Lincoln industrial QLS 321 User manual

Lubrication System QLS 321
for Trailers/Semitrailers
4302a00
810-55251-1
Owners Manual
Installation and Operation Instructions
Form 403012 2.1B-38010-A00
Subject to modifications
Section - Q3 Page - 17

Page 2 of 26
Owner Manual
Installation and Operation Instructions
Subject to modifications
2.1B-38010-A00 Form 403012
Safety Instructions
Appropriate Use
 Use QLS 321 only for dispensing lubricants. QLS 321 is
designed for intermittent operation only. QLS 321 is
designed for supplying lubricant to a maxim m of 18 l be
points per cycle.
General Safety Instr ctions
 Lubrication systems QLS 321
- are state of the art
- can be assembled for safe operation.
 Refill QLS 321 ith clean lubricant.
 Do not over pressurize reservoir hen filling the pump.
 Each outlet needed must be equipped ith an
appropriate check valve.
Important: Do not paint pump. Before painting a commercial
vehicle make sure to either remove or completely cover the
pump.
 Unauthorized modifications or changes to an installed
system are not recommended and ill void arranty. Any
modifications must be subject to prior consultation ith the
manufacturer of the lubrication system or the
manufacturers contract partner.
Reg lations for prevention of accidents
 To prevent accidents, observe all city, state and federal
safety regulation of the country in hich the product ill be
used.
Operation, Maintenance and Repair
 Repairs should only be performed by authorized
personnel ho are familiar ith the instructions.
 QLS 321 operates automatically. Ho ever, a regular check
(approx. every 2 eeks) should be made to ensure that
lubricant is being dispensed from all lube points.
 Used or contaminated lubricants must be disposed of in
accordance ith local environmental regulations, see
technical data sheets of lubricants used.
 The manufacturer of the centralized lubrication system ill
not accept any liability for
- damage caused by insufficient lubricant and irregular
refilling of pump
- damage caused by inadequate or only conditionally
pumpable lubricants
- damage due to the use of contaminated lubricants.
- damage caused by the inadequate disposal of used or
contaminated lubricants.
- damage caused by unauthorized modification of system
components.
- damage caused by the use of unapproved parts (voids the
pump arranty).
Table of Contents
 QLS 321 must only operate ith mounted or connected
SSV divider blocks.
 QLS 321 must be regularly refilled ith clean lubricant.
Safety Instr ctions ........................................................ 2
Installation Instr ctions ............................................... 3
Pump .............................................................................. 3
SSV Divider Block ............................................................ 3
Crossporting of the SSV Divider Block ........................... 3
Check valves .................................................................... 4
Feedback of supplied lubricant ....................................... 4
Lubrication point .............................................................. 4
Installing Quicklinc-tube fittings ...................................... 4
Installing Zerk-Locks onto grease fittings ....................... 4
Connecting feed lines ...................................................... 5
Filling of reservoir ...................................................... 5
QLS 321 selection guide ................................................. 6
Electrical Connection Diagrams ..................................... 7
Description of QLS 321 ................................................ 7
Operating of QLS 321 ................................................... 8
Flexible time of availability - operating time ................... 9
Flexible time of availability ........................................ 9
Operating time ......................................................... 10
Pressure relief valve ...................................................... 10
Display indo of the key pad ..................................... 10
Lo -level control ............................................................. 11
Malfunction ..................................................................... 12
Setting and Operation of the QLS 321 ..................... 13
Display mode ................................................................. 13
Operating mode ............................................................. 14
Programming mode ....................................................... 16
Maintenance, Repair and Tests ................................. 17
Maintenance .................................................................. 17
Refilling of reservoir ................................................. 17
Repair 17
Functional test ................................................................ 17
Tro bleshooting .......................................................... 18
Technical Data .............................................................. 21
Dimensions .................................................................... 22
Option for metrical fittings ............................................. 23
Service parts of the QLS 321 ..................................... 24
Manufacturers declaration ........................................... 26
Explanation of symbols:
 = explanation
* = describes an action
- = listing ithin a section

