SKF Lincoln P653S Instruction Manual

User and maintenance instructions
Models  and ,  V
Electric operated Centro-Matic
pump PS
Date of issue November 
Form number 
Version 

*Indicates change
Contents
Declaration of Incorporation* . . . . . . . . . . . . . . . . . . . . . . . . . . 
U.K. Declaration of Incorporation* . . . . . . . . . . . . . . . . . . . . . . 
Safety* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
User’s responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Environmental protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Appropriate use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Misuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Exclusion of liability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Regulations for prevention of accidents. . . . . . . . . . . . . . . . . . . . 
General safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Operation, maintenance and repair . . . . . . . . . . . . . . . . . . . . . 
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Operation/maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Installation and maintenance of hydraulic hoses . . . . . . . . . . 
Lubrication hose lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Single–line pump PS, no follower. . . . . . . . . . . . . . . . . . . . . . 
Jumper setting combinations – Centro–Matic pumps. . . . . . . . . 
Description of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Disassembled pump housing – view from bottom. . . . . . . . . . . . 
Idle run of switch joint on venting element . . . . . . . . . . . . . . . . . 
Pump operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Lube cycle/pressurization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Activated vent cycle diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Display during braking application of pump motor . . . . . . . . . . . 
Display during change of moving direction of pump motor. . . . . 
Rotating segmented display during venting. . . . . . . . . . . . . . . . . 
Venting in vent valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Pump element operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Pump element Z for internal lubricant crossporting . . . . . . . . . 
Pump with internal and external pressure switch . . . . . . . . . . . . 
Vent cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Fill reservoir with grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Stirring paddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Low–level control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Grease reservoir full of grease . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Grease reservoir empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Keypad and display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Membrane key pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
PS membrane key pad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Test display of
membrane key pad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Operating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Green segment right, power supply “on”. . . . . . . . . . . . . . . . . . . 
Green segment left “on”.  V pulse on black wire. . . . . . . . 
Green circulating illuminated segment,
lubricating time, pump is running. . . . . . . . . . . . . . . . . . . . . . . . . 
Display of holding time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Display of a low–level indication. . . . . . . . . . . . . . . . . . . . . . . . . . 
Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Display of malfunction E, failure to build pressure at pump . . . 
Display of malfunction E, failure to build pressure at end of line 
Display of the malfunction E, failure to vent at the pump . . . . . 
Display of the malfunction E, failure to vent at the end of the line.

Operator key to trigger additional
lubrication cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Operator key to acknowledge fault. . . . . . . . . . . . . . . . . . . . . . . . 
Factory settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Acknowledge fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
To acknowledge a malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Operating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Connections for  V  pump . . . . . . . . . . . . . . . . . . 
Jumper settings for  pump PCB . . . . . . . . . . . . . . . . . . . . . 
Centro-Matic system schematic with PS pump . . . . . . . . 
Lincoln list of lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Proven lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Lincoln list of lubricants, continued . . 
Lubricant recommendations based on the
manufacturer’s data sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Lincoln list of lubricants, continued . . . . . . . . . . . . . . . . . . . . . . . 
Biodegradable lubricants, proven lubricants . . . . . . . . . . . . . . . . 
Dimensions PS,  liter reservoir . . . . . . . . . . . . . . . . . . . . . . 
Dimensions PS,  liter reservoir . . . . . . . . . . . . . . . . . . . . . 
Refill and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Pump without follower plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Pump cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Pump without follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Pump without follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
PS pump without follower (housing and reservoir). . . . . . . . 
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 


