Lincoln Auto Lube Manual

Owner Manual
Technical Description
2.1A-30001-B96
QUICKLUB
Subject to modifications
10071327
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LINCOLN GmbH Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259 Tx 466088
Owner Manual
2.1A-30001-B96
Pump Types
1173b95
Fig. 1 - The different types of pump 203
The 203 pumps differ from each other only in the design and Control unit models 203
reservoir size as well as in the type of the electric connection
(different plugs with or without electric cable). The following control units can be used for the 203 pumps: (refer to
the respective Technical Description)
Reservoir sizes:
2 l transparent plastic reservoir a) external control units
4 l transparent plastic reservoir
8 l transparent plastic reservoir PSG 01
PSG 02 (Industry)
Electric connection
For the industrial applications, the pumps are only equipped with b) integrated control units
plugs.
The pumps model 203 used in commercial vehicles are equip- - with fixed pause time (6 hours) and adjustable operating time, F*
ped with a 10 m electric cable. - with adjustable pause and operating times, V00-V03*
- with metering device monitoring (microprocessor control), F
All other data such as: M 00 - M 23*
- motor voltage
- version of the control unit c) integrated control unit (trailers)
- remote control for triggering an additional lubrication
- cycle (2A1) - with fixed time of availability (6 hours) and adjustable operating
- design and number of pump elements time, H *
- design and number of safety valves
- filling type
- use of return line connections * Refer to the designation on the pump nameplate.
- low - level control (option) Example: P203 -2XNBO - 1 K6 - 24 - 2A1.10 - V00
can be learnt from the pump type designation code. Also refer to the designation code on page 6.
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Owner Manual
2.1A-30001-B96
Identification Code - Pump Models 203

Examples of model designations
P203- 2 X N - 1 K6- 24- 1A 1. 01- V00
P203- 4 X L - 1 K7- 24- 2A 1. 10- V02
P203- 2 X N - 1 K6- 12- 1A 8. 00
P203- 2 X N - 1 K6- 24- 2A 1. 11- V00-ADR
P203- 2 y N BO- 2 K5- 24- 1A 1. 01- F
P203- 4 X N BO- 1 K6- 24- 2A 4. 12- M00
Basicpump model for grease or oil

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

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

BO = Filling from top
FL = Flat-type reservoire (2 Litre)
Pump elements
1-3 = Number of the use elements
K 5 = Piston diameter = 5 mm
Motor
12 V DC or 24 V DC motor
Number of the possible connections

1A = 1 connection,supply voltage
2A = 2 connections, supply voltage +
remote control for additional lubrication,
for low - level control, piston detector (microprocessor)
Type of connection
1 = Hirschmann plug
4 = AMP - flanged plug (microprocessor)
8 = PG - cable gland
Connection outside the pump

00 = without socket-outlet, without cable
01 = with socket-outlet, without cable
10 = with 10 m cable
11 = with 10 m ADR cable
12 = with 10 m cable, 4 - wire (microprocessor M00 - M07)
13 = with 10 m cable, 5 - wire (microprocessor M08 - M23)
Control p. c. b. s. 12V / 24 V
F - with fixed pause time and variable adjustable operating time
F ADR - with fixed pause time and variable adjustable operating time**
V00 -V03 -with adjustable pause and operating time
V00 -V03 - ADR with adjustable pause and operating time **
M 00 ...M 23* - with microprocessor control (various
adjustments - see combinations of the jumper - positions)
H - for trailer or semitrailers
H - ADR for trailors and semitrailors**
No designation: Pump without control p. c. b.
* Not in conjunction with Hirschmann plugs (type of connection 1)

** for transport of hazard materials
Note: Any pumps combinations other the above standard pumps can be composed and ordered in accorcance with the valid model identification code.
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Owner Manual
2.1A-30001-B96
Description of the QUICKLUB 203 Central Lubrication Pump
The QUICKLUB 203 central lubrication pump
- is a compact multiline pump consisting of the following compon-

ents:
Housing with integrated motor

Reservoir with stirring paddle
Printed circuit board
Pump element
Safety valve
Filling nipple
Electrical connection parts
- can drive up to 3 pump elements