Subject to modifications
Page 3 of 262.1B-38010-A00
Form 403012
Owner Manual
Installation and Operation Instructions
Installation
 Do not remove, modify or alter any safety equipment
already installed on the vehicle.
 QLS 321 must be kept a ay from sources of heat. (See
Operating Temperature Specification).
 Use only original QLS 321 service parts (see Service Parts
of the QLS 321) or parts approved by LINCOLN.
 Adhere to:
- the installation instructions of the vehicle manufacturer as
regards all drilling and elding procedures,
- the specified minimum distances bet een the bore holes
and the upper/lo er rim of the frame or bet een t o bore
holes.
 Keep feed lines to each lube point as short as possible.
 Provide access to fill, clean and visually monitor the pump
operation.
Installation Instructions
Pump
 Use drilling template to mark and drill mounting holes of the
QLS 321. Drilling template and mounting bolts are included
in the package of the QLS 321.
SSV Divider Block Crossporting of the SSV divider blocks
 The single output is the quantity of lubricant supplied to a
lube point by a piston per stroke and per outlet borehole. It
amo nts to approx. 0.2 cm³.
 By closing outlet boreholes ith closure plugs (also part of
the package) the amount of lubricant for a particular outlet
can be increased.
 Lubricant from a plugged outlet is redirected to the next
outlet on the same side of the SSV divider block in descen-
ding numerical order.
 For instance, plugging outlets 5 and 3 ill triple the amount
of lubricant at outlet 1.
 Unneeded lubricant quantities can be returned to the
reservoir, see Return of Lubricant Quantities.
Fig. 1 - Singe, double and triple lubricant output
* Install a closure plug in each outlet borehole hich is not
required (see fig. 1 or 4).
Fig. 2 - Closure plug, provided in the accessory kits
1014b00
4163a98
x - Outlet quantity (single, double, etc.)
1...6 Outlet numbers C - Grease enclosed
A - Clamping ring (brass) - eturn
B - Grease supply

Page 4 of 26
Owner Manual
Installation and Operation Instructions
Subject to modifications
2.1B-38010-A00 Form 403012
Check valves
* Install one complete check valve in each outlet borehole
hich ill be used.
 For pressure plastic tubes (ø 6x1.5 mm; 1/ 4 in.) use check
valves ith standard collar and knurled flange.
Ret rn of l bricant
 QLS 321 ith back mo nted SSV divider block (vertical
outlets) have the capability to internally feed back
unneeded lubricant directly from the divider block to the
reservoir.
 This happens automatically if o tlet 2 is closed ith a
closure plug (fig. 4). Lubricant quantities from even and
odd o tlets can be fed back to the reservoir by
combining the o tlets 1 and 2.
 To feed back lubricant, al ays start ith the lo est outlet
numbers, for instance, 2, 4, 6... or 1, 3, 5 ... pl s o tlet 2.
Fig. 4 sho s ho the lubricant quantities of outlets 1, 2 and
4 (3xR) return to the reservoir.
 The remaining outlets are to be used for the connection to
the lube point or to increase the lubricant quantity (double
or triple).
Maximum of internally combinable outlets:
SSV 6 = 3
SSV 12 = 6
SSV 18 = 9
Important: If o tlet 2 is connected to a l be point, then o tlet
1 m st not be closed (see fig. 1).
Fig. - Internal return of supplied lubricant on back-mounted SSV divider blocks
Installing Zerk-Locks onto grease fittings
(for inch size accessory kits only)
 The Zerk-Lock fitting consists of the Zerk-Lock body, insert
and a Quicklinc fitting.
* Place the Zerk-Lock body onto the grease fitting.
* Use a staking tool (part of the accessory kit) and a hammer
to push in the Zerk-Lock insert until the grease fitting is
tightly enclosed by the insert.
Fig. 6 - Installation of Zerk-Lock body
with staking tool
Fig. 5 - Place the Zerk-Lock body
over the grease fitting
4180a99
Fig. 3 - Check valve, push-in type
4188b99
4200a99 4201a99
L be points
x - outlet quantity (single, double, etc)
1...6 outlet numbers C - lubricant enclosed
A - clamping ring (brass) - return line borehole
B - lubricant supply
Installing Q icklinc fittings into l be points
(for metric size accessory kits only)
* Remove lube fittings from lube points and install
appropriate Quicklinc fittings into the bore holes of the lube
points.

