Lincoln C Series User manual

Model 94822
CHASSIS LUBE ELECTRIC GREASE PUMP
Series "C"
Section Page
- Q3
FEB - 2006 FORM 403599 - 14C

Page 2 Form 403599
Figure 1
17.72"
(450 mm)
6.37"
(162 mm)
Mounting Holes
8"
(202 mm)
9.84"
(250 mm)
4.72"
(120 mm)
.35"
(9 mm)
Mounting
Holes
13.00"
(330 mm)
SPECIFICATIONS
Electrical Requirements
Input 24 VDC @ 2 amps
Enclosure Rating IP 6K9K - Protected from water
sprayed in all directions.
Alarm Time 30 minutes
Interval betwee lube
cycles 4 minutes minimum
60 minutes maximum
Pump Output 0.171 cu. in./min (2.8 cm³/min)
Outlet Connection 1/8" NPT (female)
Maximum Recommended
Operating Pressure 3600 psi (248 bar)
Reservoir Capacity 488 cu. in. (8000 cc)
Lubricant Greases up to NLGI grade 2
(depending on the operating
temperature and type of
lubricant)
Temperature Range -13°F (-25°C) to + 158°F (+70°C)
Pressure Relief Valve 4000 psi +/- 250 psi
(276 bars) +/- (1 7 bars)
DESCRIPTION
The chassis lube pump is electrically operated and is used in
a progressive type centralized lubrication system. The pump
incorporates a low-level sensor which will cause a LED light on
the circuit board to blink if a low-level condition occurs. This
signal may also be sent to an optional dash mounted light if
desired.
The frequency of the pump's lubrication cycles is controlled by
the internal microprocessor. A proximity switch, installed on
one of the systems secondary divider valves, must be utilized
to signal completion of a lubrication cycle. If a signal is not
received within 30 minutes a fault signal, as described above,
will also occur. This feature is used to monitor the pump's
operation and to detect any blocked or broken supply lines.
Do not use pump without pressu-
re relief valve.
The pump consists of a pump housing, electric gear motor, the
microprocessor and a plastic reservoir with stirring paddle. The
high operating pressure capability allows the pump to supply
lubricant up to NLGI #2 grease.
MOUNTING THE PUMP
Select an easily accessible place of installation which allows
access to the timer and lubricant reservoir ller tting. The pump
must be mounted vertically on an even surface by means of
three bolts. (See Fig. 1 on page 3.)
TO FILL RESERVOIR
Fill the reservoir through the grease tting located at the base
of the reservoir. Reservoir can be lled using a hand operated
grease pump, a pneumatic pump or electronic transfer pump.
Rell reservoir when grease reaches “MIN” mark located on
the reservoir. Fill the reservoir up to the “MAX” mark located
on the reservoir.
TO PRIME SYSTEM
Pump & Supply Line: After reservoir has been lled with
recommended lubricant, loosen the supply line tting. Operate
the pump until lubricant ows from outlet, then tighten tting.
Feed Lines: Pre-ll each feed line with lubricant before
connecting to outlet of divider valve and bearing.
Caution must be used when
lling reservoir with pneumatic
or electric transfer pump so as
not to burst reservoir.

Form 403599 Page 3
MOUNTING HOLE LOCATIONS
Figure 3
Figure 2

Page 4 Form 403599
Proximity Switches
The following proximity switches
for black colored blocks only:
234-13188-2 3-meter (9.8 ft)
cable length
234-13188-3 7-meter (23.0 ft)
cable length
PARTS LIST
ITEM DESCRIPTION QTY. PART NUMBER
NO. /KIT NUMBER
1 Reservoir 1 247674
2 Hose 1 247676
3 Stirring paddle 1 544-31954-1©
4 Control Cam 1 249903
5 Bearing ring 2 part of Kit 246434
6 Bearing 1 part of Kit 246434
7O-ring 2 246424
8 Intermediate plate 1 246425
9 Shim 1 part of Kit 246434
10 Snap ring 2 part of Kit 246434
11 Inner ring 1 part of Kit 246434
12 Eccentric cam 1 246427
13 Screw 3 part of Kit 246436
14 Washer 3 part of Kit 246436
15 O-ring 3 part of Kit 246436 & 246437
16 Pump housing 1 246426
17 Closure plug 2 246422
18© 3 wire internal plug 1 273483
19© 5 wire internal plug 1 273484
20© 5 wire power cord/plug 4 273485
22 Sealing plug 1 246423
23 Nipple 1 226-14105-5
24 Screw 10 206-13796-7
25 Grease tting 1 5050
26 Microprocessor 1 249905
27 Woodruff key 1 part of Kit 246436
28 Radial seal 1 part of Kit 246436 & 246437
29 24 VDC motor 1 part of Kit 246436
30 Housing cover 1 246421
31 Hose 1 not sold
33 Proximity Switch 1 See above
34 Check valve 1 part of Kit 600-26876-2
35 Pump element 1 part of Kit 600-26876-2
36 Gasket 1 part of Kit 600-26876-2
37 Pressure relief assy. 1 270864
38 Plug for motor 1 part of Kit 246436
39 Grease cap 1 242125
41 Adapter for relief assy. 1 304-19614-1
42 Lid 1 247671
43 Fixed paddle 1 444-70490-1©
44 O-ring 1 247677
45 Adapter 1 247678
46 O-ring 1 219-14138-2
48 Magnetic Switch 1 249904
Figure 4 - Proximity Switch
© Indicates change

