Lincoln Centralized Lubrication System

Benutzerlntormatlon LINCOLN
Betriebsanleitung
lnstrucciones de funcionamiento
Instructions de service
lstruztoni per II Funzionamento
Zentralschmierpumpe 203 DC
Centralized Lubrication Pump 203 DC
Bomba de lubricaci6n central 203 DC
Lubrification centralisee pompe 203 DC
Lubrificazione Centralizzata Pompa 203 DC
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20011327
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810-55168·1
Ben utzerlntormatlon LINCOLN
Betriebsanleitung G
2.1l-38002-E04
o
Aile Rechte vorbehalten.
Jegliche Vervieltaltiqunq dieser Benulzerinfonnation, gleich
nach welchem Verfahren, ist ohne vorhelige schriftliche Ge-
nehmigung durch die Fa. Lincoln GmbH & CO. KG, auch
auszugsweise, untersagt.
Anderungen ohne vorherige Ankundigung bleiben vorbehal-
ten.
GB/USA
All lights 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.
F
Reservados todos los derechos.
Ninguna parte de este manual para el usuario puede ser
reproducida, almacenada 0 transmitida, de manera alguna ni
por ningun medio, ya sea electrico, quimico, rnecanico,
optico, de grabacion 0 de fotocomposici6n, sin el permiso
previo y por escrito de los titulares del Copyright.
Salvo modificaciones sin aviso previo.
E'
Tous droits reserves.
Toute reproduction, marne partielle, du present manuel, quel
que soit Ie precede utilise, est interdite sans l'autorisation
ecrite prealable de la societe Lincoln GmbH & CO. KG.
Sous reserve de modifications sans notification prealable.
I
Tutti i diritti riservati.
E' vietata qualsiasi riproduzione, anche parziale, del presente
manuale d'uso senza previa approvazione scritta della ditta
Lincoln GmbH & CO. KG.
Con riserva di apportare modifiche senza previa notifica.
LINCOLN
User Manual
Ooeratino lnstructlons
2.1A-381l02-E04
Table of Contents
Page Page
Introduction . A 2 Maintenance A 11
Explanation of Symbols Used A 2 Pump Filling .. A 11
User's Responsibility . .. A 2 Repair .. A 12
Environmental Protection A 2 Pump . A 12
Service A 2 Replace pump element A 12
Printed Circuit Boards A 12
Safety instructions .. A 3 Tests A13
Appropriate Use . A 3 Operational Test! Triggering an
Misuse A 3 Additional Lubrication Cycle A 13
Generai Safety Instructions A 3 To Check the Pressure Relief Valve A 13
Regulations for Prevention of Accidents A 3
Disposal A 3 Troubleshooting A 14
Exclusion of Liability A 3
Operation, Maintenance and Repair A 3 Technical Data A 15
Installation A 4 Pump A 15
Motor . A 15
A5 Pump element with fixed lubricant output A 15
The 203 central lubrication pump . A5 Pump element with adjustable lubricant output A 15
Low-level control (optional) .. A5 Pressure relief valve A 15
Tightening torques A 15
Mode of Operation . A6 Connection Diagram . A 16
Pump elements with fixed lubricant output A6
Pump element 87 with 8ypass-Check Valve A7 Lubricants. .. G16
Pump element with adjustable lubricant output A7 Lubricating greases for QUICKLUB systems A 17
Selling of adjustable pump elements . A8 8io-degradabie greases A 17
Retrofit adjustment of max. lubricant output A8
Pressure Relief Valve A9 Installation A 18
without grease return A9 Specifications for the installation of electric equipment
with grease return (optional) A9 for ADR-application in comercial vehicles A 18
Return Line Connection A ill Lines .. A 18
Control Unit . A 10 Mounting of the Pump -Areas of Risk- . .... A 19
Commissioning . A 10
Certificate for ADR Pump. ..... A20
For further information refer to:
Technical Description Progressive Metering Devices for Grease and Oil, model SSV
Technical Description for" Pump 203 for 94 to 265 VAC application
Technical Description for "Electronic Control Units" 01 pump 203 :
Printed circuit board 236-13891-1 -Model V1Q-V13"

Printed circuit board 236-13857-1 -Model H
Printed circuit board 236-13870-1 - Models M 08-M 15"
Printed circuit board 236-13870-1 - Models M 16-M 23"
Controller PSA 02
Installation Instructions
§ Parts Catalog
1§
;g "The model designation of the printed circuit board is part of the pump model designation code mentioned on the pump nameplate.
~ Example:B.: P 203 - 2XN -1K6 - 24 -1A1.10 - M08, - V10, -!:! or.
Page A 10120
User Manual
Operating Instructions
2.1A-38002-E04
Introduction
Explanation of Symbols Used

The following description standards are used in this manual: Furthermore, you will find the following tex! symbols in this
Safety Instructions manual:
Structure of safety instructions: Usting of applicable statements
Pictogram - Subpoint of applicable statements
Signal word 1. Determination of the number or sequence of contents
Danger text :::l Procedural instruction
- Danger note
- How to avoid danger
User's Responsibility
correspondinq "'" -'I i

The following pictograms are used in this manual and are
I'~ I
To ensure the safe operation of the unit, the user is responsi-
ble for the following:
1. The pump I system shall be operated Q!l!y for the in-
tended use (see next chapter "Safety Instructions") and
its design shall neither be modified nor transformed.
2. The pump I 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.
1013A94 4273aOO 5001a02 3. The operating personnel must be familiar with this Owner
ATTENTION ATTENTION NOTE Manual and the safety instructions mentioned within and
observe these carefully.
CAUTION CAUTION IMPORTANT
The correct installation and connection of tubes and hoses, if
f WARNING WARNING
The signal words give the seriousness of danger if the follow-
not specified by Uncoln GmbH & Co. KG, is the user's re-
sponsibility. Uncoln GmbH & Co. KG will gladly assist you
ing text is not observed: with any questions pertaining to the installation.
ATTENTION refers to faults or damages on

Environmental Protection
machines.
CAUTION refers to bad damages and possi- Waste (e.g. used oil, detergents, lubricants) must be dis-
ble injuries. posed of in accordance with relevant environmental regula-
WARNING refers to possible dangerous inju- tions.
ries.
NOTE refers to improvements in handling Service
of systems.
IMPORTANT refers to considerable disadvan- The personnel responsible for the handling of the pump I
tages in handling of systems. system must be suitably qualified. If required, Uncoln GmbH
& Co. KG offers you full service in the form of advice, on-site
Example: installation assistance, training, etc. We will be pleased to
inform you about our possibilities to support you purposefully.
ATTENTION! In the event of inquiries pertaining to maintenance, repairs
and spare parts, we require model specific data to enable us
When making use of other than the origi- to clearly identify the components of your pump I system.
nal spare parts, serious damage may Therefore, always indicate the part, model and series number
affect your device.
of your pump I system .
~ Therefore, for the operation of your device
• always use original spare parts made by
1013A94
Lincoln GmbH & Co. KG.
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User Manual
2.1A·38002·E04
Safety Instructions
Appropriate Use Disposal

Use the 203 pump only for dispensing lubricants in cen- Dispose of used or contaminated lubricants as well as of
tralized lubrication systems. The pump is designed for in- parts that were in touch with lubricant according to the legal
termittent operation. requlations pertaining to environmental protection. Make
sure to observe the safety data sheets of the lubricants
used.
Misuse
Any use of the 203 pump that is not expressly mentioned in this Exclusion of liability
User Manual will be regarded as misuse.
If the 203 pump is used or operated in a different manner other The manufacturer of the pump 203 will not accept any liability
than specified, any claim for warranty or liability will be null and for damages:
void. caused by a lack of lubricant due to an irregular refilling of
NOTE the pump.
6001a02 caused by the use of contaminated lubricants.
If personal injury or malerial damage
occurs as a resufl of inappropriate opera- caused by the use of greases which are not or only condi-
tion, e.q. if the safety instructions are tionally pumpable in centralized lubrication systems (see
ignored or resulting from an incorrect pages 16 ff).
installation of the 203 pump, no claims or caused by chemical or biological modifications of the
legal actions may be taken against lubricant used.
Lincoln GmbH & Co. KG.
caused by inadequate disposal of used or contaminated
lubricants as well as of components that have been in
General Safety Instructions touch with lubricant
Lincoln QuickLub centralized lubrication systems caused by unauthorized moditication of the system com-
ponents.
- are designed state-of-the-art.
caused by the use of unapproved parts.
- can be assembled for safe operation.
Incorrect use may result in bearing damage caused by
Operation, Maintenance and Repair
poor or over-lubrication.
::l Unauthorized modifications or changes to an installed CAUTION!
system are not admissible. Any modification must be
subject to prior consultation with the manufacturer of the The centralized lubrication system may be
lubrication system. installed by qualified personnel only. Be·
fore beginning with the installation or
service work, disconnect the power
Regulations for Prevention of Accidents supply!
4273aOO
To prevent accidents, observe all city, state and federal
safety regulation of the country in which the product will be WARNING!
used. Failure to observe the safety instructions,
Avoid the operation with e. g. touching electrically charged parts
unapproved parts. when the system is opened, or improper
handling of pump 203 may be dangerous
insufficient or contaminated lubricants. to health. If the values specified in the
4273aOO
Technical Data are exceeded, the device
may overheat. It may damage the central-
ized lubrication system and thus impair the
electric safety.
Repair should only be performed by authorized and in-
structed personnel who are familiar with the instructions.
Defective printed circuit boards should be suitably packed
and returned to the factory (see page 12, paragraph
"Printed Circuit Boards").
PageA30120
User Manual
lnstructlons, continuation
Operation, Maintenance and Repair, continuation

