Lincoln QUICKLUB 203 User manual

Subject to change without notice
Owner Manual
Technical Description
2.1A-30001-F03
LINCOLN GmbH & Co. KG • Postfach 1263 • D-69183 Walldorf • Tel [phone] • Fax [phone]
Page 1 from 32
QUICKLUB®
Pump Model 203
10011327

Subject to change without notice
Owner Manual
Technical Description
2.1A-30001-F03
Page 2 from 32
LINCOLN GmbH & Co. KG • Postfach 1263 • D-69183 Walldorf • Tel [phone] • Fax [phone]
All rights reserved.
Any duplication of this Owner Manual, in its entirety or in part,
by whatever means is prohibited without the prior consent in
writing of Lincoln GmbH & CO. KG.
Subject to modifications without prior notification.
© 2002 by
LINCOLN GmbH & Co. KG
Postfach 12 63
D-69183 Walldorf
Phone: [phone]
Fax: [phone]

Subject to change without notice
Owner Manual
Technical Description
2.1A-30001-F03
LINCOLN GmbH & Co. KG • Postfach 1263 • D-69183 Walldorf • Tel [phone] • Fax [phone]
Page 3 from 32
Fields of Applications of the QUICKLUB Progressive Central Lubrication Pumps
Industry - Machines - Commercial Vehicles -
Building Machinery - Agricultural Machines Pump Type
Pump
QUICKLUB 203
Reservoir
2 l -2XN2),2XNFL2), 2YN3), 2XNBO1), 2YNBO3)
4 l -4XNBO1), 4YNBO3)
8 l - 8XNBO1), 8YNBO3)
1) Filling from the top or bottom
2) Filling only from the bottom
3) Filling only from the top
4 l, 8 l with lockable reservoir lid (option)
Low-level control (option)for all reservoir sizes
available, on request
Control
Without control unit for 12/24 VDC or 120, 230 VAC
Integrated control units (V10-V13) 4) for 12/24 VDC
Integrated control units (V10-V13)4) for 120, 230
VAC
Integrated control unit with metering device monitor-
ing (M 00 - 23) 4)
External control units
- PSG 01 (Commercial vehicles)
- PSG 02 (Industry)
Control H4)
Control V10 - ADR4)
Control H - ADR4)
4)See the respective model designation on the pump nameplate e.g. P203 - 2XN - 1K6 - 24 - 1A1.10 - V10

Subject to change without notice
Owner Manual
Technical Description
2.1A-30001-F03
Page 4 from 32
LINCOLN GmbH & Co. KG • Postfach 1263 • D-69183 Walldorf • Tel [phone] • Fax [phone]
Table of Contents
Page
Fields of applications of QUICKLUB progressive
central lubrication pumps ................................................ 3
Introduction ...................................................................... 5
Safety instructions ........................................................... 6
Installation ....................................................................... 8
Specifications for the installation of electric equippment ... 8
Pump installations – Areas of risk...................................... 9
Pump types ..................................................................... 10
Identificatiom Code - Pump Models 203........................ 11
Description....................................................................... 12
Electric connections ......................................................... 12
The QUICKLUB 203 central lubrication pump................... 13
Low-level control (optional) ......................................... 13
Mode of operation ........................................................... 14
Pump elements with fixed Lubricant output ...................... 14
Suction phase ............................................................. 14
Delivery phase ............................................................ 14
Check valve ................................................................. 15
Arrangement of the pump elements............................. 15
Page
Setting for the lubricant output on an adjustable
pump element ....................................................................15
Retrofit adjustment of max. lubricant output.................16
Adjusting of small lubricant output................................17
Pressure relief valve ..........................................................17
Return line connection ......................................................18
Control unit ........................................................................18
Low-level control (optional) ...............................................19
Low-level for grease.....................................................19
Low-level for oil ............................................................20
Measures for contact protection ..................................20
Maintenance, repair and tests........................................ 21
Maintenance ..................................................................... 21
Pump filling.................................................................. 21
Repair ........ ....................................................................... 21
Tests................................................................................. 22
Operational test/To trigger an additional
lubrication.................................................................... 22
To check the pressure relief valve............................... 22
Troubleshooting.............................................................. 23
Technical data................................................................. 24
Torques ............................................................................ 24
Weights ............................................................................ 24
Connection diagram Pump without control unit................ 25
Dimensions ...................................................................... 26
Lubricants ....................................................................... 32
Further information can be found in the following manuals:
Technical Description for ‘‘Electronic Control Units” of the pump model 203
Technical 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 Pump 103 and 203