Form 403599 Page 5
SERVICE PARTS/KITS
Part No. Qty. Description Item No.
5050 1 Grease tting 25
242125 1 Grease cap 39
246421 1 Housing cover 30
246422 1 Closure plug 17
246423 1 Sealing plug 22
246424 2 O-ring 7
246425 1 Intermediate plate 8
246426 1 Pump housing 16
246427 1 Eccentric cam 12
Bearing & Seal Kit contains:
2 Bearing ring 5
246434 1 Bearing 6
1 Shim 9
2 Snap ring 10
1 Inner ring 11
24 VDC Motor Kit contains:
3 Screw 13
3 Washer 14
3O-ring 15
246436 1 Woodruff key 27
1 Radial seal 28
1 24 VDC motor 29
1 Plug for motor 38
Housing Seal Kit contains:
246437 3 O-ring 15
1 Radial seal 28
247671 1 Lid 42
247674 1 Reservoir 1
247676 1 Hose 2
247677 1 O-ring 44
247678 1 Adapter 45
249903 1 Control Cam 4
249904 1 Magnetic Switch 48
249905 1 Microprocessor 26
270864 1 Pressure relief assembly 37
273483© 1 3 wire internal plug 18
273484© 1 5 wire internal plug 19
273485© 1 5 wire power cord/plug 20
206-13796-7 10 Screw 24
219-14138-2 1 O-ring 46
226-14105-5 1 Nipple 23
304-19614-1 1 Adapter for relief assembly 41
444-70490-1 1 Fixed paddle 43
544-31954-1 1 Stirring paddle 3
Pump Element Assembly contains:
600-26876-2 1 Check valve 34
1 Pump element 35
1 Gasket 36

Page 6 Form 403599
When replacing service part 249905 microprocessor circuit board
check to see that the jumpers in the new board are positioned the
same as the old board. See illustration below showing location of the
ve jumpers.

Form 403599 Page 7
SYSTEM ACCESSORIES
DESCRIPTION PART NO.
PUSHBUTTON & LIGHT (24 VDC) 241484
8 AMP FUSE 241052
FUSE HOLDER 241053
Figure 5