CAUTION! lincoln Quicklub centralized lubrication systems
Electric Voltagel must be operated only with installed pressure relief
In the case of pumps which are filled valve.
from the Dower S,UDI,lv must be must be refilled in recIIJI,,, intervals
switcbed ott betore the tubricent is recommended
rnents.
4273aOO
operate automatically. However, a regular check (approx.
ATTENTION! every 2 days) should be made to ensure that lubricant is
Risk of bursting If the reservoir is emerging from all lubrication points.
overfilledl
When filling the reservoir by means of CAUTION!
pumps with a large delivery volume It is not allowed to use the pump in
do not exceed the max. filling mark. potentially explosive fields.
1013A94
1013A94
Installation
safety equipment already fitted to the vehicle or the 1. The ADR Quicklub centralized lubrication pump complies
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
(ADR ' J) and that valid for the Federal Republic of Ger-
should only be removed for the purpose of fitting the many (GGVS 2)
system;
2. Moreover, the pump and its electrical equipment comply
must be reinstalled after fitting the system, with the regulations of annex B.2 (ADR I GGVS regula-
Keep Ouickl.ub centralized lubrication away from tions for electrical equipment) according to Rn 220000 in
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 IP6K9K.
Adhere to:
Install the ADR Quicklub203 pump, the metering devices,
the installation instructions of the vehicle or machine
lines and tube fittings as well as the electrical connection
manufacturer as regards all drilling and welding proce-
parts in accordance with the Installation Instructions. Use
dures.
only original lincoln parts.
the minimum distances between the boreholes
5. After completion of the proper installation and commis-
and upper/lower rim of the frame or between two
sioning, the installation of the must be certl-
boreholes.
fled by means of a stamp and of the
cialized workshop or expert. use
form attached to the Operating 203).
6. If the pump and the installation do not comply with the
construction regulations of ADR and GGVS, the type ap-
proval is no longer valid.
7. The Instructions
filled in must added to the
be submitted at the inspection in accordance wilth
clause 4 GGVS (see page 20).
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PageA40120
User Manual LINCOLN
OperatingInstructions
2.1A-38002-E04
Description
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
can supply up to 300 lubrication points depending on the
line lengths
00OO2618b is designed for the automatic lubrication of the connected
Fig. Pump components lubrication points
1- Reservoir 5- Plug 2A1 is designed for the delivery of greases up to NLGI grade 2
2~ Pump element 6- Filling nipple. pump at temperatures from - 25 0 C to 70° C or of mineral oils of at
3 Safety valve 7- Printedcircuitboard least 40 mrnvs (cST)
4 ~ Filling nipple,system S- Plug 1A1
Emergency lubrication 9- Returnlineconnection can be used at low temperatures down to - 40° C.
possible 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
V10-V13 ')
Low-level control in conjunction with printed circuit board
MOO-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 partof the pumptypedesignation code mentioned on
the nameplate of each pump. Example: P203 - 2XN - 1K6 - 24 -
1A1.10 - MOS.V12.!::! or ..
w 1006a93
51-----------------------'
~ Fig. 2
QUICKLUB central lubrication pump,2 I reservoir
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PageA50f20
User Manual LINCOLN
2.1A·38002·E04
Mode of Operation
Pump elements with fixed lubricant output

The electric motor drives the eccentric (see fig. 4 and 5,
pas. 1).
During the operating time:
piston (pas. 2) sucks in lubricant from the reservoir.
Refer to fig. 4.
piston (pos. 2) dispenses the lubricant to the connected
lubrication points via the metering device.
The following designs are available:

Piston diameter, K5....................... . 5 mm
200020688
Lubricant output.. approx. 2 cm'/min
Piston diameter K6 (Standard) ..... 6 mm
Fig. 3 Pump element
1- Piston Returnspring Lubricant output., approx. 2,8 cm'lmin
3- Checkvalve Piston diameter, K7 . 7 mm
[]]
Lubricant outpuL............... . approx. 4 cm'lmin
Pump elements with piston diameter C 7 Piston diameter, G7 ') ... 7 mm

must be used for supplying of chisel paste. Lubricant outpuL........... .....approx. 4 cm'lmin
6001a02
The design and the mode of operation are
the same as those of the pump elements
with piston diameter K 7.
3 4
1003a95
Fig. 4 The pump element sucksin lubricant
2 4
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1Q04a95
~ Fig. 5 The pumpelementdispenses lubricant

1 1- Eccentric 2- Piston 3- Spring 4- Checkvalve
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PageA6of20
User Manual LINCOLN
2.1 A-38002-E04
Mode of Operation, continuation
Pump elements with fixed lubricant output, continuation

Pump element B7 with Bypass Check Valve
Pump element B7 is especially suitable for an application in
contaminated environments as the supplied lubricant is
passing by the check valve (pos.t) via a bypass borehole
(pos. 2).
The output amounts to 2 cmvmln.
6251h04
Fig. 6
1- Checkvalve
2- Bypass
1 3 3- Pumppiston
625Ob04
4- Returnspring
Fig. 7 Sectional view: pump element 87
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 ad~ustable from 0.04 to
0.18m 3/slroke, or 0.7 to scm Imin.
The pump elements are factory-adjusted to the maximum
lubricant output; the adjusting dimension "S" should be
29 ± 0.1 mm (see page 8, fig. 9).
4158a99
Fig. 8 Adjustablepumpelement
PageA7of20
User Manual LINCOLN
Operating Instructions ®
2.1A·38002·E04
2 3 4
G 1/4
s 4159a98
Fig. 9 Sectional view: adjustable element

1- adjustingspindleSW 16 3- pump elementbody 6- control piston
(spannerwidth) 4- gasket 7- delivery piston
2- countemutSW 24 5- pump cylinder S dimension
Adjustment of the lubrication output Retrofit adjustment of maximum lubricant output
::P Unscrew the coupling nut for fixing the pressure relief NOTE
valve.
In order to ensure that the lubricant output
::P Loosen counter nut (pOS.2") while holding in position pump setting will be as exact as possible, first
element body (pos.3) by means of a second wrench. the actual dimension "S·I) of the maxi-
~ Change the position of the adjusting spindle (pos.1) by 6001a02 mum lubricant output must be ascertained
means of a wrench, see supply diagram. as follows. The measured difference from
the nominal value 29 must be considered
~ The dimension "S" (fig. 9) for the desired lubricant output
for all other settings values (e.g. ± 0.1).
can be ascertained by using the supply diagram.
::P Unscrew the adjusting spindle (pos.t" from the pump
A B element body (pos.3) until "S" is approx. 30 mm.
3,0 0,18 ::P Screw counter nut (pos.2) onto stop collar of the adjusting
2,7 0,16
/ spindle (pos.1).
::P Screw adjusting spindle (pos.1) with counter nut (pos.2)
2,4 0,14 / into pump element body (pos.3) until stop.
2,0 0,12
/ Adjusting of small lubricant outputs
1,7 0,10
/ ::P Before the pump element can be adjusted to a smalllu-
bricant output, the dimension "S"') for the maximum lubri-
1,4 0,08
_/ cant output must be ascertained, and the difference from
vrI
the nominal value 29 must be transferred to any desired
1,0 0,06 settings between 25.5 ... 28.5.
::P Dimension "S" must be adjusted to the desired value in
0.7 0,04 accordance with the delivery diagram.
i I
25,5 26.0 26,5 27,0 27,5 28,0 28,5 29,0
NOTE
S
6001a02 At maximum setting "S" is 29 ±O.1 mm.
~L. _ _--:- 4179a99....J
~ Fig. 10 Supply diagram

- A- lubricant output 8- lubricant output S- 1) All indications of positions refer to fig. 9.
i cm
3/min
cm3/Hub
Dimension
mm
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Page A 8 of 20
User Manual LINCOLN
2.1A-38002·E04
Pressure Relief Valve Without grease return
[]]
IMPORTANT
Each pump element must be secured with
a pressure relief valve.
The pressure relief valve is not included in
6001a02 the scope of supply of pump 203 but must
be ordered separately (see Parts Cata-
log).
The pressure relief valve
limits the pressurization in the system.
opens whenever the respective overpressure has been
reached.
is to be selected according to the requirements of the
lubrication system (see the different opening pressures:
10022618a 200,270,350 bar).
Fig. 11 Pressure relief valve If lubricant leaks from the pressure relief valve, this indi-
cates that the system is malfunctioning.
Despite existing fault monitoring devices a regular visual
and functional control must be carried out on the lubrication
system.
NOTE
Between a malfunction (blockage) and the following fault indication (lubricant leakage; moniloring intermit-
tent LED display on the control p.c.b. M08-M15) there may be a longer time delay.
Tha duration of the delay depends on the type and length of the lines, the type of lubricant, the ambient
6001a02 temperature and other influences.
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.
Fig. 12 Pressurerelief valve with grease return
PageA90f20
User Manual
2.1A-38002-E04
Pressure Relief Valve, continuation Return line Connection
00002629a 10032618
Fig. 13 Fault indicationin the case of a blockage Fig. 14 Return line connection
In the case of a blockage in the system, the grease pushes The lubricant quantities which cannot be dispensed by the
out the red pin at the pressure relief valve, thus indicating metering device must be returned to the pump via the re-
that there is a fault. turn line connection.
Control Unit
NOTE
The present Technicat Description de-
scribes the "Pump model 203 without
control unit". tnformation concerning the
6001a02
design and operation of the individual con-
trol units can be found in the respective
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.
Fig. 15 Printed circuitboard integrated in the housing

Depending on its application, the pump 203 is ready to operate,
Commissioning either
as soon as the machine contact is switched on,
as soon as the driving switch is switched on,
as soon as the trailerlsemitrailer begins to move or
after the voltage supply is applied and the machine contact
or the driving switch is additionally switched on.
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PllgeA 100120
User Manual UNCOLN
2.1A-38002-E04
Maintenance, ~""n,.; .. and Tests
Maintenance
The maintenance is essentially limited to refilling the res-
ervoir with clean lubricant in good time. However, check
regularly whether the lubricant is really dispensed to all the
lubrication points. I
• NOTE
Whenever work is done on the centralized
lubrication system, particular attention
should be paid to absolute cleanliness.
Also check the main lines and lubricant feed lines for 6001a02 Dirt in the system will cause malfunctions.
damage and replace them, if necessary.
For cleaning the system use benzine or petroleum. Do not

use trio, perchloroethylene or similar solvents.
Also do not use polar organic solvents such as alcohol,
methylacohol, acetone or similar.
2 I, 4 I, 8 I - Reservoir
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
grade 2 or mineral oils of at least 40 mm'ls (cST).
IMPORTANT
The grease or oil must be free from im-
purities and must not be liable to change
its consistency in the course of time.
6001a02
CAUTION!
If the pump is filled via the upper filling
opening, switch off the power supply
before starting filling.
1011a93
Fig. 16 Fill pump reservoir 4273aOO
CAUTION!
Risk of bursting if the reservoir is over-
filled.
When filling the reservoir by means of
pumps with a large delivery volume do not
exceed the max. filling mark.
1013A94
NOTE
If the reservoir has been completely
emptied, the pump may require until 10
minutes before it operates with its full
6001a02 output.
Page A 11 of 20
User Manual LINCOLN
Operating Instructions G
2.1A-38002-E04
Maintenance, ~on",; .. and Tests, continuation
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.
Replace pump element
:l Remove the pressure relief valve from the pump element.
:l Unscrew the pump element.
IMPORTANT
Take care that the piston, the pull-back
spring and the washer are not left lying in
the grease, otherwise the reservoir must be
6001302
disassembled in order to remove these
pieces.
IMPORTANT
Do not leave the piston, spring and washer
in the housing because they may block the
motor.
NOTE
Pump elements with adjustable lubricant
output are to be set to the required output
before installation.
:l Install a new pump element with a new sealing ring.