- operates according to lubrication cycles (pause and operating
times)
- can be equipped with a low-level control
- can supply up to 300 lubrication points depending on the line
lengths
- is designed for the automatic lubrication of the connected lubrica-
tion points
00002618
- is designed for the delivery of greases up to NLGI 2 at tempera-
Fig. 2 - Pump components
tures from - 25 C to 70 C or of mineral oils of at least 40 mm/s
1- Reservoir 5- Plug 2A1 (cST)
2- Pump element 6- Filling nipple, pump - can be used at low temperatures down to - 40 C.
3- Safety valve 7- Printed circuit board During the operating time the pump dispenses lubricant to the
4- Filling nipple, system 8- Plug 1A1 connected lubrication points via one or several metering devices.
Emergency lubrication 9- Return line connection
possible
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
F* and V00-V03*
- Low-level control in conjunction with printed circuit board
M00-M23*
- Low-level control for pumps without printed circuit board.
When the reservoir is empty, the signal lamp flashes, thus indica-
ting the low level. Refer to the chapter Low-level control.
* The designation indicates the version of the printed circuit board. It

is part of the pump type designation code mentioned on the name-
plate of each pump. Example: P203 ...- 2XN - 1K6 - 24 - 1A1.10 -
V00
1006a93
Fig. 3 - QUICKLUB central lubrication pump, 2 l reservoir
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Owner Manual
2.1A-30001-B96
Mode of Operation
Pump Elements
The electric motor drives the eccentric 1 (Fig. 5, 6).
During the operating time:
- piston 2 sucks in lubricant from the reservoir. Refer to Fig. 5.
- piston 2 dispenses the lubricant to the connected lubrication
points via the metering device. Refer to Fig. 6.
The following designs are available:

Piston diameter, K5 ..................................................... 5 mm
Lubricant output ........................................ approx. 2 cm/min
Piston diameter K6 (standard) ...................................... 6 mm
Lubricant output ..................................... approx.. 2.8 cm/min
Piston diameter, K7 ..................................................... 7 mm
Lubricant output ........................................ approx. 4 cm/min
20002068
Fig. 4 - Pump element
1 - Piston
2 - Return spring
3 - Check valve
Suction Phase
1003a95
Fig. 5 - The pump element sucks in lubricant
1 - Eccentric 3 - Spring
2 - Piston 4 - Check valve
Delivery Phase
1004a95
Fig. 6 - The pump element dispenses lubricant
1 - Eccentric 3 - Spring
2 - Piston 4 - Check valve
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Owner Manual
2.1A-30001-B96
Check valve
The check valve:

- closes the pressure line during suctionstroke
- prevents the lubricant from flowing back to the housing or reservoir
1 - Reservoir with stirring paddle
2 - Pump
3 - Check valve, spring-loaded
4 - Pressure limiting valve
R - Return line
p - Pressure line
1164b95
Fig. 7 - Hydraulic diagram of the pump Arrangement of the pump elements
If several pump elements are to be installed, the installation arran-

gement shown in Fig. 8 must be adhered to.
If there is only one pump element , it can be installed in any posi-
tion. Standard position is no. 3.
If there are two elements, install one in position 3 and the other in
position 1.
1163a95
Fig. 8 - Arrangement of the pump elements
Pressure limiting valve without grease return
Pressure Limiting Valve (safety valve)
Important: Each pump element must be secured with a pressure
limiting valve.
The pressure limiting valve
- limits the pressure build-up in the system
- opens at an overpressure of 250 or 350 bar depending on the
safety valve design.
If lubricant is leaking at the pressure limiting valve, this indicates
that the system is malfunctioning.
Note: The pumps model 203 are equipped without pressure limiting
valve. When ordering the pumpe, order the safety valve seperatly.
See the Parts Catalog under Safety valves.
10012618 Pressure limiting valve with grease return (optional)

Fig. 9 - Pressure limiting valve
If the system is blocked, grease will leak from the pressure limiting
valve. This grease quantity is returned to the reservoir.
00002626
Fig. 10 - Pressure limiting valve with grease return
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Owner Manual
2.1A-30001-B96
Technical Data
Pump Pump element