Declaration of Incorporation* DOCUMENT NUMBER
404684.DoI
Manufacturer name/address:
Lincoln Industrial Corporation
 N. Hanley Road
St. Louis, MO  U.S.A.
TEL: + () - FAX: + () -
Authorized to compile the technical file:
SKF Lubrication Systems Germany GmbH
Heinrich-Hertz-Straße -
 Walldorf, Germany
TEL: + () -
EMAIL: [e-mail] WEBSITE: www.skf.com
This Declaration of Incorporation is issued
under sole responsibility of the
manufacturer. Lincoln Industrial Corporation
hereby declares that the partly completed
machinery stated below:
Name: PS (V)
Model number(s):
Description:
and conforms to the following harmonized
standards:
EN ISO : 
Hydraulic fluid power - general rules and
safety requirements for systems and their
components
EN ISO : 
Safety of machinery. General principles
for design. Risk assessment and risk
reduction
DIN EN ISO :
Pumps and pump units for liquids -
common safety requirements
EN :+A:
Liquid pumps. Safety requirements.
Proceedure for hydrostatic testing
The following EHSR (Essential Health and
Safety Requirements) have been applied:
..a – ..b – ..c – .. – .. –
.. – .. – .. – .. – .. – ..
– .. – .. – .. – .. – . – ..
– ... – .. – ..
I, the undersigned of Lincoln Industrial Corporation, do hereby declare that the equipment specified above, in its intended use, conforms to
the requirements of the above EC Directive(s).
___________________________________
Robert Collins
Technical Compliance Manager
St. Louis, MO, U.S.A.
The manufacturer maintains a technical file
summary sheet containing test reports and
product documentation:
Technical file summary sheet number:
The partly completed machinery shown
above should not be put into service until the
final machinery into which it is to be
incorporated has been declared in conformity
with the provisions of the directive, where
appropriate.
Year of CE: 
in its intended use, is in conformity with the
relevant union harmonization legislation:
Machinery Directive //EC
(article  Partly Completed Machinery)
, 
Electric operated Centro-Matic pump
RA
//
*Indicates change


U.K. Declaration of Incorporation* DOCUMENT NUMBER
UK404684CA
Manufacturer name/address:
Lincoln Industrial Corporation
 N. Hanley Road
St. Louis, MO  U.S.A.
TEL: + () - FAX: + () -
Authorized to compile the technical file:
SKF (U.K.) Limited
 Canada Close
Banbury, Oxfordshire, OX RT, GBR
EMAIL: [e-mail] WEBSITE: www.skf.com
This U.K. Declaration of Incorporation is
issued under sole responsibility of the
manufacturer. Lincoln Industrial Corporation
hereby declares that the partly completed
machinery stated below:
Name: PS (V)
Model number(s):
Description:
along with the following Directive(s) that
were also applied with the above legislation:
EN ISO : 
Hydraulic fluid power - general rules and
safety requirements for systems and their
components
EN ISO : 
Safety of machinery. General principles
for design. Risk assessment and risk
reduction
DIN EN ISO :
Pumps and pump units for liquids -
common safety requirements
EN :+A:
Liquid pumps. Safety requirements.
Proceedure for hydrostatic testing
I, the undersigned of Lincoln Industrial Corporation, hereby declare that the equipment specified above, in its intended use, conforms with the
Essential Health and Safety Requirements of U.K. legislation Supply of Machinery (Safety) Regulations  No.  Annex I, Declaration of
Incorporation by the time of placing it on the market.
___________________________________
Robert Collins
Technical Compliance Manager
St. Louis, MO, U.S.A.
The following EHSR (Essential Health and
Safety Requirements) have been applied:
..a – ..b – ..c – .. – .. –
.. – .. – .. – .. – .. – ..
– .. – .. – .. – .. – . – .. –
... – .. – ..
The manufacturer maintains a technical file
summary sheet containing test reports and
product documentation:
Technical file summary sheet number:
The partly completed machinery shown
above should not be put into service until the
final machinery into which it is to be
incorporated has been declared in conformity
with the provisions of the directive, where
appropriate.
Year of CE: 
in its intended use, is in conformity with the
relevant union harmonization legislation:
Supply of Machinery (Safety) Regulations
 (S.I. :)
, 
RA
//
Electric operated Centro-Matic pump
*Indicates change