5026a9£
Fig. 17 Replace pumpelement
Printed circuu Boards :l Note down the jumper positions of the defective control
p.c.b. Therefore, make use oflhe chapter "Configuration of
printed circuit boards" in the User Manual of the respective
control p.c.b,
:l Pack the defective control p.c.b. properly so that it will
reach the factory without any further damages.
::l Set the jumper configuration on the new control p.c.b.
according to the one noted down from the old control p.c.b,
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User Manual UNCOLN
Operating Instructions ®
2.1A-38002-E04
Repair and Tests, continuation
Tests
Operational Test I Triggering an Additional lubrication To check the pump operation it is possible to perform an
additional test. Refar to the Technical Description of the
respective printed circuit board.
Check the Pressure Relief Valve

1st option
:l Connect the pressure gauge (0-600 bar; 0-8708 psi) to the
pressure relief valve (see page 9, fig. 11).
:l Trigger an additional lubrication cycle.
2nd option
:l Connect the manual pump of the pressure and checking
set 604-36879-1 to the pressure relief valve and check the
opening pressure by means of the manual pump.
:l The pressure relief 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
may exceed the above-mentioned range,
6001a02 causing the motor to stall. The motor is
designed in such a way that it can stall for
about 30 minutes withou: being damaged.
1- Hose line, min. length1m

2- Tvpiece
3 Pressuregauge
4- Relief cock
Fig. 1B Check the pressurereliefvalve
Page A 130120
User Manual
2.1A-38002-E04
NOTE
The pump operation can be checked from the outside by observing whether the stirring paddle is rotaling (e.g.
by triggering an additionallubricalion).
For troubleshooting in the case with integrated control units, please refer to the respective Technical
Cause: Remedy:
Power supply interrupted ::> Check the power supply and fuses.
::> If necessary rectify the fault and/or replace the fuses.
Electric motor defective ::> Check the line leading from the fuses to the pump plug.
::> Check the power supply to the motor. If necessary, replace
the motor.
Defective control printed circuit board ::> Verify the function of the control p.c.b. (see Operating
Instructions ofthe respective control p.c.b.)
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 frequency
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, also see Operating
Instructions of the respective control p.c.b.) until lubricant
penetrates from all the lubrication points.
NOTE
Depending on the ambient temperature
andlor sort of lubricant it may take 10 min-
utes of operation before the pump elements
6001,02 reach their full lubricant output.
Air bubbles in the lubricant ::> Trigger an additional lubrication cycle (also see Operating
Instructions ofthe respective control p.c.b.). Loosen the
outlet fitting or the main line on the pressure relief valve.
The lubricant must penetrate without air bubbles.
NOTE
When push-in type fittings are used, the
high-pressure hose, which is under pressure,
cannot be easily disconnected from the
6001a02 pressure relief vetve. For this purpose,
loosen the pressure relief valve or, if exists,
the filling nipple on the pressure relief valve
in order to relieve the high-pressure hose.
Unsuitable lubricant has been used ::> Renew the lubricant. See the Lubricant List pages16 ff.
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 the element.
Page A 140/20
User Manual UNCO
2.1 A-38002-E04
Technical Data
PUMP MOTOR
Admissible operating temperature .. -40 0 C to 70 °C 1j DC gear motor (interference-suppressed)
Number of outlets . . 1,2 or 3 Operating voltage .. 12 VDC or 24 VDC
Reservoir capacity 2 I, 4 I, 8 I Max. current input
Refilling via hydraulic lubrication fitting or from top -12VDC .......... 6,5A
Lubricant greases up to NLGI grade 2 -24VDC. ....................... 3A
& mineral oils of at least 40mm'Is (cST) at 40° C Speed, dependent on the counter-pressure approx.17 rpm
Type of protection IP6K 9K ace. to DIN 40050 T9
NOTE
....................UL type 4X only lor indoor use, 12 and 13
The pump motor is designed for inter-
mittent operation. For continuous opera-
11 NOTE tion applications contact the manufacturer
The pump is designed for the above first.
6001a02
mentionad temperature range. However,
most times the lubricants are pumpable
up to -25°C only. For lower temperatures
6001a02
use low-temperature lubricants.
Pump element with fixed lubricant output Pump element with adjustable lubricant output
Piston diameter r, K5 .. 5 mm KR . 7 mm
- Lubricant output .. approx. 2 cm'/min - Lubricant output 0.04 to 0,18 cm'/stroke
Piston diameter, (standard) K6 . . 6 mm ........................... . 0,7 to 3 cm'lmin
- Lubricant output ;;; approx. 2,8 cm'lmin Max. operating pressure. 350 bar
Piston diameter, K7, C7 mm Connection thread ... G 1/4"
- Lubricant output approx. 4 cm'/min - suitable for tube dia . 6 mm
Piston diameter, B7 . . 7 mm - suitable for tube dia .. 8 mm
- Lubricant output approx, 2 cm'/min
Max. operating pressure. . 350 bar
IMPORTANT
Connection thread. . G 1/4"
The lubricant outputs listed refer to
- suitable for tube dia . . 6 mm
grease of NLGI grade 2 measured at
suitablefor chiselpaste;contactthe manufacturer of the lubrication
2) 20°C, backpressure 100 bar, and nominal
system. voltage 12/24 V. Any differing pressures
6001002
or temperatures result in different lubri-
cant outputs. Any system design must be
based on the above values.
PRESSURE RELIEF VALVE

SVETVT-350-G 1/4A-D6 ..624-28894-1
SVETVT-350-G 1/4A-D8 624-28774-1
TIGHTENING TORQUES
Install pump . 18Nm
Electric motor on housing 12Nm
Pump element in housing .. 25Nm
Closure plug in housing . 12Nm
Return line connector in housing . 10-12Nm
c
o
~
'8E
"
Page A 150120
User Manual LINCOLN
2.1A-31l002-E04
Technical continuation
Connecting Diagram
~ _._------
Fig. 19 Connection diagram Ouickl.ub 203 without control unit (connection by means of Hirschmann square type plug DIN 43650-A)
A~ pumphousing F- low-levelcontrol
8 connection plug 1 switching capacity max. 60 W N A
"-' - line socket1 withconnection cable, 3-wire switching voltagemax. 230 VAC
D- connection plug2 switching currentmax. 1 A
E- line socket2 M- electricmotor
IMPORTANT
All further connection diagrems can be seen in the respective Technical Description "Electronic control units for
centralized lubrication pump 203".
lubricants
The manufacturer of the centralized lubrication system
IMPORTANT can accept no liability for:
The manufacturer of the centrelized 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-
tems.
The lubricants tested did not cause any damage due to in-
compatibility on the material used by us. The composition of IMPORTANT
Ihe lubricants, their behavior during the transport and their The lubricants released by us have not
compatibility with other material are not known to us. lubri- been tested with regard to their long-term
cant recipes may change. In case of doubt, send your re- behavior. Therefore, we can giva no guar-
quest for more information to the manufacturer of the central- anty for damages caused by chemical
ized lubrication system. reactions of the lubricant with components
of the centralized lubrication system.
Page A 16of20
User Manual LINCOLN
2.1 A-38002-E04
lubricants, continuation
NOTE
Ouickl.ub centralized lubrication systems can supply com- Absolute cleanliness is essential when
mercial greases up to NlGI grade 2 or mineral oils of at least handling lubricants. Impurities will remain
40 mm'lsec (cST) at 40"C. suspended in the lubricant and cannot
6001a02
settle. This will block the deliver; channels
causing damage to the bearings.
Recommended grease for Quicklub systems

'fYI',i Mil1.u,,,.. ,,,.
AGIP F1 Grease 24 Ca
ARAl Multipurpose grease ZS 1/2 Calli 20"C
AUTOl Top 2000 Ca -10'C
AUTOl Top2000W Ca -20'C
BP lubricating grease Ca
BP C1 lubricating grease Ca
CASTROl Cl-Grease Calli
ESSO Cazar K2 Ca
ESSO High-pressure grease Ca
FIAT lUBRIFICANTI Comar2 Li -25'C
FINA CERAN IT Ca -20'C
, FINA CERAWR2 Ca
FUCHS FN 745 Ca - 25' C
,FUCHS Renocal FN3 Ca -20'C

FUCHS Renolit HlT 2 Li _25' C
KlOBER Centoplex 2 EP
MOBil MObilgrease28 Li _30' C
MOlYKOTE TTF52 anorg. thickener - 30' C
OPTIMOl longtime PO 2 Li -20'C
,OPTIMOl OUT ClS Calli -15'C
SHEll Retinax C Ca
WESTFAlEN Greasalit ZSAZ Li _15' C
ZEllER & GMEUN ZG450 Li
ZEllER & GMEUN ZG 736 Li
Biodegradable
~ ..,...
IARAl BAB EP2 LiICa
AUTOl Top 2000 Bio Ca _25' C
'AVIA Biogrease 1 Li up to 0' C
DEA Dolon E 2 Li -15' C
FUCHS Plantogel S2 LiICa
ro
c
o KlOBER KIOberbioM32-82 Li _20' C
~
:g Use lubricants with solid matter additives only after having consulted the manufacturer of the system!
E
B
1ij
:g
</)
Page A 17 0120
User Manual LINCOLN
2.1A·38002·E04
Installation
Specifications for the installation of electric equipment in ADR 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.
To avoid short-circuits, please note the following:
current return lines must be insulated
4244a99
they must be connected to the vehicle frame (MASS 31)
Fig. 20 Measures of protectionfor electric lines below the driver's cab (up to the back wall).
1 Conductor insulation 3- Frame housings and connectors must be of protection class IP 54
2- Conductor 4- Coating
according to DIN 40050
coating (pos. 3) of tube lines 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 Zone 2 is located around zones 0 and 1.
with hazardous goods type FL are divided into zones, ac- The installation of the centralized lubrication system is
cording to the EX prescriptions, see Fig. 21. allowed outside of zones 0, 1 and 2, only, whereby the
These are the correspondences: extension is not determined in the ADR directive.
tank inside zone 0, ::> Regarding this use the form to confirm the ADR-concurring
filting cabinet zone 1 installation (see page 20).
shut-off devices zone 1

venting devices zone 1
xn
c;
o
S
~E
$)
I
<J)
Page A 180f20
User Manual UNCOLN
2.1A·38002·E04
Installation, continuation
Mounting of the Pump - Areas of Risk, continuation
Zone 0
Zone 1
ro
c
o
~ L-
u --'
4332a01
~ Fig. 21 Areas of risk on vehicles with hazardous goods
Page A 190120
User Manual
2.1A·38002·E04
Certificate for 203- -ADR
Essen, January 17~, 2002
Report: 054-01
Component designation: TO.EGG.054-01
th
For presentation at the inspection performed according to ADR chapters 9.2.2, 9.3.7 and 9.7.8 (status 15 modification);
VdTOV-explanatory leaflet 5205; ISO 6722-4; ISO/DIS 14572; EN 40050 and EN 60079-14 by an officially authorized expert of
automotive traffic.
This is to certify that the P 203-ADR Centralized lubrication Pump has been properly installed by us in the following vehicle:
Type ..
Manufacturer .
Model
Vehicle Ident. No.
in accordance with the works installation instructions using original parts of the manufacturer.
The original parts of
Lincoln GmbH & Co. KG