Subject to modifications
Page 5 of 262.1B-38010-A00
Form 403012
Owner Manual
Installation and Operation Instructions
4202a99
* Scre the Quicklinc fitting into the Zerk-Lock body and
tighten until parts resist further tightening, (about 1 1/ 2
turns).
Note: Quicklinc hex. is 12 mm. Zerk-Lock body hex. is 1/2.
* Move the Zerk-Lock and tube fitting from side to side on the
grease fitting to insure the Zerk-Lock is firmly seated on the
fitting.
Fig. 7 - Screwing Quicklinc fitting into the Zerk-Lock body
Connection of Feed Lines
* Measure, cut and route the feedlines included in the kit.
Note: Avoid sh rp bends of the pl stic tubing nd the moving
p rts of the m chine th t could d m ge the lubric tion lines.
Minimum bending r dius is 50 mm (2in).
* Secure the lubrication lines using nylon ties or corrugated
tube provided in the accessory kit.
* If the lines are not primed, prime all lubrication feed lines
before connecting them to the lube point (by means of a
filling pump, a manual pump or by triggering additional
lubrications).
* Connect feed lines to the check valves of the divider block
and to the Quicklinc fittings of the lube point.
Note: Push the end of the line firmly into the Quicklinc fitting
until it is fully se ted in the body. The primed feed lines re
m rked with white lines (fig. 8, 9) s n inst ll tion id.
* Cut the feed line off at one of the hite lines before it is
mounted.
* Then insert the feed line into the fitting up to the next hite
mark.
 This ill ensure a correct installation of the feed line in the
tube fitting.
Fig. 9 - Feed line insert into the Quicklinc fitting up to the next white mark
Fig. 8 - Connect feed line to the Quicklinc fitting
4203a99
4157a98
Filling of reservoir
* Fill the reservoir ith clean suitable lubricant.
Ca tion: When filling the reservoir avoid air pockets in the lub-
ricant. Make sure that the follo er plate seal moves above the
vent hole to ensure that all air pockets are vented (see fig.11).
Ca tion: When filling the reservoir make sure that the
maxim m marking will not be exceeded. When overfilling
the reservoir this might b rst!
4204a99
Fig. 10 - Vent hole on reservoir

Page 6 of 26
Owner Manual
Installation and Operation Instructions
Subject to modifications
2.1B-38010-A00 Form 403012
QLS 321 Selection Guide
P mp models P32131210531
Examples of part numbers P32191410531
P321 61410531
P mp
For grease..........................................P321
SSV Divider Block
None.............................................................0
SSV 6.............................................................3
SSV 12...........................................................6
SSV 18...........................................................9
SSV Divider Block Position
None.............................................................0
Back.............................................................1
Operating Voltage
12 VDC..........................................................2
24 VDC..........................................................4
Reservoir Low-level Control
1 l reservoir with low-level control.............1
Dry Contacts
None......................................................................0
Type of Plug Connector
Scart plug (quarter-turn type)................................5
Electrical Connectors
With socket, with cable, 6 m .................................3
Control p.c.b.
With flexible time of availability and operating time ..1
Example of an explained model n mber
Pump model P32131410531- Grease pump, SSV 6 block mounted on the back, 24 VDC, ith lo -level control and ithout
dry contact, ith scart plug, socket and 6 m cable, control p.c.b.
* Note: 1. Pumps are equipped with scart plug and connection cable of 6 m length (only connection type 3)
Accessory Kits:
Inch Size Kits: Metric Size Kits:
SSV 6/8 part n°. 550-36971-1 SSV 6/8 part n°. 550-36970-1***
SSV 12 part n°. 550-36971-2 SSV 12 part n°. 550-36970-2***
SSV 18 part n°. 550-36971-3 SSV 18 part n°. 550-36970-3***
***Lube fittings must be ordered separately.