Safety*
The assembly must be installed, maintained
and repaired exclusively by persons familiar
with the instructions.
Always disconnect power source
(electricity, air or hydraulic) from the
equipment when it is not being used.
This equipment generates high pressure.
Extreme caution should be used when
operating this equipment as material leaks
from loose or ruptured components can
inject fluid through the skin and into the
body. If any fluid appears to penetrate the
skin, seek attention from a doctor
immediately. Do not treat injury as a simple
cut. Tell attending doctor exactly what type of
fluid was injected.
Any other use not in accordance with
instructions will result in loss of claim for
warranty or liability.
• Do not misuse, over-pressurize, modify
parts, use incompatible chemicals, fluids,
or use worn and/or damaged parts.
• Do not exceed the stated maximum
working pressure of the equipment or of
the lowest rated component in your
system.
• Always read and follow the manufacturer’s
recommendations regarding fluid
compatibility, and the use of protective
clothing and equipment.
• Failure to comply may result in personal
injury and/or damage to equipment.
CAUTION
Do not operate equipment without
wearing personal protective gear.
Wear eye protection. Protective
equipment such as dust mask, non-skid
safety shoes, hard hat, or hearing pro-
tection used for appropriate conditions
will reduce personal injuries.
Failure to comply may result in light
personal injury.
WARNING
Do not allow any body part
to be trapped by equipment.
Body parts can be crushed
by subassemblies during
operation.
Failure to comply may result in death
or serious physical injury.
WARNING
Do not allow fluid to leak
onto floor when operating
equipment. If spill occurs,
clean any fluid on floor before continuing
operation.
Failure to comply may result in death
or serious personal injury.
WARNING
Do not use this equipment to supply,
transport, or store hazardous
substances and mixtures in accordance
with annex I part - of the CLP
regulation (EG /) or HCS 
CFR . marked with GHS,
GHS and GHS hazard pictograms
shown:
Explanation of signal
words for safety
NOTE
Emphasizes useful hints and
recommendations as well as
information to prevent property damage
and ensure efficient trouble-free
operation.
CAUTION
Indicates a dangerous situation that can
lead to light personal injury if
precautionary measures are ignored.
WARNING
Indicates a dangerous situation that
could lead to death or serious injury if
precautionary measures are ignored.
DANGER
Indicates a dangerous situation that will
lead to death or serious injury if
precautionary measures are ignored.
WARNING
Do not operate equipment
without reading and fully
understanding safety
warnings and instructions.
Failure to follow warnings and
instructions may result in serious injury.
*Indicates change


Exclusion of liability
Manufacturer of PS pump will not accept
any liability for damages caused by:
• lack of lubricant due to irregular
refilling of pump.
• use of contaminated lubricants.
• use of greases that are not, or only
conditionally pumpable by PS pump.
• inadequate disposal of used or
contaminated lubricants and components
that have been in touch with lubricant.
• unauthorized modification of system
components.
• use of unapproved parts.
• operation without adhering to minimum
pause time and respectively maximum
lubrication time († Technical data,
page ).
Appropriate use
Electric Centro–Matic pump PS has been
designed for automatic lubrication of
commercial vehicles, industrial, construction
and agricultural machines and wind
power plants.
PS pump has been designed for
intermittent operation and is not suitable for
continuous operation. Pump is capable of
supplying lubricants up to NLGI  grades.
(† List of lubricants, pages –).
Misuse
Any use of PS pump that is not expressly
mentioned in user manual will be regarded
as misuse. If PS pump is used or
operated in manner other than specified, any
claim for warranty or liability will be voided.
Regulations for prevention
of accidents
To prevent accidents, observe all city, state
and federal safety regulation of country
where product will be used.
General safety instructions
• Pump PS is designed for
safe operation.
• Incorrect use may result in bearing
damage caused by poor or
excessive lubrication.
• PS pump with follower can be
mounted vertically, horizontally or
upside down.
•
Pump without follower should be mounted
vertically upright only.
• Unauthorized modifications or changes
to installed system are not admissible. Any
modification of pump must be subject to
prior authorization by manufacturer.
• Install components of PS pump in
such way that operator can always see
low–level position of pump reservoir.
• Each time reservoir has been refilled,
make sure no air has been trapped under
follower and pump is pumping lubricant.
CAUT ION
If personal injury or material damage occurs
as result of inappropriate operation, (e.g. if
safety instructions are ignored or result from
incorrect installation of PS pump), no
claims or legal actions may be taken against
Lincoln Industrial.
Introduction
User’s responsibility
To ensure safe operation of unit, user is
responsible for the following:
 Pump/system should be operated only for
intended use († Safety instructions) and
its design should neither be modified nor
transformed.
 Pump/system shall be operated only if it is
in proper functioning condition and in
accordance with maintenance
requirements.
 Operating personnel must be familiar with
manual and safety instructions mentioned
within, and observe these carefully.
Correct installation and connection of tubes
and hoses, if not specified by Lincoln
Industrial, is user’s responsibility.
Lincoln Industrial technical services will
gladly assist with any questions pertaining to
installation.
Environmental protection
Waste (e.g. used oil, detergents, lubricants)
must be disposed of in accordance with
relevant environmental regulations.
Comply with material safety data sheets of
lubricants used.
Service
Personnel responsible for handling of pump/
system must be suitably qualified. If
required, Lincoln Industrial offers full service
in form of advice, on–site installation
assistance, training, etc. Please contact
technical service department for assistance.
In event of inquiries pertaining to
maintenance, repairs and spare parts, we
require model specific data to enable
technical services to clearly identify
components of pump/system.
Therefore, always indicate part, model
and series number.