Heinrlch-Hertz-Str, 2-8
D-69190 Walldorl, Germany
include
a) Centralized lubrication pump with integrated control unit, model P 203- .....-ADR
Component designation: TO.EGG.054-01
b) Add-on lubricant metering device and lubricant lines
c) Electric lines for the centralized lubrication pump in accordance with the
regulations of chapter 9.2.2 01the ADR
Furthermore, this is to certify that the system has been properly installed in
consideration of the construction regulations of ADR.
................... ................ ........, date .
Signature and stamp of workshop that has installed the system.
l'ageA200f20
Owner Manual
Technical Description
2.6A-20002-C00
Printed Circuit Board for Pump 203

236-13891-1 Models V10 - V13*
236-13891-2 Models V20 - V23*
with Adjustable Pause and Operating Times

Applications for Commercial Vehicles or Industrial Applications
Subject to change without notice
*See page 4 Applications

10051327a
LINCOLN GmbH Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259
Owner Manual
2.6A-20002-C00
Survey
Pump Voltage [V] Control unit Setting ranges Part no. Applications
P1: 4 to 60 minutes
12/24 P2: 1 hour to 15 hours
203 integrated A 1: 8 seconds to 120
V10-V13*,** seconds 236-13891-1
V20-V23*,** A 2: 2 to 30 minutes 236-13891-2
integrated P : 4 to 60 minutes
M00-M23*** P : 1 to 15 hours 236-13870-1
Ü : 5 or 30 minutes
without control
unit or with
external control
unit*
12/24
203 integrated
V10-V13*,** ADR 236-13891-1
12/24
203 integrated B : 6 hours, fixed 236-13857-1
H* A: 2 to 30 minutes
12/24
203 integrated B : 6 hours, fixed 236-13857-1
H * ADR A : 2 to 30 minutes
24 VDC external P : 0.5, 1, 2...to 12 hrs 236-13834-1

203 PSG 01 A : 2, 4, 8, 16, 32 min 664-36875-1
24 VDC, 115 VAC,

203 230 VAC external P : 1 min to 160 hrs 236-13860-2
PSG 02 A : 1 min to 160 min
A - Operating time ranges B - Time of availability P - Pause time range Ü - Monitoring 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 corresponding control unit available for each
individual application.
Page 2 from 16
Owner Manual
2.6A-20002-C00
Table of Contents
Page Page
Survey ............................................................................. 2 Repair .............................................................................. 9

Printed circuit board V10-V13 and V20-V23 ............. 4 Operational test/To trigger an additional lubrication ..... 9
Applications ..................................................................... 4 Troubleshooting .......................................................... 10
Mode of operation ........................................................... 4 Technical data ............................................................... 11
Pause time ................................................................ 6 Connection diagram - Industrial applications .............. 12
Operating time .......................................................... 6 Connection diagram - Appplications for
Time storage when the power supply commercial vehicles ...................................................... 13
is switched off ............................................................. 6 Connection diagram - Appplications for
Time setting ...................................................................... 7 commercial vehicles ...................................................... 14
Combinations of the jumper positions .................... 15
Further information can be found in the following manu-

als:
Technical Description Pump Model 203

Technical Description Progressive Metering Devices for Grea-
se and Oil, model SSV
Technical Description for Electronic Control Units of the 203
pump
Printed Circuit Board 236-13857-1 - Model H
Printed Circuit Board 236-13870-1 - Models M 00 - M 15
Printed Circuit Board 236-13870-1 - Models M 16 - M 23
Timer 236-13860-2 Model PSG 02
Parts Catalog
Page 3 from 16
Owner Manual
2.6A-20002-C00
Printed Circuit Board V10-V13 and V20-V23

Applications
The printed circuit boards can be used for the following
applications
1.) Lubrication cycles only as a function of the machine wor-

king hours.
When the machine contact (external contact) is switched on

the centralized lubrication system is ready for operation.
Caution: On the PCB 236-13891-1 (V10-V13)* do not con-

nect the red core of the connecting cable to connection 1,
Fig. 1, 14, 16 (terminal 30) since terminal 30 is connected
internally with terminal 15.
1191c95
Fig. 1 - Machine contact, printed circuit board 236-13891-1 (V10-V13)
Note: The PCBs 236-13891-1 and 236-13891-2 differ only

as regards their connection of the terminals. In the case of
PCB 236-13891-2 the terminals 30 and 15 are not connec-
ted.
1191d95
Fig. 2 - Machine contact, printed circuit board 236-13891-2 (V20-V23)
2.) Lubrication cycles only as a function of the running hours

of the commercial vehicle.
When the driving switch (terminal 15) is switched on, the cen-
tralized lubrication system is ready for operation
Note: In the case of PCB 236-13891-2 also connect the

battery voltage (terminal 30).
1060a95
Fig. 3 - Driving switch

*
This designation shows the version of the PCB installed in the pump. It forms part of the pump designation on the name-
plate on each pump.
In the case of P 203-...-.K.-.A. ...-V10 the PCB 236-13891-1 is installed, see connection diagrams 1, 14 and 16.
In the case of P 203 - ... - .K. - .A.. ..-V20 the PCB 236-13891-2 see connection diagram 2, 17.
Page 4 from 16
Owner Manual
2.6A-20002-C00
Mode of Operation
The printed circuit board is integrated in the pump hou-
sing.
00002616
Fig. 4 - Printed circuit board installed in the housing
The printed circuit board automatically controls the sequence

of the pause and operating times of the model 203 central
lubrication pump as a function of the vehicle or machine wor-
king hours tB (Fig. 5).
The sequence of the pause and operating times is activated
when the machine contact or driving switch is switched on.
20002443b
Fig. 5 - Printed circuit board 236-13891-1
A lubrication cycle consists of one pause time and one ope-

rating time. Once the pause time has elapsed, the operating
time starts to run. This lubrication cycle is repeated perma-
nently after the machine or vehicle has been put into opera-
tion. Refer to Fig. 5.
During the operating time the pump element dispenses the
lubricant to the lubrication points via progressive metering
devices.
1059a95
Fig.6 - Time sequence diagram
tB - Working hours T - Lubrication cycle

tP - Various pause times T1 -Stored pause times
T2 -Operating times
Page 5 from 16
Owner Manual
2.6A-20002-C00
The pause time The operating time
- determines the frequency of the lubrication cycles within a - depends on the systems lubricant requirement ;
working cycle; - is adjustable;
- is started and stopped via the machine contact or driving - is finished when the machine contact or the driving switch is
switch; switched off.
- is adjustable. The longer the operating time, the greater the lubricant re-
When the machine contact or the driving switch is switched quirement and vice-versa.
off, the pause times which have already elapsed are stored When the machine contact or the driving switch is switched
and added up (refer to T1, Fig. 6) until the time which has off, the operating times which have already elapsed are
been set on the blue rotary switch (Fig.8) is reached. stored and added up until the time which has been set on the
The pause time setting may be different for each application. red rotary switch (Fig. 10) is reached. After this, the lubricati-
It must be adjusted in accordance with the respective lubri- on cycle starts again.
cation cycles. Also see To set the pause time. The operating time setting may be different for each applica-
tion. It must be adjusted in accordance with the respective
lubricant requirement. Also see To set the operating time.
Time storage
When switching off the ignition voltage and/or the opera-

ting voltage the times already expired are saved for an un-
limited duration.
When the power supply is switched on again the printed cir-
cuit board continues to operate from the point where it had
been interrupted.
Page 6 from 16
Owner Manual
2.6A-20002-C00
Time Setting
* To set the pause or operating time, remove the cover on the
pump housing.
Note: To reset a jumper (Fig. 9), remove the printed circuit

board.
Important: After having set the pause time or operating time,

screw the cover on the pump housing again
00002617
Fig. 7 - The cover to access the printed circuit board has been removed
To set the pause time
The pause time can be set to 15 different settings by means of

the blue rotary switch.
Time ranges: Minutes or hours

20002451b
Fig. 8 - 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: When the switch is on 0 a fault is shown at the right-

hand LED 3, see page 9.
At the same time the factory-set pause time is accepted.
Factory setting
Rotary switch on : ........................................................... 6 hours

or ................................................................................ 24 minutes
The time ranges can be modified by replugging the jumper

(Fig. 9) on the printed circuit board.
Factory setting of the jumper: see chart page 15. The combi-
20002452a nation number can be learnt from the pump type designation
Fig. 9 - Preselection of the time range
code mentioned on the nameplate of each pump.
Page 7 from 16
Owner Manual
2.6A-20002-C00
To set the operating time
The operating time can be set to 15 different setting by me-

ans of the red rotary switch.
Time ranges: Seconds or minutes
20002453b
Fig. 10 - Rotary switch - Operating time
Switch position 1 2 3 4 5 6 7 8 9 A B C D E F
Seconds 8 16 24 32 40 48 56 64 72 80 88 96 104 112 120
Minutes 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
Note: When the switch is on 0 a fault is shown at the right-

hand LED 3 Fig. 12. At the same time the factory-set opera-
ting time is accepted.
Factory setting
Rotary switch on : ...................................................... 6 minutes

or ............................................................................... 24 seconds
The time ranges can be modified by replugging the jumper