Subject to modifications
Page 7 of 262.1B-38010-A00
Form 403012
Owner Manual
Installation and Operation Instructions
Electrical Connecting Diagram
Electrical Connection
Warning: Before commissioning make sure
that the electrical s pply is off. The de-
vice may not be connected or discon-
nected when the power is on.
* Connect the electrical ires according to the follo ing
electrical connecting diagram.
Note: The protection IP6K9K is gu r nteed when the socket is
tightened.
Direct C rrent (VDC)
4276a00
Fig. 11 - Electrical Connecting Diagram, direct current
Description of QLS 321
4286a00
1 - Control pin 3 - Nipple for external manual
2 - SSV divider block lubrication
Fig. 12 _ QLS 321 with back position of the SSV divider block
The QLS321 is a compact centralized lubrication system for
providing a maxim m of 18 l be points on trailers and
semitrailers ith lubricant.
 The QLS 321 is available in the follo ing basic
configurations:
- SSV divider block mounted on the back (see fig. 12)
- Pump ithout the SSV divider block attached (no fig.).
 The standard lubrication line to be used is high pressure
plastic tubing (ø 6x1.5 mm; 1/4 in.) included in the
accessory kit.
Note: The oper tion of the QLS 321 is independent of the
mounting position of the SSV divider block.
 When braking, a signal from the control p.c.b. starts the
electrical motor and the pumping element starts pumping
the lubricant to the SSV divider blocks and to the lube
points.
 As soon as the flexible time of availability has finished and
all lube points have received lubricant, one lubrication cycle
is completed.

Page 8 of 26
Owner Manual
Installation and Operation Instructions
Subject to modifications
2.1B-38010-A00 Form 403012
peration of the QLS 321
P mp
Fig. 13 - QLS 321 unit
4205a00
 The QLS 321 operates according to lube cycles (flexible
time of availability and operating time).
 The first braking starts the flexible time of availability as ell
as the operating time.
 A division of the lube points (option) via secondary metering
devices (SSV 6) and one main divider block (SSV 6) is
possible only p to a maxim m of 18 l be points per
l be cycle.
 Most of the times, trailers and semitrailers do not
dispose of a permanent po er supply. The stop light
voltage provides the po er supply (terminal 54). Further,
trailers and semitrailers lack the operation dependent
signal of terminal 15 (ignition voltage) hich exists for
trucks.
1062a95
1 - Low-level control 2 - Control pin
3 - Keypad 4 - Control unit
5 - Pump 6 - SSV 6, 8, 12, 18
Fig. 1 - Stop light voltage
 In the control p.c.b., this task is provided by an integrated
motion sensor 1 (fig. 15). It records travelling motions of the
trailer/ semitrailer. Out of this recorded material, it forms the
necessary operation dependent signal for controlling the
time of availability.
 Normally, the stop light voltage lasts for a short instance
only. Therefore, a condensator is needed to record the
times (see fig. 15). On the braking process, the
condensator loads and is then available as a continuous
po er supply in order to provide the operation dependent
signal.
Fig. 15 - Control p.c.b. 236-10028-1
4303a00
1 - Motion sensor
2 - Condensator

