041327
Page 1 from 19
LINCOLN GmbH & Co. KG Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259
Owner Manual
2.6A-20003-C02
Survey
Pump Voltage [V] Control unit Setting ranges Part no. Applications
integrated P : 6 hours, fixed

F *,** A : 2 to 30 minutes 236-13856-1
P 1 : 3.75 to 56.25 mi-

nutes
203 12/24 integrated P 2: 1 hour to 15
V 00-V 03*,** hours 236-13862-1
A 1 : 7.5 seconds to
112.5 seconds
A 2 : 2 to 30 minutes
integrated P : 4 to 60 minutes 236-13870-1

M 00- M 23*** P : 1 to 15 hours
Ü : 5 or 30 minutes
without control
unit or with
external control
unit*
integrated
203 12/24 F *,** ADR 236-13859-1
V 00- V 03*,** 236-13862-1
ADR
203 12/24 236-13857-1

integrated B : 6 hours, fixed
H* A: 2 to 30 minutes
203 12/24 236-13857-1

integrated B : 6 hours, fixed
H * ADR A : 2 to 30 minutes
236-13834-1
203 24 VDC external P : 0.5, 1, 2...to 12 hrs. 664-36875-1
PSG 01 A : 2, 4, 8, 16, 32 min
203 24 VDC, 115 VAC, 236-13860-2

230 VAC external
PSG 02 P : 1 min to 160 hrs.
A : 1 min to 160 min
Ü : 1 min to 160 min
A - Operating time ranges B - Time of availability P - Pause time range Ü - Monito-

ring time
* 1A1 - Version - Pump without connection for the illuminated pushbutton

**2A1 - Version - Pump with connection for the illuminated pushbutton
***2A4 - Version - Pump with microprocessor control
Note: The applications of the progressive systems are various. There is therefore a control unit available for each individual
application.
Page 2 from 19
Owner Manual
2.6A-20003-C02
Table of Contents
Page Page
Survey .............................................................................. 2 Time setting ................................................................... 10

Printed circuit board M 00 - M 15 ................................ 4 Operational Test /
Applications ..................................................................... 4 To trigger an additional lubrication cycle .................... 12
Advantages ...................................................................... 5 Repair12
Power Supply .................................................................. 6 The faults and their causes ....................................... 13
Mode of operation ........................................................... 6 Fault indication .............................................................. 13
Pause time ................................................................ 7 Troubleshooting ............................................................ 14
Operating time .......................................................... 8 Technical data .............................................................. 15
Monitoring time ......................................................... 8 Connection diagram - Industrial applications ........... 16
Functional check ....................................................... 9 Connection diagram - Commercial vehicles ............ 17
Functions of the Pushbutton and Signal Lamp ........... 9 Combinations of the jumper positions ..................... 18
To acknowledge a fault ................................................ 10
To remedy to a fault ...................................................... 10
Further information can be found in the following manuals:

Technical Description Pump Model 203
Technical Description Progressive Metering Devices for
Grease and Oil, model SSV
Technical Description for Electronic Control Units of the 203
pump
Printed Circuit Board 236-13862-1 - Model V 10-V 13
Printed Circuit Board 236-13857-1 - Model H
Printed Circuit Board 236-13870-1 - Models M 16 - M 23
Timer 236-13860-2 Model PSG 02
Installation Instructions
Parts Catalog
Page 3 from 19
Owner Manual
2.6A-20003-C02
Printed Circuit Boards M 00...M 15*

Applications
The printed circuit boards can be used for the following

applications
Printed circuit boards M00...M 07
1. Lubrication cycles only as a function of the machine ope-

rating hours.
When the machine contact (external contact) is switched
on the centralized lubrication system is ready for operati-
on.
Fault indication ......................................... intermittent flashing
Printed circuit boards M00...M 07

1199a95
Fig. 1 - Machine contact 2. Lubrication cycles only as a function of the working hours
of the commercial vehicle.
When the driving switch (terminal 15) is switched on, the

centralized lubrication system is ready for operation
Printed circuit boards M07...M15
3. Lubrication cycles
- as a function of the machine working hours and
1160a95 - in addition, as a function of add-on units, auxiliairy units,
Fig. 2 - Driving switch
etc. which temporarily run during the machine working
hours and must be lubricated only within their running
time.
The power supply (+ and - ) is applied. When the machine
contact (external contact) is switched on, the centralized
lubrication system is ready for operation.
Printed circuit boards M07...M15
4. Lubrication cycles
- as a function of the vehicle working hours and
1196a95
Fig 3 - Supply voltage and machine contact - in addition, as a function of add-on units, auxiliairy units,
etc. which temporarily run during the machine operating
hours and must be lubricated only within their running
time.
The battery voltage (terminals 30 and 31) is applied. When
the driving switch (terminal 15) is switched on, the centrali-
zed lubrication system is ready for operation.

1061a95
Fig. 4 - Battery voltage and driving switch
* M 00 - M 15 is the designation of the respective version of the printed circuit board (see page 18 Combinations of the
jumper positions). It is part of the pump type designation code mentioned on the nameplate of each pump.
Page 4 from 19
Owner Manual
2.6A-20003-C02
Advantages
The central lubrication system is monitored.
- The signal lamp and the operating time as well as the faults are indicated (flashing signal in the case of commercial
vehicles and industrial applications).
Note: Industrial applications with external relay: refer to Technical Description of printed circuit board 236-13870-1, models
M 16 - M 23
The following functions and operations are monitored and indicated as a fault in the case of a malfuncion.
Pump: System:
Function of the drive motor Lubrication point or metering device blocked

Function of the signal lamp Main line leaking (from pump to the monitored metering de-
Supply voltage failure - no lubrication vice)
Pump element does not suppply - no lubrication Air bubbles in the grease
Reservoir empty (if low-level control not available) - no lubri- Lubrication circuit 1 and/or - if any - lubrication circuit 2 mal-
cation functioning
Note: The fault is only indicated when the reservoir is com-

pletely empty and as soon as the pump element stops dis-
pensing the lubricant.
Reservoir empty (in the case of low-level control) - The lubri-

cation cycle occurs until the end of the operating time.
Note:The fault is indicated when the reservoir is empty, but if

the pump element is still surrounded with lubricant.
The indication is made via a signal lamp.

The signal output via the signal lamp is as follows:
Intermittent flashing signal (B)

Jumper plugged on B/D
System Signal lamp
Motor check Is lit for approx. 2 seconds

Check of the signal lamp
Operating time Is lit
Flashes with different

Fault frequencies according to
the fault - See Fault
indication
00002429a
Fig. 5 - Jumper plugged on B/D
Page 5 from 19
Owner Manual
2.6A-20003-C02
Power Supply
Printed circuit boards M 00...M 07
When the jumper is plugged on 30/15 the connections 15

and 30 are connected (bridged) within the printed circuit
board. Refer to Fig. 1.
The connection cable has 4 wire.
00002433
Fig. 6 - Jumper plugged on 15/30
Printed circuit boards M 08.... M 15

Jumper 30/15 has been removed. The printed circuit board
must be connected to the power supply (+ and -) or to the
battery voltage (terminals 30 and 31). Refer to Fig. 3.
The connection 15 is used for the additional activation as a
function of auxiliary units or drives, etc. Refer to Fig. 3.
The connection cable has 5 wire.
00002613
Fig. 7 - Jumper 15/30 has been removed
Signal output Industrial applications Applications for commercial

vehicles
Supply voltage (+ and - ) plus machi-

Intermittent flashing signal ne contact Battery voltage (terminals 30 and 31)
Only machine contact plus driving switch (terminal 15)
Only driving switch (terminal 15)
Mode of Operation
The printed circuit board is integrated in the pump housing
00002616
Fig. 8 - Printed circuit board installed in housing
Page 6 from 19
Owner Manual
2.6A-20003-C02
The printed circuit board automatically controls the se-

quence of the pause and operating times of the 203 cen-
tral lubrication pump as a function of the vehicle or machi-
ne working hours tB (Fig. 10).
The sequence of the pause and operating times is activa-
ted when the machine contact or driving switch is switched
on.
20002441a
Fig. 9 - Printed circuit board 236-13870-1
A lubrication cycle consists of one pause time and one

operating time. Once the pause time has elapsed, the ope-
rating time starts to run. This lubrication cycle is repeated
permanently after the machine or vehicle has been put into
operation. Refer to Fig. 10.
During the operating time the pump element dispenses
the lubricant to the lubrication points via progressive mete-
ring devices.
Pause time
The pause time

1059a95
Fig.10 - Time sequence diagram
- determines the frequency of the lubrication cycles within a
working cycle;
tB - Working hours T - Lubrication cycle - is started and stopped via the machine contact or driving
tP - Various pause times T1 - Stored pause times switch;
T2 - Operating times - is adjustable.
When the machine contact or the driving switch is switched
off, the pause times which have already elapsed as well
as the momentary operating conditions (faults) are stored
and added up by an electronic memory (EEPROM) until the
time which has been set on the blue rotary switch is rea-
ched.
After the machine contact or driving switch is switched on
again, the printed circuit board operates from the point
where it had been interrupted.
If the setting is modified within the pause time, the printed
circuit board takes over the new value only at the end of the
operating time.
The pause time setting may be different for each applicati-
on. It must be adjusted in accordance with the respective
1158b95
lubrication cycles. Also refer to To set the pause time.
Fig. 11 - Sequence of a lubrication cycle
A - Monitoring of the motor and signal lamp

B - Sequence of the operating time
C - Sequence of the monitoring time
I - Operating time
P - Pause time
Page 7 from 19
Owner Manual
2.6A-20003-C02
Operating time
A piston detector (initiator) which has been installed on a

metering device instead of a piston closure plug monitors
and brings the pump operating time to a close after all the
pistons of this metering device have dispensed their lubri-
cant quantity.
The operating time depends on the systems lubricant re-
quirement and on the location of the piston detector (either
on the main metering device or on the secondary metering
device).
Note: If two lubrication cycles are monitored, the operating

time ends after the two piston detectors have transmitted
00002634 their signal to the printed circuit board.
Fig. 12 - Piston detector
During the operating time, the signal lamp is permanently
lit.
M 00 - M 07
If the operating time is interrupted (within the monitoring
time) because the machine contact or the driving switch
has been switched off, it will start again from the begin-
ning after it is switched again.
M 08 - M 16
The operating time always completely elapses even if the
machine contact or the driving switch is switched off.
Monitoring time
A fixed monitoring time of maximum 5 or 30 minutes (de-

pending on the jumper position) runs in parallel to the ope-
rating time.
Note: Normally, the monitoring time ends at the same time

as the operating time.
If there is no switching off signal from the piston detector
to the printed circuit board within 5 or 30 minutes, a fault
signal will occur.
The signal lamp flashes with the corresponding flashing
frequency. See Fault indication.
20002459a
If the operating time exceeds 5 minutes, the monitoring
time can be changed from 5 to 30 minutes by replugging
Fig. 13- Monitoring ranges the jumper.
If there are two monitored lubrication cycles, the jumper
1 - Jumper for monitoring time
must be plugged to (2 O).
5 min 5 minutes
30 min 30 minutes
2 - Jumper for 1 circuit 1 O
or 2 circuits 2 O
Page 8 from 19
Owner Manual
2.6A-20003-C02
Functional check
Each time the machine contact (external contact) or the dri-

ving switch is switched on, a functional check of the drive
motor and signal lamp takes place automatically.
During the functional check the motor is switched on for
0.1 second (the stirring paddle slightly rotates) and the si-
gnal lamp lights up for 2 seconds.
If there is a fault, the signal lamp flashes. See Fault Indi-
cation.
Note: LED display fig.14 indicates the same operating state

10012434a as the signal lamp.
Fig. 14 - LED for the monitoring time or fault indication
Functions of the Pushbutton and Signal Lamp

Pushbutton (Fig. 16)
The following functions can be performed with the push-

button:
- triggering an additional lubrication cycle - Press pushbut-
ton for over 2 seconds (> 2 s)
- fault acknowledgement < 1 s
- in the case of a fault, switching on pump again by pressing
pushbutton (> 2 seconds)
Note: It is also possible to acknowledge any fault or to trigger

an additional lubrication cycle via pushbutton 4 of the prin-
ted circuit board (Fig. 20).
1052b95
Fig. 15 - Indicated operating states
Signal lamp
A - Fault indication
B - Indication of operation or acknowledged fault The signal lamp or the LED fig. 14 indicates the operating
state of the centralized lubrication system.
The faults are indicated by different flashing frequencies of
the signal lamp or the LED fig. 14. See Fault Indication.
Fault Indication
See The Faults and Their Causes

Page 9 from 19
Owner Manual
2.6A-20003-C02
To acknowledge a Fault
When the pushbutton is pressed briefly (< 1 second) the
fault is acknowledged, i.e. the lamp stops flashing and is
permanently lit.
Note: Any acknowledged fault remains stored even after the

driving switch or machine contact has been switched off.
Upon switching on again, the signal lamp flashes again in
accordance with the fault.
20002458
Fig. 16 - To acknowledge a fault
To Remedy to a Fault
* In the case of a malfunctioning, check the central lubricati- Important: If there has been any fault, the pump will not start
on pump and the connected system for faults. automatically after the elimination of that fault. It must be
* Eliminate the cause of the fault. switched on, i.e. an additional lubrication cycle must be trig-
* Switch on the pump again by triggering an additional lubri- gered. See To trigger an additional lubrication cycle.
cation cycle. For this, press the pushbutton >2 seconds.
· When the fault is eliminated, the signal lamp will extin- Note: It is also possible to acknowledge/reset a fault or trig-
guish at the end of the lubrication cycle. ger an additional lubrication cycle by means of the pushbut-
ton on the printed circuit board (Fig. 20). For this, press it < 1
second and > 2 seconds. Condition: The machine contact
or driving switch must be switched on.
Time Setting
* To set the pause time, remove the cover on the pump hou-
sing.
Note: To reset a jumper, remove the printed circuit board.
Important: After having set the pause time, screw the cover
on the pump housing again.
00002617
Fig. 17 - The cover to the printed circuit board has been removed
Page 10 from 19
Owner Manual
2.6A-20003-C02
To set the pause time
The pause time can be adjusted to 15 settings by means of

the blue rotary switch.
Time ranges: Minutes or hours

20002454a
Fig. 18 - Rotary switch - Pause time
Switch position 1 2 3 4 5 6 7 8 9 A B C D E F
Minutes 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60
Hours 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Note: The 0 position corresponds to the shortest time, see pos. 1.
Factory setting
The time ranges (hours or minutes) can be modified by

replugging the jumper on the printed circuit board (Fig. 19).
Pause time
Rotary switch either on ................................................. 6 hours

or ............................................................................... 24 minutes
Monitoring time
20002448a
For the factory setting of the jumper see the chart page 18.
Fig. 19 - Preselection of the time ranges The combination number can be learnt from the type desi-
gnation code mentioned on the nameplate of each pump.
Page 11 from 19
Owner Manual
2.6A-20003-C02
Operational Test /To Trigger an Additional Lubrication Cycle

