Lincoln industrial QUICKLUB 203 User manual

2.1A-30001-D00
LINCOLN GmbH  Postfach 1263  D-69183 Walldorf  el [phone]  Fax [phone]
Page 1 from 28
Subject to change without notice
Owner Manual
Technical Description
10071327
QUICKLUB®
Pump Model 203
Without Control Unit

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Owner Manual
Technical Description
2.1A-30001-D00
Subject to change without notice
Fields of Applications of the QUICKLUB Progressive Central Lubrication Pumps
Industry - Machines - Commercial ehicles -
Building Machinery - Agricultural Machines
Pump Type
Pump : QUICKLUB 203
Reservoir:
2 l - 2XN** 2XNFL**, 2YN***, 2XNBO*, 2YNBO***
4 l - 4XNBO*, 4YNBO***,
8 l - 8XNBO*, 8YNBO***
* Filling from t e top or bottom
** Filling only from t e bottom
***Filling only from t e top
4 l, 8 l wit lockable reservoir lid (option)
Low-level control (option)for all reservoir sizes
available , on request
Control:
Wit out control unit for 12/24 VDC or 120, 230 VAC
Integrated control units (V10-V13)
1
for 12/24 VDC
Integrated control units (V10-V13)
1
for 120, 230 VAC
Integrated control unit wit metering device
monitoring (M 00 - 23)
1
External control units
PSG 01 (Commercial ve icles)
PSG 02 (Industry)
Control
H
1
Control
V10 - ADR
1
Control
H - ADR
1
1
See the respective model designation on the pump nameplate e.g. P203 - 2XN - 1K6 - 24 - 1 1.10 - V10

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Owner Manual
Technical Description
Page
Fields of applications of QUICKLUB
progressive central lubrication pumps ...................... 2
Safety instructions ....................................................... 4
Pump types ................................................................... 5
Identificatiom Code - Pump Models 203 .................... 6
Description of the QUICKLUB 203
central lubrication pump ............................................. 8
Mode of operation ........................................................ 9
Pump elements wit fixed Lubricant output .................... 9
Suction p ase ........................................................... 9
Delivery p ase .......................................................... 9
C eck valve ............................................................ 10
Arrangement of t e pump elements ........................ 10
Pump element wit adjustable lubricant output ............ 10
Setting of adjustable pump elements ............................ 11
Setting for t e lubricant output on an adjustable
pump element .............................................................. 11
Retrofit adjustment of max. lubricant output ........... 11
Adjusting of small lubricant output .......................... 11
Pressure relief valve ..................................................... 12
Return line connection .................................................. 13
Control unit ................................................................... 13
Page
Low-level control (optional) ....................................... 14
Low-level for grease ..................................................... 14
Low-level for oil ............................................................ 15
Measures for contact protection ................................... 15
Maintenance, repair and tests ................................... 16
Maintenance ................................................................. 16
Pump filling .................................................................. 16
Repair .......................................................................... 16
Tests .......................................................................... 17
Operational test/To trigger an additional
lubrication ............................................................... 17
To c eck t e safety valve ........................................ 17
Troubleshooting ......................................................... 18
Technical data ............................................................. 19
Torques ......................................................................... 19
Weig ts ........................................................................ 19
Connection diagram
Pump wit out control unit ............................................. 20
Specifications for t e installation of electric
equippment .................................................................. 21
Dimensions .................................................................. 22
Lubricants ................................................................... 28
Table of Contents
Further information can be found in the following manuals:
Tec nical Description for Electronic Control Units of t e pump
model 203
Tec nical Description Progressive Metering Devices for Grease
and Oil, model SSV
Printed Circuit Board 236-13862-1 - Model V10-V13
Printed Circuit Board 236-13857-1 - Model H
Printed Circuit Board 236-13870-1 - Model M 00 - M 15
Printed Circuit Board 236-13870-1 - Models M 16 - M 23
Control unit 236-13860-2 Model PSG02
Installation Instructions
Parts Catalog