Operation,
maintenance and
repair
Repair
Repair should only be performed by
authorized and instructed personnel who
are familiar with instructions.
Defective printed circuit boards should be
appropriately packed and returned to
factory.
Operation/maintenance
Pumps PS:
• Must be refilled at regular intervals with
clean lubricant recommended by
manufacturer without air entrapments
under follower plate.
• Operate automatically. However, regular
check (approximately every two days)
should be made to ensure lubricant is
pumped to all lubrication points.
CAUT ION
Do not exceed maximum filling mark on
reservoir due to risk of burst.
Failure to comply may result in minor or
moderate injury.
WARNING
Before carrying out any maintenance or
repair on PS pump, make sure all
lubrication lines of carrier unit are
depressurized.
Failure to comply may result in death or
serious injury.
WARNING
Pump PS must be installed by qualified
personnel. Connection of  V AC must be
done according to National Electrical Code.
Before installing or working on pump,
disconnect and lock out incoming power.
Failure to comply may result in death or
serious injury.
WARNING
Failure to observe safety instructions, (e.g.
touching electrically charged parts when
pump is opened, or improper handling of
pump PS) may cause death or serious
injury. If values specified in technical data are
exceeded, device may overheat. It may
damage pump PS and impair electrical
safety.
WARNING
In case of pumps where grease is filled from
top, power supply must be switched off
before lubricant is filled in.
Failure to comply could result in death or
serious injury.
WARNING
Never put hand into open reservoir while
pump is running. Danger of injury if pump is
being filled from reservoir top.
Failure to comply may result in death or
serious injury.
WARNING
Do not use pump in potentially explosive
applications.
Failure to comply may result in death or
serious injury.


Installation
• Any safety equipment already installed on
vehicle:
–should not be modified or made
ineffective.
–should only be removed for purpose of
installing system and must be replaced
afterwards.
• Use only original Lincoln spare parts or
parts approved by Lincoln.
Installation and
maintenance of
hydraulic hoses
Lubrication hose lines
• Must never be subjected to torsion.
• Must be installed twist–free.
• Must not rub against metal components or
edges.
• Are to undergo regular visual checks and
must be exchanged in case of wear
(at latest  years after installation).
Pay attention to non–linear installations to
allow for larger bending radius as possible.
Avoid kinks. In constricted installation
conditions use pipe elbow unions to avoid
danger of kinking behind hose socket. Use
high pressure hydraulic hose for
lubrication lines.
NOTE
Adhere to:
• Installation instructions of vehicle
manufacturer with regard to all drilling and
welding procedures.
–specified minimum distances between
holes and upper/lower rim of frame or
between two holes.
CAUT ION
Operational safety of PS pump can only
be ensured in case of professional installation
and maintenance of hose lines. Be sure to
observe the following recommendations.
NOTE
Route supply lines professionally.
Firmly bolt together any components that
are subject to pressure.