(Fig. 11) on the printed circuit board.
Factory setting of the jumper: see chart page 15. The com-
bination numbers can be learnt from the pump type desi-
gnation code mentioned on the nameplate of each pump.
20002437
Fig. 11 - Preselection of the time range
Fault indication
Rotary switch set at 0 Pushbutton 5 Fig. 12 continuously actuated (short circuit)
When one of the rotary switches 2, 3 Fig. 12 is on the 0 If a short circuit occurs at the pushbutton or is present at
setting a fault is shown at the right-hand LED 3. the external illuminated pushbutton Fig.13 or at the con-
The fault is indicated by 4 flashes of the LED. necting parts a fault is shown at the red LED 3, fig. 12.
The pump motor also runs according the flash frequency. If The fault is indicated by 3 flashes of the LED when the
the warning is ignored the controller automatically adopts voltage supply is switched on.
the factory-set values for the operating or pause time The motor of the pump also runs according to the flash
frequency.
Page 8 from 16
Owner Manual
2.6A-20002-C00
Repair
The defective printed circuit boards should be suitably packed If the printed circuit board must be replaced, a model
and returned to the factory. V 10 (V20) will always be delivered. See chart page 15.
Before installing another printed circuit board, take care that
the setting of the jumper or that of the operating/pause time
is the same as on the old printed circuit board.
Operational Test / To Trigger an Additional

Lubrication Cycle
To check the pump operation it is possible to perform an ope-
rational test.
Pumps model 203 installed on machines
* Switch on the machine contact.
Pumps model 203 installed on commercial vehicles
* Switch on the driving switch
For all pumps

To check whether power is applied to the printed circuit
board, observe whether the LED 1 Fig. 12 is lit.
20002457b * Press pushbutton 5 on the printed circuit board (> 2 secon-
Fig. 12 - LED on the printed circuit board ds) until the right-hand LED 3 lights up.
1 - LED, left-hand 4 - Rotary switch, operating time
2 - Rotary switch, pause time 5 - Pushbutton for additional A shorter pause time elapses, followed by a normal lubricati-
3 - LED, right-hand lubrication on cycle.
Additional lubrication cycles can be triggered at any time.
Note: In the case of model 203 pump, version 2A1, with exter-
nal illuminated pushbutton, it is also possible to trigger an addi-
tional lubrication cycle via this pushbutton.
20002458
Fig. 13 - To trigger an additional lubrication cycle, only pumps with illuminated

pushbutton
Page 9 from 16
Owner Manual
2.6A-20002-C00
Troubleshooting
Note: The pump operation can be checked from the outside by circuit board are lit or whehter the signal lamp of the illumi-
observing whether the stirring paddle is rotating (e.g. by trigge- nated pushbutton (if any) is lit.
ring an additional lubrication), whether the LED on the printed
Fault: the pump motor does not run

Cause: Remedy:
Voltage supply interrupted Check the voltage supply to the pump. If necessary, elimina-
te the fault.
Voltage supply to the printed-circuit interrupted Check the line leading from the pump plug to the printed cir-
cuit board.
If the voltage is applied, the left-hand LED is lit.
Voltage supply interrupted betweeen the printed circuit board Triggering an additional lubrication cycle
and the motor If the voltage is applied, the right-hand LED is lit.
Printed-circuit board defective Replace the printed circuit board.
Fault: Right-hand LED 3 Fig. 12 flashes

Cause: Remedy:
One of the two rotary switches 2, 4 Fig. 12 is on 0. Set rotary switch to a number or a letter.
Signal: 4 flashes
Short circuit at pushbutton 5 Fig. 12 or, if present, at the illu- Check whether the short circuit is at he PCB or, if present,
minated push button or at their connecting parts at the illuminated pushbutton.
Signal: 3 flashes If necessary, exchange the PCB or the illuminated pushbut-
ton.
.
Page 10 from 16
Owner Manual
2.6A-20002-C00
Technical Data
Rated voltage ............................................................ 12/24V DC Time setting

Operating voltage
12V/ 24V .......................................................... 9V to 30V Pause time, depending on the jumper position:
Residual rippple in relation ............................................... 4; 8; 12; 24 to 60 minutes
with the operating voltage ................... ± 5% acc. to DIN 41755 ......................................................... 1, 2, 3...to 15 hours
Motor output ............................ Transistor 7A/short-circuit proof Operating time, depending on the jumper position
Reverse voltage protection: ............................................ 8; 16; 24;....to 120 seconds
The operating voltage inputs are protected against ................................................... 2, 4, 6,....to 30 minutes
polarity reversal Factory setting
Temperature range .................................. -25°C to 70°C Pause time .......................................................... 6 hours
Lamp current in the case of pump 2A1 ....................... max. 2 A or .................................................................... 24 minutes
Class of protection Operating time ................................................ 6 minutes
Printed circuit board installed in housing .................... IP 6K 9K or .................................................................. 24 seconds
In order to protect the printed circuit board against condensati-

on it has been covered with a protective varnish.
All the printed circuit boards comply with the EMC (Electroma-
gnetic compatibility) guidelines for road vehicles acc. to DIN
40839 T1, 3 and 4
and the EMC guideline 89 / 336 / EWG
Emitted interference acc. to ................. EN 55011 / 03.91 and
........................................................ EN 50081-1 / 01.92
Noise immunity acc. to ............................. EN 50082-2 / 03.95
The type 203 pumps with PCB V10 - V13 (V20 - V23) comply
with the Automotive EMC Directive 95/54/EEC and with the
EC approval mark e1
021016
shown on the nameplate
Page 11 from 16
Owner Manual
2.6A-20002-C00
Connection Diagram - Industrial Applications, Printed Circuit Board 236-13891-1 (V10-V13)
1192c95
Fig. 14 - Connection diagram Quicklub 203 with adjustable pause time

Connection via Hirschmann type-in connectors DIN 43650-A
A- Printed circuit board 1A1 - Pump without illuminated pushbutton G- Cable connector 2*
B- Pump housing 2A1 - Pump with cable connection for H- Line socket 2 (grey)
C- Cable connector 1 illuminated pushbutton* for connection cable, 3-wire*
D- Line socket 1 (black) F - Machine contact I- Pushbutton for additional lubrication
for connection cable, 3-wire J - Signal lamp in the case of low-level
* on request control
Attention! If a pump model 103 CS...E2 is replaced by a pump model P203-...-...-2A1.10, the lamp connection of the
illuminated pushbutton must be changed from minus to plus.
- Low-level control*
31 - Earth N- Level control*
15 - Driving switch Z- Additional lubrication*

M - Motor - Signal lamp*

1009c93
Fig. 15 - Terminals of the printed circuit board
* equipment available on request
Page 12 from 16
Owner Manual
2.6A-20002-C00
Connection Diagram - Applications for Commercial Vehicles

Printed Circuit Board 236-13891-1 (V10-V13)
1155d95

Connection via square type plug DIN 43650-A
A- Printed circuit board 2A1 - Pump with cable connection K- Cable connector 2**
B- Pump housing for illuminated pushbutton** L- Line socket 2 (grey)
C- Cable connector 1 F - Driving switch with connection cable, 3-wire**
D- Line socket 1 (black) G - Fuse 10 A M- Illuminated pushbutton**
with connection cable, 3-wire H - Cable, black O- Signal lamp in the case of low-level
1A1 - Pump without illuminated pushbutton I- Cable, brown control
P- Battery cutoff*
*does not belong to the scope of delivery

**equipment available on request
Caution: Do not connect the red core (not shown: cf. J Fig. 17)
of the 3-core connecting cable to the wire box 1 (D, Fig. 16)
since the PCB is connected internally between 30 and 15.
Page 13 from 16
Owner Manual
2.6A-20002-C00
Connection Diagram - Applications for Commercial Vehicles

Printed Circuit Board 236-13891-2 (USA)
1155e95

Connection via square type plug DIN 43650-A
A- Printed circuit board 2A1 -Pump with cable connection K- Cable connector 2**
B- Pump housing for illuminated pushbutton** L- Line socket 2 (grey)
C- Cable connector 1 F - Driving switch with connection cable, 3-wire**
D- Line socket 1 (black) G - Fuse 10 A M- Illuminated pushbutton**
with connection cable, 3-wire H - Cable, black O- Signal lamp in the case of low-level
1A1 - Pump without illuminated pushbutton I- Cable, brown control
J - Cable, red P- Battery cutoff*
*does not belong to the scope of delivery

**equipment available on request
30 - Battery voltage - Low-level control*
31 - Earth N- Level control*

15 - Driving switch Z- Additional lubrication*
M - Motor - Signal lamp*
1009b93
* equipment available on request
Fig. 18 - Terminals of the printed circuit board 236-13891-2
Page 14 from 16
Owner Manual
2.6A-20002-C00
Combinations of the jumper positions - Survey
Pause time ranges Operating time ranges Jumper positi-

Possibilities of
P I ons
preselection 4 - 60 min 1 - 15 h 8 - 120 s 2 - 30 min See Fig. 8, 10
Combination no.
V 10, V 20
Standard X X
V 11, V 21 X X
V 12, V 22 X X
V 13, V 23 X X
Page 15 from 16
Owner Manual
2.6A-20002-C00
Page 16 from 16
Owner Manual
2.2A-10001-C99
QUICKLUB
Progressive Metering Devices
for Grease and Oil
Typ SSV
Planning and Layout of Progressive Centralized Lubrication

Systems
4137b97
Subject to modifications
Page A 1
Owner Manual
2.2A-10001-C99
Safety Instructions
Appropriate Use Regulations for Prevention of Accidents

Use the SSV lubricant metering devices only for dispensing Adhere to the regulations for prevention of accidents which
lubricants in centralized lubrication systems. are effective in the country where the system is to be used.
General Safety Instructions Operation, Repair and Maintenace

The progressive centralized lubrication system connected to Repair should only be performed by:
the QUICKLUB pump model 203 must always be secured - authorized and
with a safety valve. - instructed personnel
LINCOLN SSV lubricant metering devices are state of the who are familiar with the centralized lubrication systems.
art.
Incorrect use may result in bearing damage caused by poor
or over-lubrication. Installation
Each outlet which will be used must be equipped with a Install the metering devices at a suitable location in accor-
check valve. dance with the lubrication diagram.
In the case of the metering devices model SSV 6 - 12 the It is recommended that the metering devices be installed in
outlets 1 and/or 2 must never be closed. In the case of the such a way that the outlets are not close to the chassis or the
metering devices model SSV 14 - 22, the two outlets with attaching plate. This will facilitate troubleshooting in the case
the highest numbers must never be closed. the system is blocked.
Unauthorized modifications or changes to an installed sy- The main metering devices with indicator pin must be instal-
stem are not admissible. Any modification must be subject to led in such a way that the indicator pin is easily visible.
prior consultation with the manufacturer of the lubrication sy- When the push-in type fittings are used, note the follo-
stem. wing:
Use only original LINCOLN spare parts (see Parts Catalog) For the metering device inlet use only push-in type fittings
or the parts approved by LINCOLN. with reinforced collar and sealing ring.
For the outlet fittings of the main metering device use only
valve bodies with reinforced collar.
NOTE: In the case of construction machines or agricultural
machines use high pressure plastic hoses for the lubricant
feet lines. In such cases the outlet fittings of the secondary
metering devices and the connection fittings to the lubricant
points must have a reinforced collet.
Use only the main and feed lines specified by LINCOLN and
adhere to the specified system pressures.
Page A 2
Owner Manual
2.2A-10001-C99
Table of Contents
Page Page
Safety instructions ....................................................... 2 Tube fittings, push-in type ........................................ 11