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Owner Manual
Technical Description
2.1A-30001-D00
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Safety Instructions
Appropriate Use
 Use t e 203 pump only for dispensing lubricants in centrali-
zed lubrication systems.T e pump is designed for intermit-
tent operation.
General Safety Instructions
 LINCOLN - QUICKLUB - centralized lubrication systems
- are state of t e art;
- can be assembled for safe operation.
 Incorrect use may result in bearing damage caused by poor
or over-lubrication.
 Unaut orized modifications or c anges to an installed sy-
stem are not admissible. Any modification must be subject to
prior consultation wit t e manufacturer of t e lubrication sy-
stem.
Regulations for Prevention of Accidents
 Ad ere to t e regulations for prevention of accidents w ic
are effective in t e country w ere t e system is to be used.
Operation, Maintenance and Repair
 Repair s ould only be performed by aut orized and instruc-
ted personnel w o are familiar wit t e regulations.
 LINCOLN QUICKLUB central lubrication pumps must only
be operated wit a fitted safety valve.
 LINCOLN QUICKLUB central lubrication pumps must be re-
gularly refilled wit clean lubricant.
Attention: In the case of pumps which
are filled from the reservoir cover,
switch off the power supply before fil-
ling in the lubricant.
Attention: W en filling t e reservoir by
means of pumps with a large delivery
volume do not exceed the max. filling
mark. Risk of bursting if the reservoir
is overfilled.
 LINCOLN QUICKLUB centralized lubrication systems opera-
te automatically. However, a regular c eck (about every two
weeks) s ould be made to ensure t at lubricant is actually
reac ing all t e lubrication points.
 Defective printed circuit boards s all be suitably packed and
returned to t e factory.
 Dispose of used or contaminated lubricants in accordance
wit t e legislation concerning t e environment.
 T e manufacturer of t e centralized lubrication system will
not accept any liability
- for damages due to t e use of greases w ic are not or only
conditionally pumpable in centralized lubrication systems
- for damage caused by insufficient lubricant and irregular
pump refilling;
- for damage caused by t e use of contaminated lubricants
- for damage caused by an environmentally incompatible dis-
posal of used or contaminated lubricants.
Installation
 Any safety equipment already fitted to t e ve icle or t e ma-
c ine:
- s ould not be modified or made ineffective;
- s ould only be removed for t e purpose of fitting t e system;
- must be replaced afterwards.
 Keep QUICKLUB centralized lubrication systems away from
sources of eat. Ad ere to t e operating temperature.
 Use only original LINCOLN spare parts (see Parts Catalog)
or parts approved by LINCOLN.
 Ad ere to:
- t e installation instructions of t e ve icle or mac ine manu-
facturer as regards all drilling and welding procedures.
- t e specified minimum distances between t e bore oles
and t e upper/lower rim of t e frame or between two bore
oles.
 T e manufacturer of t e centralized lubrication system will
not accept any liability for:
- damage caused by unaut orized modification of t e system
components;
-damage caused by t e use of unapproved spare parts.
Important Information
Only for use in commercial vehicles
1. T e ADR QUICKLUB central lubrication pump complies wit
t e design regulations of annex B of t e act governing t e
road aulage of azardous materials valid for Europe (ADR)
and t at valid for t e Federal Republic of Germany (GGVS)
2. Moreover, t e pump and its electrical equipment comply wit
t e regulations of annex B.2 (ADR / GGVS regulations for
electrical equipment) according to Rn 220000 in conjunction
wit t e transport units mentioned in Rn 10251.
3. T e ADR central lubrication pump is in conformity wit t e
protection class IP 54.
Important! It is not allowed to use t e pump in ot er potentially
explosive fields.
4. Install t e ADR QUICKLUB 203 pump, t e metering devices,
lines and tube fittings as well as t e electrical connection
parts in accordance wit t e Installation Instructions. Use
only original LINCOLN parts.
5. After completion of t e proper installation and commission-
ing, the installation of the system must be certified by
means of a stamp and signature of the specialized work-
shop or expert. For t is purpose, use t e form attac ed to
t e Operating Instructions (pump 203).
6. If t e pump and t e installation do not comply wit t e con-
struction regulations of ADR and GGVS, t e type approval is
no longer valid.
7. T e Operating Instructions along wit t e certificate duly fil-
led in must be added to t e ve icle papers. It is to be submit-
ted at t e inspection in accordance wit § 6, clause 4 GGVS.

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Owner Manual
Technical Description
Pump T pes
Fig. 1 - The different types of pump 203
 Control unit models 203
T e following control units can be used for t e 203 pumps: (re-
fer to t e respective Tec nical Description)
a) external control units
PSG 01
PSG 02 (Industry)
b) integrated control units
-wit adjustable pause and operating times, 10- 13*
-wit adjustable pause and operating times, 10- 13* for al-
ternate current 120, 230 VAC, separate owner manual
-wit metering device monitoring (microprocessor control), M
00 - M 23*
c) integrated control unit (trailers)
- wit fixed time of availability (6 ours) and adjustable opera-
ting time, H *
* Refer to t e designation on t e pump nameplate.
Example: P203 -2XNBO - 1 K6 - 24 - 2A1.10 - 10
Also refer to t e designation code on page 6.
The 203 pumps differ from eac ot er only in t e design and
reservoir size as well as in t e type of t e electric connection
(different plugs wit or wit out electric cable).
 Reservoir sizes:
2 l transparent plastic reservoir
4 l transparent plastic reservoir
8 l transparent plastic reservoir
Electric connection
For t e industrial applications, t e pumps are only equip-
ped wit plugs.
T e pumps model 203 used in commercial vehicles are
equipped wit a 10 m electric cable.
 All ot er data suc as:
- motor voltage
- version of t e control unit
- remote control for triggering an additional lubrication
- cycle (2A1)
- design and number of pump elements
- design and number of safety valves
- filling type
- use of return line connections
- low - level control (option)
can be learnt from t e pump type designation code.
1173b95