Page 8 Form 403599
Fig. 6 - Printed circuit board 236-13870-1
• The printed circuit board automatically controls the
sequence of the pause and operating times of the 203 central
lubrication pump as a function of the vehicle or machine wor-
king hours tB (Fig. 7).
• The sequence of the pause and operating times is
activated when the machine contact or ignition switch is swit-
ched on.
• A lubrication cycle consists of one pause time and one ope-
rating time. Once the pause time has elapsed, the operating
time starts to run. This lubrication cycle is repeated perma-
nently after the machine or vehicle has been put into operati-
on. Refer to Fig. 7.
• During the operating time the pump element dispenses the
lubricant to the lubrication points via progressive metering de-
vices.
Fig. 7 - Time sequence diagram
tB - Working hours T - Lubrication cycle
tP - Various pause times T1 - Stored pause times
T2 - Operating times
Pause time
• The pause time
- determines the frequency of the lubrication cycles within a
working cycle;
- is started and stopped via the machine contact or ignition
switch;
- is adjustable.
• When the machine contact or the ignition switch is
switched off, the pause times which have already
elapsed as well as the momentary operating conditions (faults)
are stored and added up by an electronic memory (EEPROM)
until the time which has been set on the blue rotary switch is
reached.
• After the machine contact or ignition switch is switched on
again, the printed circuit board operates from the point where
it had been interrupted.
• If the setting is modied within the pause time, the printed cir-
cuit board takes over the new value only at the end of the
operating time.
•The pause time setting may be different for each application. It
must be adjusted in accordance with the respective lubrication
cycles. Also refer to ”To set the pause time”.
Fig. 8 - Proximity Switch
Operating time
• A proximity switch (initiator) which has been installed on a
metering device instead of a piston closure plug monitors and
brings the pump operating time to a close after all the pistons
of this metering device have dispensed their
lubricant quantity.
• The operating time depends on the system’s lubricant require-
ment and on the location of the proximity switch (either on the
main metering device or on the secondary metering device).
• During the operating time, the signal lamp is
permanently lit.
Monitoring time
• A xed monitoring time of maximum 30 minutes.
Note: Normally, the monitoring time ends at the same time as
the operating time.
•If there is no switching off signal from the proximity switch to
the printed circuit board within 30 minutes, a fault
signal will occur.
The signal lamp ashes with the corresponding ashing fre-
quency. See ”Fault indication”.

Form 403599 Page 9
Figure 11 - To acknowledge a fault
• When the pushbutton is pressed briey (< 1 second) the fault
is acknowledged, i.e. the lamp stops ashing and is perma-
nently lit.
Note: Any acknowledged fault remains stored even after the
driving switch or machine contact has been switched off. Upon
switching on again, the signal lamp ashes again in accordance
with the fault.
To Remedy to a Fault
* In the case of a malfunctioning, check the central
lubrication pump and the connected system for faults.
* Eliminate the cause of the fault.
* Switch on the pump again by triggering an additional
lubrication cycle. For this, press the pushbutton >2
seconds.
· When the fault is eliminated, the signal lamp will
extinguish at the end of the lubrication cycle.
Important: If there has been any fault, the pump will not start
automatically after the elimination of that fault. It must be swit-
ched on, i.e. an additional lubrication cycle must be triggered.
See ”To trigger an additional lubrication cycle”.
Note: It is also possible to acknowledge/reset a fault or
trigger an additional lubrication cycle by means of the
pushbutton on the printed circuit board (Fig. 14). For this, press
it < 1 second and > 2 seconds. Condition: The
machine contact or driving switch must be switched on.
To acknowledge a Fault
Functional check
• Each time the machine contact (external contact) or the
driving switch is switched on, a functional check of the drive
motor and signal lamp takes place automatically.
• During the functional check the motor is switched on for 0.1
second (the stirring paddle slightly rotates) and the signal
lamp lights up for 2 seconds.
• If there is a fault, the signal lamp ashes. See ”Fault
Indication”.
Note: LED display Figure 9 indicates the same operating state
as the signal lamp.
Figure 9 - LED for the monitoring time or fault indication
Pushbutton (Fig. 11)
• The following functions can be performed with the
pushbutton:
- triggering an additional lubrication cycle - Press
pushbutton for over 2 seconds (> 2 s)
- fault acknowledgement < 1 s
- in the case of a fault, switching on pump again by
pressing pushbutton (> 2 seconds)
Figure 10 - Indicated operating states
A - Fault indication
B - Indication of operation or acknowledged fault
Functions of the Pushbutton and Signal Lamp
Note: It is also possible to acknowledge any fault or to
trigger an additional lubrication cycle via pushbutton 4 of the prin-
ted circuit board (Fig. 14).
Signal lamp
• The signal lamp or the LED Figure 9 indicates the operating
state of the centralized lubrication system.
• The faults are indicated by different ashing frequencies of the
signal lamp or the LED Figure 9. See ”Fault
Indication”.