 Reservoir
 Mounting plate
 Pump elements
 Pump housing
 Pump outlet
 Relief valve
 Keypad
 Stirring paddle
 Refill grease fitting
 Stationary paddle
 Top lid
Description
Models  and  initiate lube cycle
on count pulse instead of time between lube
cycles. These are set for one count to start a
lube cycle. This one count feature allows
machine controller to initiate lube cycles.
This one count is  V pulse lasting from
to  seconds. Pump operates on  V .
Alarm contacts are set to open position.
When power is applied, alarm contacts will
close. If alarm condition occurs, alarm
contact will open.
Changing of programming parameters,
via keypad, is prohibited due to setting of
internal jumper pin. Refer to page ,
Jumper settings for  Pump PCB.
On power up model will wait for  V
pulse before initiating lube cycle. If pump
was in lube cycle when power was turned
off, it will start with lube cycle upon
power up.
 and  pump are designed for
single line (S) parallel Centro–Matic type
lubrication systems. Pumps integrate all of
the following necessary components to
support Centro–Matic lubrication systems:
• controller to program and monitor
lubrication cycle
• contacts for remote monitoring
• internal pressure switch and end-of-
lubrication-line pressure switch
• internal vent valve
• three pumping elements connected
together
• external pressure relief valve
• reservoir low–level control
• electric cable  ft ( m) and –pole
bayonet type connector
• pumps greases up to NLGI  (per
approved list) at temperatures from
– to  °F (– to  °C)
• develops maximum pressure up to
  psi ( bar) with pressure switch
• . gallon ( liter) transparent plastic
reservoir, 
• . gallon ( liter) transparent plastic
reservoir, 
•  V
Pump can supply adequate lubricant to
bearings using SL–V, SL–V XL, SL–, SL–
and SL– injectors. Number of injectors
should be based on output of pump
being . in/minute.
Typical Centro–Matic system schematic is
shown on page .
CAUT ION
Use only supply line hose and fittings that are
appropriate for the programmed/set system
pressure.
Failure to comply could result in minor or
moderate injury.
Fig. 
Single–line pump PS, no follower
(Note: Low–level control † Fig.  and ,
page ).
NOTE
Installations using SL– and SL– Lincoln
injectors can lubricate more than 
bearings.
1
2
3
3
4
5
6
7
8
9
10
11


Diagram 
Identificaton code P653S pump
-
- -
Pump model, basic
Reservoir size and configuration
4 = 4L, transparent plastic
8 = 8L, transparent plastic
15 = 15L, transparent plastic
20 = 20L, transparent plastic
X = grease pump
Y= oil pump
L = low level control
BO = Without follower
F = With follower
Power supply
24 = 24 VDC
AC = 110 – 240 V ; 50 – 60 Hz
Electrical cord and connections
1A DC;
- 33 ft (10 m) cord, 7 conductors
2A DC;
- 33 ft (10 m) cord, 7 conductors
- 33 ft (10 m) cord, 4 conductors with bayonet plug for external
pressure switch or transducer
4A DC:
- 13 ft (4 m) cord, 7 connector
Pressure control, PCB setting
AS01 - AS08 = Pressure switch (see jumper setting table)
AS17 - Pressure swith, count control
Example: P653S-4VLBO-24-2A-AS06 Pump P653S-4YLBO-AC-2A-AS11
●
Four liter reservoir
●
Low level control
●
Internal pressure transducer
● 33 ft (10 m) power cord
P653S AC 2A AS11
Example
Y L4 BO-
consists of the following:


Jumper setting combinations – Centro–Matic pumps
Pump combinations
Application:
Industrial (S) – o;
Mobile (M) – x
Time (TC) or count
control (cc);
TC – o; CC – x
Number of pressure
switches or transduc-
ers. o – one x – two
Low–level control;
NO – o; NC – x
F fault relay; ()
switch to ground – x
F fault relay;
() switch to
ground – x
Jumper setting (plugged –x, unplugged – o)
Pressure switch
AS
Industrial (S)
o o o x x x
AS o o x x x x
AS o o o o x x
AS o o x o x x
AS x x o o x x
AS x x x o x x
AS
Mobile (
) (M)
x o o x x x
AS x o x x x x
AS x o o o x x
AS x o x o x x
Pressure transducer
AS
Industrial (S)
o o o x x x
AS o o x x x x
AS o o o o x x
AS o o x o x x
AS
Mobile (
) (M)
x o o x x x
AS x o x x x x
AS x o o o x x
AS x o x o x x
External pressure switch or external pressure transducer is included with pumps that have feature of external pressure monitoring. Also included is  ft ( m) cord to connect external monitoring
device to pump.