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Owner Manual
Technical Description
2.1A-30001-D00
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Identification Code - Pump Models 203
Examples of model designations
Basic pump model for grease or oil
with 1-3 outlets and 12 V C or 24 V C motor
Reservoir design
2 = 2 l transparent plastic reservoir
4 = 4 l transparent plastic reservoir
8 = 8 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
K 6 = Piston diameter = 6 mm
K 7 = Piston diameter = 7 mm
K R = Pump element, adjustable
C 7 = Piston diameter = 7 mm ***
Motor
12 V C or 24 V C motor
AC = 94 - 265 VAC with 24 V C direct current motor
(see documentation P203 with power supply unit for 94-265 VAC)
Number of electric connecting possibilities (on pump housing only
1A = 1 connection for power supply, on the left
2A = 1A (on the left) + second connection (2 A  on the right) for illuminated pushbutton
(external additional lubrication, not possible with variant AC) and/ or external low-level control
(with or without control p.c.b. V10-V13, possible with variant AC)****
or second connection (2 A  on the right) for piston detector (for M00-M23 control p.c.b.)
also see table on page 7
Type of connection
1 = cube-type plug, acc. to DIN 43650, type of construction A
4 = AMP - flanged plug (microprocessor)
8 = PG - cable gland
9 = AMP plug, wire to wire
Connection outside the pump
00 = without socket-outlet, without cable
01 = with socket-outlet, without cable
10 = with 10 m cable
11 = with 10 m A R cable
12 = with 10 m cable, 4 - wire (microprocessor M00 - M07)
13 = with 10 m cable, 5 - wire (microprocessor M08 - M23)
Control p. c. b. s. 12V / 24 V
V10 -V13 -with adjustable pause and operating time
V10 -V13 - A R 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 - A R for trailers and semitrailers**
No designation: Pump without control p. c. b.
* Not in conjunction with Hirschmann plugs (type of connection 1)
** for transport of hazard materials
*** C 7 = esignation of pump elements for supplying of paste for chisel (C = chisel), C 5 or C 6 on request
Note: Any pumps combinations other the above standard pumps can be composed and ordered in accorcance with the valid model identification code.
P203- 2 X N - 1 K6- 24- 1A 1. 01- V10
P203- 4 X L - 1 K7- 24- 2A 1. 10- V12
P203- 2 X N - 1 K6- 12- 1A 8. 00
P203- 2 X N - 1 K6- 24- 2A 1. 11- V10-ADR
P203- 2 y N BO- 2 K5- 24- 1A 1. 01
P203- 4 X N BO- 1 K6- 24- 2A 4. 12- M00

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Owner Manual Technical Description
Electric connections for pump 203
for example P203-2XN-1K6-24-... . ..-V10
Operating time
Connecting plug, on the left Connecting plug, on the right
Pump
Power suppl Illuminated push button External Lamp
-1A1.01-cube-type plug, left wit out cable -2A4.12-AMP-plug, 4-wires
without p. c. b. VDC
without p. c. b. VAC
Low-level
control
with p. c. b. V......
for grease, VDC
with p. c. b V......
for grease, VAC
with p. c. b V......
for oil, VDC
with p. c. b V......
for oil, VAC
with p. c. b H
for grease, VDC
with p. c. b M00-M07
for grease , oil, VDC
with p. c. b M08-M23
for grease , oil, VDC
possible connections
Activit t/displa
-1A1.10-cube-type plug, left wit cable
-2A1.01-cube-type, rig t wit out cable
-2A4.13-AMP-plug, 5-wires -1A8.00-cable gland wit out cable
-2A9.12-AMP-plug, wire to wire, 4-wires
-2A9.13-AMP-plug, wire to wire, 5-wires -1A8.XX-cable gland wit cable (option,OEM)
Printed circuit boards V10-
V13, V20-V23, H
Connecting plug, on the left
Printed circuit boards M00-
M23
Connecting plug,
on the right
Power suppl
Possible connections
Activit /displa
Pump
Illuminated push button Piston detector
Trigger additional
lubrication Operating
time
1 or 2 piston detector(s)
1 or 2 piston detector(s)
1A1.01/1A1.10
1A1.01
1A1.01/1A1.10
1A1.01
1A1.01/1A1.10
1A1.01
1A1.10
2A4/9.12
2A4/9.13
--------
2A1.01/2A1.10
2A1.01/2A1.10
--------
2A1.01/2A1.10
2A1.01/2A1.10
-------
-------
2A1.01/
2A1.10
2A1.01/
2A1.10
2A1.01
2A1.01
separate plug on
lid of reservoir
2A1.01/
2A1.10
-------
2A4/9.12 2A4/9.12 2A4/9.12
2A4/9.13 2A4/9.13 2A4/9.13
Fault/low-level control/
readiness for service
-------*
--------*
--------*
--------*
-------*
-------*
* possible on the control p.c.b. only
-2A1.10-cube-type, rig t wit cable
Trigger additional
lubrication