Admissible operating temperature ...................... -40 C to 70 C* Piston diameter, K5 ........................................................... 5 mm
Number of outlets .......................................................... 1,2 or 3 Lubricant output ........................................ approx. 2 cm/min
Reservoir capacity ....................................................... 2 l, 4 l, 8 l Piston diameter, (standard) K6 ........................................... 6 mm
Refilling ........................ via hydraulic lubrication fitting or from top Lubricant output ...................................... approx. 2.8cm/min
Lubricant .................................. greases of at least NLGI grade 2 Piston diameter, K7 ........................................................... 7 mm
mineral oils up to 40mm/s (cST) at 40 C Lubricant output ........................................ approx. 4 cm/min
Class of protection ......................... IP6K 9K acc. to DIN 40050 T9 Max. operating pressure. ................................................ 350 bar
Connection thread. ............................................................ G 1/4
*Note: The pump is designed for the above mentioned tempera- suitable for tube DIA .................................................... 6 mm
ture range. The lubricants used must still be pumpable at the
temperatures mentioned above. In case of doubt, consult the Important! The lubricant output listed refers to grease of NLGI grade
lubricant manufacturer. 2 measured at 20C, backpressure 100 bar, nominal voltage 12/24
V. Any differing pressures or temperatures result in different lubricant
Motor: outputs. Any system design must be based on the above values.
DC gear motor (interference-suppressed)
Operating voltage. .................................... 12VDC or 24VDC

Max. current input
12V ............................................................................. 6.5 A
24V ................................................................................ 3 A
Speed ........................................................... approx.17 rpm
Note: The pump motor is designed for intermittent operation. For

continous operation, contact the pump manufacturer.
Torsion torques
Electric motor on housing ................................................. 12 Nm
Pump element in housing ................................................ 25 Nm
Closure plug in housing .................. ..........................................12 Nm
Weights In the case of pump versions deviating from those mentioned, add
the weights of the following components to the mentioned weights.
The weights below include the following individual weights:
- Pump kit with one pump element, safety valve, grease filling Per pump element .......................................................... +0.2 kg
(0.75 kg, 1.5 kg) Per safety valve ............................................................... +0.1 kg
- Packing (cardboard box)
- Attaching parts 10 m monitoring cable, 5-wire
- Operating Instructions (microprocessor) E 4 ....................................................... +1.1 kg
10 m monitoring cable, 4-wire
2 l reservoir, standard design (0.75 kg) (microprocessor) E 4 ....................................................... +0.4 kg
Connection cable with piston detector ............................... 0.1 kg
Pump 203 without connection cable ................................. 5.4 kg Reservoir version Filling from top (only 2 l)* .................. +0.15 kg
Pump 203, version E 1 ..................................................... 6.5 kg 2 l flat-type reservoir ........................................................ +0.5 kg
Pump 203, version E 2 ..................................................... 7.1 kg
* Note: The 4l and 8l reservoirs have the standard design filling from
4 l reservoir, standard design (1.5 kg) top.
Pump 203 without connection cable ................................. 8.3 kg

Pump 203, version E 1 ..................................................... 9.3 kg
Pump 203, version E 2 ..................................................... 9.9 kg
8 l reservoir, standard design (1.5 kg)
Pump 203 without connection cable ................................. 8.6 kg

Pump 203, version E 1 ..................................................... 9.6 kg
Pump 203, version E 2 .................................................... 10.2 kg
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2.6A-20002-B96
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 working hours tB
(Fig. 5).
The sequence of the pause and operating times is activated when
the machine contact or driving switch is switched on.
20002443
Fig. 4 - Printed circuit board 236-13870-1
A lubrication cycle consists of one pause time and one operating

time. Once the pause time has elapsed, the operating time starts to
run. This lubrication cycle is repeated permanently after the machi-
ne or vehicle has been put into operation. Refer to Fig. 5.
During the operating time the pump element dispenses the lubri-
cant to the lubrication points via progressive metering devices.
1059a95
Fig.5 - Time sequence diagram
tB - Working hours T - Lubrication cycle