Description of
operation
Pump operation
Drive
• Pump housing consists of the following
components: gear motor, final gear drive,
three pumping elements connected
together by internal passages and vent
valve. Pump can be configured with
internal pressure switch or transducer.
• Gear motor shaft is connected to final
stage gear drive. Final gear has
incorporated eccentric and cam to drive
pumping elements and to control internal
vent valve († Fig. ).
• Vent valve is two-way, normally closed,
spring biased valve.
• Pressure switch is not adjustable and
preset to   psi ( bar).
• Pressure transducer is adjustable.
Factory setting is   psi ( bar).
Pressure setting of pressure transducer
can be adjusted from   to   psi
( to  bar) in  psi (, bar)
increments.
 Venting element
 Integrated pressure switch
 Motor
 Pump elements with intergrated
lubrication lines
Inactive venting element
Switch joint
Cam (driven clockwise by motor)
Lube cycle/pressurization
• Motor turns cam () clockwise to start
lubrication cycle. As soon as pump starts
to operate, display rotating segment is
turning clockwise also († Fig. ,
page ). Maximum time to build preset
pressure is  minutes.
If pump does not build preset pressure,
fault signal E or E will appear on display.
• Vent valve () is normally closed and stays
closed during lubrication cycle, preventing
lubricant flow back to reservoir († Fig. ).
• Output of three pump elements ()
(† Fig. ) is combined by internal
passages.
• Eccentric drives pump elements to pump
lubricant from reservoir and build line
pressure.
• Cam () will keep vent valve () closed.
• Supply line can be connected to pump
element outlet. Remaining two pump
elements outlets should be plugged.
Fig. 
Disassembled pump housing –
view from bottom
Fig. 
Idle run of switch joint on venting element
1
2
3
4
1 6 7
1.7 in
(43 mm)
2 in
(52 mm)


Fig. 
Activated vent cycle diagram
Fig. 
Display during braking application of
pump motor
Fig. 
Display during change of moving direction
of pump motor
Fig. 
Rotating segmented display during
venting (counter-clockwise)
Fig. 
Venting in vent valve
Inactive venting element
Vent lever
Cam (driven clockwise by motor)
1 6 7
1.7 in
(43 mm)
2 in
(52 mm)
1 1.1 1.2
8
 Venting element
. Inlet hole
. Outlet hole
Valve plunger


Pump element
operation
Pump element († Fig.  and ) is a single
stroke spring biased pump. Motor drives
eccentric (). Eccentric is in constant contact
with plunger ().
Compression spring () is pushing
plunger () to open lubricant passage to
create vacuum to prime pump with lubricant
from reservoir. Check valve () is closed to
isolate supply lines of system.
Eccentric () is pushing plunger () in
opposite direction to pump lubricant,
developing operating pressure.
Check valve () is open to pass lubricant to
supply lines.
Body of pump element has
lateral outlet () († Fig. ) for lubricant
crossporting to internal material passages to
combine outlet of all three pump elements.
Any of the three elements can be used as
a pump outlet. Remaining two elements
should be closed with plug (A) († Fig. ).
1
2
3 4
1 2
3
4
A 2 3
5
AClosure plug (connection G /in for main line)
Piston
Spring
Lateral outlet for lubricant crossporting
Fig. 
Pump element Z for internal lubricant crossporting
Fig. 
Fig. 
NOTE
Use only pump elements designed for
operation in PS pump. No other pump
elements should be used. See parts listing
for correct pump element part number.


Pump with internal and
external pressure switch
Internal pressure switch will close at
  psi ( bar) and open at   psi
( bar). External pressure switch will close
at   psi ( bar) and open at
  psi ( bar).
After pump starts lubrication cycle, motor
stops when pressure at pump reaches preset
pressure of   psi ( bar). Pump can
go through three holding periods: H, H
and H.
Holding time (H)
• Internal pressure switch must stay closed
for  consecutive seconds before going to
H. If internal pressure switch opens
during  seconds, pump will restart and
run until internal pressure switch closes.
Holding time (H) – will last
for  seconds
• At the end of H, if internal pressure
switch is closed and external pressure
switch is closed, pump will begin
vent cycle.
• At the end of H, if internal pressure
switch is open or both internal and
external pressure switches are open,
H will appear on display. Pump will turn
on again and pump until internal pressure
switch is closed. When both internal and
external pressure switches are closed,
vent cycle will take place.
•
If at the end of H internal pressure switch
is closed but external pressure switch is
open, pump will turn on for  seconds and
then stop and wait until external pressure
switch closes. H will appear on display.
When both internal and external pressure
switches are closed, vent cycle will take
place.
Holding time (H)
• Holding time H will remain until both
internal and external pressure switches
are closed and vent cycle will take place. If
both pressure switches do not close within
allotted pumping time of  minutes,
alarm will occur. If internal pressure
switch opens during H, it will repump
until internal pressure switch closes.
Possible faults
• E Fault – Failure to build pressure at
pump within allotted  minutes of
pumping time.
• E Fault – Failure to build pressure at end
of supply line.
• E Fault – Failure to vent at pump.
Internal pressure switch has  seconds to
open when motor reverses to locate vent
position.
• E Fault – Failure to vent at end of
supply line. External pressure switch must
be open before next lube cycle takes place.