To check the function of the pump it is possible to perform
an operational test.
Pumps model 203 installed on machines

* If necessary, switch on the power supply
* Switch on the machine contact
Pumps model 203 installed on commercial vehicles

* If necessary, switch on the battery voltage
* Switch on the driving switch
To check whether power is applied to the printed circuit

board, observe whether the left-hand LED 1, Fig. 20, is lit.
* Press the pushbutton (> 2 seconds) for triggering an ad-

10012426a ditional lubrication (illuminated pushbutton, Fig. 16, or pu-
shbutton on the switch cabinet) until the right-hand LED 3
Fig. 20 - LED of the printed circuit board lights up.
1 - LED, left-hand 3 - LED, right-hand, The right-hand LED indicates the following functions:
Power supply Indication of operation - operating time
2 - Rotary switch 4 - Pushbutton for - monitoring time (in normal cases it is as long as the ope-
pause time additional lubrication cycle
rating time, in the case of a fault: 5 or 30 minutes)
- faults
When an additional lubrication cycle has been triggered, a

shorter pause time occurs, followed by a normal lubricati-
on cycle.
Repair
Additional lubrication cycles can be triggered at any time
The defective printed circuit boards should be suitably pak- If the printed circuit board must be replaced, a model M 00
ked and returned to the factory. will always be delivered. See chart page 18.
Before installing another printed circuit board, take care
that the jumper is set to the same position as on the old
printed circuit board.
Page 12 from 19
Owner Manual
2.6A-20003-C02
The Faults and Their Causes

Fault Indication
Drive motor defective
If the motor does not run when the driving switch or machine
contact is switched on or if the feed line to the motor is da-
maged, the signal lamp flashes after 2 seconds as follows:
A 1 second - ON - 1 second - OFF
Malfunctions
such as
- blocked lubrication point (s)
- blocked metering devices (s)
- interruption in the main line leading to the metering device
equipped with a piston detector
- air in system
- reservoir empty (only if the pump is not equipped with an
optional low-level control)
are indicated as described under B, C or D.
The above mentioned faults cause the pistons in the monito-

red metering device to stop. The signal lamp indicates the
respective fault signal with the following flashing frequen-
cies:
Lubrication circuit 1 malfunctioning
B 0.5 second - ON - 1 second - OFF
Lubrication circuit 2 malfunctioning

1053b95
C 1 second - ON - 0.5 second - OFF
Fig. 21 - Flashing frequencies in the case of malfunctions
A - Drive motor defective Lubrication circuits 1 and 2 malfunctioning

B- Lubrication circuit 1 malfunctioning
C- Lubrication circuit 2 malfunctioning D 2 seconds - ON - 2 seconds - OFF
D- Lubrication circuits 1 and 2 malfunctioning
E- In the case of low-level control: reservoir empty Low-level control (optional)
F- Fault acknowledged (maintained lightening)
The signal lamp is flashing with the following frequency:
Reservoir empty
E 0.5 second - ON - 0.5 second - OFF
Note: The low-level signal is converted into a flashing signal

with the a.m. frequency only after 6 motor revolutions.
In the case of a malfunction the piston detector (initiator)
can no longer record the piston movements and therefore,
it cannot switch off the pump.
Due to the monitoring time which runs in parallel to the
operating time, the printed circuit board switches off the
pump at the end of the monitoring time.

A fault signal occurs.
The signal lamp is flashing.
The pump no longer starts automatically. See To Remedy
to a Fault
Page 13 from 19
Owner Manual
2.6A-20003-C02
Troubleshooting
Note: The pump operation can be checked from the outside printed circuit board are lit or the signal lamp of the illumina-
by observing whether the stirring paddle is rotating (e.g. by ted pushbutton/switch cabinet is lit.
triggering an additional lubrication), whether the LED on the
Fault: The pump motor does not run

Cause: Remedy:
Voltage supply interrupted Check the voltage supply to the pump. If necessary, elimi-
nate the cause of the fault.
Voltage supply to the printed-circuit board is interrupted Check the line leading from the pump plug to the printed
circuit board.
If the voltage is applied, the left-hand LED is lit.
Printed circuit board defective Replace the printed circuit board.
Fault: The pump motor runs permanently (5 minutes or 30 minutes )- Duration of the monitoring time
Cause: Remedy:
Piston detector (initiator) defective. Disconnect the main line leading to the monitored mete-
ring device.
Unscrew the piston detector and check it. For this, insert a
metallic pin into the borehole of the detector. Let it there
over 2 seconds and then remove it. If the pump is not swit-
ched off afterwards, check the cable connections to the
pump. If necessary, replace the piston detector along with
the connector.
Cable connection of the piston detector to the pump inter-
rupted Check the cable connections to the pump. If necessary,
replace the piston detector with the connector.
Printed circuit board defective
Replace the printed circuit board
Page 14 from 19
Owner Manual
2.6A-20003-C02
Technical Data
Rated voltage ........................................................... 12/24V DC All the printed circuit boards comply with the EMC (Electro-
Operating voltage. magnetic compatibility) guidelines for road vehicles acc. to
12V/ 24V .......................................................... 9V to 30V DIN 40839 T1, 3 and 4.
Residual rippple in relation
with the operating voltage ................. ± 5% acc. to DIN 41755 The printed circuit boards model M additionally comply with
Motor output ........................... transistor 7A/short-circuit proof the EMC guideline 89 / 336 / EWG
Reverse voltage protection: Emitted interference acc. to ................. EN 55011 / 03.91 and
The operating voltage inputs are protected against ........................................................ EN 50081-1 / 01.92
polarity reversal Noise immunity acc. to .......................... prEN 50082-2 / 1993
Temperature range ................................ -25°C to 70°C
Output fault/readiness for service Time setting
transistor 3A/short-circuit proof
Class of protection Pause time, acc.to jumper position:
Printed circuit board installed in housing ................. IP 6K 9K ................................................. 4, 8, 12,...to 60 minutes
........................................................ 1, 2, 3...to 15 hours
In order to protect the printed circuit board against conden- The operating time is switched off via the piston detector.
sation, it has been covered with a protective varnish.
Factory setting
Pause time ........................................................ 6 hours
or ................................................................... 24 minutes
Monitoring time .............................................. 5 minutes
or ................................................................... 30 minutes
Page 15 from 19
Owner Manual
2.6A-20003-C02
Connection Diagram - Industrial Applications M 08 - M 15
1197b95
Fig. 22 - Connection diagram QUICKLUB 203 with monitoring of the metering devices (Industry)
Connectors AMP, type Superseal
A - Printed circuit board G- Cable, white N- Cable connector 2

B - Pump housing H- Cable, red O- Line socket 2 with
C - Cable connector 1 I- Cable, black 1 or 2 connection cables,
D - Line socket 1 J- Pushbutton for additional lubrication 2-wire
with connection cable, 5-wire K - Machine contact P- Cable, blue
E- Cable, brown L- Signal lamp Q- Cable, brown
F- Cable, yellow R- Piston detector (initiator)
Monitoring circuit 1
3 0 -Battery voltage - Low-level control

3 1 -Earth
1 5 -Driving switch/machine contact Z - Additional lubricationv
M -Motor - Signal lamp
20002460 - Lubrication circuit 1 - Lubrication circuit 2

Fig. 23 - Terminals of the printed circuit board
Page 16 from 19
Owner Manual
2.6A-20003-C02
Connection Diagram - Commercial Vehicles M 00 - M 07
1200b95
Fig. 24- Connection diagram QUICKLUB 203 with monitoring of the metering devices
Connectors AMP, type Superseal
A -
Printed circuit board G- Illuminated pushbutton O - Cable connector 2
B -
Pump housing H- Battery cutoff Q - Line socket 2 with
C -
Cable connector 1 I- Driving switch 1 or 2 connection cables
D -
Line socket 1 J- Fuse, 10 A 2-wire
with connection cable, 4-wire K- Cable, white R - Cable, blue
E - Cable, brown L- Cable, red S - Piston detector (initiator)
F - Cable, yellow Monitoring circuit 1
T - Cable, brown
Page 17 from 19
Owner Manual
2.6A-20003-C02
Combinations of the jumper positions - Survey
Connection of the Signal indication Pause time Monitoring time Number of the
Possibilities of supply voltage in the case of ranges ranges monitored lubri-
preselection faults h min (min) cation circuits
Signal output
only terminal intermit- perma-
Setting terminal 15;30 tend nent 1 - 15 4 - 60 5 30 1 2
15
Jumper position
Kombination Nr.
M 00 X X X X X
M 01 X X X X X
M 02 X X X X X
M 03 X X X X X
M 04 X X X X X
M 05 X X X X X
M 06 X X X X X
M 07 X X X X X
M 08 X X X X X
M 09 X X X X X
M 10 X X X X X
M 11 X X X X X
M 12 X X X X X
M 13 X X X X X
M 14 X X X X X
M 15 X X X X X
M 16 X X X X X
M 17 X X X X X
M 18 X X X X X
M 19 X X X X X
M 20 X X X X X
M 21 X X X X X
M 22 X X X X X
M 23 X X X X X
Page 18 from 19
Owner Manual
2.6A-20003-C02
Page 19 from 19
User Manual 4.2A-68351-E05
Centro-Matic Injector SL-1 Page 1 of 5

Injector No. 81713, No. 81713A & No. 81770-1 thru 81770-6
Operating Instructions & Service Parts List

1Adjusting screw
2Indicator stem
(visual function indicator)
3 Lock nut
4 Piston with packing
5 Spring
6 Slide valve piston
7 Second outlet, closed.
Outlet for control of output,
for pre-filling of feed line,
also permits application of
combined discharge of
injectors through one feed
line.
P1 I n l e t ; grease supply line
from pump.
P2 Outlet; grease feed line
Injector type SL-1, model no. 81770-3 to lubrication point.
1. Foreword I Stage during pause time
Installation work, setting-up, operation and maintenance of II Stage on build-up of pressure and lubricating
Injectors and the Central Lubrication System shall be executed III Stage after completion of lubricant discharge
by qualified, trained personnel. IV Stage after pressure is relieved
This User Manual is primarily intended to familiarize the user
of Centro-Matic central lubricating equipment with the supplied
product ‘Injector’ and its specifications. It shall also aid to
identify parts by part number and parts for service part
inventory.
2. Safety Instructions
Warnings for exposure to hazards that may
result in serious personal injury if ignored,
are marked in the manual by the general
safety symbol
Safety Symbol
according to DIN 4844-W9
CAUTION
Safety instructions that might result in equipment damage and
machine malfunction if ignored, are marked by the word
‘CAUTION’.
Also heed safety instructions of the manufacturer of the
machine! a Discharge chamber b Measuring chamber
3. Specifications of the Product
General description
Manufacturer Sales & Service
LINCOLN Lincoln GmbH & Co. KG Principal operation of Injector SL-1
St. Louis, Mo 63120-1578 Heinrich-Hertz-Str. 2-8 Fig. I Pause time. Injector relieved from pressure and spring
USA D-69190 Walldorf / Germany (5) released. Discharge chamber (a) is filled with lubricant from
Contact customer service if requiring additional the previous cycle. Chambers (a) and (b) connected through
information or service: bores in valve piston (6) and passage.
⇒ See bottom line for telephone- and telefax number Fig. II Pressure build-up and lubricating. The central
Designated Use lubrication pump builds up pressure in the lubricant supply line
• Single-line metering device for grease up to class NLGI #2, and inlet (P1) of the injector. Valve piston (6) forced to move
for use in Centro-Matic single-line lubrication systems. under the pressure of incoming lubricant and opens the
passage leading to the piston, admitting the flow of lubricant to
• Metering device for petroleum based lubricants; if using
the top of the piston into chamber (b) and forcing piston (4)
synthetic lubricants, the subject lubricant must be compatible with
down as well as causing the retract of indicator stem (2).
the construction parts (steel, FKM seals) of the injector.
Whilst the filling of chamber (b), the piston (4) forces a
• Designed for pressure range of 128-240 bar for operating
precharge of lubricant under pressure from the discharge
during lubrication cycle and residual pressure < 41 bar
chamber (a) through the outlet port (P2).
between lubricating intervals in the pause time.
Note: The feed line to the lube point is connected either to
Note: The recommended operating pressure is 173 bar for the
P2 or to the (plugged) outlet above.
lubrication cycle.
The working pressure (fluid pressure) of the pump must be at
Injector SL-1 can be used in a single-line circuit of injectors
least 128 bar for lubricating and shall not exceed 240 bar. The
type SL-11, SL-V, SL-V XL, SL-32 or SL-33 in Centro-Matic
recommended pressure for standard application of Centro-
central lubrication systems for grease.
Matic single-line grease systems is 173 bar.
Attention: When used together with injectors type SL-32 &
SL-33 in a system, the pressure relief must be < 13 bar.
Subject to change
LINCOLN GmbH & Co. KG ∗ Postfach 1263 ∗ D-69183 Walldorf ∗ F a x + ( 4 9 ) 6 2 2 7 3 3 2 5 9 ∗ T e l + ( 4 9 ) 6 2 2 7 3 3 0