Progressive metering devices model SSV ............... 4 (secondary metering device)
Suitable lubricants ........................................................... 4 Single lubricant output .............................................. 11
Progressive metering devices - General .................. 4 Double or multiple lubricant output .......................... 11
Features of a progressive metering Lubricant metering devices model SSV 14
device ......................................................................... 4 to SSV 22 ....................................................................... 12
Applications ...................................................................... 5 Tube fittings, push-in type ............................................. 12
Lubricant distribution within the metering device .......... 6 Metering device ....................................................... 13
Interruption of the lubricant supply ........................... 7 Connection of the lubricant feed lines
Monitoring of the operation ............................................. 8 and main line ............................................................ 14
System-dependent monitoring .................................. 8 Protective cap for push-in type fittings ................... 14
Visual monitoring ....................................................... 8 Pressure plastic tubes and high-pressure
Electrical monitoring .................................................. 8 plastic hoses ................................................................ 15
Dertermining the lubricant output by Troubleshooting ............................................................. 16
combining outlets ............................................................. 9 Planning and layout .................................................... 18
Tube fittings, screw-type Instructions for QUICKLUB progressive systems ........ 18
(main and secondary metering devices) .................. 9 Technical data ................................................................ 26
Tube fittings, push-in type Tightening torques ......................................................... 26
(main metering device) ............................................ 10 Dimensions .................................................................... 27
Lubricants ....................................................................... 28
Further information can be found in the following manu-

als:
Technical Description QUICKLUB Pump 203

Technical Description for Electronic Control Units of pump 203 :
Printed-Circuit Board 236-13856-1 - Model F *
Printed-Circuit Board 236-13891-1 - Model V10 - V13*
Printed-Circuit Board 236-13857-1 - Model H *
Printed-Circuit Board 236-13870-1 - Models M 00 - M 15*
Printed-Circuit Board 236-13870-1 - Models M 16 - M 23*
Timer 236-13860-1 - Model PSG 02
Parts Catalog
* The design of the printed circuit board is indicated by the model designation which is part of the pump type identification code mentioned on the
pump nameplate. Example: B. : P 203-2XN - 1K6 - 24 - 1A1.10 - V00
Page A 3
Owner Manual
2.2A-10001-C99
Progressive Metering Devices Model SSV

Suitable Lubricants
The progressive metering devices model SSV can be used NOTE: It must nevertheless be ensured that the oils or greases
for dispensing used do not alter their consistency significantly in the course of
- mineral oils of at least 40 mm²/s (cST) or time or under the influence of temperature or pressure.
- greases up to the penetration class NLGI 2
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;
- have a lubricant output of 0.2 cm³ per outlet and piston stro-
ke;
- when one or more outlets are closed (see Combining out-
lets) they can dispense a double or multiple lubricant quan-
tity;
- 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 quan-
tities.
- can be monitored visually or electronically.
Any blockage in a lubrication circuit is indicated by grease
leaking from the respective pressure relief valve.
10002709
Fig. 2 - 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 cycles
are repeated constantly;
- each piston must have completed its movement fully before
the next piston can be moved, no matter whether the lubri-
cant is dispensed continuously or intermittently;
- the pistons operate interdependently of one another;
- no lubrication point which is connected to the system is omit-
ted.
10002710
Fig. 3 - Sectional view of a SSV 8 metering device

Page A 4
Owner Manual
2.2A-10001-C99
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. 4 which illu-
strates this basic feature.
1205a95
Fig. 4 - Central lubrication point
When they are used in connection with hand-operated

pumps, pneumatic or electric pumps the progressive mete-
ring devices are a simple and low-cost centralized lubrication
system. See Fig. 5.
1 - Hand-operated pump
2 - Pneumatically operated pump
3 - Electrically operated pump
4 - Lubrication fitting block
4024a95
5 - Hand-operated filling pump
Fig. 5 - Possible pump connections
4025a95
Fig. 6 - Multiline pump expanded by a progressive metering device
Progressive metering devices can be used in two-line or sin-

gle-line centralized lubrication systems in order to increase
the number of outlets of multiline pumps or to subdivide the
single metering devices and measuring valves (Fig. 4 - 8)
also as secomdary metering devices in large and small oil
circulating systems.
1207a95
Fig. 7 - Two-line system expanded by a progressive metering device
Page A 5
Owner Manual
2.2A-10001-C99
1206a95
Fig. 8 - Single-line system expanded by a progressive metering device
Lubricant Distribution Within the Metering

Device The 5 following illustrations show how the lubricant distributi-
on is made to the individual outlets.
Note: To simplify the description we only show the lubricant dis-

tribution for outlets 2, 7, 5, 3 and 1. The remaining distribution
operations are derived from the logical pumping sequence.
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 pressure
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. 9 - 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 lubricant
quantity ahead of the the left-hand end of piston B to be dis-
pensed to outlet 7 (dashed arrow).
2008a95
Fig. 10 - Phase 2
Page A 6
Owner Manual
2.2A-10001-C99
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 quan-
tity ahead of the left-hand end of piston C to be dispensed to
outlet 5 (dashed arrow).
2009a95
Fig. 11 - Phase 3 Lubricant, pressureless
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 me-
tering device via outlet 3 (dashed arrow).
2010a95 Lubricant, pressureless

Fig. 12 - 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 dis-
pensed 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
Fig.13 - Phase 5
When the lubricant supply is interrupted
- the pistons come to a halt;

- the lubricant is no longer dispensed to the lubrication point.
When the lubricant is fed again to the metering device, the
cycle begins from the point where it had been interrupted.
Page A 7
Owner Manual
2.2A-10001-C99
Monitoring of the Operation

System-dependent monitoring
The main metering device (B, Fig. 14) and the secondary
metering devices are connected by a main line G. This fea-
ture automatically causes the linkage of the progressive sy-
stem 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 lubricant 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 progressive sy-
stem installed downstream of the pump stops operating.
The fundamental internal structure of the progressive mete-
ring device guarantees the self-monitoring of the sequence
1064b95 within the metering device.
Fig. 14 - Example of a lubrication system The linkage makes it possible to monitor the operation of the
whole system.
A - Safety valve E - Pressure plastic tube (Ø 6 x 1.5 mm)
B - Main metering device SSV 6 F - Secondary metering device
C - Secondary metering device SSV 8 SSV 12
D - Secondary metering device SSV 6 G - High pressure plastic hose
(Ø 8.6 x 2.3 mm)
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
control switch (KS) or a proximity switch (KN).
Electrical monitoring (microprocessor control)
1011a96
Fig. 15 - Indicator pin installed on metering device
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 reservoir is
empty, the piston detector can no longer record the piston
movements. The switching off signal is not transmitted to the
control unit. A fault signal occurs.
Important! For the system monitoring it is recommended that

one SSV metering device with pre-assembled piston de-
tector be used per lubrication circuit. These special metering
devices must be ordered separately for each lubrication sy-
stem. Refer to the Parts Catalog.
The pre-assembled metering devices have the designation
00002634 SSV ... - N (they are available for SSV 6, 8, 10 and 12). They
Fig. 16 - Piston detector installed on the metering device must be installed in the system instead of a normal metering
device.
Page A 8
Owner Manual
2.2A-10001-C99
The whole system can be monitored visually via the pressure

relief valve. If lubricant is leaking at the pressure relief valve
during the distribution sequence, this indicates that there is a
blockage in the system.
Important: In the case of the progressive metering devices mo-

dels SSV 6 - 12 the outlets 1 and/or 2 must never be closed.
In the case of the progressive metering devices model SSV 14
- 22, the two outlets with the highest numbers must never
be closed, otherwise the system would block owing to the
structure of the metering device.
4092a97
Fig.17 - Pressure relief valve
Determining the Lubricant Output by Combining Outlets
Tube Fittings, Screw-Type
1012c96
Fig. 18 - Install the outlet fittings and closure plugs in accordance with the dosage
1 - Inlet fitting 5 - Outlet fitting assembly 9 - Junction channel

2 - Delivery hole of the piston 6 - Valve body with clamping ring (brass) 10 - New closure plug (M 10 x 1), outlet
3 - Closure plug (M 10 x 1), installed with 7 - Cutting ring borehole with hex. socket head and
copper washer (old) 8 - Coupling nut sealing edge, replacement for pos. 3
4 - Closure plug (new M 11 x 1, old R 1/8),
piston (with champfered)
Page A 9
Owner Manual
2.2A-10001-C99
The output quantities can be raised by closing outlet boreho- Clamping ring (Fig. 18) closes the junction channels 9 to the
les. other outlet channels.
Install an outlet fitting assembly 5 (M 10x1) in each outlet Note: In the case of push-in type fittings the clamping ring is
borehole which will be used. Refer to Fig. 18, 19, 20. always a firm component part of the valve body.
Never remove closure plug 4 (M 11x1 chamfered) on the
piston side or remove it only for installing a piston detector. Important: In the case of the progressive metering devices
model SSV 6 - 12 and the divider blocks SSV 14 - SSV 22
Note: Never use closure plug 12 (Fig. 18) or 7 (Fig.19, 20) as a the outlets 1 and/or 2 must never be closed. In the case of
piston closure plug 4 (G 1/8) on older models of meteringde- the combined progressive metering devices model SSV 14 -
vices. 22, the two outlets with the highest numbers must never
Never use closure plug 12 (Fig. 18) or 7 (Fig. 19, 20) as a be closed, otherwise the system would block due to the struc-
piston closure plug 4. ture of the metering device.
Important: Always use valve body (Fig. 18) in conjunction with

clamping ring.
Tube Fittings, Push-in-Type (main metering device)
1203c95
Fig. 19 - Install the push-in type outlet fittings and the closure plugs in accordance with the dosage
1 - Inlet fitting with protective cap * 5 - Valve body assembly (with reinforced collar)
2 - Delivery borehole of the piston 6 - Junction channels
3 - Closure plug (M 10x1) with copper washer installed in outlet 7 - New closure plug with hex. socket head and sealing edge,
borehole (old) outlet borehole replacement for pos. 3
4 - Closure plug (new M 11x1, old R 1/8 chamfered), piston
* on request
Page A 10
Owner Manual
2.2A-10001-C99
Tube Fittings, Push-in Type (secondary metering devices)
1204c95
Fig. 20 - Install the push-in type outlets fittings and closure plugs in accordance with the dosage
1 - Inlet fitting 4 - Closure plug (M11x1) (chamfered), piston