Page 10 Form 403599
* To set the pause time, remove the cover on the pump
housing.
Important: After having set the pause time, screw the cover on
the pump housing again.
Fig. 12 - The cover to the printed circuit board has been remo-
ved
Time Setting
Fig. 13 - Rotary switch - Pause time
To set the pause time
The pause time can be adjusted to 15 settings by means of the
blue rotary switch.
Note: The 0 position corresponds to the shortest time, see pos.
1.
• To check the function of the pump it is possible to perform an
operational test.
* If necessary, switch on the battery voltage
* Switch on the driving switch
• To check whether power is applied to the printed circuit board,
observe whether the left-hand LED 1, Fig. 14, is lit.
* Press the pushbutton (> 2 seconds) for triggering an additio-
nal lubrication (illuminated pushbutton, Fig. 11, or pushbutton
on the switch cabinet) until the right-hand LED 3 lights up.
• The right-hand LED indicates the following functions:
- operating time
- monitoring time (in normal cases it is as long as the
operating time, in the case of a fault: 30 minutes)
- faults
• When an additional lubrication cycle has been triggered, a
shorter pause time occurs, followed by a normal
lubrication cycle.
• Additional lubrication cycles can be triggered at any time.
Fig. 14 - LED of the printed circuit board
1 - LED, left-hand 3 - LED, right-hand,
Power supply Indication of operation
2 - Rotary switch 4 - Pushbutton for
”pause time” additional lubrication
cycle
Operational Test /To Trigger an Additional
Lubrication Cycle
Switch position 1 2 3 4 5 6 7 8 9 A B C D E F
Minutes 4812 16 20 24 28 32 36 40 44 48 52 56 60

Form 403599 Page 11
Drive motor defective
If the motor does not run when the driving switch is
switched on or if the feed line to the motor is damaged, the signal
lamp ashes after 2 seconds as follows:
A1 second - ”ON” - 1 second - ”OFF”
Malfunctions
such as
- blocked lubrication point (s)
- blocked metering devices (s)
- interruption in the main line leading to the metering device
equipped with a proximity switch
- air in system
- reservoir empty
are indicated as described under B.
The above mentioned faults cause the pistons in the
monitored metering device to stop. The signal lamp
indicates the respective fault signal with the following ashing
frequencies:
Lubrication circuit 1 malfunctioning
B0.5 second - ”ON” - 1 second - ”OFF”
Low-level control
The signal lamp is ashing with the following frequency:
Reservoir empty
E 0.5 second - ”ON” - 0.5 second - ”OFF”
Fault Indication
Fig. 15 - Flashing frequencies in the case of malfunctions
A - Drive motor defective
B - Lubrication circuit 1 malfunctioning
E - In the case of low-level control: reservoir empty
F - Fault acknowledged (maintained lightening)
Note: The low-level signal is converted into a ashing
signal with the a.m. frequency only after 6 motor
revolutions.
• In the case of a malfunction the proximity switch (initiator) can
no longer record the piston movements and
therefore, it cannot switch off the pump.
• Due to the monitoring time which runs in parallel to the opera-
ting time, the printed circuit board switches off the pump at the
end of the monitoring time.
• A fault signal occurs.
• The signal lamp is ashing.
• The pump no longer starts automatically. See ”To
Remedy to a Fault”

Page 12 Form 403599
circuit board are lit or the signal lamp of the illuminated pushbut-
ton/switch cabinet is lit.
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), whether the LED on the printed
Troubleshooting
•Fault: The pump motor does not run
•Remedy:
• Check the voltage supply to the pump. If necessary,
eliminate the cause of the fault.
• Check the line leading from the pump plug to the printed circuit
board.
• If the voltage is applied, the left-hand LED is lit.
• Replace the printed circuit board.
•Cause:
• Voltage supply interrupted
• Voltage supply to the printed-circuit board is interrupted
• Printed circuit board defective
•Remedy:
• Disconnect the main line leading to the monitored
metering device.
•Unscrew the proximity switch and check it. For this, insert a
metallic pin into the borehole of the detector. Let it there over 2
seconds and then remove it. If the pump is not
switched off afterwards, check the cable connections to the
pump. If necessary, replace the proximity switch along with the
connector.
• Check the cable connections to the pump. If necessary, replace
the proximity switch with the connector.
• Replace the printed circuit board.
•Fault: The pump motor runs permanently (30 minutes)- Duration of the monitoring time
• Cause:
•Proximity switch (initiator) defective.
•Cable connection of the proximity switch to the pump
interrupted.
• Printed circuit board defective
Americas:
One Lincoln Way
St. Louis, MO 63120-1578
USA
Phone [phone]
Fax [phone]
Europe/Africa:
Heinrich-Hertz-Str 2-8
D-69183 Walldorf
Germany
Phone [phone]
Fax [phone]
© Copyright 2006
Printed in USA
Web site:
www.lincolnindustrial.com
Asia/Pacic:
51 Changi Business Park
Central 2
#09-06 The Signature
Singapore 486066
Phone [phone]
Fax [phone]