Fig. III Completion of the lubricating phase. As piston (4) Dimensions
completes its stroke, it pushes the slide valve piston (6) past
the passage, cutting off further admission of lubricant to the
passage. The discharge from chamber (a) of the preset
amount of lubricant to the outlet is completed; piston and slide
valve remain in this position until lubricant pressure in the
supply line is vented (relieved) at the pump.
Fig. IV Pressure relief. After completion of the lubricating
phase, the supply line (lubricant line between pump and
injector) must be relieved from pressure. The pressure at
injector inlet (P1) must drop below 41 bar. The re-charge with
lubricant will be initiated at a pressure of ~ 41 bar, permitting
the compressed spring (5) to release. The spring moves the
slide valve to closed position. This opens the port from the
measuring chamber and permits the lubricant to be transferred
from the top of the piston (4) to the discharge chamber (a).
After the preset amount of lubricant is shifted from chamber
(b) to chamber (a) and the pressure is vented, the injector Assy. Unit Manifold Dim. A Dim. B
returns to its normal (rest) position (Fig. I). -1 No. 1 2 6 5 8 * 64 mm
Note: Injector SL-1 is a so-called ‘direct’ single-line metering -2 No. 1 1 9 6 2 76 mm
*
device. The injector lubricates under pressure applied by the -3 No. 1 1 9 6 3 32 mm 108 mm
pump to the injector piston (4). The spring of the injector is -4 No. 1 1 9 6 4 64 mm 140 mm
only for re-charging purposes. -5 No. 1 1 9 6 5 95 mm 171 mm
Injector output adjustment:
-6 No. 2 4 6 9 6 5 127 mm 203 mm
⇒ See Section 5 ‘Operation’.
* Manifold with 1 mtg. hole
Technical Data
Injector type Series SL-1 4. Erection & Installation
Part number 81770 - * Injectors with manifold )1 Warning
81713 Single unit injector w. thread )2 Never exceed the maximum working pressure of
the Centro-Matic system.
81713A Replacement injector
Do not carry out any assembly or disassembly
Output range 0,131-1,31 cm3 works when the system is pressurized or
Output adjustment Setting by adjusting screw, pump/machine are in operation.
min. to max. = 8 turns )3 Before using synthetic lubricants, check
Operating minimum normal maximum CAUTION compatibility with the construction materials of
pressure )4 128 bar 173 bar 240 bar injectors and other system components.
Vent pressure < 41 bar
Required tools
Constr. materials Steel, Seals : FKM
Amb. temperature TMIN TMAX Ring & Open end wrenches of inch-size series are required for
(constr. materials) - 26° C + 176° C the installation of injectors.
Connections: Mounting of injectors
Manifold 2 connections of 3/8“ NPTF female The injectors have two outlets; one outlet must be be closed
Injector Outlet: 1/8“ NPTF female by the fitting supplied with. The outlet for connecting the feed
Note: line has a female thread of 1/8“ NPTF.
)1 Character - * of part number stands for substitution If the lube point (bearing) to be connected requires more than
by number of injectors mounted on manifold: 1,31 cm3 of lubricant per lube cycle, the outlets of two or more
- 1, - 2, - 3, - 4, - 5, -6. injectors can be externally linked by a connector tube for
)2 Single unit injector not illustrated. combined discharge of lubricant; one connector tube is
required for each injector connection.
Injector inlet: 3/8“ NPTF male.
The injector manifolds have a female thread of 3/8“ NPTF at
)3 Attention: Check output if Adjusting Screw is adjusted both ends.
to less than ½ turn from minimum. Order connectors separately if required.
)4 ‘normal’ = recommended operating pressure. The manifolds have mounting holes; see figure above.
During pause time, after completion of the lubrication cycle, a • Injectors can be mounted in any position.
pressure relief below 41 bar must follow. Mount injector in a position which permits access for output
Also note: When used together with injectors type SL-32 & SL- adjustment and visual function control of the injector.
33 in a system, the pressure relief must be < 13 bar. • Location of injectors
⇒ See drawing & instructions of the machine manufacturer.
• Allocation of injector/lubricating point
⇒ See drawing & instructions of the machine manufacturer.
Subject to change

Note: When using feed line tubing of 1/4“ O. D. (~ 6,4 mmØ), Setting-up for operation
the feed line must not exceed a length of approx. 5 m (based For setting-up of Centro-Matic Central Lubrication Pump and
on grease NLGI #1 at 18° C). Controller:
Observe on mounting that injector and routing of lines (supply ⇒ See User Manual of supplied components.
line / feed line) do not interfere with the machine operation. ⇒ See specific instructions and safety instructions of the
Keep lines clear from damage. Consider max. ambient manufacturer/supplier of the machine.
temperature in case of heat radiation of the machine.
Initial operation
• Replacement Injector; pls. note for assembly/disassembly:
Safety instruction
The injector is fastened with a torque of 61-67,8 Nm to the
Wear safety glasses when venting lubricant supply
injector manifold; adhere to torque specification on reassembly
lines. Avoid splashing.
of adapter bolt (hex. hd. 7/8“). Have also regard that the
adapter gaskets are perfectly seated. Prior to the initial operation:
When the injector has been replaced: ⇒ Read specific instructions as well as safety instructions of
− Vent injector and relevant line. the manufacturer/supplier of the machine.
− Adjust lubricant output of the injector.
Filling and venting of the lubricant supply line
⇒ See Section 5. ‘Operation’.
Before the injectors may be operated the following steps are
General information concerning the lines for lubricant
necessary:
Piping and fastening material :
− Fill main line with lubricant
⇒ See drawing & parts list of the machine manufacturer.
As for material quality, resistance to pressure, nominal width − Vent branch lines and supply line riser.
and length, the lines used must correspond to the individual − Flush supply line while carrying-out the venting procedure.
operating conditions and must be suitable for the central • Operate pump with low pressure when filling and venting
lubrication system. lines.
• Install lines in accordance with good plumbing practice. • Provide assistant with a can to collect the expelled
− Securely tighten connectors to avoid leakage; when lubricant when venting the lines.
installing, follow procedure recommended by the fitting • Check lubricant supply line for any leakage
manufacturer. Please note: The max. working pressure of Injector SL-1
− Tubing and hoses must be clean inside before installing; is 240 bar.
remove all foreign particles. Steel tubing must be free from
Output adjustment of injector type SL-1
rust.
− Use tube cutter for cutting steel tubing. Make rectangular Legend:
cuts and avoid burrs. 1 Adjusting screw
− Observe manufacturer standards concerning the bending 2 Indicator stem
radius of steel tubing & pipes and flexible tubes. (visual function indicator)
− Lines should be securely anchored; use tube clamps to 3 Lock nut hex. 5/8“
avoid vibration and tearing off of lines. CAUTION
Lubricant feed lines (example)
Legend: Adjustment is only permitted
when supply line / injectors are
P1 Supply line inlet depressurized.
P2 Outlet
a Outlet 1/8“ NPTF
Observe lubricant requirement of each lubricating point and
plugged with fitting.
the lubricant output setting of the individual injectors:
b Outlet 1/8“ NPTF ⇒ See lubrication chart and instructions of the machine
with tube connector manufacturer.
c Lubricant Feed Line Loosen lock nut (3).
* Connector tube, Turn adjusting screw (1) clockwise into injector body to its
combines discharge stop. Use open-end wrench 3/16“ (approx. 5 mm).
of two injectors to Then turn adjusting screw (1) counter-clockwise. After 8 full
one feed line. turns of the adjusting screw the injector is set to the max.
output of 1,31 cm3. If a lower output setting is desired, turn the
adjusting screw proportionally.
Outlet of Injector SL-1 When the injector has been adjusted for the proper lubricant
output, lock adjusting screw (1) with lock nut (3).
5. Operation
Note: Retracting the adjusting screw beyond 8 full turns will
Warning n o t increase the lubricant output beyond the max. output!
Never exceed the maximum working pressure of When the injector is not under pressure, the indicator stem (2)
the Centro-Matic system. should contact the crosshead of adjusting screw (1).
Do not carry out any assembly or disassembly A t t e n t i o n : Check output of lubricant directly at the outlet of
works when the system is pressurized or the injector if the adjusting screw is adjusted to less than
pump/machine are in operation. ½ turn from minimum.
Subject to change

Note: Before operating the machine, for example after Inspection and maintenance
installation works or repairs: Warning
• Main supply line / branch lines and injectors must be filled Never attempt to disassemble the equipment while
with lubricant and vented. pump is in operation or system is pressurized.
• Feed lines must be filled with lubricant and connected with Do not perform adjustment of injectors while the
lube points. system is pressurized.
• The function of all injectors must have been checked. − Check all lubricant lines and injectors regularly for
• All injectors and the system control for the lubricating leakproof and proper condition.
intervals must have been adjusted in compliance with the − Check function of the central lubrication equipment
specifications. (pump/controller/injectors) regularly.
⇒ See specific instructions of the machine manufacturer. • Eliminate defects immediately.
Functional check of injectors Maintenance
The recommended system operating pressure is 173 bar; Warning
adjust pump and control system accordingly. Never attempt to disassemble the equipment while
⇒ See User Manual of the relevant central lubrication pump is in operation or system is pressurized.
pump / control system and injectors. Before performing any works the machine must be
• Initiate manual starting of the lubricating cycle. out of operation.
After the rising of the pressure to ~ 128 bar the indicator stem Heed safety instructions of the machine manufacturer.
of the injector must be retracted; after pressure relief If machine components being also part of the central
< 41 bar the indicator stem must return, back to rest position. lubrication system were removed for service, they shall be
Insufficient venting of the supply line system may impair the properly reassembled before the machine is operated again.
function of injectors. Then check the function of the centralized lubrication system
Note: When used together with injectors type SL-32 & SL-33 in as specified. The same applies to maintenance work performed
a system, the pressure relief must be < 13 bar. on parts of the Centro-Matic central lubrication system.
When all injectors of the system have been checked and Avoid contamination of the indicator stem in order to prevent
function properly: premature wear of the injector seal. If necessary, provide
Fill feed lines with lubricant. protective injector cover cap;
No. 83272 Cover Cap, Vinyl plastic material.
Before connecting the feed lines to the lubricating points:
Trouble shooting
• Fill feed lines with lubricant.
Use only lubricant specified by the machine manufacturer for ⇒ See User Manual of the relevant central lubrication pump.
pre-filling. ⇒ See User Manual of the relevant system control &
− Fill lines with lubricant by means of a grease gun. monitoring equipment and instructions of the manufacturer
The feed line can be filled via the alternate outlet port in the of the machine.
injector body. CAUTION
− Check feed line outlet for evidence of lubricant flow. Operation of the machine with inactive or defective central
− Collect emerging lubricant at the end of the line. lubrication system will cause damages to the machine.
When all lines have been filled: ⇒ See instructions of the machine manufacturer.
• Connect feed lines. Malfunction of individual lubricant metering devices or
Operation damaged lubricant feed lines will cause damage of parts
During operation of the central lubrication system connected to because of lack of lubrication.
− all injectors must have been set to the lubricant output 6. Repair
specified by the machine manufacturer. Repairs must be carried out by qualified, trained personnel only.
− the lubrication system controller must have been set to Warning
pause time as specified by the machine manufacturer.
− the required operating pressure (fluid pressure) for Do not disassemble injectors when pump/central
operating the injectors (lubricant discharge) as well as the lubrication system are pressurized.
subsequent pressure relief of the lubricant supply line for Before performing any works the machine must be out of
re-charge of the injectors have to be observed. operation.
When the machine is put out of operation Before servicing shut off pump/central lubrication system and
− the central lubrication system must be switched off. perform pressure relief procedure. Depressurize pump and
supply line system.
CAUTION Always collect lubricant in a can.
Excess lubrication or insufficient lubrication may result in After repair of injectors:
machine damages. − Check function of injectors.
Do not use contaminated lubricants. Replacement Injector no. 81713A recommended for service
Warning parts inventory. Permits change of injector without remove of
Never exceed the admissible working pressure of the injector manifold.
the central lubrication system. After repair, before restart of normal operation of the
Switch off pump immediately in case of defects or machine/central lubrication system:
abnormal operating performance. − Adjust output of the relevant injectors as described.
Vent lubrication line system and check function of the central
When putting machine and central lubrication system in lubrication system.
operation after a longer shut-off period:
− Check function of the central lubrication system.
Subject to change

Service parts drawing Injector SL-1, Ser. H
At t e n t i o n : Adhere to torque specifications on re-assembly Note: Single Unit Injector no. 81713 ref. to left figure.
Item 3 Piston stop plug torque 34-40,5 Nm Replacement Injector no. 81713A for use on manifold
Item 19 Adapter bolt torque 61-67,8 Nm consists of item 1 thru 19
Item 20 Adapter torque 61-67,8 Nm Item # M a n i f o l d ref. to chart
MANIFOLDS Item # © = change - Note -
No. 12658 1-unit No. 1 1 9 6 4 4-unit The thickness of Lock Nut item 2) has been increased
No. 11962 2-unit No. 1 1 9 6 5 5-unit from 3,8 mm to 7,6 mm. Therefore the maximum output
No. 11963 3-unit No. 2 4 6 9 6 5 6-unit setting by item 1) changed to 8 turns (was 12 turns).
Service parts list Injector SL-1, Ser. H, no. 81713A and no. 81770 - **
Item Description @ Qty. Part no. Item Description @ Qty. Part no.
1 ADJUSTING SCREW 1 11623 15 PACKING, FKM z 1 -
2 LOCK NUT (hex. 5/8“) 1 11624 16 WASHER z 1 -
3 PISTON STOP PLUG 1 11450 17 GASKET 1 31064
4 GASKET z 2 - 18 PACKING, FKM z 1 -
5 WASHER z 1 - 19 ADAPTER BOLT (hex. 7/8“) 1 11961
6 O-RING, FKM z 1 -
7 INJECTOR BODY ASSY. 1 241427
8 PISTON w. indicator stem z 1 - 20 ADAPTER 1 13216
9 FITTING ASSY. 1 90471 used on injector no. 81713
10 PLUNGER SPRING z 1 -
11 SPRING SEAT z 1 - # MANIFOLD see chart
12 PLUNGER z 1 - with 2 inlet connections of 3/8“ NPTF female
13 PACKING, FKM z 1 - column @: z Item included in no. 2 5 0 1 5 8 Repair Kit
14 INLET DISC z 1 - column @: Item included in no. 2 4 6 0 0 0 Soft Parts Kit
Subject to change
User Manual
Injector LM5
4.2A-18002-B05
General Information
Appropriate Use
Use the single-line metering devices of the LM5 series only

for the supply of lubricant in centralized lubrication systems.
General Safety Instructions
Do not install or remove the metering devices when the

system is under pressure or the pump in operation.
• Always protect the centralized lubrication system

connected to the pump with a pressure relief valve.
• Incorrect operation may lead to damage resulting from
poor or excessive lubrication of bearings or lubrication
points.
• Alterations or modifications of an installed system may
be carried out only upon prior approval by the manu-
facturer or his appointed dealer.
• Use only original LINCOLN spare parts or parts
authorized by LINCOLN.
4552a05
Fig. 1 - Metering device LM5 Regulations for Prevention of Accidents
• Adhere to the rules valid in the country where the unit