2 - Delivery borehole of the piston 5 - Valve body assembly (with knurled collar)
3 - Closure plug (M10x1) installed in outlet borehole with copper 6 - Junction channels
washer (old) 7 - New closure plug with hex. socket head and sealing edge,
outlet borehole
Single lubricant output
The simple lubricant output is the lubricant quantity dispen-

sed by a piston per stroke and per outlet borehole to one
lubrication point. It amounts to 0.2 cm³.
Double or multiple lubricant output
If one or more lubrication points require a double or a multi-

ple lubricant amount, this can be performed by closing one
or more outlets.
As shown in Fig. 21, outlet borehole 10 has been closed.
The lubricant quantity supplied by this outlet flows out of the
metering device via outlet 8.
1014b96 Total quantity at outlet 8:
Fig. 21 - Single, double and triple lubricant output - is the quantity of outlet 8
- plus the lubricant quantity of outlet 10.
If a triple quantity is needed (at outlet 1), close the outlet
x - Outlet quantity (1x: single, 2x: double, etc.) borehole located above the discharge borehole. Refer to
1... 10 Outlet numbers outlets 3 and 5 on Fig. 21.
A - Clamping ring (brass)
Page A 11
Owner Manual
2.2A-10001-C99
Lubricant Metering Devices SSV 14 up to SSV 22

The 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 combined 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 high-
est numbers must never be closed, otherwise the system
would be blocked.
- if, for example, outlet 8 is closed, the lubricant quantity dis-
pensed to this outlet flows out of the metering device via out-
let 10, etc. Refer to item Double or multiple lubricant output
above.
00002633
The lubricant metering device blocks model SSV 14 to SSV
Fig. 22 - Lubricant metering device Model SSV 16
22 function in the same way as the metering devices model
SSV 6 to SSV 12
The outlets 1and/or 2 must never be closed.
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.
Check valves for tube dia. 4 mm and 6 mm are available.
4239a99
Fig. 23 - Single parts of the check valve
1 - coupling nut 3 - valve body with seal and clamp ring

2 - ferrule
Page A 12
Owner Manual
2.2A-10001-C99
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. 24) and sealing ring 1b at the thread.
1a - Collet
1b - Sealing ring
1008a98
Fig. 24 - Inlet fittings
Check valves
Main metering device

Use check valves type A, Fig. 25 with reinforced collet 1a and
smooth flange (Part no. 226-14091-4).
Secondary metering device

Use check valves type B, Fig. 25 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 secondary metering devices must have a reinforced collet
1009a98 and smooth flange.
Fig. 25 - The different types of check valve
A - Check valve with reinforced collet

B - Check valve with knurled collet
1a - reinforced collet
1b - knurled collet
Page A 13
Owner Manual
2.2A-10001-C99
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 check valves with reinforced collar.
4156a98
Fig. 26 - 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 fit-
tings 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
the low-pressure section. Applications for construction machi-
nes or agricultural machines, however, require the use of check
valves and inlet fittings (towards the lubrication point) with rein-
forced collet for the low-pressure range. Refer to Parts Cata-
log.
The pressure plastic tubes are marked with white lines (Fig.
27) as an installation aid.
* Cut the pressure plastic tube off at one of the white lines be-
4157a98
fore it is mounted. Then insert the plastic pressure tube into
Fig. 27 - Check valve with knurled collet and pressure plastic tube 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 fit-
tings, check valves and safety valves can be equipped with pro-
tective caps.
00002632
Fig. 28 - Push-in type fitting with protection cap

Page A 14
Owner Manual
2.2A-10001-C99
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 lubri-
cation 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. 29, counterclockwise

onto the high pressure plastic hose 2 until the illustrated di-
1028a96 mension of 11 mm is reached. Then screw the hose stud 3
Fig. 29 - Preassembly of the threaded sleeves and hose studs on the main line into the threaded sleeve 1.
1 - Threaded sleeve Important: Before screwing the parts 1 and 3, rub them with
2 - High - pressure plastic hose Ø 8.6 x 2.3 mm oil.
3 - Hose stud
Note: The outside diameter of the main line may show variati-
ons in dimension. In such a case, press the threaded sleeve 1
at the end where it will be screwed onto the main line so that it
becomes oval in shape (1 to 2 mm). This will prevent the high
pressure 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 counterclockwi-
se onto the main line until the gauge inserted in the sleeve be-
gins to rise.
1029a96
Fig. 30 - Preassembly of the threaded sleeve by

means of an adjusting gauge
1 - Threaded sleeve
2 - High - pressure plastic hose Ø 8.6 x 2.3 mm
3 - Adjusting gauge 432-23077-1
Page A 15
Owner Manual
2.2A-10001-C99
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
In the case of the metering devices SSV 6 through 12 and accordance with he following example:
the metering device blocks SSV 14 to SSV 22 the outlet
boreholes 1 and/or 2 are closed. In the case of the combined
metering devices SSV 14 through 22 the two outlet boreho- Allow pump to run (see To trigger an additional lubrication
les with the highest numbers are closed. cycle).
Loosen all main line connections G one after the other from
The fault can be identified by: the main metering device (B, Fig. 31) leading to the secon-
a)grease leaking at the safety valve; dary metering devices. If f. ex. grease or oil emerges under
b) the fact that the indicator pins installed on the metering de- pressure from outlet 1 of main metering device B, the blocka-
vices (if any) no longer move; ge will be found in the lubrication circuit of the secondary me-
c) the fault signal of the signal lamp (if any) or LED display tering device D.
Note: 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 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 mete-
ring device D one after the other. If f. ex. grease or oil emer-
ges under pressure from outlet 3 of metering device D, the
blockage will be found in the line of outlet 3 or in the connec-
ted 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 only one piston stroke. A complete cycle of all metering
devices requires several strokes.
Check safety valve A. Replace it, if necessary.
1064a95
Fig. 31 - Example of a lubrication system
A - Safety valve E - Pressure plastic tubes

B - Main metering device F - Secondary metering device SSV
C - Secondary metering device 12
SSV 8 G - High-pressure plastic hose
D - Secondary metering device
SSV 6
Page A 16
Owner Manual
2.2A-10001-C99
Fault: Blockage in the downstream progressive system (continued)
Cause: Correction:
Replace the metering device or clean it in accordance with

Metering device blocked the following procedure:
Remove all tube fittings.
Unscrew the piston closure plugs.
If possible, try to eject the piston using a smooth drift (Ø smal-
ler than 6 mm; 0.24 in.).
Important: The pistons are precision-fitted into the holes.
Mark the pistons with regard to their installation position and
direction after they have been removed. They must not be
exchanged.
Thoroughly clean the metering device bodies in fat-dissol-
ving washing agent, blow them through with compressed 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 de-
vices 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 clam- Remove the valve body and install a clamping ring
ping 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 In-
structions.
Page A 17
Owner Manual
2.2A-10001-C99
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 lub-
ricant 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.
4093a97
Fig. 32 - Selecting the pumps
2. Determining the number of lubrication points to be con-

nected
Exception: High-speed rotating parts. Also consider the lubri-
cation points on auxiliary units or other superstructures.
1007a96
Fig. 33 - 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. 34 - Combining the lubrication points into groups
Page A 18
Owner Manual
2.2A-10001-C99
4. Determining the lubricant requirement of the combi-

ned lubrication points
The lubricant requirement depends on the design and ope-
rating conditions of the individual bearings.
The lubricant quantities can be adapted to the requirement
of the respective lubrication points by closing outlets (ex-
ception: 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 mul-
tiple lubricant quantity.
1016a96
Fig. 35 - Adapting the lubricant quantities
5. Allocating a metering device with the appropriate num-

ber 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.
In the case of a monitored system, check where the mete-
ring device with the pre-assembled piston detector is to be
used (as a main metering device or as a secondary mete-
ring device). The condition for this is that each lubrication
point receives lubricant at least once per lubrication cycle.
Note: Metering devices with up to 22 outlets can be used in

the case of special superstrucutures.
1004a96
Fig. 36 - Allocating the metering devices
6. Connecting the metering device outlets with the lubri-

cation points to be connected
Attention: 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 14 to SSV 22 the two
outlets with the highest numbers (examples: 21 and 22 in the
case of SSV22) must always be connected to a lubrication
point.
1005a96
Fig. 37 - Connecting the metering device to the lubrication points
Page A 19
Owner Manual
2.2A-10001-C99
If there is an odd number of lubrication points or if the lubrica-

tion points require a large lubricant quantity, select the next
larger metering device.
Close the outlets which are not required (see Fig. 36, 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. 38 - 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 lub-
rication points.
Check whether one or more secondary metering devices re-
quire larger lubricant quantities. See direct connection of the
metering device to respectively one single pump element,
example Fig. 37.
If necessary, modify the allocation of the lubrication points.
Maximum size of the main metering device: SSV 12
1003a96
Fig. 39 - Determining the size of the main metering device
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 supp-
lies 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 application conditi-
ons of the machine or vehicle.
1002a96
- Divide the lubricant quantities as shown in the example Fig.
36. Also see the calculation example in Fig. 37.
Fig. 40 - Divided lubricant quantity Connect the outlets of the main metering device which are
not used to the pump via a return line R.
Page A 20
Owner Manual
2.2A-10001-C99
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
- at 24 V rated voltage Lubricant output per piston stroke:
Pump element K5 ........... 2 cm3/min*; 0.10 cm³/stroke** Pump element piston dia. 6 mm ........................ 0.10 cm³
Pump element K6 ........ 2.8 cm3/min*; 0.15 cm³/stroke** Pump element piston dia. 7 mm ........................ 0.23 cm³
Pump element K7 ........... 4 cm3/min*; 0.22 cm³/stroke**
Adjustable pump element K7...0.04 - 0.18 cm³/stroke* ** Adjusting range ............................................ 25% to 100%
1001a96
Fig. 41 - Dividing the lubricant quantity - Calculation example
10. Adjusting the running time (operating time) of the For the running time of a system select the time for the big-
pump (not for pumps with microprocessor control) gest secondary metering device, as a function of the main
The chart below shows the required pump operating times in metering device used.
the case of various combinations of the main metering de- If the time mentioned below cannot be preselected, take the
vice and the biggest secondary metering device. next larger time value.
With the indicated times each lubrication point receives
lubricant at least once a day.
Required minimum running times