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Owner Manual
Technical Description
2.1A-30001-D00
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Description of the QUICKLUB 203 Central Lubrication Pump
 The QUICKLUB 203 central lubrication pump
- is a compact multiline pump consisting of t e following com-
ponents:
Housing wit integrated motor
Reservoir wit 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 opera-
ting times)
- can be equipped wit a low-level control
- can supply up to 300 lubrication points depending on t e
line lengt s
- is designed for t e automatic lubrication of t e connected
lubrication points
- is designed for t e delivery of greases up to NLGI 2 at tem-
peratures from - 25° C to 70° C or of mineral oils of at least
40 mm²/s (cST)
- can be used at low temperatures down to - 40° C.
 During t e operating time t e pump dispenses lubricant to
t e connected lubrication points via one or several metering
devices.
Fig. 2 - Pump components
1 - Reservoir 5 - Plug 2 1
2 - Pump element 6 - Filling nipple, pump
3 - Safety valve 7 - Printed circuit board
4 - Filling nipple, system 8 - Plug 1 1
Emergency lubrication 9 - Return line connection
possible
00002618
Low-level control (optional)
Te pump model 203 can be equipped wit a low-level con-
trol.
 T e following versions are available:
-Low-level control in conjunction wit printed circuit boards
10- 13*
-Low-level control in conjunction wit printed circuit board
M00-M23*
-Low-level control for pumps without printed circuit board.
 W en t e reservoir is empty, t e signal lamp flas es, t us
indicating t e low level. Refer to t e c apter Low-level con-
trol.
* The designation indicates the version of the printed circuit board. It is part of
the pump type designation code mentioned on the nameplate of each
pump. Example: P203 - 2XN - 1K6 - 24 - 1 1.10 - V10
Fig. 3 - QUICKLUB central lubrication pump, 2 l reservoir
1006a93

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Owner Manual
Technical Description
Mode of Operation
 T e electric motor drives t e eccentric 1 (Fig. 5, 6).
 During t e operating time:
- piston 2 sucks in lubricant from t e reservoir. Refer to Fig. 5.
- piston 2 dispenses t e lubricant to t e connected lubrication
points via t e metering device. Refer to Fig. 6.
 T e following designs are available:
Piston diameter, K5 ........................................................ 5 mm
Lubricant output ........................................ approx. 2 cm³/min
Piston diameter K6 (standard) ...................................... 6 mm
Lubricant output .................................... approx.. 2.8 cm³/min
Piston diameter, C7, K7 ................................................. 7 mm
Lubricant output ........................................ approx. 4 cm³/min
Note: Pump elements with piston diameter C 7 must be used
for supplying of chisel paste. The design and the mode of ope-
ration are the same as those of the pump elements with piston
diameter K 7.
20002068
Fig. 4 - Pump element
1 - Piston
2 - Return spring
3 - Check valve
1003a95
1004a95
Fig. 6 - The pump element dispenses lubricant
Fig. 5 - The pump element sucks in lubricant
1 - Eccentric 3 - Spring
2 - Piston 4 - Check valve
Pump Elements with fixed Lubricant output
Suction Phase
Delivery Phase
1 - Eccentric 3 - Spring
2 - Piston 4 - Check valve