Installation will be in operation.
CAUTION
Operation, Maintenance and Repair
For all works at the metering device, observe Repairs must be carried out only by authorized and qualified
extreme cleanliness! persons familiar with centralized lubrication systems.
Since the pistons in the metering devices are fit with smallest
tolerances, the metering device must be replaced complete-
– Attach the metering device to an even surface without ly if the pistons are worn.
tension. When synthetic lubricants are used, bear in mind that they
– Protect the metering device from dust and influences of must be compatible with the sealing material of the metering
heat (observe the maximum admissible operating tem- devices (polyurethane or Viton).
peratures). Use only lubricants that are appropriate for centralized lubri-
– The metering device must be easily accessible for cation systems. In case of doubt, ask the supplier.
check and installation work.
• Before connecting the feed lines to the metering

devices, fill them with lubricant. Environmental Protection
Waste (e.g. used oil, detergents, lubricants) must be

disposed of in accordance with relevant environmental
regulations.
Page 1 of 5
User Manual
Injector LM5
4.2A-18002-B05
Technical Data
4553a05
Fig. 2 - Dimensions
1 - Injector LM5 assy Part no. 553-34162-2-L

Injector LM5 assy (1.4571) Part no. 553-34200-2-L
2,3 Closure kit for divider bar Part no. 553-34184-1
Technical Data:
Output volume: 0.5 cm3 to 5 cm³/ stroke (infinitely adjustable)
Operating pressure: minimum: 128 bar, standard: 173 bar, maximum: 240 bar
relief pressure < 80 bar
Operating temperature: - 40°C to + 93°C

Page 2 of 5
User Manual
Injector LM5
4.2A-18002-B05
Functional Description
4554a05
Fig. 3 - Function LM5
I Metering device without pressure 4 Indicator pin

II Metering device pressurized 5 Connecting channel
P1 Inlet (pressure line from the pump) 6 Discharge chamber
P2 Outlet (pressure line to lubrication point) 7 Compression spring
1 Adjusting screw 8 Valve piston
2 Indicator pin
3 Measuring chamber
Fig. I Stage of Lubrication Pause Fig. II Stage of Lubrication

The metering device is relieved and the compression spring The centralized lubrication pump builds up the lubricating
(7) without tension. The discharge chamber (6) is filled with pressure in the main line and in the metering device inlet
lubricant by the prior cycle. The measuring chamber (3) and (P1). The valve piston (8) is forced to move under the pressu-
the discharge chamber (6) are connected via the connecting re and opens the bore to the measuring chamber. Lubricant
channel (5). flows through the connecting channel to the discharge cham-
The lubricant pressure on the metering device inlet (P1) ber; thereby the measuring piston (4) is pressurized and
drops below 80 bar. actuated thus retracting the control pin (2). On the one side
The stroke of the measuring piston is limited by the adjusting the measuring chamber is filled, on the other side the
screw. During the stroke the indicator pin extracts thus ma- measuring piston pushes a metered amount of lubricant un-
king a visual control of the function possible. der pressure to outlet P2.
After completion of the lubrication cycle the main line is
relieved from pressure. The compression spring can release.
First, the valve piston is pushed downward thus connecting
the measuring chamber with the discharge chamber. Then

the measuring piston pushes a premeterd amount of lubri-
cant from the measuring chamber to the discharge chamber.
The metering device is now in the lubrication pause and rea-
dy for the next cycle.
Page 3 of 5
User Manual
Injector LM5
4.2A-18002-B05
Adjusting the Output Volume
An infinitely variable adjustment of the output volume is

possible by regulating the adjusting screw (fig. pos.1). To
reach the full output volume, the adjusting screw must be in
top position. The more it is screwed in, the smaller the
output volume will be. It will go almost to zero when the
adjusting screw is in the bottom position and the indicator
pin cannot move any more.
Adjusting is effected during the lubrication pause times (main
line relieved). After the adjustment, secure the adjusting
screw with a fastening screw.
4555a05
Fig. 4 - Adjustment
Output (cm³/stroke)
4556a05
Fig. 5 -Diagram
Position of adjusting screw (mm)
Page 4 of 5
User Manual
Injector LM5
4.2A-18002-B05
Spare Parts
Repairkit Part-No. 553-34256-2 - Liebherr Id.-No. 10217426

for Injector LM5 Part-No. 553-34162-2-L
consisting of:
Item Designation Qty.
1 Control body assy. with O-Rings 1

2 USIT-RING 20,7 x 28 x 1,5 1
3 Spring 9,6 x 1,6 x 65,5 1
4 Spring 19,4 x 2,9 x 64 1
5 O-Ring 16 x 3 1
6 O-Ring 21 x 2 1
7 Adjusting device assy. with protection cap 1
and screw rings
4557a05
Fig. 6 - sectional drawing

Page 5 of 5
Owner Manual
Operating Instructions
2.2A-10001-D01
QUICKLUB - Progressive Metering Devices

for Grease and Oil
Model SSV and SSV M
Planning and Layout of Progressive Centralized Lubrication Systems
4328a01
Subject to modifications
Owner Manual
2.2A-10001-D01
All rights reserved.

Any duplication of this Owner Manual, in its entirety or in part,
by whatever means is prohibited without the prior consent in
writing of Lincoln GmbH & CO. KG.
Subject to modifications without prior notification.
© 2002 by
LINCOLN GmbH & Co. KG
Postfach 12 63
D-69183 Walldorf
Phone: +49 (6227) 33-0

Fax: +49 (6227) 33-259
Page 2 of 36
Owner Manual
2.2A-10001-D01
Table of Contets
Page Page
Introduction ..................................................................... 4 Operation .........................................................................11

Explanation of Symbols Used ............................................ 4 Applications ...................................................................... 11
User´s Responsibility ......................................................... 4 Lubricant Distribution within the Metering Device ............ 13
Environmental Protection .................................................. 4 Phase 1 + 2 ................................................................ 13
Service .............................................................................. 4 Phase 3 - 5 ................................................................. 14
Safety instructions .......................................................... 5 Monitoring of the Operation ............................................. 15
Appropriate Use ................................................................ 5 System-dependent monitoring ................................... 15
General Safety Instructions ............................................... 5 Visual monitoring ........................................................ 15
Accident Prevention Regulations ....................................... 5 Electrical monitoring (microprocessor control)
Operation, Maintenance, Repair ........................................ 5 SSV only ..................................................................... 16
Installation ......................................................................... 6 Pressure relief valve ................................................... 16
Installation ....................................................................... 6 Determining the Lubricant Output by Combining Outlets 17
Tube Fittings, Screw-Type ................................................. 7 Tube Fittings, Screw-Type ......................................... 17
Main- and secondary Metering devices ....................... 7 Tube Fittings, Push-in-Type (main metering device) .. 18
Tube Fittings, Push-in Type ............................................... 7 Tube Fittings, Push-in-Type
Metering Devices ......................................................... 7 (secondary metering devices) .................................... 19
Connection of the High-pressure Plasitc Hose and Planning and Layout ...................................................... 20
the Pressure Plastic Tube ............................................ 7 Instructions for QUICKLUB Progressive Systems ............ 20
Pressure Plastic Tubes and High-pressure Plastic Hoses . 8 Troubleshooting ............................................................. 29
Description ....................................................................... 9 Technical Data ................................................................ 31
Progressive Metering Devices Model SSV and SSV M ..... 9 Metering Devices ............................................................. 31
Progressive Plunger Metering Devices – General ....... 9 Screw-Type and Push-in-Type Tube Fittings ................... 31
Features of a Progressive Metering Device ................. 9 Lines ................................................................................ 31
Tightening torques ........................................................... 31
Dimensions ...................................................................... 32
Metering Devices Model SSV 6 to SSV 12 (Blocks) ... 32
Metering Devices SSV 14 to SSV 22 (assembled) ..... 32
Metering Devices SSV M 6 to SSV M 12 ................... 33
Lubricants ....................................................................... 33
Recommended grease for QUICKLUB systems
down to -25 °C ........................................................... 34
Biodegradable ............................................................ 34
Page 3 of 36
Owner Manual
2.2A-10001-D01
Introduction
Explanation of Symbols Used

The following description standards are used in this manual: Furthermore, you will find the following text symbols in this
Safety Instructions manual:
Structure of safety instructions: Listing
Pictogram - Subpoint
Signal word Procedural instruction
Danger text
- Danger note
User's Responsibility
- How to avoid danger To ensure the safe operation of the unit, the user is responsi-
The following pictograms are used in this manual and are ble for the following:
combined with the corresponding signal words: 1. The pump / system shall be operated only for the in-
tended use (see next chapter "Safety Instructions") and
its design shall neither be modified nor transformed.
2. The pump / system shall be operated only if it is in a
proper functioning condition and if it is operated in accor-
dance with the maintenance requirements.
3. The operating personnel must be familiar with this Owner
1013A94 4273a00 6001a02 Manual and the safety instructions mentioned within and
- ATTENTION - ATTENTION - NOTE observe these carefully.
The correct installation and connection of tubes and hoses, if
- CAUTION - CAUTION - IMPORTANT
not specified by Lincoln GmbH & Co. KG, is the user's re-
- WARNING - WARNING sponsibility. Lincoln GmbH & Co. KG will gladly assist you
The signal words give the seriousness of danger if the follow- with any questions pertaining to the installation.
ing text will be not observed:
Environmental Protection
ATTENTION refers to faults or damages on
machines. Waste (e.g. used oil, detergents, lubricants) must be dis-
CAUTION refers to bad damages and possi- posed of in accordance with relevant environmental regula-
ble injuries. tions.
WARNING refers to possible dangerous inju-
ries. Service
NOTE refers to improvements in handling
of systems. The personnel responsible for the handling of the pump /
IMPORTANT refers to considerable disadvan- system must be suitably qualified. If required, Lincoln GmbH
tages in handling of systems. & Co. KG offers you full service in the form of advice, on-site
installation assistance, training, etc. We will be pleased to
Example: inform you about our possibilities to support you purposefully.
In the event of inquiries pertaining to maintenance, repairs
and spare parts, we require model specific data to enable us
ATTENTION!
to clearly identify the components of your pump / system.
When making use of other than the origi- Therefore, always indicate the part, model and series number
nal spare parts, serious damage may of your pump / system.
affect your device.
Therefore, for the operation of your device
always use original spare parts made by
1013A94
Lincoln GmbH & Co. KG.
Page 4 of 36
Owner Manual
2.2A-10001-D01
Safety Instructions
Appropriate Use Operation, Repair and Maintenace

Use the SSV and SSV M lubricant metering devices only for Repair should only be performed by:
dispensing lubricants in centralized lubrication systems. - authorized and
Suitable Lubricants - instructed personnel
The progressive metering devices model SSV can be used who are familiar with the centralized lubrication systems.
for dispensing
- mineral oils of at least 40 mm²/s (cST) or Installation
- greases up to the penetration class NLGI 2 Install the metering devices at a suitable location in ac-
cordance with the lubrication diagram.
IMPORTANT
It is recommended that the metering devices be installed in
It must nevertheless be ensured that the such a way that the outlets are not close to the chassis or
oils or greases used do not alter their the attaching plate. This will facilitate troubleshooting in the
consistency significantly in the course of case the system is blocked.
6001a02 time or under the influence of temperature The main metering devices with indicator pin must be
or pressure. installed in such a way that the indicator pin is easily visible.
When the push-in type fittings are used, note the follow-
General Safety Instructions ing:
For the metering device inlet use only push-in type
The progressive centralized lubrication system connected fittings (R 1/8) with reinforced collar and sealing ring.
to the QUICKLUB pump model 203 must always be se-
cured with a safety valve. For the outlet tube fittings of the SSV divider valve
(M 10x1) depending on the design of the lubricant line, for
Lincoln SSV and SSV M lubricant metering devices are
example
state of the art.
- high pressure plastic hose (ø 8,6 x 2,3) use valve bodies
Incorrect use may result in bearing damage caused by
with reinforced collar only, or,
poor or over-lubrication.
- pressure plastic tube (ø 6 x 1,5) use valve bodies with
Each outlet which will be used must be equipped with a
knurled collar only
check valve.
For the outlet fittings of the SSV M divider divider valve
In the case of the metering devices model SSV 6 - 22
(M 8x1) pressure plastic tube (ø 4 x 1) use valve bodies
the outlets 1 and/or 2 must never be closed. In the case of
with knurled collar only.
the assembled metering devices model SSV 14 - 22,
the two outlets with the highest numbers must never be
closed. NOTE
Unauthorized modifications or changes to an installed
system are not admissible. Any modification must be In the case of construction machines or
subject to prior consultation with the manufacturer of the agricultural machines use high pressure
lubrication system. plastic hoses for the lubricant feet lines. In
6001a02 such cases the outlet fittings of the se-
Use only original Lincoln spare parts (see Parts Catalog) or condary metering devices and the connec-
the parts approved by Lincoln. tion fittings to the lubricant points must
have a reinforced collet.
Regulations for Prevention of Accidents
Use only the main and feed lines specified by Lincoln and
Adhere to the regulations for prevention of accidents which are
adhere to the specified system pressures.
effective in the country where the system is to be used.
Page 5 of 36
Owner Manual
2.2A-10001-D01
Installation
Tube Fittings, Screw-Type

Main- and secondary Metering devices
Inlet tube fittings, straight and 90°
As inlet fitting use only tube fittings R1/8” thread.
Check valves
Install one complete check valve in each outlet borehole
which will be used.
Install one closure plug in each outlet borehole which will be
not used. Exception: outlet bore hole 1 and/or 2 on SSV 6 to
SSV 22. In both boreholes check valves have to be installed.
Check valves for tube dia. 4 mm and 6 mm are available.
1- coupling nut 3- valve body with seal and
2- ferrule clamp ring
4239a99
Fig. 1 Single parts of the check valve
Tube Fittings, Push-in Type

Metering Devices
Inlet tube fittings, straight and 90 °
IMPORTANT
For the inlet fittings use only tube fittings
with reinforced collet 1a (Fig. 2) and
sealing ring 1b at the thread.
6001a02
1a - Collet
1b - Sealing ring
1008a98 Check valves

Fig. 2 Inlet fittings Main metering device
Use check valves type A, Fig.3 with reinforced collet 1a
and smooth flange (Part no. 226-14091-4).
Secondary metering device
Use check valves type B, Fig. 3 with standard collet 2a
and knurled flange (Part no. 226-14091-2).
NOTE
On construction machines or agricultural
machines use high pressure plastic hoses.
In such cases the check valves of the
6001a02 secondary metering devices must have a
reinforced collet and smooth flange.
A- Check valve with reinforced collet

B- Check valve with knurled collet
1a - reinforced collet
1009a98
2a - knurled collet
Fig. 3 The different types of check valve
Page 6 of 36
Owner Manual
2.2A-10001-D01
Tube Fittings, Push-in Type, continuation

Connection of the High-pressure Plastic Hose and the Pressure Plastic Tube
High-pressure range (main metering device)
IMPORTANT
Connect only main lines (ø 8,4 x 2,3 mm)
with threaded sleeve and hose studs may
be connected to the inlet fitting and to the
6001a02 check valves with reinforced collar.
4156a98
Fig. 4 Check valve with reinforced collet and hose stud