(pump element K6)
Main metering device SSV 6 SSV 8 SSV 10 SSV 12
Lubricant output of Single Double Single Double Single Double Single Double
the 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

Page A 21
Owner Manual
2.2A-10001-C99
During the operating time (pump running time) the used lub- It is important to take care that the lubricant is renewed or top-
ricant is renewed or topped up in the bearings. ped up within a predetermined time of application of the machi-
The frequency of renewal/topping up and the quantity which ne or vehicle so that there is no damage to the bearings.
must be supplied to a single lubrication point depends on If normal or larger bearings are connected to the secondary
several factors, e.g.: metering devices model SSV 10 or SSV 12 or up to SSV 22,
- bearing size these metering devices must receive the double or multiple
- kind of bearing - open or closed bearing, rolling bearing or quantity.
friction bearing In the case of smaller bearings with a small lubricant require-
- frictional force ment the SSV 10 or SSV 12 will receive a single lubricant
- bearing loads quantity.
- adjustable running times of the pump, etc.
The required quantity may be very different as a result of the
above mentioned factors.
11. Connecting machine bearings
4022a95
Fig. 42 - Example of connection for machine bearings
12. Connecting a fifth-wheel

Fifth-wheels must be supplied from the main metering de-
vice with a double quantity.
1018a96
Fig. 43 - Fifth-wheel with 6 lubrication points
Page A 22
Owner Manual
2.2A-10001-C99
1019a96
Fig. 44 - Fifth-wheel with 7 lubrication points
13. Connecting a liftgate
1020a96
Fig. 45 - Liftgate with 12 lubrication points
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 superstructure (e.g. cra-
ne) 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 safe-

ty valve.
1021a96
Fig. 45 - System using two pump elements

Page A 23
Owner Manual
2.2A-10001-C99
15. Using quick coupling 504-36804-1

For removable superstructures, i.e. loading cranes, use a re-
movable quick coupling with integrated return line.
Important: If a simple coupling (which can be coupled under

pressure) is used instead of a quick coupling, the lubricant line
must be connected to the pump via a return line after the su-
perstructure has been uncoupled, otherwise the system will
be blocked.
1022a96
Fig. 46 - Using a quick coupling with integrated return line
1 - Pump 5 - Progressive metering device

2 - Return line (secondary metering device)
3 - Progressive metering device can be uncoupled
(main metering device) 6 - Lines to the secondary
4 - Quick coupling metering devices
16. Maximum line lengths
Important: The lubricant division should be made only via 2 steps of metering devices, i.e. main metering device - secondary
metering device - lubrication point
1023a96
Fig. 47 - Maximum line lengths

A - Main metering device

B - Secondary metering device
C - Lubrication point
Page A 24
Owner Manual
2.2A-10001-C99
17. Pressure losses
1024a96
Fig. 48 - Pressure losses in the metering devices or tube lines
PA Pressure loss, main line PC Pressure loss, main line PD Pressure loss, secondary metering device
PB Pressure loss, main metering device between main and secondary metering device PE Pressure loss, lubricant feed line
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.
Lubricant penetration class Maximum pressure loss with tube 6x1,5 mm (NW 3 mm)
Temperature 0° C 15° C 25° C

NLGI 0 5 bar/m 4 bar/m 2,5 bar/m
NLGI1 8 bar/m 7bar/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 data relating to the pressure loss per metering de-
vice refer to metering devices with 6, 8, 10 and 12 outlets, na-
mely the main and secondary metering devices.
The sum of all pressures, from PA to PE plus 5 bar for the All the values mentioned in the tablet are average values
rolling bearings (lubrication point) or plus 15 bar for friction based on real test results.
bearings must not exceed 80% of the recommended wor- The NLGI class of the grease only indicates the statistical
king pressure of the pump. 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 A 25
Owner Manual
2.2A-10001-C99
Technical Data
Metering Device Model SSV Lines
Lubricant output per outlet and per stroke ............ 0.2cm³ MainLine
Max. operating pressure ....................................... 350 bar Min. bursting pressure (in connection with
Min. operating pressure .......................................... 20 bar hose clamp, screwed). .......................................... 600 bar
Max.differential pressure Min. bending radius. ............................................... 35 mm
between two outlets ............................................... 100 bar Min. temperature .................................................... - 40° C
Outlet connection for tube ..................................... Ø 6mm
Inlet connection ......................................................... G 1/8 Lubricant Feed Line
Operating temperature ............................. - 25° C to 70°C Min. bending radius ................................................ 50 mm
Bursting pressure at 20° C .........................approx. 210 bar
Screw-Type and Push-inType Tube Fittings Min. temperature .................................................... - 40° C
High pressure range, p max. ................................ 350 bar
Inlet tube fittings of the metering devices
Outlet fittings, main metering device
Low-pressure range, p max. ................................. 250 bar
Outlet fittings, secondary metering devices
Inlet fittings to the lubrication point
Tightening torques
Closure plug (piston) in metering device ....................... 10 Nm

Closure plug (outlets) in metering device ...................... 10 Nm
Inlet fitting in metering device

screw-type .................................................................... 17 Nm
plug-type ....................................................................... 10 Nm
Outlet fitting in metering device

screw-type .................................................................... 10 Nm
plug-type ......................................................................... 8 Nm
Compression nut onto inlet fitting ................................... 10 Nm
Compression nut onto outlet fitting, screw-type

plastic tube ..................................................................... 5 Nm
steel tube ...................................................................... 10 Nm
Control pin in metering device ........................................ 12 Nm
Piston detecteur in metering device ............................... 12 Nm
KN - switch on metering device ...................................... 12 Nm
Install metering device ..................................................... 10 Nm
Page A 26
Owner Manual
2.2A-10001-C99
Dimensions
Metering Devices Model SSV 6 to SSV 22 Model SSV Dimensions A in mm

(Blocks) 6 60
8 75
10 90
12 105
14 120
16 135
18 150
20 165
22 180
2012a95
Metering devices SSV 14 ... 22 (combined)

Model SSV Dimensions A in mm
14 135
16 150
18 165
20 180
22 195
1015a96
Page A 27
Owner Manual
2.2A-10001-C99
Lubricants
The QUICKLUB pump 203 can dispense greases up to NLGI Important: Absolute cleanliness is essential when handling
class 2 or mineral oils with min. 40 mm²/s (cST) at 40°C. lubricants. Impurities will remain suspended in the lubricant
and cannot 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 Multipurpose grease ZS 1/2 Ca/Li
AUTOL Top 2000 Ca -10 ° C
BP Lubricating grease Ca
BP C1 lubricating grease Ca
CASTROL CL - Grease Ca
ESSO Cazar K2 Ca
ESSO High-pressure grease Ca
FIAT LUBRIFICANTI Comar 2 Li
FUCHS FN 745 Ca
FUCHS Renocal FN3 Ca
FUCHS Renolit HLT 2 Li
MOBIL Mobilgrease Li
MOLYKOTE TTF 52 anorg. Verd.
OPTIMOL Longtime PD 2 Li - 20 ° C
OPTIMOL OLIT CLS Li/Ca - 15 ° C
SHELL Retinax C Ca
ZELLER & GMELIN ZG 450 Li
ZELLER & GMELIN ZG 736 Li
Biodegradable greases
Manufacturer Type Base-soap Min.delivery temperature
ARAL BAB EP 2 Li/Ca
AVIA Biogrease 1 Li to 0 ° C
DEA Dolon E 2 Li
FUCHS Plantogel S2 Li/Ca
Page A 28

Lincoln Centralized Lubrication System

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Benutzerlntormatlon LINCOLN

For further information refer to:

Technical Description for "Electronic Control Units" 01 pump 203 :

Printed circuit board 236-13891-1 -Model V1Q-V13"

Explanation of Symbols Used

correspondinq "'" -'I i

ATTENTION refers to faults or damages on

Appropriate Use Disposal

Operation, Maintenance and Repair, continuation

The Quicklub 203 central lubrication pump

can drive up to 3 pump elements

Low-level control (optional)

The pump model 203 can be equipped with a low-level

1) The designation indicates the version of the printed circuit

Pump elements with fixed lubricant output

The following designs are available:

Pump elements with piston diameter C 7 Piston diameter, G7 ') ... 7 mm

Fig. 4 The pump element sucksin lubricant

~ Fig. 5 The pumpelementdispenses lubricant

Pump elements with fixed lubricant output, continuation

Fig. 7 Sectional view: pump element 87

Pump element with adjustable lubricant output

Fig. 9 Sectional view: adjustable element

~L. _ _--:- 4179a99....J

~ Fig. 10 Supply diagram

Pressure Relief Valve Without grease return

Pressure relief valve with grease return (optional)

Fig. 12 Pressurerelief valve with grease return

Pressure Relief Valve, continuation Return line Connection

If the pump is to be equipped with a control unit, it is pos-

Fig. 15 Printed circuitboard integrated in the housing

For cleaning the system use benzine or petroleum. Do not

Fig. 16 Fill pump reservoir 4273aOO

:l Install a new pump element with a new sealing ring.

Fig. 17 Replace pumpelement

Check the Pressure Relief Valve

1- Hose line, min. length1m

PRESSURE RELIEF VALVE

Recommended grease for Quicklub systems

,FUCHS Renocal FN3 Ca -20'C

Specifications for the installation of electric equipment in ADR vehicles

Mounting of the Pump - Areas of Risk

shut-off devices zone 1

Mounting of the Pump - Areas of Risk, continuation

~ Fig. 21 Areas of risk on vehicles with hazardous goods

Essen, January 17~, 2002

Component designation: TO.EGG.054-01

Vehicle Ident. No.

The original parts of

Lincoln GmbH & Co. KG

b) Add-on lubricant metering device and lubricant lines

................... ................ ........, date .

Signature and stamp of workshop that has installed the system.

Printed Circuit Board for Pump 203

with Adjustable Pause and Operating Times

*See page 4 Applications

24 VDC external P : 0.5, 1, 2...to 12 hrs 236-13834-1

24 VDC, 115 VAC,

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

*See page 4 Applications

Note: The PCBs 236-13891-1 and 236-13891-2 differ only

The printed circuit board automatically controls the sequence

A lubrication cycle consists of one pause time and one ope-

When switching off the ignition voltage and/or the opera-

Note: When the switch is on 0 a fault is shown at the right-

The time ranges can be modified by replugging the jumper

The operating time can be set to 15 different setting by me-

Note: When the switch is on 0 a fault is shown at the right-

The time ranges can be modified by replugging the jumper

Additional lubrication cycles can be triggered at any time.

Fault: the pump motor does not run

Printed-circuit board defective Replace the printed circuit board.

Fault: Right-hand LED 3 Fig. 12 flashes