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Technical Description
2.1A-30001-D00
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Check valve
 T e c eck valve:
- closes t e pressure line during suctionstroke
- prevents t e lubricant from flowing back to t e ousing or
reservoir
1 - Reservoir wit stirring paddle
2 - Pump
3 - C eck valve, spring-loaded
4 - Pressure relief valve
R - Return line
p - Pressure line
Arrangement of the pump elements
 If several pump elements are to be installed, t e installation
arrangement s own in Fig. 8 must be ad ered to.
 If t ere is only one pump element , it can be installed in any
position. Standard position is no. 3.
 If t ere are two elements, install one in position 3 and t e
ot er in position 1.
Fig. 7 - Hydraulic diagram of the pump
Fig. 8 - Arrangement of the pump elements
Fig. 9 - Adjustable pumpelement
4158a99
1163a95
1164b95
Pump element with adjustable lubricant output
 T e mode of operation (suction and supply p ase) is t e
same as t at of t e pump elements wit an invariable lubri-
cant output.
 T e lubricant outputs are adjustable from 0.04 to 0.18m
3
/
stroke, or 0.7 to 3cm
3
/min.
 T e pump elements are factory-adjusted to t e maximum
lubricant output; t e adjusting dimensions S s ould be 29 ±
0.1 mm.

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Owner Manual
Technical Description
Fig. 10 - Sectional view: adjustable element
4159a98
1 - adjusting sindle SW 16 3 - pump element body 6 - control piston
(with over flats) 4 - gasket 7 - delivery piston
2 - counternut SW 24 5 - pump cylinder S - dimension
 Unsrew t e coupling nut for fixing t e safety valve
 Loosen counter nut (2, Fig. 10) w ile olding in position
pump element body (3) by means of a seconf wrenc .
 C ange t e position of t e adjusting spindel (1) by means of
a wrenc .
etting of adjustable pump elements turning clockwise = decreasing piston
turning counterclockwise = increasing piston
 T e dimension S (see Fig. 10) for t e desired lubricant out-
put can be ascertained by using t e delivery diagram s own
in Fig. 11.
 T e pump elements are factory set to maximum lubricant
output.
etting for the lubricant output on an adjustable pump element
Retrofit adjustment of maximum lubricant output:
Note: In order to ensure that the lubricant output setting will
be as e cat as possible, first the actual dimensions S of the
ma . lubricant output must be ascertained as follows. The
measured difference from the nominal value 29 must be
considered for all other settings values (e.g. ± 0.1).
 Unsrew t e adjusting spindle (1, Fig 10) from t e pump ele-
ment body (3) until S is approx. 30 mm.
 Srew counter nut (2) onto stop collar of t e adjusting spindle (1)
 Screw adjusting spindle (1) wit counter nut (2) into pump
element body (3) until stop.
Adjusting of small lubricant output:
 Before t e pump element can be adjusted to small lubricant out-
put, t e dimension S for max lubrcant output must be ascertai-
ned, and t e difference from t e nominal value 29 must be tranfer-
red to any desired settings between 25.5 ... 28,.5.
 Dimension S must be adjusted to t e desired value in ac-
cordance wit t e delivery diagramm (Fig. 11).
Note: At ma imum steeing S is 29 ±0.1 mm.
A = Lubricant output cm
3
/min B = Lubricant output cm
3
/stroke
S = Dimension
Fig.11- Supply diagram
4179a99

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Owner Manual
Technical Description
2.1A-30001-D00
Subject to change without notice
P ressure relief valve without grease return
Important! Eac pump element must be secured wit a pres-
sure limiting valve.
 T e pressure relief valve
- limits t e pressure build-up in t e system
- opens at an overpressure of 250 or 350 bar depending on
t e safety valve design.
 If lubricant is leaking at t e pressure relief valve, t is
indicates t at t e system is malfunctioning.
Note: The pumps model 203 are equipped without pressure
relief valve. When ordering the pumpe, order the pressure reli-
ef valve seperatly. See the Parts Catalog under pressure relief
valves.
Pressure relief valve with grease return (optional)
If t e system is blocked, grease will leak from t e pressure reli-
ef valve. T is grease quantity is returned to t e reservoir.
Fig. 12 - Pressure relief valve
Fig. 13 - Pressure relief valve with grease return
10022618a
00002626a
Pressure Relief Valve

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Owner Manual
Technical Description
00002616
10032618
00002629
Fig. 15- Return line connection
Note: The present Technical Description describes the Pump
model 203 without control unit . Information concerning the
design and operation of the individual control units can be
found in the respective Technical Descriptions.
 If t e pump is to be equipped wit a control unit, it is possible
to use an integrated printed circuit board or an external con-
trol unit.
Fig. 14 - Fault indication in the case of a blockage
Fig. 16 - Printed circuit board integrated in the housing
In t e case of a blockage in t e system, t e grease pus es out
t e red pin at t e pressure relief valve, t us indicating t at t e-
re is a fault.
T e lubricant quantities w ic cannot be dispensed by t e me-
tering device must be returned to t e pump via t e return line
connection (Fig. 15).
Return Line Connection
Control Unit