Low-pressure range (secondary metering device)
Connect the pressure plastic tube (ø 6x1.5 mm) to the check
valve with standard collet (knurled collet) and to the inlet
fittings towards the lubrication point (knurled collet).
NOTE
Exceptionally the high-pressure plastic
hose (ø 8.6 x 2.3 mm) with threaded
sleeve and hose stud may also be used for
6001a02 the low-pressure section. Applications for
construction machines or agricultural ma-
chines, however, require the use of check
valves and inlet fittings (towards the lubri-
4157a98
cation point) with reinforced collet for the
low-pressure range. Refer to Parts Cata-
Fig. 5 Check valve with knurled collet and pressure plastic tube log.
The pressure plastic tubes are marked with white lines
(Fig. 5) as an installation aid.
Cut the pressure plastic tube off at one of the white lines
before it is mounted. Then insert the plastic pressure tube
into the fitting up to the next white mark. This will ensure a
correct installation of the pressure plastic tube in the
threaded tube fitting.
Protection Cap for Push-in Type Fittings

To prevent dirt from entering the systen, the push-in type
fittings, check valves and pressure relief valves can be
equipped with protective caps.
00002632
Fig. 6 Push-in type fitting with protection cap

Page 7 of 36
Owner Manual
2.2A-10001-D01
Pressure Plastic Tubes and High-pressure Plastic Hoses

Pressure Plastic Tube Ø 6 x 1.5 mm
Use the pressure plastic tubes only in the low pressure area, i.e. between the secondary metering devices and the lubrica-
tion point.
Adhere to the pressures and bending radiuses mentioned in the chapter ”Technical Data” when installing the parts.
High - pressure plastic hose Ø 8.6 x 2.3 mm

Use the high pressure plastic hose in the high-pressure
area, i.e. between the pump, main metering device and
secondary metering devices.
Adhere to the pressures and bending radiuses mentioned
in the chapter ”Technical Data” when installing the parts.
Installing the threaded sleeves and hose studs on the
high pressure plastic hose
Screw the threaded sleeve, item 1 Fig. 30, counterclock-
wise onto the high pressure plastic hose 2 until the illus-
trated dimension of 11 mm is reached. Then screw the
hose stud 3 into the threaded sleeve 1.
IMPORTANT
1028a96
Before screwing the parts 1 and 3, rub
them with oil.
Fig. 7 Preassembly of the threaded sleeves and hose studs on
the main line NOTE
6001a02
The outside diameter of the main line may
show variations in dimension. In such a
case, press the threaded sleeve 1 at the
end where it will be screwed onto the main
1- Threaded sleeve
line so that it becomes oval in shape (1 to
2- High - pressure plastic hose Ø 8.6 x 2.3 mm 2 mm). This will prevent the high pressure
3- Hose stud plastic hose from being pushed out of the
sleeve when the hose stud is screwed.
NOTE
When using the special adjusting gauge
432-23077-1 (see Parts Catalog) screw the
threaded sleeve counterclockwise onto the
6001a02 main line until the gauge inserted in the
sleeve begins to rise.
1029a96
Fig. 8 Preassembly of the threaded sleeve by means of an ad-

justing gauge
Page 8 of 36
Owner Manual
2.2A-10001-D01
Description
Progressive Metering Devices Model SSV and SSV M

Progressive Plunger Metering Devices - General
The progressive metering devices
- are piston-operated metering devices;
- automatically (progressively) dispense the lubricant fed
by the pump to the connected lubrication points;
- model SSV have a lubricant output of 0.2 cm³ per
outlet and piston stroke;
- model SSV M have a lubricant output of 0.07 cm³ per
outlet and piston stroke;
- when one or more outlets are closed (see ”Combining
outlets”) they can dispense a double or multiple lubri-
cant quantity;
- are available with 6 to 12 outlets or up to 22 outlets;
- offer the option of combining several lubrication points
into one centralized lubrication point.
- meter the supplied lubricant into predetermined single
quantities.
- can be monitored visually (SSV and SSV M)or elec-
tronically (only SSV).
Any blockage in a lubrication circuit is indicated by grease
leaking from the respective pressure relief valve.
10002709
Fig. 9 Metering device type SSV 8 shown as a demonstration

model
Features of a Progressive Metering Device

The term ”progressive” refers to the special features of
the lubricant distribution within the metering devices,
e.g.
- the successive movements of the individual pistons
within the metering device due to the supplied lubricant
being under pressure;
- the pistons move in a predetermined order and the cy-
cles are repeated constantly;
- each piston must have completed its movement fully
before the next piston can be moved, no matter whether
the lubricant is dispensed continuously or intermittently;
- the pistons operate interdependently of one another;
- no lubrication point which is connected to the system is
10002710 omitted.
Fig. 10 Sectional view of a SSV 8 metering device
Page 9 of 36
Owner Manual
2.2A-10001-D01
Description, continuation
Progressive Metering Devices Model SSV and SSV M, continuation

Different of Features from SSV M - SSV
Progressive divider valves SSV M and SSV operate in
the same way. Apart from their outer dimensions (see be-
low dimensions) they also differ in the following data (also
see fig. 11).
SSV
Lubricant output per outlet and per stroke .................... 0.2cm³
Max. operating pressure .............................................. 350 bar
Min. operating pressure ................................................. 20 bar
Max. differential pressure between two outlets............ 100 bar
Outlet connection for tube..................................Ø 4 and 6 mm
SSV M
Lubricant output per outlet and per stroke .................. 0.07cm³
Max. operating pressure .............................................. 200 bar
Min. operating pressure ................................................. 20 bar
Max. differential pressure between two outlets.............. 40 bar
4330a01
Outlet connection for tube............................................Ø 4 mm
Fig. 11 Differences between SSV M and SSV
Assembled Lubricant Metering Devices SSV 14 up to SSV

22, if equipped
The assembled lubricant metering devices model SSV 14
to SSV 22
- function in the same way as the metering devices model
SSV 6 to SSV 12
- are assembled from the basic metering devices SSV 6
to SSV 12.
The following differences must, however, be noted:
- the outlet numbers of the metering devices SSV 14 to
SSV 22 are marked in the opposite direction to those of
the SSV 6 to SSV 12 metering devices. Outlets 1 and 2
are close to the inlet borehole.
- the two outlets -right-hand and/or left-hand - with the
highest numbers must never be closed, otherwise the
system would be blocked.
- if, for example, outlet 8 is closed, the lubricant quantity
dispensed to this outlet flows out of the metering device
via outlet 10, etc. Refer to item ”Double or multiple lu-
bricant output” above.
Die Blockverteiler SSV 14 bis SSV 22 funktionieren in der
gleichen Weise wie die Typen SSV 6 bis SSV 12.
NOTE
00002633
Die Auslässe 1 und/oder 2 niemals ver-
Fig. 12 Lubricant metering device, assembled model SSV 16 schließen.
6001a02
Page 10 of 36
Owner Manual
2.2A-10001-D01
Operation
Applications
QUICKLUB progressive metering devices offer the option
of combining several lubrication points on a machine to
one or more central lubrication points, as shown in Fig. 13
which illustrates this basic feature.
1205a95
Fig. 13 Central lubrication point
When they are used in connection with hand-operated

pumps, pneumatic or electric pumps the progressive me-
tering devices are a simple and low-cost centralized lubri-
cation system. See Fig. 14.
1- Hand-operated pump
2- Pneumatically operated pump
3- Electrically operated pump
4024b95 4- Lubrication fitting block
Fig. 14 Possible pump connections 5- Hand-operated filling pump
4025a95
Fig. 15 Multiline pump expanded by a progressive metering device
Page 11 of 36
Owner Manual
2.2A-10001-D01
Operation, continuation
Applications, continuation
Progressive metering devices can be used in two-line or
single-line centralized lubrication systems in order to in-
crease the number of outlets of multiline pumps or to sub-
divide the single metering devices and measuring valves
(Fig. 13 to 17) also as secondary metering devices in
large and small oil circulating systems.
1207a95
Fig. 16 Two-line system expanded by a progressive metering

device
1206a95
Fig. 17 Single-line system expanded by a progressive metering

device
Page 12 of 36
Owner Manual
2.2A-10001-D01
Lubricant Distribution Within the metering Device

The 5 following illustrations show how the lubricant distribu- NOTE
tion is made to the individual outlets.
To simplify the description we only show
When the lubricant supply is interrupted the lubricant distribution for outlets 2, 7, 5,
- the pistons come to a halt; 3 and 1. The remaining distribution opera-
- the lubricant is no longer dispensed to the lubrication 6001a02 tions are derived from the logical pumping
point. sequence.
When the lubricant is fed again to the metering device, the
cycle begins from the point where it had been interrupted.
Phase 1
The lubricant enters the metering device from above
(white arrow) and flows to the right-hand end of piston A.
Piston A (black arrow) is moved to the left under the pres-
sure of the lubricant, causing the lubricant ahead of the
left-hand end of piston A to be dispensed to outlet 2
(dashed arrow).
Lubricant under pump pressure
Lubricant under delivery pressure of the piston
Lubricant, pressureless
2007a99
Fig. 18 Phase 1
Phase 2
Once piston A has reached its left-hand final position, the
junction channel to the right-hand end of piston B is
opened.
The lubricant which arrives from above (white arrow) also
moves piston B (black arrow) to the left, causing the lubri-
cant quantity ahead of the left-hand end of piston B to be
dispensed to outlet 7 (dashed arrow).
2008a95
Fig. 19 Phase 2
Page 13 of 36
Owner Manual
2.2A-10001-D01
Lubricant Distribution Within the Metering Device, continuation

Phase 3
Once piston B has reached its left-hand final position, the
junction channel to the right-hand end of piston A is
opened.
The lubricant which flows from above (white arrow) moves
piston C (black arrow) to the left, causing the lubricant
quantity ahead of the left-hand end of piston C to be dis-
pensed to outlet 5 (dashed arrow).
2009a95 Lubricant, pressureless
Fig. 20 Phase 3
Phase 4
The channel to the right-hand end of piston D is now open
(black arrow).
The lubricant which is fed from above (white arrow)
moves piston D to the left, causing the lubricant quantity
ahead of the left-hand end of piston D to be dispensed out
of the metering device via outlet 3 (dashed arrow).
2010a95
Fig. 21 Phase 4
Phase 5
In phase 4, piston D had opened the junction channel to
the left-hand end of piston A.
The lubricant flowing in (white arrow) moves piston A to
the right (black arrow), causing the lubricant quantity to be
dispensed to outlet 1(dashed arrow).
In the subsequent distribution sequence, pistons B - D are
moved from the left to the right one after the other.
A complete distribution sequence is finished and a new
cycle can begin.

2011a95 Lubricant, pressureless

Fig. 22 Phase 5
Page 14 of 36
Owner Manual
2.2A-10001-D01
Monitoring of the Operation

System-dependent monitoring
The main metering device (B, Fig. 23) and the secondary
metering devices are connected by a main line G. This
feature automatically causes the linkage of the progres-
sive system connected downstream of the pump.
If only one piston does not move in any metering device
or if the metering device can no longer dispense any lu-
bricant via its outlets, this metering device will block itself.
If one of the secondary metering devices is blocked, the
main metering device is also blocked. The whole progres-
sive system installed downstream of the pump stops op-
erating.
The fundamental internal structure of the progressive
metering device guarantees the self-monitoring of the se-
quence within the metering device.
The linkage makes it possible to monitor the operation of
the whole system.
A - Safety valve B - Main metering device SSV 6

1064b95
C - Secondary metering device D - Secondary metering device
Fig. 23 Example of a lubrication system SSV 8 SSV 6
E - Pressure plastic tube F - Secondary metering device
SSV 12
G - High pressure plastic hose
Visual monitoring
The metering devices can be equipped with an indicator
pin which is connected to the piston and moves back and
forth during lubricant distribution.
If there is a blockage in the system, the indicator pin stops
moving.
NOTE
It is also possible to electrically check the
movements of the indicator pin or any
blockage in the system by means of a
6001a02 control switch (KS) or a proximity switch
(KN).
1011b96
Fig. 24 Indicator pin installed on metering device

Components of the control pin tube fitting
Closure plug M 11x1x5 MS, assy (pos. 1) .......... 519-32123-1
Page 15 of 36
Owner Manual
2.2A-10001-D01
Monitoring of the Operation, continuation

Electrical monitoring (microprocessor control) SSV only
A piston detector (initiator) which has been installed on a
metering device instead of a piston closure plug (M 11 x
1) monitors the pump operating time and brings it to a
close after all the pistons of this metering device have
dispensed their lubricant quantity.
If there is a blockage in the system or if the pump reser-
voir is empty, the piston detector can no longer record the
piston movements. The switching off signal is not trans-
mitted to the control unit. A fault signal occurs.
NOTE
For the system monitoring it is recom-
00002634
mended that one SSV metering device
Fig. 25 Piston detector installed on the metering device with pre-assembled piston detector be
6001a02 used per lubrication circuit. These special
metering devices must be ordered sepa-
rately for each lubrication system. Refer to
the Parts Catalog.
The pre-assembled metering devices have the designa-

tion SSV ... - N (they are available for SSV 6, 8, 10, 12
and up to 22). They must be installed in the system in-
stead of a normal metering device.
Pressure relief valve

The whole system can be monitored visually via the pres-
sure relief valve. If lubricant is leaking at the pressure re-
lief valve during the distribution sequence, this indicates
that there is a blockage in the system.
IMPORTANT
In the case of the progressive metering
devices models SSV 6 - 22 the outlets 1
and/or 2 must never be closed. In the
6001a02 case of the assembled progressive meter-
ing devices model SSV 14 - 22, the two
outlets with the highest numbers must
4092a97 never be closed, otherwise the system
would block owing to the structure of the
Fig. 26 Pressure relief valve
metering device.
Page 16 of 36
Owner Manual
2.2A-10001-D01
Determining the Lubricant Output by Combining Outlets