tP - Various pause times T1 - Stored pause times
T2 - Operating times
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2.6A-20002-B96
The pause time The operating time
- determines the frequency of the lubrication cycles within a wor- - depends on the systems lubricant requirement ;
king cycle; - is adjustable;
- is started and stopped via the machine contact or driving switch; - is finished when the machine contact or the driving switch is swit-
- is adjustable. ched off.
When the machine contact or the driving switch is switched off, the The longer the operating time, the greater the lubricant require-
pause times which have already elapsed are stored and added ment and vice-versa.
up (refer to T1, Fig. 5) until the time which has been set on the blue When the machine contact or the driving switch is switched off, the
rotary switch (Fig.8) is reached. operating times which have already elapsed are stored and ad-
The pause time setting may be different for each application. It ded up until the time which has been set on the red rotary switch
must be adjusted in accordance with the respective lubrication (Fig. 10) is reached. After this, the lubrication cycle starts again.
cycles. Also see To set the pause time. The operating time setting may be different for each application. It
must be adjusted in accordance with the respective lubricant re-
quirement. Also see To set the operating time.
Time storage when the power supply is switched off

When the ignition voltage or operating voltage is switched off, a
capacitor takes over the power supply to the printed circuit board,
thus the times which have already elapsed are not lost.
Switching off until 5 days
When the power supply is switched on again the printed circuit
circuit board continues to operate from the point where it had been
interrupted.
Switching on after 5 days
When the power supply is switched on again, the capaci-
tor is charged. The printed circuit board immediatel
immediatelyy
starts with an operating time.
20002438
Fig. 6 -Capacitor
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2.6A-20002-B96
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
20002451
Fig. 8 - Rotary switch - Pause time
Switch position 1 2 3 4 5 6 7 8 9 A B C D E F
Minutes 3,75 7,5 11,25 15 18,75 22,5 26,25 30 33,75 37,5 41,25 45 48,75 52,5 56,25
Hours 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Note: The 0 setting has no function.
Factory setting
Rotary switch on : ............................................................ 6 hours

or ........................................................................... 22.5 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 14. The combination
number can be learnt from the pump type designation code men-
20002452 tioned on the nameplate of each pump.
Fig. 9 - Preselection of the time range
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2.6A-20002-B96
To set the operating time
The operating time can be set to 15 different setting by means of

the red rotary switch.
Time ranges: Seconds or minutes
20002453
Fig. 10 - Rotary switch - Operating time
Switch position 1 2 3 4 5 6 7 8 9 A B C D E F
Seconds 7,5 15 22,5 30 37,5 45 52,5 60 67,5 75 82,5 90 97,5 105 112,5
Minutes 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
Note: The 0 setting has no function.
Factory setting
Rotary switch on : ........................................................ 6 minutes

or ......................................................................... 22.5 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 14. The combination
numbers can be learnt from the pump type designation code men-
tioned on the nameplate of each pump.
20002437
Fig. 11 - Preselection of the time range

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2.6A-20002-B96
Repair
The defective printed circuit boards should be suitably packed and If the printed cir cuit boar
circuit dm
board ust be replaced, a model V 00 will
must
returned to the factory. always be delivered. See chart page 14.
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 Trigg er an Ad