Subject to change without notice
Owner Manual
Technical Description
2.1A-30001-F03
LINCOLN GmbH & Co. KG • Postfach 1263 • D-69183 Walldorf • Tel [phone] • Fax [phone]
Page 5 from 32
Introduction
Explanation of Symbols Used
The following description standards are used in this manual:
Safety Instructions
Structure of safety instructions:
Pictogram
Signal word
Danger text
- Danger note
- How to avoid danger
The following pictograms are used in this manual and are
combined with the corresponding signal words:
1013A94 4273a00 6001a02
- ATTENTION
- CAUTION
- WARNING
- ATTENTION
- CAUTION
- WARNING
- NOTE
- IMPORTANT
The signal words give the seriousness of danger if the follow-
ing text will be not observed:
ATTENTION refers to faults or damages on
machines.
CAUTION refers to bad damages and possi-
ble injuries.
WARNING refers to possible dangerous inju-
ries.
NOTE refers to improvements in handling
of systems.
IMPORTANT refers to considerable disadvan-
tages in handling of systems.
Example:
1013A94
ATTENTION!
When making use of other than the origi-
nal spare parts, serious damage may
affect your device.
Therefore, for the operation of your device
always use original spare parts made by
Lincoln GmbH & Co. KG.
Furthermore, you will find the following text symbols in this
manual:
Listing
- Subpoint
Procedural instruction
User's Responsibility
To ensure the safe operation of the unit, the user is responsi-
ble for the following:
1. The pump / system shall be operated only for the in-
tended use (see next chapter "Safety Instructions") and
its design shall neither be modified nor transformed.
2. The pump / system shall be operated only if it is in a
proper functioning condition and if it is operated in accor-
dance with the maintenance requirements.
3. The operating personnel must be familiar with this Owner
Manual and the safety instructions mentioned within and
observe these carefully.
The correct installation and connection of tubes and hoses, if
not specified by Lincoln GmbH & Co. KG, is the user's re-
sponsibility. Lincoln GmbH & Co. KG will gladly assist you
with any questions pertaining to the installation.
Environmental Protection
Waste (e.g. used oil, detergents, lubricants) must be dis-
posed of in accordance with relevant environmental regula-
tions.
Service
The personnel responsible for the handling of the pump /
system must be suitably qualified. If required, Lincoln GmbH
& Co. KG offers you full service in the form of advice, on-site
installation assistance, training, etc. We will be pleased to
inform you about our possibilities to support you purposefully.
In the event of inquiries pertaining to maintenance, repairs
and spare parts, we require model specific data to enable us
to clearly identify the components of your pump / system.
Therefore, always indicate the part, model and series number
of your pump / system.