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Owner Manual
Technical Description
2.1A-30001-D00
Subject to change without notice
00002444
When the reservoir is filled
T e stirring paddle rotates clockwise during t e operating
time.
Due to t e rotating motion of t e stirring paddle in t e lubri-
cant t e pivoting guiding plate wit t e round solenoid, item
1 Fig.17, is pressed backwards. T e solenoid moves toward
t e center of rotation of t e stirring paddle. T e electroma-
gnetic switc item 2 cannot be activated.
Control cam item 3 guides t e round solenoid wit t e pivo-
ting guiding plate automatically outwards, in t e direction of
t e reservoir wall. After t e lubricant as left t e control cam,
it flows against t e guiding plate, t us displacing t e soleno-
id again onto t e center of rotation of t e stirring paddle.
When the reservoir is empty
During t e rotating motion of t e stirring paddle t ere is no
backpressure from t e lubricant. T e guiding plate wit t e
round solenoid no longer moves towards t e center of rotati-
on of t e stirring paddle. After control cam 3 as been over-
travelled, t e solenoid remains in t e outer position and
overruns electromagnetic switc 2. T e solenoid activates
t e electroma- gnetic switc contact-free, t us triggering a
low-level signal.
T e flas ing frequency in t e case of printed circuit boards
236-13856-1 (F) and 236-13862-1 ( 00- 03) and in t e
case of pumps wit out control units depends on t e motor
speed.
T e flas ing frequency in t e case of printed circuit board
236-13870-1 (only M 00 - M 15) is:
0.5 second ON - 0.5 second OFF
Note: The flashing signal starts only after the solenoid has acti-
vated the electromagnetic switch 6 times contact-free.
M16 - M 23
T e external relay drops out and t e LED is extinguis ed once
t e operating time as expired. T e pump stops operating and
no longer restarts automatically.
Fig. 17 - Switching parts of the low-level control
1 - Guiding plate with round solenoid
2 - Electromagnetic switch (at stirring paddle)
3 - Control cam
Low-Level Control (optional)
Low-level control for Grease
Fig. 18 - Connection diagram
4237a99
Magnetic switch
T e electromagnetic switc is activated contact-free and
wit -out wear by t e magnetic field of t e magnetic fitted to
t e stirring paddle.
Note: The life of the magnetic circuit breaker strongly depends
on the conditions under which it is loaded. Since the data rela-
tive to the ma imum switching capacity refer to strictly resistive
loads, which cannot be always guaranteed in practice, it is ne-
cessary to take the corresponding contact protection measures
in the case of deviating loads.
Tec nical data:
Maximum switc ing capacity: 60 VA
Maximum switc ing voltage: 230 V
Current switc ed: 3 A

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Owner Manual
Technical Description
Contact Protection Measures
Fig. 20 - Contact protection measures
1201a95
1 - Electromagnetic switch
2 - RC element
3 - Diode
4 - Load
Low-level control for Oil
1202a99
Fig. 19 - Connection diagram
Magnetic floating switch
T e electromagnetic switc is activated contact-free and
wit -out wear by t e magnetic field of t e solenoid fitted to
t e float.
Note: The life of the magnetic circuit breaker strongly depends
on the conditions under which it is loaded. Since the data rela-
tive to the ma imum switching capacity refer to strictly resistive
loads, which cannot be always guaranteed in practice, it is ne-
cessary to take the corresponding contact protection measures
in the case of deviating loads.
Tec nical data:
Maximum switc ing capacity: 60 VA
Maximum switc ing voltage: 230 V
Current switc ed: 3 A