rigg ditional
Additional
Lubrication Cycle
To check the pump operation it is possible to perform an operatio-
nal 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. 10 is lit.
20002457 * Press pushbutton 5 on the printed circuit board (> 2 seconds) until
Fig. 12 - LED on the printed circuit board the right-hand LED 3 lights up.
1 - LED, left-hand 4 - Rotary switch, operating time
A shorter pause time elapses, followed by a normal lubrication
2 - Rotary switch, pause time 5 - Pushbutton for additional
3 - LED, right-hand lubrication cycle.
Additional lubrication cycles can be triggered at any time.
Note: In the case of model 203 pump, version 2A1, with external
illuminated pushbutton, it is also possible to trigger an additional
lubrication cycle via this pushbutton.
20002458
Fig. 13 - To trigger an additional lubrication cycle, only pumps with illuminated pushbutton
Page 9 from 15
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2.6A-20002-B96
Technical Data
echnical
Rated voltage ............................................................ 12/24V DC All the printed circuit boards comply with the EMC (Electromagnetic
Operating voltage compatibility) guidelines for road vehicles acc. to DIN 40839 T1, 3
12V/ 24V .......................................................... 9V to 30V and 4.
Residual rippple in relation The printed circuit boards model V additionnally comply with the
with the operating voltage ....................... 5% acc. to DIN 41755 EMC guideline 89 / 336 / EWG
Motor output ................................ Transistor 7A/short-circuit proof Emitted interference acc. to, ....................... EN 55011 / 03.91 and
Reverse voltage protection: ......................................................... EN 50081-1 / 01.92
The operating voltage inputs are protected against Noise immunity acc. to ................................. prEN 50082-2 / 1993
polarity reversal
Temperature range .................................... -25C to 70C Time setting
Lamp current in the case of pump 2A1 ........................... max. 2 A
Class of protection Pause time, depending on the jumper position:
Printed circuit board installed in housing ........................ IP 6K 9K ...................................... 3.75; 7.5; 11.25; to 56.25 minutes
.......................................................... 1, 2, 3...to 15 hours
In order to protect the printed circuit board against condensation it Operating time, depending on the jumper position
has been covered with a protective varnish. ....................................... 7.5; 15; 22.5;....to 112.5 seconds
..................................................... 2, 4, 6,....to 30 minutes
Factory setting
Pause time .......................................................... 6 hours
or ............................................................... 22.5 minutes
Operating time .................................................. 6 minutes
or ............................................................. 22.5 seconds
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2.6A-20002-B96
Connection Diagram - Industrial Applications
1192b95
Fig. 14 - Connection diagram Quicklub 203 with adjustable pause time

Connection via Hirschmann plug-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
1009a93
M
- Motor - Signal lamp
Fig. 15 - Terminals of the printed circuit board
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2.6A-20002-B96
Connection Diagram - Applications ffor

Diagram or Commercial Vehic
Commercial les
ehicles
1155b95
Fig. 16 - Connection diagram Quicklub 203 with adjustable pause time

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

**equipment available on request
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.
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Owner Manual
Operating Instructions
2.2A-10001-A96
Progressive Metering Devices Model SSV

Suitable Lubricants
The progressive metering devices model SSV can be used for Note: It must nevertheless be ensured that the oils or greases used
dispensing do not alter their consistency significantly in the course of time or
- mineral oils with min. 40 mm/s (cST) 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 cm per outlet and piston stroke;
- when one or more outlets are closed (see Combining outlets)
they can dispense a double or multiple lubricant quantity;;
- are available with 6 to 12 outlets or up to 22 outlets;
- offer the option of combining several lubrication points into one
centralized lubrication point.
- meter the supplied lubricant into predetermined single quantities.
- can be monitored visually or electronically.
The installation of max. 3 pump elements allows the supply of
lubricant to max. 3 separate lubrication circuits.
Each lubrication circuit is equipped with a pressure relief valve
(safety valve) which limits the pressure to the maximum admissi-
ble value.
Any blockage in a lubrication circuit is indicated by grease leaking
from the respective pressure relief valve.
10002709
Fig. 2: Metering device typel SSV 8 shown as a model
Features of a Progressive Metering Device

The term progressive refers to the special features of the lub-
ricant 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 pressu-
re;
- 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 lubricant is dis-
pensed continuously or intermittently;
- the pistons operate interdependently of one another;
- no lubrication point which is connected to the system is omitted.
10002710
Fig. 3: Sectional view of a SSV 8 metering device

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2.2A-10001-A96
Applications
QUICKLUB progressive metering devices offer the option of com-
bining several lubrication points on a machine to one or more
central lubrication points, as shown in Fig. 4 which illustrates 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 metering 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
4024b95 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 single-

line centralized lubrication systems in order to increase the num-
ber of outlets of multiline pumps or to subdivide the single mete-
ring 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
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2.2A-10001-A96
1206a95
Fig. 8: Single-line system expanded by a progressive metering device
Lubricant Distribution Within the Metering

Distribution
Device The 5 following illustrations show how the lubricant distribution is
made to the individual outlets.
Note: To simplify the description we only show the lubricant distribu-

tion 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 pi-
ston A to be dispensed to outlet 2 (dashed arrow).
Lubricant under pump pressure
Lubricant under delivery pressure of the piston
Lubricant, pressureless
2007a95
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 left-hand end of piston B to be dispensed to
outlet 7 (dashed arrow).
2008a95
Fig. 10: Phase 2