Tube Fittings, Screw-Type
1012c96
Fig. 27 Install the outlet fittings and closure plugs in accordance with the dosage
1- Inlet fitting 4- Closure plug (new M 11 x 1), piston 8- Coupling nut
(with champfered)
2- Delivery hole of the piston 5- Outlet fitting assembly 9- Junction channel
3- Closure plug (M 10 x 1), installed 6- Valve body with clamping ring (brass) 10 - New closure plug (M 10 x 1), outlet
with copper washer (old) borehole with hex. socket head and
7- Cutting ring sealing edge, replacement for pos. 3
The output quantities can be raised by closing outlet Clamping ring (Fig. 27) closes the junction channels 9 to
boreholes. the other outlet channels.
Install an outlet fitting assembly 5 (M 10x1) in each outlet NOTE
borehole which will be used. Refer to Fig. 27, 29, 29.
In the case of push-in type fittings the
Never remove closure plug 4 (M 11x1 chamfered) on clamping ring is always a firm component
the piston side or remove it only for installing a piston de- part of the valve body.
tector. 6001a02
NOTE IMPORTANT
Never use closure plug 3 (Fig. 27) or 7 In the case of the progressive metering
(Fig.28, 29) as a piston closure plug 4 (G devices model SSV 6 - 22 the outlets 1
1/8) on older models of meteringdevices. and/or 2 must never be closed. In the
6001a02
case of the assembled progressive meter-
IMPORTANT ing devices model SSV 14 - 22, the two
Always use valve body (Fig. 27) in con- outlets with the highest numbers must
junction with clamping ring. never be closed, otherwise the system
would block due to the structure of the
metering device.
Page 17 of 36
Owner Manual
2.2A-10001-D01
Determining the Lubricant Output by Combining Outlets , continuation

Tube Fittings, Push-in-Type (main metering device)
1203c95
Fig. 28 Install the push-in type outlet fittings and the closure plugs in accordance with the dosage
1- Inlet fitting with protective cap 3- Closure plug (M 10x1) with copper 6- Junction channels
washer installed in outlet borehole (old)
2- Delivery borehole of the piston 4- Closure plug (new M 11x1 chamfered), 7- New closure plug with hex. socket head
piston and sealing edge, outlet borehole
5- Valve body assembly replacement for pos. 3
(with reinforced collar)
NOTE
Bei Baumaschinen oder Landmaschinen
sind als Schmierstellenleitungen Hoch-
druckkunststoffschläuche zu verwenden. In
6001a02 diesen Fällen sind die Unterverteiler wie in
Abb. 27 gezeigt, auszurüsten.
Page 18 of 36
Owner Manual
2.2A-10001-D01
Determining the Lubricant Output by Combining Outlets , continuation

Tube Fittings, Push-in Type (secondary metering devices)
1204c95
Fig. 29 Install the push-in type outlets fittings and closure plugs in accordance with the dosage
1- Inlet fitting 3- Closure plug (M10x1) installed in 6- Junction channels
outlet borehole with copper washer (old)
2- Delivery borehole of the piston 4- Closure plug (M11x1) (chamfered), 7- New closure plug with hex. socket head
piston and sealing edge, outlet borehole
5- Valve body assembly
(with knurled collar)
Single lubricant output
- The simple lubricant output is the lubricant quantity dis-
pensed by a piston per stroke and per outlet borehole to
one lubrication point. It amounts to 0.2 cm³ on SSV
and 0.07 cm³ on SSV M.
Double or multiple lubricant output
If one or more lubrication points require a double or a
multiple lubricant amount, this can be performed by clos-
ing one or more outlets.
As shown in Fig. 30, outlet borehole 10 has been closed.
The lubricant quantity supplied by this outlet flows out of
the metering device via outlet 8.
Total quantity at outlet 8:
1014b96
- is the quantity of outlet 8
Fig. 30 Single, double and triple lubricant output
- plus the lubricant quantity of outlet 10.
... x - Outlet quantity (1x: single, 2x: double, etc.)

If a triple quantity is needed (at outlet 1), close the outlet

1 .. 10 - Outlet numbers
A- Clamping ring (brass) borehole located above the discharge borehole. Refer to
outlets 3 and 5 on Fig. 30.
Page 19 of 36
Owner Manual
2.2A-10001-D01
Planning and Layout
Instructions for QUICKLUB Progressive Systems
To achieve the appropriate planning and layout of a system,

you should obeserve the following rules:
1. Selecting the pump
Select the pump in accordance with its application and
lubricant requirement (2-l, 4-l or 8-l reservoir pump model
203 or 4-l, 8-l, 10-l or 30-l pump model 215)
Adhere to the supply voltage of the drive motor.
Select the printed circuit board or timer in accordance with
the application. Note the application possibilities for the
metering device monitoring.
Pumpe mit einem entsprechenden Druckbegrenzungs-
ventil absichern, siehe Teilekataloge.
4093a97
Fig. 31 Selecting the pumps
2. Determining the number of lubrication points to be

connected
Exception: High-speed rotating parts. Also consider the lubri-
cation points on auxiliary units or other superstructures.
1007a96
Fig. 32 Determining the number of lubrication points
3. Combining the lubrication points into groups

A group should contain not more than 12 lubrication
points, if possible fewer.
If possible, also combine the lubrication points according
to their lubricant requirement.
1006a96
Fig. 33 Combining the lubrication points into groups

Page 20 of 36
Owner Manual
2.2A-10001-D01
Planning and Layout, continuation
Instructions for QUICKLUB Progressive Systems, continuation
4. Determining the lubricant requirement of the combined

lubrication points
The lubricant requirement depends on the design and
operating conditions of the individual bearings.
The lubricant quantities can be adapted to the require-
ment of the respective lubrication points by closing outlets
(exception: outlet 1 or 2) of the metering blocks.
Small bearings with or without sealing rings must always
be supplied with a single lubricant quantity.
Bigger bearings without sealing rings (length > 70 mm) or
heavy duty bearings shall be supplied with a double or
multiple lubricant quantity.
1016a96
Fig. 34 Adapting the lubricant quantities
5. Allocating a metering device with the appropriate

number of outlets to each group
It is recommended that metering devices with 6, 8 10 or
12 outlets be used, in special cases up to 22 outlets are
possible.
NOTE
Metering devices with up to 22 outlets can
be used in the case of special superstrucu-
tures.
6001a02
In the case of a monitored system, check where the me-

1004a96
tering device with the pre-assembled piston detector is to
Fig. 35 Allocating the metering devices be used (as a main metering device or as a secondary
metering device). The condition for this is that each lubri-
cation point receives lubricant at least once per lubrication
cycle.
6. Connecting the metering device outlets with the

lubrication points to be connected
CAUTION!
In the case of the metering devices model
SSV 6 to SSV 12 the outlets 1 and 2 must
always be connected to a lubrication
point.
In the case of the metering devices SSV
1013A94
14 to SSV 22 the two outlets with the
highest numbers (examples: 21 and 22 in
1005a96
the case of SSV22) must always be con-
Fig. 36 Connecting the metering device to the lubrication points nected to a lubrication point.
Page 21 of 36
Owner Manual
2.2A-10001-D01

If there is an odd number of lubrication points or if the
lubrication points require a large lubricant quantity, select
the next larger metering device.
Close the outlets which are not required (see Fig. 37,
outlet 5 or 6), except for outlets 1 and 2.
Outlets whose lubricant output is higher due to the closing
of preceding outlets must be connected to the lubrication
points with an increased lubricant requirement.
1017a96
Fig. 37 Allocating the lubrication points

7. Determining the size of the main metering device
First, allocate one outlet of the main metering device to
each secondary metering device.
If possible, supply the same lubricant quantities to similar
lubrication points.
Check whether one or more secondary metering devices
require larger lubricant quantities. See direct connection
of the metering device to respectively one single pump
element, example Fig. 38.
If necessary, modify the allocation of the lubrication
points.
Maximum size of the main metering device: SSV 12
NOTE
In besonderen Fällen sind auch größere
Verteiler (bis 22 Auslässe) als Hauptvertei-
1003a96 ler einsetzbar.
Fig. 38 Determining the size of the main metering device 6001a02
8. Dividing the lubricant quantity

Each lubrication point should be supplied with lubricant at
least once every day, at the latest on the next day.
Avoid overlubrication, i.e. too much lubricant per day and
per lubrication point.
Avoid underlubrication, i.e. too little lubricant per day and
per lubrication point.
To fulfill these conditions, adhere to the following:
- Adjust the operating time in such a way that the pump
supplies lubricant to the lubrication points at least once
a day. See ”Determining the operating time of the
pump”.
- Adjust the pause time in such a way that the frequency
of the lubricant supply meets the operating or applica-
tion conditions of the machine or vehicle.
- Divide the lubricant quantities as shown in the example
1002a96 Fig. 39. Also see the calculation example in Fig. 40.
Fig. 39 Divided lubricant quantity Connect the outlets of the main metering device which are
not used to the pump via a return line R.
Page 22 of 36
Owner Manual
2.2A-10001-D01
9. Lubricant output of the pumps 203* and 205** Lubricant output of the pump 215
at 100 bar backpressure Max. number of outlets....................................................15
at 20°C Lubricant output per piston stroke:
at 24 V rated voltage * Pump element piston dia. 6 mm ................................ 0.10 cm³
Pump element K5................... 2 cm3/min*; 0.10 cm³/stroke** Pump element piston dia. 7 mm ................................ 0.23 cm³
Pump element K6................ 2.8 cm3/min*; 0.15 cm³/stroke**
Pump element K7................... 4 cm3/min*; 0.22 cm³/stroke** Adjusting range...................................................25% to 100%
Adjustable pump element K7 ..........0.04 - 0.18 cm³/stroke* **
1001a96
Fig. 40 Dividing the lubricant quantity - Calculation example

Page 23 of 36
Owner Manual
2.2A-10001-D01
10. Adjusting the running time (operating time) of the pump (not for pumps with microprocessor control)
The chart below shows the required pump operating times For the running time of a system select the time for the
in the case of various combinations of the main metering biggest secondary metering device, as a function of the
device and the biggest secondary metering device. main metering device used.
With the indicated times each lubrication point re- If the time mentioned below cannot be preselected, take
ceives lubricant at least once a day. the next larger time value.
Required minimum running times

(pump element K6)
Main metering device SSV 6 SSV 8 SSV 10 SSV 12
Lubricant output of the
Single Double Single Double Single Double Single Double
main metering device
Secondary metering
device
SSV 6 3 min 4 min 5 min 6 min
SSV 8 4 min 5,5 min 6,5 min 8 min
SSV 10 5 min 2,5 min 6,5 min 3,5 min 8,5 min 4,5 min 10 min 5 min
SSV 12 6 min 3 min 8 min 4 min 10 min 5 min 12 min 6 min
During the operating time (pump running time) the used It is important to take care that the lubricant is renewed or
lubricant is renewed or topped up in the bearings. topped up within a predetermined time of application of the
The frequency of renewal/topping up and the quantity machine or vehicle so that there is no damage to the bear-
which must be supplied to a single lubrication point de- ings.
pends on several factors, e.g.: If normal or larger bearings are connected to the secondary
- bearing size metering devices model SSV 10 or SSV 12 or up to SSV 22,
- kind of bearing - open or closed bearing, rolling bearing these metering devices must receive the double or multiple
or friction bearing quantity.
- frictional force In the case of smaller bearings with a small lubricant re-
- bearing loads quirement the SSV 10 or SSV 12 will receive a single lubri-
cant quantity.
- adjustable running times of the pump, etc.
The required quantity may be very different as a result of
the above mentioned factors.
Page 24 of 36
Owner Manual
2.2A-10001-D01

11. Connecting machine bearings
Fig. 41 Example of connection for machine bearings

4022b95
12. Connecting a fifth-wheel

Fifth-wheels must be supplied from the main metering
device with a double quantity.
Fig. 42 Fifth-wheel with 6 lubrication points

1018a96
13. Connecting a liftgate

Fig. 43 Liftgate with 12 lubrication points

1020a96
Page 25 of 36
Owner Manual
2.2A-10001-D01
14. Using a second pump element

(2nd lubrication circuit)
If the vehicle chassis or the machine is already equipped
with a centralized lubrication system and if a superstruc-
ture (e.g. crane) or an auxiliary unit must be connected
subsequently, this superstructure or auxiliary unit can be
supplied from a specially installed pump element.
IMPORTANT
Each pump element must be equipped
with a safety valve.
1021b96
Fig. 44 System using two pump elements 6001a02
15. Verwendung der Schnellkupplung 504-36804-1

Für abnehmbare Aufbauten, z.B. Ladekräne, eine ab-
nehmbare Schnellkupplung mit integriertem Rücklauf
verwenden
NOTE
Wird statt der Schnellkupplung eine einfa-
che Kupplung (unter Druck koppelbar)
verwendet, muss nach dem Abkuppeln des
6001a02 Aufbaus die Zulaufleitung mit einer Rück-
laufleitung zur Pumpe verbunden werden,
da sonst die Anlage blockiert.
1022a96
Fig. 45 Einsatz einer Schnellkupplung mit integriertem Rücklauf

Page 26 of 36
Owner Manual
2.2A-10001-D01

16. Max. Leitungslängen
IMPORTANT
The lubricant division should be made only via 2 steps of metering devices, i.e. main metering device -
secondary metering device - lubrication point.
6001a02
1023b96
Fig. 46 Maximum line lengths A- Main metering device B- Secondary metering device
C- Lubrication point
17. Pressure losses
1024b96
Fig. 47 Pressure losses in the metering devices or tube lines

PA - Pressure loss, main line PB - Pressure loss, main metering device PC - Pressure loss, main line between main
and secondary metering device
PD- Pressure loss, secondary metering PE - Pressure loss, lubricant feed line
device
Page 27 of 36
Owner Manual
2.2A-10001-D01

The following chart serves as a reference when calculating the maximum size of a QUICKLUB system, under consideration of
the lubricant sorts and ambient temperature.
Maximum pressure loss with tube 6x1,5 mm (NW 3 mm)