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Owner Manual
Technical Description
2.1A-30001-D00
Subject to change without notice
 T e maintenance is essentially limited to refilling t e reser-
voir wit clean lubricant in good time. However, c eck regu-
larly w et er t e lubricant is really dispensed to all t e lubri-
cation points.
Also c eck t e main lines and lubricant feed lines for dama-
ge and replace t em, if necessary.
Note: Whenever work is done on the centralized lubrication sy-
stem, particular attention should be paid to absolute cleanli-
ness. Dirt in the system will cause problems.
 For cleaning t e system use benzine or petroleum. Do not
use tri-, perc loroet ylene or similar solvents.
Also do not use polar organic solvents suc as alco ol,
met ylaco ol, aceton or similar
Maintenance, Repair and Tests
1011a93
Abb. 21: - Behälter der Pumpe befüllen
Pump Filling
Maintenance
2 l, 4 l, 8 l - reservoirs
Fill t e reservoir up to t e Max. mark via t e filling nipple, if
any, or via t e upper filling opening.
It is possible to use greases up to penetration class NLGI 2 or
mineral oils of at least 40 mm²/s (cST).
Important! T e grease or oil must be free from impurities and
must not be liable to c ange its consistency in t e course of
time.
Attention: If the pump is filled via the upper filling opening,
switch off the power supply before starting filling.
Attention: W en filling t e reservoir by
means of pumps with a large delivery
volume do not exceed the max. filling
mark. Risk of bursting if the reservoir
is overfilled.
Note: If the reservoir has been complete-
ly emptied, the pump may require until 10
minutes before it operates with its full
output.
Repair
Pump
 Use only original LINCOLN spare parts for repair on t e
pumps.
 T e pump s ould be returned to t e factory for warranty work
or major repairs.
 Defective printed circuit boards s ould be suitably packed
and returned to t e factory.

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Owner Manual
Technical Description
Operational Test / Triggering an Additional Lubrication
Cycle
Tests
To Check the Safety Valve
1005a93
Fig. 23 - To check the safety valve
1 - Hose line, min.length 1m
2 - T-piece
3 - Pressure gauge
4 - Relief cock
1st option
* Connect t e pressure gauge (0-600 bar; 0-8708 psi) to t e
safety valve (Fig. 23).
* Trigger an additional lubrication cycle.
2nd option
* Connect t e manual pump of t e pressure and c ecking set
604-36879-1 to t e safety valve and c eck t e opening pres-
sure by means of t e manual pump.
* T e safety valve s ould open at a pressure of 250 or 350 bar
depending on its design.
Important : Do not connect t e pressure gauge directly to t e
pump element. Hig pressure may exceed t e above mentio-
ned range, causing t e motor to stall. T e motor is designed in
suc a way t at it can stall for about 30 minutes wit out being
damaged.
Replace the pump element
Fig. 22 - Replacing the pump elememt
* Remove t e pressure relief valve from t e pump element
* Unscrew t e pump element. Take care t at t e piston, t e
pull-back spring and t e was er are not left lying in t e grea-
se, ot erwise t e reservoir must be disassembled in order to
remove t ese pieces
Important: Do not leave t e piston, spring and was er in t e
ousing because t ey may block t e motor.
* Install a new pump element and a new sealing ring
Note: Pump element with adjustable lubricant output is set to
the same output as the old pump element
5026a96
 To c eck t e pump operation it is possible to perform an ad-
ditional test. Refer to t e Tec nical Description of t e respec-
tive printed circuit board.

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Owner Manual
Technical Description
2.1A-30001-D00
Subject to change without notice
Troubleshooting
Note: The pump operation can be checked from the outside by
observing whether the stirring paddle is rotating (e.g. by trigge-
ring an additional lubrication). For troubleshooting in the case
of pumps with integrated control units, please refer to the re-
spective Technical Description of the printed circuit board.
 Remedy:
 C eck t e power supply and fuses. If necessary rectify t e
fault and/or replace t e fuses.
 C eck t e line leading from t e fuses to t e pump plug.
 C eck t e power supply to t e motor. If necessary, replace
t e motor.
Fault: The pump motor does not run
 Cause:
 Power supply interrupted
 Electric motor defective
Fault: The pump does not deliver the lubricant
 Cause:
 Reservoir empty
 Air bubbles in t e lubricant
 Unsuitable lubricant as been used
 Suction ole of t e pump element clogged
 Pump piston worn
 C eck valve in t e pump element defective or clogged.
Remedy:
Note: If a lubricant low-level is available, the low level is indi-
cated by the flashing light of the signal lamp in the case of
pumps without printed circuit board. The flashing frequency
depends on the speed of the motor.
 Fill up t e reservoir wit clean grease or oil. Allow pump to
run (trigger an additional lube cycle) until t e lubricant issu-
es from all t e lubrication points.
Note: Depending on the ambient temperature and/or sort of
lubricant it may take 10 minutes of operation before the
pump elements reach their full lubricant output.
 Trigger an additional lubrication cycle. Loosen t e outlet fit-
ting or t e main line at t e safety valve. T e lubricant must
issue wit out air bubbles.
Note: When push-in type fittings are used, the high-pressure
plastic hose which is under pressure cannet be easily discon-
nected from the safety valve. For this purpose, loosen the
safety valve. For this purpose, filling nipple on the safety valve
in order to relieve the high-pressure hose.
 Renew t e lubricant. See t e Lubricant List.
 Remove t e pump element. C eck t e suction ole for for-
eign particles. If t ere are any, remove t em.
 Replace t e pump element.
 Replace t e pump element.