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2.2A-10001-A96
Phase 3
Once piston B has reached its left-hand final position, the junction
channel to the right-hand end of piston A is opened.
The lubricant which flows from above (white arrow) moves piston
C (black arrow) to the left, causing the lubricant quantity ahead of
the left-hand end of piston C to be dispensed to outlet 5 (dashed
arrow).
2009a95
Fig. 11: Phase 3
Phase 4
The channel to the right-hand end of piston D is now open (black
arrow).
The lubricant which is fed from above (white arrow) moves piston
D to the left, causing the lubricant quantity ahead of the left-hand
end of piston D to be dispensed out of the metering device via
outlet 3 (dashed arrow).
2010a95
Fig. 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 dispensed to
outlet 1(dashed arrow).
In the subsequent distribution sequence, pistons B - D are moved
from the left to the right one after the other.
A complete distribution sequence is finished and a new cycle can
begin.
2011a95 Lubricant under delivery pressure of the piston

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.
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2.2A-10001-A96
Monitoring of the Operation

System-dependent monitoring
The main metering device (B, Fig. 14) and the secondary metering
devices are connected by a high pressure plastic hose G. This
feature 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 out-
lets, 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 system
installed downstream of the pump stops operating.
The fundamental internal structure of the progressive metering
device guarantees the self-monitoring of the sequence within the
1064a95 metering device.
Fig. 14: Example of a lubrication system The linkage makes it possible to monitor the operation of the who-
le system.
A - Safety valve D - Secondary metering device SSV 6
B - Main metering device SSV 6 E - Lubricant plastic tube
C - Secondary metering device F - Secondary metering device SSV 12
SSV 8 G - High pressure plastic hose
Visual monitoring
The metering devices can be equipped with an indicator pin which

is connected to the piston and moves back and forth during lubri-
cant distribution.
If there is a blockage in the system, the indicator pin stops moving.
Note: It is also possible to indicate 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 mete-

ring device instead of a piston closure plug 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 detector be
used per lubrication circuit. These special metering devices must be
ordered separately for each lubrication system. Refer to the Parts
Catalog.
The pre-assembled metering devices have the designation
SSV ... - N (they are available for SSV 6, 8, 10 and 12). They must
00002634 be installed in the system instead of a normal metering device.
Fig. 16 - Piston detector installed on the metering device
Page A 8
Owner Manual
2.2A-10001-A96
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
Important: In the case of the progressive metering devices models
SSV 6 - 12 the outlets 1 and/or 2 must never be closed
closed. In the case
of the progressive metering devices model SSV 14 - 22, the two
outlets with the highest numbers must never be closed, otherwi-
se 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
Screw-T
Tube Fittings, Scre w-Type
w-T ype
1012a96
Fig. 18: Install the outlet fittings and closure plugs in accordance with the dosage
1- Inlet fitting 5- Outlet fitting assembly 10 - Junction channel

2- Delivery hole of the piston 6- Clamping ring (brass) 11 - Copper washer

3- Closure plug, installed 7- Valve body 12 - Closure plug, outlet borehole
4- Closure plug, piston (with champfered), 8- Cutting ring
piston 9- Coupling nut
Page A 9
Owner Manual
2.2A-10001-A96
The output quantities can be raised by closing outlet boreholes. Clamping ring 6 (Fig. 18) closes the junction channels 10 to the
Install an outlet fitting assembly in each outlet borehole which will other outlet channels.
be used. Refer to Fig. 18, 19, 20.
Never remove closure plug 4 (chamfered) on the piston side.
Never use closure plug 12 (Fig. 18) or 7 (Fig. 19, 20) as a piston Note: In the case of push-in type fittings the clamping ring is always a
closure plug 4. firm component part of the valve body.
Important: Always use valve body 7 (Fig. 18) in conjunction with Important: In the case of the progressive metering devices model
clamping ring 6. 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, otherwi-
se the system would block due to the structure of the metering de-
vice.
Push-in-Type
Tube Fittings, Push-in-T device)
ype (main metering device)
1203a95
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 installed in outlet borehole 7 - Closure plug, outlet borehole
4 - Closure plug (chamfered), piston 8 - Copper washer
* on request
Page A 10
Owner Manual
2.2A-10001-A96
Push-inType
Tube Fittings, Push-inT (secondary
ype (secondar devices)
y metering de vices)
1204a95
Fig. 20: Install the push-in type outlets fittings and closure plugs in accordance with the dosage
1 - Inlet fitting 5 - Valve body assembly (with knurled collar)