Subject to change without notice
Owner Manual
Technical Description
2.1A-30001-F03
Page 6 from 32
LINCOLN GmbH & Co. KG • Postfach 1263 • D-69183 Walldorf • Tel [phone] • Fax [phone]
Safety Instructions
Appropriate Use
Use the 203 pump only for dispensing lubricants in cen-
tralized lubrication systems.The pump is designed for in-
termittent operation.
General Safety Instructions
Lincoln-QUICKLUB - centralized lubrication systems
- are state of the art;
- can be assembled for safe operation.
Incorrect use may result in bearing damage caused by
poor or over-lubrication.
Unauthorized modifications or changes to an installed
system are not admissible. Any modification must be
subject to prior consultation with the manufacturer of the
lubrication system.
Regulations for Prevention of Accidents
Adhere to the regulations for prevention of accidents which
are effective in the country where the system is to be used.
Operation, Maintenance and Repair
Repair should only be performed by authorized and in-
structed personnel who are familiar with the regulations.
Lincoln QUICKLUB central lubrication pumps must only be
operated with a fitted safety valve.
Lincoln QUICKLUB central lubrication pumps must be
regularly refilled with clean lubricant.
4273a00
CAUTION!
High Voltage!
In the case of pumps which are filled
from the reservoir cover, switch off
the power supply before filling in the
lubricant..
1013A94
ATTENTION!
Risk of bursting if the reservoir is
overfilled!
When filling the reservoir by means of
pumps with a large delivery volume
do not exceed the max. filling mark.
Lincoln QUICKLUB centralized lubrication systems oper-
ate automatically. However, a regular check (about every
two weeks) should be made to ensure that lubricant is
actually reaching all the lubrication points.
Defective printed circuit boards shall be suitably packed
and returned to the factory.
Dispose of used or contaminated lubricants in accordance
with the legislation concerning the environment.
The manufacturer of the centralized lubrication system will
not accept any liability
- for damages due to the use of greases which are not or
only conditionally pumpable in centralized lubrication
systems
- for damage caused by insufficient lubricant and irregular
pump refilling;
- for damage caused by the use of contaminated lubri-
cants
- for damage caused by an environmentally incompatible
disposal of used or contaminated lubricants.

Subject to change without notice
Owner Manual
Technical Description
2.1A-30001-F03
LINCOLN GmbH & Co. KG • Postfach 1263 • D-69183 Walldorf • Tel [phone] • Fax [phone]
Page 7 from 32
Safety Instructions, continuation
Installation
Any safety equipment already fitted to the vehicle or the
machine:
- should not be modified or made ineffective;
- should only be removed for the purpose of fitting the
system;
- must be replaced afterwards.
Keep QUICKLUB centralized lubrication systems away
from sources of heat. Adhere to the operating temperature.
Use only original LINCOLN spare parts (see Parts Catalog)
or parts approved by LINCOLN.
Adhere to:
- the installation instructions of the vehicle or machine
manufacturer as regards all drilling and welding proce-
dures.
- the specified minimum distances between the bore holes
and the upper/lower rim of the frame or between two
bore holes.
The manufacturer of the centralized lubrication system will
not accept any liability for:
- damage caused by unauthorized modification of the
system components;
- damage caused by the use of unapproved spare parts.
6001a02
IMPORTANT
Only for use in commercial vehicles.
1. The ADR QUICKLUB central lubrication pump complies
with the design regulations of annex B of the act governing
the road haulage of hazardous materials valid for Europe
(ADR1)) and that valid for the Federal Republic of Ger-
many (GGVS2))
2. Moreover, the pump and its electrical equipment comply
with the regulations of annex B.2 (ADR / GGVS regula-
tions for electrical equipment) according to Rn 220000 in
conjunction with the transport units mentioned in Rn
10251.
3. The ADR central lubrication pump is in conformity with the
protection class IP 54.
6001a02
CAUTION!
It is not allowed to use the pump in other
potentially explosive fields.
4. Install the ADR QUICKLUB 203 pump, the metering
devices, lines and tube fittings as well as the electrical
connection parts in accordance with the Installation In-
structions. Use only original LINCOLN parts.
5. After completion of the proper installation and commis-
sioning, the installation of the system must be certi-
fied by means of a stamp and signature of the spe-
cialized workshop or expert. For this purpose, use the
form attached to the Operating Instructions (pump 203).
6. If the pump and the installation do not comply with the
construction regulations of ADR and GGVS, the type ap-
proval is no longer valid.
7. The Operating Instructions along with the certificate duly
filled in must be added to the vehicle papers. It is to be
submitted at the inspection in accordance with § 6, clause
4 GGVS.