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Owner Manual
Technical Description
Technical Data
Pump
Admissible operating temperature ................. -25° C to 70° C*
Number of outlets ........................................................... 1,2 or 3
Reservoir capacity ...................................................... 2 l, 4 l, 8 l
Refilling.................... via ydraulic lubrication fitting or from top
Lubricant ....................................... greases up to NLGI grade 2
............ mineral oils of at least 40mm²/s (cST) at 40° C
Class of protection .................... IP6K 9K acc. to DIN 40050 T9
*Note: The pump is designed for the above mentioned tempe-
rature range. The lubricants used must still be pumpable at the
temperatures mentioned above. In case of doubt, consult the
lubricant manufacturer.
Motor:
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.
Pump element with fixed lubricant output
Piston diameter, K5 ........................................................... 5 mm
Lubricant output ................................ approx. 2 cm³/min
Piston diameter, (standard) K6 ......................................... 6 mm
Lubricant output .............................. approx. 2.8cm³/min
Piston diameter, K7, C7 .................................................... 7 mm
Lubricant output ................................ approx. 4 cm³/min
Max. operating pressure. ...............................................350 bar
Connection t read. ............................................................ G 1/4
suitable for tube DIA .............................................. 6 mm
Important! T e lubricant output listed refers to grease of NLGI
grade 2 measured at 20°C, backpressure 100 bar, nominal
voltage 12/24 V. Any differing pressures or temperatures result
in different lubricant outputs. Any system design must be ba-
sed on t e above values.
Pump element with adjustable lubricant output
KR .......................................................... 0.04 to 0.18 cm
3
/stroke
.......................................................................... 0.7 to 3 cm
3
/min
Connection t read ........................................................ G 1/4 in.
suitable for tube DIA .............................................. 6 mm
suitable for tube DIA .............................................. 8 mm
Safety valve
SVEVT - 350 - G¼ A - D6 ..................................... 624-28070-1
SVEVT - 350 - G¼ A - D8 ..................................... 624-28774-1
Weights
T e weig ts below include t e following individual weights:
- Pump kit wit one pump element, safety valve, grease filling
(0.75 kg, 1.5 kg)
- Packing (cardboard box)
- Attac ing parts
- Operating Instructions
2 l reservoir, standard design (0.75 kg)
Pump 203 wit out connection cable ............................... 5.4 kg
Pump 203, version E 1 ..................................................... 6.5 kg
Pump 203, version E 2 ..................................................... 7.1 kg
4 l reservoir, standard design (1.5 kg)
Pump 203 wit out 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 wit out connection cable ............................... 8.6 kg
Pump 203, version 1A1 .................................................... 9.6 kg
Pump 203, version 2A1 .................................................. 10.2 kg
In t e case of pump versions deviating from t ose mentioned,
add t e weig ts of t e following components to t e mentioned
weig ts.
Per pump element .......................................................... +0.2 kg
Per safety valve .............................................................. +0.1 kg
10 m monitoring cable, 5-wire
(microprocessor) E 4 ...................................................... +1.1 kg
10 m monitoring cable, 4-wire
(microprocessor) E 4 ...................................................... +0.4 kg
Connection cable wit piston detector ............................ 0.1 kg
Reservoir version Filling from top (only 2 l)*............. +0.15 kg
2 l flat-type reservoir ....................................................... +0.5 kg
* Note: The 4l and 8l reservoirs have the standard design fil-
ling from top.
Torsion torques
install pump ...................................................................... 18 Nm
Electric motor on ousing ............................................... 12 Nm
Pump element in ousing ............................................... 25 Nm
Closure plug in ousing .................................................. 12 Nm
Return line connector in ousing ............................. 10 - 12 Nm

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Owner Manual
Technical Description
2.1A-30001-D00
Subject to change without notice
1165b95
F - Low-level control
Switching capacity max. 60 W/V
Switching voltage max. 230 V C
Switched current max. 3
M - Electric motor
- Pump housing
B - Connector 1
C - Line socket 1 with connection cable, 3-wire
D - Connector 2*
E - Line socket 2*
* Only if a low-level control is available
Note: All the other connection diagrams can be found in the respective Technical Description Electronic Control Units for Central
Lubrication Pump Model 203.
Fig. 24 - Connection diagram QUICKLUB 203 without control unit
Connection via cube-type-in connectors IN 43650-A
Connection Diagram - Pump without Control Unit