Subject to modifications
Page 9 of 262.1B-38010-A00
Form 403012
Owner Manual
Installation and Operation Instructions
Time of Availability
Time of Availability - perating Time
Time Seq ence Diagram
1063a95
Fig. 16 -Time sequence diagram
1 - Time of availability (2 cycles shown)
2 - Braking time sequence
3 - Operating time sequence
T - Time of availability, flexibly adjustable
T1...TX - Individual travelling times
TB1...TBX - Individual braking times
A - Preset operating time
TA1...TAX - Individual operating times
P - Pause time
 The time during hich the printed circuit board records the
travelling motions by means of the motion sensor 1 (fig. 15)
is defined as the time of availability.
 The time of availability T (fig. 16) starts ith the operating
time (A), i.e. the QLS 321 is prepared to turn individual
braking operations (TB1...TBX) into lubrication cycles
(TA1...TAX, operating times) until the preset operating time
(A) elapses.
 As soon as the vehicle starts travelling, the motion sensor
starts the time of availability (T1 ..TX).
 Each time the vehicle stops, the time of availability also
stops. The electronic unit records the times hich have
elapsed so far (T1...TX).
 When the vehicle moves again, the time of availability
continues to run from the point here it had been interrup-
ted hen the vehicle stopped.
 The travelling times are stored until the preset time of
availability is reached.
 The layout of the control unit is such that during the preset
time of availabilty (T, pure travelling time) one operating
time (A) elapses.
 Once the time of availability (T) has elabsed, a ne cycle
begins.
 The time of availability (T) can be modified and is
adjustable on the key pad from 1, 2, 3...up to 16 hours
(increment 1 hour).

Page 10 of 26
Owner Manual
Installation and Operation Instructions
Subject to modifications
2.1B-38010-A00 Form 403012
Press re Relief Valve
Fig. 17-Pressure relief valve (cartridge) in housing
 The QLS 321 is protected ith a pressure relief valve.
 The pressure relief valve limits the pressure build-up in the
QLS 321 and opens at an overpressure of 205 bar.
 If the pressure relief valve is actuated, this indicates that
the system is malfunctioning. The lubricant flo s back into
the reservoir (hardly visible).
 If this is the case, trigger an additional lubrication and
observe the control pin on the divider block (fig. 12). If the
control pin does not move, either the system is blocked or
the reservoir is empty, see fault indication LL on the
display.
Note: To trigger n ddition l lubric tion, connect the tr iler to
the truck, connect the driving switch nd ctu te the br ke so
th t the stop light of the tr iler will fl sh.
Display Window on the Key Pad
Fig. 19 - Green rotating display, operating time
 Pump operation is indicated on the display indo of the
key pad by a rotating green light movement.
4304a00
4209a99
 All settings (programmings) are effected via the key pad (2
key buttons) on the front side of the QLS 321, also see
under Setting and Operation of the QLS 321.
 The operating conditions are indicated via an LED display
of seven segments (alphanumerically). The display is
visible through a indo in the key pad.
 The reservoir of the 321 is equipped ith a lo -level
control, hich indicates an LL on the display.
 During each actuation of the brake here no operating time
takes place the display is tested, i.e. all segments and
decimal points flash for 2 seconds, see Display mode.
Operating Time
 The operating time stands for the run time of the QLS 321
hereby the motor of the QLS 321 is s itched on.
 The operating time elapses during the time of availability.
When braking, the voltage of the stop light (terminal 54)
provides the motor of the QLS 321 ith po er. The motor
then runs during the braking process.
 The operating time (TA1, fig. 16) starts ith the first braking
actuation (TB1 = TA1, etc.).
 The electronic unit records the duration of each braking
operation (operating time) hich is added to the
 The operating time
- depends on the lubricant requirement;
- is adjustable.
 The longer the operating time, the greater the lubricant
requirement and vice-versa.
preceding one until the preset operating time (A) is rea-
ched.
 After each further braking (example: TB 4) there is no more
operation time until the time of availability (T) is completed
and starts again.
 The operating time (T) may be preset from 1, 2, 3... up to
32 minutes (increment 1 minute) on the key pad.
Fig. 18 - Key pad with display of a fault indication
4228b00