Vent cycle
• After pump completes preset hold time
and pump maintains specified pressure,
controller will initiate vent cycle. Vent cycle
will last for ten seconds.
• Motor will turn counter-clockwise to
engage and open internal vent valve.
Display’s rotating segment is turning
counter clockwise.
• Motor will stop in position to hold vent
valve open. “Hr” will be displayed for
remainder of  seconds.
• Cam () († Fig. , page ) engages vent
lever () depressing vent valve plunger ()
(† Fig. , page ). This opens valve
passage of supply line to reservoir.
• Lubricant is flowing back to reservoir
venting pressure from system. Valve stays
open during pause time.
Fill reservoir with grease
Use grease fitting () († Fig. , page ) to fill
reservoir. Filling reservoir first time is critical
to proper pump operation. Make sure no air
is trapped under follower plate. Grease
should be in full contact with surface of
follower. It is recommended to run motor by
initiating lubrication cycle during first
reservoir fill. Stirring paddle of running
motor will help to evenly spread grease
under follower minimizing air pockets.
Stirring paddle
Stirring paddle () († Fig. , page ) is
attached to motor and rotates during
lubrication cycle. Paddle is working grease in
reservoir to make it more pumpable and
pushing grease down into housing and
pumping elements to prevent cavitation.
Low–level control
Pump model PS is equipped with low–
level grease control as standard feature.
Grease reservoir full of
grease
• Stirring paddle rotates clockwise
during lubrication cycle.
• Pivot bracket of stirring paddle (B)
(† Fig. ) is completely submerged into
grease and grease resistance to paddle
rotation guides bracket with round
magnet  inward to orbit (A).
• Control cam () († Fig. ) guides pivot
bracket with magnet and outwards, in
direction of reservoir wall. Since reservoir
is full, grease resistance guides pivot
bracket inward to orbit (A) as soon as
bracket passes cam ().
• Magnet and low–level switch ()
(† Fig. ) are not aligned and switch can
not be activated.
1
2 3
C
D
A
B
1 3
Pump without follower plate – Switching
parts of the low–level control for grease
(when reservoir is filled).
 Pivot bracket with round magnet
 Control cam
A Inner orbit of the round magnet
B Position of the pivot bracket (LL not
activated)
Switching parts of the low–level control for
grease (when the reservoir is empty).
Pivot bracket with round magnet
Low–level switch
Control cam
COuter orbit of the round magnet
DPosition of the pivot bracket (LL activated)
Fig. 
Fig.  NOTE
Switching parts (to ) († Fig.  and )
must not be used with fluid grease or oil.
Instead, use float magnetic switch.
Grease reservoir empty
• Control cam () († Fig. ) guides pivot
bracket with magnet () outward. Since
there is no grease resistance, bracket with
magnet () will stay outward in Orbit C.
• Magnet () will align with low–level switch
and activate LL indicator on pump display.


Keypad and display
Membrane key pad
Test display of
membrane key pad
 Display
 Key for acknowledgment of fault
indications and changing programming
screens.
 Key for triggering an additional lubrication
cycle and for changing programming
values.
Test display is made when voltage is applied:
all segments and decimal points are
illuminated for  seconds.
When power is applied to pump, display will
indicate if pressure switch or pressure
transducer is connected to pump. Example
indicates internal pressure switch. There are
four possibilities:
• S – Internal pressure switch
• T– Internal pressure transducer
• TT – Internal and external pressure trans-
ducer (must be connected)
• SS – Internal and external pressure switch
(must be connected)
Operating mode
• If lower right-hand segment is on, this
indicates there is  V going to red
wire in  conductor cable.
• When there is a  V pulse on black
wire lower left-hand segment will be on.
• During lubricating time of pump,
circulating illuminated segment appears in
display window of membrane key pad
(† Fig. ).
• If power supply is interrupted during
lubricating time operating time will start at
beginning after switching power on again.
Segment
Low–level control
In the event of a low–level signal the display
will flash LL.
Display is indicating holding times when
pump reaches preset pressure.
Fig. 
PS membrane key pad
NOTE
EP will briefly appear after display test. If EP
remains on after display test, this indicates
that remote lube pushbutton is in closed
position or keypad pushbutton is defective.
Fig. 
Green segment right, power supply “on”.
Fig. 
Green segment left “on”.  V pulse
on black wire.
NOTE
If low–level signal occurs during lubricating
time, current operating cycle will still be
completed; however pump does not switch
on automatically any more. It can only be
switched on again by a manual lube cycle.
Furthermore, it is not possible to change to
programming mode while there is a low–
level signal.
Fig. 
Green circulating illuminated segment,
lubricating time, pump is running.
Fig. 
Display of holding time
Fig. 
Display of a low–level indication.
1
2 3