Lubricant penetration class
Temperatur 0° C 15° C 25° C
NLGI 0 5 bar/m 4 bar/m 2,5 bar/m
NLGI 1 8 bar/m 7 bar/m 5 bar/m
NLGI 2 12 bar/m 8 bar/m 6 bar/m
Maximum pressure loss through each SSV 6 to SSV 12
NLGI 0 20 bar 15 bar 10 bar
NOTE The sum of all pressures, from PA to PE plus 5 bar for the
rolling bearings (lubrication point) or plus 15 bar for friction
The data relating to the pressure loss per
bearings must not exceed 80% of the recommended
metering device refer to metering devices working pressure of the pump.
with 6, 8, 10 and 12 outlets, namely the
6001a02 main and secondary metering devices. All the values mentioned in the tablet are average values
based on real test results.
The NLGI class of the grease only indicates the statistical
density. It does not indicate the dynamic pumpability of
the grease. The flow properties of greases of the same
NLGI class may be very different.
Page 28 of 36
Owner Manual
2.2A-10001-D01
Troubleshooting
Fault: Blockage in the downstream progressive system
Cause: Correction:
Bearing, lines or metering device clogged. Find out which is the cause of the blockage and rectify it in
accordance with he following example:
In the case of the metering devices SSV 6 through 22 the Allow pump to run (see ”To trigger an additional lubrication
outlet boreholes 1 and/or 2 are closed. In the case of the cycle”).
assembled metering devices SSV 14 through 22 the two Loosen all main line connections G one after the other
outlet boreholes with the highest numbers are closed. from the main metering device (B, Fig. 48) leading to the
The fault can be identified by: secondary metering devices. If f. ex. grease or oil emerges
under pressure from outlet 1 of main metering device B,
a) grease leaking at the safety valve; the blockage will be found in the lubrication circuit of the
b) the fact that the indicator pins installed on the metering secondary metering device D.
devices (if any) no longer move; NOTE
c) the fault signal of the signal lamp (if any) or LED display
If there is a blockage in the downstream
system, the main lines are under pressure.
In such a case, it is difficult to detach the
6001a02 push-in type connecting parts of the main
line. Relieve the system by removing the
closure plug on the push-in type safety
valve or, if any, by removing the filling
nipple.
Let the pump run.
Disconnect all lubricant feed lines E from secondary me-
tering device D one after the other. If f. ex. grease or oil
emerges under pressure from outlet 3 of metering device
D, the blockage will be found in the line of outlet 3 or in the
connected bearing.
Pump the blocked bearing or line through by means of a
manual pump.
NOTE
When checking the individual outlets, keep
each outlet loosened for quite a while
because per each motor revolution there is
6001a02 only one piston stroke. A complete cycle of
all metering devices requires several
1064b95
strokes.
Fig. 48 Example of a lubrication system Check safety valve A. Replace it, if necessary.
A- Safety valve B- Main metering device
C- Secondary metering device D - Secondary metering device

SSV 8 SSV 6
E- Pressure plastic tubes F- Secondary metering device
SSV 12
G- High-pressure plastic hose
Tab. 1 Troubleshooting
Page 29 of 36
Owner Manual
2.2A-10001-D01
Troubleshooting, continuation
Fault: Blockage in the downstream progressive system, continuation
Cause: Correction:
Metering device blocked Replace the metering device or clean it in accordance with
the following procedure:
Remove all tube fittings.
Unscrew the piston closure plugs.
If possible, try to eject the piston using a smooth drift
(Ø smaller than 6 mm; 0.24 in.).
IMPORTANT
he pistons are precision-fitted into the
holes. Mark the pistons with regard to their
installation position and direction after they
6001a02 have been removed. They must not be
exchanged.
Thoroughly clean the metering device bodies in fat-
dissolving washing agent, blow them through with com-
pressed air.
Press free the slant ducts (Ø 1.5 mm; 0.59 in.) at the
thread ends of the piston holes using a pin.
Clean the metering devices again and blow them through.
Reassemble the metering devices.
Replace the copper washers.
Before the tube fittings are reassembled, the metering
devices should be pumped with oil several cycles by
means of a manual pump. Check that the pressure in the
metering device does not exceed 25 bar (362.8 psi).
If the pressure is higher, replace the metering device.
Fault: Differing lubricant amounts at the lubrication points
Cause: Correction:
Lubricant metering not correct Check the lubricant metering acc. to the lubrication chart
Respective valve body has been assembled without clamp- Remove the valve body and install a clamping ring.
ing ring
Setting of the pause time or operating time incorrect Check the time setting. Refer to the corresponding setting
in the respective “Operating Instructions”.
Fault: Over- or underlubrication of the lubrication points
Cause: Correction:
Setting of the operating time or pause time incorrect Check the time setting at the printed circuit boards. Refer
to the corresponding setting in the respective “Operating
Instructions”.
Tab. 1 Troubleshooting, continuation

Page 30 of 36
Owner Manual
2.2A-10001-D01
Technical Data
Metering Devices Lines

Metering Device Model SSV MainLine (ø 8,6 x 2,3 mm)
Lubricant output per outlet and per stroke .....................0.2cm³ Min. bursting pressure
Max. operating pressure...............................................350 bar (in connection with hose clamp, screwed). .................. 600 bar
Min. operating pressure................................................. 20 bar Min. bending radius. ..................................................... 35 mm
Max.differential pressure Min. temperature........................................................... - 40° C
between two outlets......................................................100 bar
Feedline (ø 6 x 1,5 mm)
Outlet connection for tube .................................. Ø 4 and 6mm
Inlet connection ...............................................................G 1/8 Min. bending radius....................................................... 50 mm
Outlet connection ........................................................ M 10x1 Bursting pressure at 20° C ............................ approx. 210 bar
Operating temperature .....................................- 25° C to 70°C Min. temperature........................................................... - 40° C
Metering Device Model SSV M
Lubricant output per outlet and per stroke ...................0.07cm³ Tightening torques
Max. operating pressure...............................................200 bar Metering Devices
Min. operating pressure................................................. 20 bar Closure plug (piston) in metering device........................18 Nm
Max.differential pressure Closure plug (outlets) in metering device.......................15 Nm
between two outlets....................................................... 40 bar Inlet fitting in metering device
Outlet connection for tube ............................................ Ø 4mm - screw-type ...................................................................17 Nm
Inlet connection ...............................................................G 1/8 - plug-type......................................................................10 Nm
Outlet connection ........................................................... M 8x1 Outlet fitting in metering device
Operating temperature .....................................- 25° C to 70°C - screw-type ...................................................................17 Nm
- plug-type.......................................................................12 Nm
Screw-Type and Push-inType Tube Fittings Compression nut onto inlet fitting...................................10 Nm
Compression nut onto outlet fitting, screw-type
High pressure range, p max. .......................................350 bar - plastic tube....................................................................10 Nm
Inlet tube fittings of the metering devices - steel tube .....................................................................11 Nm
Outlet fittings, main metering device Control pin in metering device........................................12 Nm
Piston detecteur in metering device ...............................15 Nm
Low-pressure range, p max..........................................250 bar KN - switch on metering device......................................18 Nm
Outlet fittings, secondary metering devices Install metering device ...................................................10 Nm
Inlet fittings to the lubrication point
Page 31 of 36
Owner Manual
2.2A-10001-D01
Dimensions
Metering Devices Model SSV 6 to SSV 22 (Blocks) Metering Devices SSV 14 to 22 (assembled)
2012a95
Fig. 49 Metering Devices Model SSV 6 to SSV 22 (Blocks)
Model SSV Dimensions A in mm

6 60
8 75
10 90
12 105
14 120
16 135 1015a96
18 150 Fig. 50 Metering devices SSV 14 to 22 (assembled)

20 165
22 180 Model SSV Dimensions A in mm
14 135
16 150
18 165
20 180
22 195
Page 32 of 36
Owner Manual
2.2A-10001-D01
Dimensions, continuation
Metering Devices Model SSV M 6 to SSV M 12
Model SSV Dimensions A in mm
6 48,5
8 60
10 71,5
12 83
Fig. 51 Metering Devices Model SSV M 6 to SSV M 12

2012a99
Lubricants
The manufacturer of the centralized lubrication system
IMPORTANT can accept no liability for:
The manufacturer of the centralized lubri- damages on parts of the centralized lubrication system
cation system tests the lubricants exclu- caused by chemical or biological changes of the lubricant
sively on their transportability in the used
6001a02
centralized lubrication systems, not on damages due to the use of greases that are not or only
their compatibility with other material. conditionally transportable in centralized lubrication sys-
The lubricants tested did not cause any damage due to in- tems.
compatibility on the material used by us. The composition of
the lubricants, their behavior during the transport and their IMPORTANT
compatibility with other material are not known to us. Lubri- The lubricants released by us have not
cant recipes may change. In case of doubts, send your been tested with regard to their long-term
request for more information to the manufacturer of the cen- behaviour. Therefore, we can give no
tralized lubrication system. 6001a02
guaranty for damages caused by chemical
reactions of the lubricant with components
of the centralized lubrication system.
Page 33 of 36
Owner Manual
2.2A-10001-D01
Lubricants, Continuation
The QUICKLUB pump 203 can dispense greases up to NLGI

NOTE
class 2 or mineral oils with min. 40 mm²/s (cST) at 40°C.
Absolute cleanliness is essential when
handling lubricants. Impurities will remain
suspended in the lubricant and cannot
6001a02
settle. This will block the delivery channels
causing damage to the bearings.
Recommended grease for QUICKLUB systems down to -25 °C

Manufacturer Type Base soap Min. delivery temperature
AGIP F1 Grease 24 Ca
ARAL Mehrzweckfett ZS 1/2 Ca/Li - 20° C
AUTOL Top 2000 Ca - 10° C
AUTOL Top 2000 W Ca - 20° C
BP Abschmierfett Ca
BP C1 Abschmierfett Ca
CASTROL CL-Grease Ca/Li
ESSO Cazar K2 Ca
ESSO Hochdruckfett Ca
FIAT LUBRIFICANTI Comar 2 Li - 25° C
FINA CERAN LT Ca - 20° C
FINA CERAWR 2 Ca
FUCHS FN 745 Ca - 25° C
FUCHS Renocal FN3 Ca - 20° C

FUCHS Renolit HLT 2 Li - 25° C
KLÜBER Centoplex 2 EP
MOBIL Mobilgrease 28 Li - 30° C
MOLYKOTE TTF 52 anorg thickener - 30° C
OPTIMOL Longtime PD 2 Li - 20° C
OPTIMOL OLIT CLS Ca/Li - 15° C
SHELL Retinax C Ca
WESTFALEN Greasalit ZSAZ Li - 15° C
Biodegradable
Manufacturer Type Base soap Min. delivery temperature
ARAL BAB EP 2 Li/Ca
AUTOL Top 2000 Bio Ca - 25° C
AVIA Biogrease 1 Li to 0° C
DEA Dolon E 2 Li - 15° C
FUCHS Plantogel S2 Li/Ca
KLÜBER Klüberbio M32-82 Li - 20° C
Page 34 of 36
Owner Manual
2.2A-10001-D01
Note:
Page 35 of 36
Owner Manual
2.2A-10001-D01
America: Europe/Africa: Asia/Pacific:

Lincoln Industrial Lincoln GmbH & Co. KG Lincoln Industrial
One Lincoln Way Heinrich-Hertz Straße 2-8 Asia Pacific Regional Office
St. Louis, MO 63120-1578 69190 Walldorf 25 International Business Park
USA Tel: (+49) 6227 33-0 #01-65/67 German Centre © Copyright 2002
Phone: (+1) 314 679 4200 Fax: (+49) 6227 33-259 Singapore 609916 Printed in Germany
Fax: (+1) 800 424 5359 Phone: (+65) 562-7960 Web site:
Fax: (+65) 562 9967 www.lincolnindustrial.com
Page 36 of 36
Owners Manual
Solenoid Valves
9.3A-68001-B00
Solenoid Valves
A4136a97
Page 1 of 7
Owners Manual
Solenoid Valves
9.3A-68001-B00
Table of Content
Page
Safety instructions ........................................................... 2

Application ........................................................................ 3
Examples of application .................................................. 3
Erection and Installation .................................................. 4
Operating instructions ..................................................... 4
Type identification ............................................................ 5
Troubleshooting ............................................................... 5
Technical Data ................................................................. 5
Dimensiones .................................................................... 6
Safety Instructions
Use in conformity with the intended application Structure
The solenoid valves are exclusively intended for use in The solenoid valves are ball seat valves equipped with a
centralized lubrication systems and centralized lubricant dry armature solenoid.
supply systems. In the 2/2-way design, the passage B -A may be closed or
The maximum ratings specified in the Technical Data, opened, in the 3/2-way design the inlet is connected to
particularly the maximum operating pressure, must not be either outlet.
exceeded on no account. The basic position (solenoid not actuated) is obtained
Any other use is not conform to the intended application. automatically via a return spring, the operating position is
The manufacturer is not liable for damage resulting from maintained as long as voltage is applied to the solenoid.
any other use. The solenoid valves are switchable and can be pressure-
loaded in both flow directions.
Maintenance and Repairs
Before maintenance or repair work is carried out on the Available Versions:

solenoid valves, observe the content of the Owners
Manual and the Safety Instructions.
The Owners Manual must be available on the site where 2/2 - way-valve 2/2 - way - valve 3/2 -way - valve
the solenoid valves are in operation. NC NO
Alterations or mofications of the solenoid valves are only
authorized if appproved by the manufacturer.
For repairs, use only original spare parts.
If other parts are used, the manufacturer may be released
from its liability for the resulting damage.
Operation of the Solenoid Valves
Use the solenoid valves only if they are in good technical

condition.
Defects and faults which impair the safety must be elimina- 4123a97 4124a97 4125a97
ted immediately.
The function of the solenoid valves is only guaranteed if
they are used with clean lubricant.
If you need more information than is given in this Owners
Manual, please contact our company (refer to the address

in the footer).
Page 2 of 7
Owners Manual
Solenoid Valves
9.3A-68001-B00
Examples of Application
4126a97 4128a97
Fig. 1 - 2/2 - way - valve used as a shut-off valve in a filling line Fig. 3 - 3/2-way valve used as a relief valve in a single-line system
4127b97
Fig. 2 - 3/2 - way valve for the connection or disconnection of a progressive

metering device
4129a97
Fig. 4 - 3/2-way valve used as a 2-pole shut-off valve in a two-line system
Erection and Installation

Requirements on the installation site:
Starting up
even, stable and vibration-free installation site
protected from dust and dirt After the connection of the tube lines and electrical system,
safe from atmospheric influences the solenoid valve is ready for operation.
Installation position : any
Electrical Connection Maintenance and Repair
Any repair will be limited to a replacement of the complete

Before the device is connected, discon- solenoid valve, since special knowledge is required for the
nect the system. repair of the inner workings.
The installation of electrical devices
should be carried out only by an electri-
cian! Before any replacement of parts of
The relevant rules of technology and the the solenoid valve observe the
respective industrial safety laws (instruc- following:
tions, standards) must be observed.
Electrical connection of the solenoid * Disconnect the system and secure it

valve in accordance with the wiring against inadvertent restarting.
diagram * Reduce the system pressure down to
zero.
* Danger due to splashing lubricant
CAUTION The supply voltage and solenoid
voltage must be identical.
Page 3 of 7
Owners Manual
Solenoid Valves
9.3A-68001-B00
Type Identification
The various versions of the solenoid valves can be ordered according to the table below.
Ordering examples:
WV - M - W 2 O - 1/2 - 24 DC
WV - M - W 2 G - 1/2 - 110 AC
WV - M - W 3 G - 3/8 - 230 AC
Basic type:
Directional control valve
Actuation:
electromagnetical
Function:
W 2 = 2/2 - way valve
W 3 = 3/2 - way valve
Off position (de-energized):