2 - Delivery borehole of the piston 6 - Junction channels
3 - Closure plug installed in outlet borehole 7 - Closure plug, outlet borehole
4 - Closure plug (chamfered), piston 8 - Copper washer
Single lubricant output
The simple lubricant output is the lubricant quantity dispensed by

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

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.
1014a96 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 borehole
x - Outlet quantity (1x: single, 2x: double, etc.) located above the discharge borehole. Refer to outlets 3 and 5 on
1 - 10 Outlet numbers Fig. 21.
A - Clamping ring (brass)
Page A 11
Owner Manual
2.2A-10001-A96
Technical Data
echnical
Metering Device Model SSV Lines
Lubricant output per outlet and per stroke ......................... 0.2cm High-pressure plastic hose
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. ........................................................ 50 mm
between two outlets ....................................................... 100 bar Min. temperature ............................................................. - 40 C
Outlet connection for tube ................................................ 6mm
Inlet connection ................................................................. G 1/8 Plastic tube
Operating temperature ........................................ - 25 C to 70C Min. bending radius ......................................................... 30mm
Bursting pressure at 20 C .............................................approx. 250 bar
Push-inT
Push-inType ype 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
Installation of metering device ........................................... 10Nm
Page A 25

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Owner Manual

Identification Code - Pump Models 203

Basicpump model for grease or oil

X = Reservoire for grease

without designation = Standard reservoire (2 Litre)

Number of the possible connections

Connection outside the pump

* Not in conjunction with Hirschmann plugs (type of connection 1)

Description of the QUICKLUB 203 Central Lubrication Pump

The QUICKLUB 203 central lubrication pump

- is a compact multiline pump consisting of the following compon-

Housing with integrated motor

- can drive up to 3 pump elements

Low-level control (optional)

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

* The designation indicates the version of the printed circuit board. It

Fig. 3 - QUICKLUB central lubrication pump, 2 l reservoir

The following designs are available:

The check valve:

If several pump elements are to be installed, the installation arran-

10012618 Pressure limiting valve with grease return (optional)

Pump Pump element

Operating voltage. .................................... 12VDC or 24VDC

Note: The pump motor is designed for intermittent operation. For

Pump 203 without connection cable ................................. 8.3 kg

8 l reservoir, standard design (1.5 kg)

Pump 203 without connection cable ................................. 8.6 kg

The printed circuit board automatically controls the sequence of

Fig. 4 - Printed circuit board 236-13870-1

A lubrication cycle consists of one pause time and one operating

Fig.5 - Time sequence diagram

tB - Working hours T - Lubrication cycle

The pause time The operating time

Time storage when the power supply is switched off

To set the pause time

The pause time can be set to 15 different settings by means of the

Time ranges: Minutes or hours

Fig. 8 - Rotary switch - Pause time

Note: The 0 setting has no function.

Rotary switch on : ............................................................ 6 hours

The time ranges can be modified by replugging the jumper (Fig. 9)

To set the operating time

The operating time can be set to 15 different setting by means of

Time ranges: Seconds or minutes

Fig. 10 - Rotary switch - Operating time

Note: The 0 setting has no function.

Rotary switch on : ........................................................ 6 minutes

The time ranges can be modified by replugging the jumper (Fig.

Fig. 11 - Preselection of the time range

Operational Test / To Trigg er an Ad

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

Additional lubrication cycles can be triggered at any time.

Connection Diagram - Industrial Applications

Fig. 14 - Connection diagram Quicklub 203 with adjustable pause time

31 - Earth N- Level control

15 - Driving switch Z- Additional lubrication