E fault is failure to build pressure at pump.
If either pressure switch or pressure
transducer fails to actuate within  minutes
of pumping, this fault will occur.
Malfunctions
• If there is no feedback from pressure
switch or pressure transducer within
 minutes of pumping time, pump
switches off immediately. One of the fault
signals E to E (Error, † Fig.  to )
will be shown flashing in display of
membrane key pad.
To trigger additional lubrication cycles
externally:
• Press pushbutton to trigger additional
lubrication cycles externally. Press
pushbutton for  seconds.
–Mobile pump w/ignition switch open up
to two times.
–Industrial pump w/machine switch
open... unlimited.
E fault is failure to vent at the end of the
supply line.You must use external pressure
switch or pressure transducer to detect this.
• If at the end of pause time external
pressure switch has not opened,
E fault will occur.
• If at the end of pause time external
pressure transducer has not dropped
below P parameter, E fault will occur.
E fault is failure to build pressure at end of
supply line.You must use external pressure
switch or pressure transducer to detect this.
• If either external pressure switch or
pressure transducer fails to reach
  psi ( bar) within  minutes of
pumping, this fault will occur.
E fault is failure to vent at pump.
• Failure of internal pressure switch to open
during  seconds that pump motor
reverses to locate vent position.
• Failure of internal pressure transducer to
drop  psi ( bar) below P parameter
(P minus  psi ( bar) during
 seconds that pump motor reverses to
locate vent position.
• If at the end of the pause time internal
pressure transducer has not dropped
below  psi ( bar),E fault will occur.
To trigger additional lubrication cycle via
pushbutton, press button for  seconds.
NOTE
If malfunction is present, E, E, E or E will
be flashing. Pump does not switch on
automatically any longer. It can only be
triggered via an additional lubrication cycle.
Furthermore, change to programming mode
is not possible while in alarm.
Fig. 
Display of malfunction E, failure to build
pressure at pump
Fig. 
Display of malfunction E, failure to build
pressure at end of line
Fig. 
Display of the malfunction E, failure to
vent at the pump
Fig. 
Display of the malfunction E, failure to
vent at the end of the line.
Fig. 
Operator key to trigger additional
lubrication cycle
Fig. 
Operator key to acknowledge fault
NOTE
Existing fault signals († Fig.  to ,
pages  and ) must be acknowledged
before triggering additional lubrication cycle.


Factory settings
Programming steps Factory setting Description
 Count
Thousands, hundreds
 Count
Tens, unit
NO
Output of both fault relays
no (normally open)
nc (normally closed)
o
Two options for signaling fault
o (Option )
F relay contact
a) Low–level fault will cause F contact to repeatedly open and close.
b) Pressure fault will cause F contact to close and stay closed.
F relay contact
Low–level fault or pressure fault will cause F contact to close and stay closed.
o (Option )
F fault relay’s contact will close on low–level fault
F fault relay’s contact will close on pressure fault
Both contacts can be used for remote signaling

P programming step will only appear if pump uses internal pressure transducer (reading x )
 x  =   psi ( bar).   psi ( bar) is maximum pressure that pump will build.
Adjustable from   to   psi ( to  bar) in  psi (, bar) increments.

P programming step will only appear if pump uses external pressure transducer (reading x )
 x  =  psi ( bar).  psi ( bar) is where external pressure transducer will open (vent)
adjustable from  to   psi in  psi (, bar) increments.


Acknowledge fault
Display Press To acknowledge a
malfunction
• Flashing display changes into continuous
light by pressing button (acknowledging).
By acknowledging fault signal, flashing E,
E, E, E or LL changes into
permanent light.
• Messages that have been acknowledged
but have not yet been remedied will flash
again after pump is switched
off and on again.
• After fault has been acknowledged, no
more lube cycles will take place until
successful manual lube cycle has
taken place.
<  seconds
<  seconds
<  seconds
<  seconds
<  seconds