Subject to change without notice
Owner Manual
Technical Description
2.1A-30001-F03
Page 8 from 32
LINCOLN GmbH & Co. KG • Postfach 1263 • D-69183 Walldorf • Tel [phone] • Fax [phone]
Installation
Specifications for the installation of electric equipment for ADR-application in
comercial vehicles
4244a99
Fig. 1 Measures of protection for electric lines
1 - Conductor insulation 3 - Frame
2 - Conductor 4 - Coating
Lines
- must be fixed by means of clamps or strips to prevent
them from rubbing, sagging or getting loose,
- must be protected from shocks, stone impact and heat,
- other than in a fixed installation, must be sufficiently
flexible in spite of their covering.
The electric circuits can optionally be interrupted by single-
or double -pole disconnecting switches.
In case of single-pole disconnecting switches, the negative
conductor must be able to be interrupted.
For avoidance of short-circuits, please note the following:
current return lines must be insulated
they must be connected to the vehicle frame (MASS 31)
below the driver’s cab.
housings and connectors must be of protection class IP 54
according to DIN 40050
plastic tubes must be of polyamide, tube coverings must be
of polyurethane according to DIN VDE 0250 (only use
original Lincoln ADR tubes).
Mounting of the Pump – Areas of Risk
According to paragraph 9.7.8 of the ADR directive, vehicles
with hazardous goods type FL are divided into zones, ac-
cording to the EX prescriptions, see Fig. 26.
These are the correspondences:
- tank inside zone 0,
- fitting cabinet zone 1
- shut-off devices zone 1
- venting devices zone 1
Zone 2 is located around zones 0 and 1.
The installation of the centralized lubrication system is
allowed outside of zones 0, 1 and 2, only, whereby the
extension is not determined in the ADR directive.

Subject to change without notice
Owner Manual
Technical Description
2.1A-30001-F03
LINCOLN GmbH & Co. KG • Postfach 1263 • D-69183 Walldorf • Tel [phone] • Fax [phone]
Page 9 from 32
Installation, continuation
Mounting of the Pump – Areas of Risk, continuation
4332a01
Fig. 2 Areas of risk on vehicles with hazardous goods

Subject to change without notice
Owner Manual
Technical Description
2.1A-30001-F03
Page 10 from 32
LINCOLN GmbH & Co. KG • Postfach 1263 • D-69183 Walldorf • Tel [phone] • Fax [phone]
Pump Types
1173a95
Fig. 3 The different types of pump 203
Pumps 203
The 203 pumps differ from each other only in the design and
reservoir size as well as in the type of the electric connection
(different plugs with or without electric cable).
Reservoir sizes:
2 l transparent plastic reservoir
4 l transparent plastic reservoir
8 l transparent plastic reservoir
Electric connection
For the industrial applications, the pumps are only
equipped with plugs.
The pumps model 203 used in commercial vehicles are
equipped with a 10 m electric cable.
All other data such as:
motor voltage
version of the 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 the pump t
y
pe desi
g
nation code.
Control unit models 203
The following control units can be used for the 203 pumps:
(refer to the respective Technical Description)
a) external control units
PSG 01
PSG 02 (Industry)
b) integrated control units
with adjustable pause and operating times, V10-V131)
with adjustable pause and operating times, V10-V131) for
alternate current 120, 230 VAC, separate owner manual
with metering device monitoring (microprocessor control),
M 00 - M 231)
c) integrated control unit (trailers)
with fixed time of availability (6 hours) and adjustable
operating time, H1)
1) Refer to the designation on the pump nameplate.
Example: P203 -2XNBO - 1 K6 - 24 - 2A1.10 - V10
Also refer to the designation code on page 6.