G = closed
O = open
Threaded connection: (G)
Operating voltages:
DC = Direct voltage
AC = Alternating voltage 50/60 Hz
Standard valves are available with the following part numbers:
Type Type designation Part - no.
2/2 - way valve, WV - M - W 2 G - 1/2 - 24 VDC 525-32080-1

NC WV - M - W 2 G - 1/2 - 110 VAC 525-32081-1
WV - M - W 2 G - 1/2 - 230 VAC 525-32082-1
2/2 - way valve, WV - M - W 2 O - 1/2 - 24 VDC 525-32083-1

NO WV - M - W 2 O - 1/2 - 110 VAC 525-32098-1
WV - M - W 2 O - 1/2 - 230 VAC 525-32084-1
3/2 - way valve WV - M - W 3 - 3/8 - 24 VDC 525-32085-1

WV - M - W 3 - 3/8 - 110 VAC 525-32086-1
WV - M - W 3 - 3/8 - 230 VAC 525-32087-1
Spare coils for all types of connections (W2G, W2O, W3):
Part-no.
24VDC for 24 VDC-valves 235-13159-5
98 VCD for 110 VAC-valves 235-13159-9
205 VDC for 230 VAC-valves 235-13159-8
Page 4 of 7
Owners Manual
Solenoid Valves
9.3A-68001-B00
Troubleshooting
Troubleshooting
* For all faults, first check the electrical voltage supply.
* If no fault is found, replace the complete valve.
* Manual emergency button: For checking the valve, press

on the magnetic pin (standing out under the rubber cap,
see fig. 5). This will release a manual impulsion.
4130a97
Fig. 5 - Manual Emergency button: Press on the Magnetic pin
Technical Datas
Valve model: 2/2 - way valve 3/2 - way valve

Threaded connection: G 1/2 G 3/8
Pressure range: 0 - 400 bar 0 - 400 bar
Max flow rate.: 2,4 dm³/min 2,4 dm³/min
Weight: 1,7 kg 1,2 kg
Mounting position: any any
Flow direction: any any
Temperature range: - 20° C bis 60° C - 20° C bis 60° C
Electrical Datas
Supply voltage: 24 VDC 110 VAC 50/60 Hz 230 VAC 50/60 Hz

Solenoid voltage: 24 VDC 98 VDC 205 VDC
Current consuption (max.): 0.83 A 0.2 A 0.1 A
Nominal power (approx.): 20 W 20 W 20 W
Operations/h, (approx.).: 2000 2000 2000
Isulation class: F F F
Type of protection: IP 54 IP 54 IP 54
Operating time: 100 % 100 % 100 %
Included in scope of supply:

Socket Part no. 236-13868-1 P. no. 236-13868-3 P. no. 236-13868-3
with rectifier with rectifier
Attention: Screw the socket on the central connector only with a torque of max. 0.7 Nm
Page 5 of 7
Owners Manual
Solenoid Valves
9.3A-68001-B00
Dimensions
2/2 - way valve
4131a97
Fig. 6 - Dimensioned drawing of 2/2 way valves (connection G 1/2)
A, B - Connectors
Z - Manual emergency button
Page 6 of 7
Owners Manual
Solenoid Valves
9.3A-68001-B00
3/2 - way valve

4132c97
Fig. 7 -Dimensioned drawing of 3/2-way valves (connection G 3/8)

Note: The plug connection of the solenoid plug
A, B - Connectors
can be turned by 180° by removing the two screws
Z - Manual emergency button
Page 7 of 7
Data Sheet
Ultrasonic Sensor Sensing Range 190 - 1300 mm
9.3A-70006-A00
Description of operation Technical Data

This remote sensor is a solid state proximity type for 24 VDC Ambient temperature.................................... - 25...70°C
which uses the echo delay time method for distance sensing. Sensing range .............................................. 190...1300 mm *
It senses a sound-reflecting object which enters the sound Sensing distance "High level" ... S1 ........... 200 mm *
cone from any direction. The objects to be sensed can be Sensing distance "Low level".... S2 ........... depends on the
solid, liquid or powdery. reservoir size
Hysteresis "High level" ... HV........... 20 mm
Hysteresis "Low level".... HL ........... 100 mm
Switching point fault ..................................... 0,17% / K
Installation * measured on the housing surface
Figure I (dimensions in mm) Supply:

any mounting position Rated operational voltage ........... UE............ 24 VDC
Keep a free space around the sound cone of a distance “x“ Operating voltage range.............. UB............ 20...30 VDC
(= 60 mm) from reflecting objects (figure II). Admissible residual ripple ............................ 10 %
Open-circuit.................................................. < 60 mA
Connection Switching output:

Rated normal current ............... Ie ................ ≤ 200 mA
By means of cable socket (figure III) part no. 237-13442-4 Voltage drop............................. Ud ............... ≤3 V
(included in delivery range) Spurious switch-on pulse ............................. suppressed
Switching function ...."High level" ................. NO contact
Pin switching on
1 L+ DC 20 ... 30 V "plus"
2 S Switching output “High level“ (NO) "Low level" .................. NC contact
3 L- Ground (GND) switching on
4 S2 Switching input “Low level“ "plus"
The connections are polarized, short-circuit proof and Typical values:

overload-proof. In the case of electrical faults it is recom- Availability delay........................................... 280 ms
mended to use shielded lines. Reflection area ............................................. 10 x 10 mm
Ultrasonic frequency .................................... 200 kHz
Switching frequency ..................................... 58 Hz
Operation Reproducibility.............................................. 2 mm
Protection ..................................................... IP 65
Switching range (figure IV)
a Unusable blind zone
b Sensing range
Part-Number
c Overfill range
HV Hysteresis high level
HL Hysteresis low level Ultrasonic sensor set for Part-No.:
reservoirs:
The objects are sensed reliably in the set switching range
within an opening angle of the sound cone of 5°. If the re- 80L (sensing distance 664-34009-1
flecting conditions are good, the objects can also be sensed low level S2 = 700 mm)
outside the sound of cone. Keep the blind zone “a“ free from 200L (sensing distance 664-34009-2
objects. These would lead to undefined switching states. Take low level S2 = 800 mm)
care that the surface of the transducer is clean.
Display:
Reservoir empty H2 is lit Extra Equipment
Filling level O.K. H2 is not lit
Reservoir full H1 is lit Cable socket with 5 m cable part-no. 237-13429-6
Supply voltage H3 is lit: green
Overfill signal H3 is lit: red
page 1 of 2
subject to change without notice

LINCOLN GmbH ∗ Postfach 1263 ∗ D-69183 Walldorf ∗ Tel +49 (6227) 33-0 ∗ Fax +49 (6227) 33-259
Data Sheet
Ultrasonic Sensor Sensing Range 190 - 1300 mm
9.3A-70006-A00
I
x
x
X = 60 mm
III
30 mm high
IV Full Empty
Surface of the transducer
S1 S2

c +9 +/ FD
b Full Empty
S1 S2
1 1
Overfull
H1 H2 H3
Rising level
on off red
6
S1 S2
Full 1 1
H1 H2 H3
on off green
Falling level
S1 S2
0 1
H1 H2 H3
off off green
6
S1 S2
Empty 0 0
H1 H2 H3
off on green
subject to change without notice page 2 of 2
LINCOLN GmbH ∗ Postfach 1263 ∗ D-69183 Walldorf ∗ Tel +49 (6227) 33-0 ∗ Fax +49 (6227) 33-259
Data Sheet
Digital Pressure Switch 0 – 400 bar Part-No. 234-10330-3
9.3A-50012-B04
Factory setting: Switching point 220 bar, Hysteresis 40 bar
Dimensions
46.3
73.4
SW27
ø32
Connection Diagram Mounting hole
Design
The electronic pressure switch is equipped with 1 digital display, 2 switching outputs and 1 analog output. The switching points
and the hysteresis can be adjusted via keys.
The display is easily readable thanks to the waterproof housing which can be rotated through 290°.
The pressure switch is maintenance-free. If faults do arise please send the complete unit to us. Interference by not authorized
personnel will invalidate all warranty claims.
Subject to change without notice page 1 of 2

Data Sheet
Digital Pressure Switch 0 – 400 bar Part-No. 234-10330-3
9.3A-50012-B04
Technical Data
Input data:
Measuring range: 0....400 bar
Overload pressure: 800 bar
Burst pressure: 1700 bar
Output data:
Accuracy: typ. ± 0.5%
Analog output:
Signal: 0/4 .. 20 mA, ohmic resistance ≤ 500 Ω
Switching output:
Type: PNP-transistor output
Switching current: Max. 0.7 A
Switch cycles: ≥ 20 millions
Ambient conditions:
Operating temperature range: -20...+85°C
CE-mark: EN 50081-1 and EN 61000-6-2
Vibration resistance: 10...500 Hz, 20 g
Other data:
Supply voltage: 15 ... 30 VDC, nominal 24 VDC
Electrical connection: M 12 x 1; 5-pol.
Current consumption: < 100 mA
Safety type: IP 67
Hydraulical connection: G 1/4" (BSPP), torque rating 45 Nm
Parts in contact with medium: Stainless steel 1.4404 (US 316L), NBR seal
Material of housing: Pressure die-cast zinc; surface-finishing
Display: 4-digit, 7-segment LED, red, figure height: 9 mm
Weight: Approx. 300 g
Additional Features
• Menu-driven parameter set-up with 3 keys

• Status display of the switching outputs
• Memory for pressure peaks
• Variable hysteresis and delay times
• Programmable parameter
• Unauthorized changes can be prevented by means of a password
• Protection against reverse polarity, over-voltage and short circuits
Subject to change without notice page 2 of 2

DATA SHEET
PART NO.: 234-13178-3
PISTON DETECTOR
9.3A-20013-A97
DIMENSIONS CONNECTION DIAGRAM
TECHNICAL DATA
OUTPUT FUNCTION NO
OPERATING VOLTAGE [VDC] 10...36
INCLUDING RESIDUAL RIPPLE
CURRENT CARRYING CAPACITY [mA] 100
VOLTAGE DROP / MAX. LOAD [V] ≤ 4,6
RESIDUAL CURRENT [mA] ≤ 1,0
MINIMUM LOAD CURRENT [mA] ≥ 5,0
OPERATING FREQUENCY [Hz] typ.800
CONTROL INDICATOR LED
TEMPERATURE RANGE [°C] -25...+80
DRIFT OF OPERATING POINT [%] < ± 10 of sr
SWITCHING HYSTERESIS [%] 3...15 of sr
RATED OPERATING DISTANCE (sn ) [mm] 2,0 flush
EFFECTIVE OPERATING DISTANCE (sr) [%] sn ± 10
ADMISSIBLE PRESSURE [bar] 400
TYPE OF PROTECTION IP67
TIGHTENING TORQUE [Nm] 18
CONNECTION CABLE [m] 2 Cable PVC 2x0.34 mm2
MATERIAL OF HOUSING V4A 1.4571
Function:
The piston detector is utilized to monitor progressive plunger metering devices type SSV. It is a pressure-resistant
inductive proximity switch detecting the movements of a metering device piston. It is screwed into the piston hole of
the SSV metering device instead of a piston closure plug. Any SSV metering devices can easily be retrofitted. Thus,
in conjunction with a control, the piston detector allows the monitoring of a progressive centralized lubrication
system
Sheet 1 of 1 subject to change

LINCOLN GmbH ∗ Postfach 1263 ∗ D-69183 Walldorf ∗ Tel +49 (6227) 33-0 ∗ Fax +49 (6227) 33-259 ∗Tx 466088

Manual: Servicing Manual Centralized Lubrication System For LIEBHERR Hydraulic Excavator R 9250

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Manual: Servicing Manual Centralized Lubrication System For LIEBHERR Hydraulic Excavator R 9250

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Servicing Manual

Centralized Lubrication System for LIEBHERR Hydraulic Excavator

A. Description of the system as a whole

1. Function of the lubrication system

2. Operation of the lubrication system

3 The lubrication system monitor

4. Inspection and maintenance

5. Exchanging / Filling the grease reservoir

6. Malfunctions and their remedy

B. Description of the components of the lubrication system

1. Description of the hydraulic pump 80l reservoir ...............................................................4.1A-68608-A05

2. Manual Flowmaster hydraulic pump.................................................................................7.5A-18100-J03

4. Preliminary - Manual 15L Pump .......................................................................................

5. Circuit Board P203............................................................................................................2.6A-20003-C02

6. Description of the injectors SL1........................................................................................4.2A-68351-E05

7. Description of the injectors LM-5 ......................................................................................4.2A-18002-B05

8. Description of the progressive plunger metering devices SSV ........................................2.2A-10001-F03

9. Description of the solenoid valves ....................................................................................9.3A-68001-B00

10. Data sheet: ultrasonic-sensor...........................................................................................9.3A-70006-A00

11. Date sheet: Digital Pressure Switch .................................................................................9.3A-50012-B04

12. Data sheet: piston detector...............................................................................................9.3A-20013-A97

13. Proximity Switch................................................................................................................234-13172-6

1 Function of the lubrication system

System 1 – Equipment lubrication- Slewing rim lubrication

Main components: Hydraulic pump "P1" 609-29333-1

System 2 – Gear rim lubrication

Main components: Hydraulic pump "P2" 644-46265-1-L

1.2 Sequence of a lubrication cycle

3 The lubrication system monitor

• Only allow operation by properly instructed personnel

When the excavator is started the lubrication system is automatically

During lubrication the diesel engine must be in operation because the

The flashing of the pushbutton C indicates a malfunction in the

The fault is also indicated by means of an intermittent whistling sound at

• Blockage or breakage of the main line

An additional lubrication cycle can be triggered at any time by pressing

On malfunction of the command unit U15, an additional lubrication cycle

4 Inspection and maintenance

• Do not perform any repairs while system is pressurized.

Daily: Visual check of the lubrication points for escaping lubricant

Weekly: Visual check of the screwed pipe connections for leakage

1000 hours: Clean filter element of grease filter

Weekly: Visual check for leaks

4. Progressive Plunger Metering Device

Weekly: Visual check for leaks

5 Exchanging / topping up grease reservoirs

CAUTION • Lines are pressurized. Be careful when decoupling.

5.1 P1 and P2: Filling of the container

Filling of the container through service-plate

6 Malfunctions and their remedy

• Malfunction: No pressure build-up in the system

• Malfunctions of the pump • See Troubleshooting: Pump

• Air trapped in the main line • De-aerate the line

• Injectors leaky or worn • See Troubleshooting: Injectors

• Solenoid valve faulty • Replace solenoid valve, check voltage supply

Änderungen vorbehalten Seite 10 von 10

Item Contents Page

3 Erection and Assembly 5

5 Spare Parts Drawing 7