Lincoln QUICKLUB 203 Owner's Manual

2.1A-30001-B96

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Page 1 from 24

Subject to modifications

Owner Manual

Tec hnical Description

10071327

QUICKLUB

®

2.1A-30001-B96

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Owner Manual

Tec hnical Description

Pump Types

Fig. 1 - The different types of pump 203

• 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 fixed pause time (6 hours) and adjustable operating time, F*

- with adjustable pause and operating times, V00-V03*

- with metering device monitoring (microprocessor control), F

M 00 - M 23*

c) integrated control unit (trailers)

- with fixed time of availability (6 hours) and adjustable operating time, H *

* Refer to the designation on the pump nameplate. Example: P203 -2XNBO - 1 K6 - 24 - 2A1.10 - V00 Also refer to the designation code on page 6.

• 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 type designation code.

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Tec hnical Description

2.1A-30001-B96

Subject to modifications

Identification Code - Pump Models 203

Examples of model designations

Basicpump model for grease or oil with 1-3 outlets and 12 VDC or 24 VDC 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

Motor

12 V DC or 24 V DC motor

Number of the possible connections

1A = 1 connection,supply voltage 2A = 2 connections, supply voltage + remote control for additional lubrication, for low - level control, piston detector (microprocessor)

Type of connection

1 = Hirschmann plug 4 = AMP - flanged plug (microprocessor) 8 = PG - cable gland

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 ADR 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

F - with fixed pause time and variable adjustable operating time F ADR - with fixed pause time and variable adjustable operating time** V00 -V03 -with adjustable pause and operating time V00 -V03 - ADR 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 - ADR for trailors and semitrailors** No designation: Pump without control p. c. b.

* Not in conjunction with Hirschmann plugs (type of connection 1) ** for transport of hazard materials

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- V00 P203- 4 X L - 1 K7- 24- 2A 1. 10- V02 P203- 2 X N - 1 K6- 12- 1A 8. 00 P203- 2 X N - 1 K6- 24- 2A 1. 11- V00-ADR P203- 2 y N BO- 2 K5- 24- 1A 1. 01- F P203- 4 X N BO- 1 K6- 24- 2A 4. 12- M00

2.1A-30001-B96

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Owner Manual

Tec hnical Description

Description of the QUICKLUB 203 Central Lubrication Pump

• The QUICKLUB 203 central lubrication pump

- is a compact multiline pump consisting of the following components:

Housing with integrated motor Reservoir with stirring paddle Printed circuit board Pump element Safety valve Filling nipple Electrical connection parts

- can drive up to 3 pump elements

- operates according to lubrication cycles (pause and operating times)

- can be equipped with a low-level control

- can supply up to 300 lubrication points depending on the line lengths

- is designed for the automatic lubrication of the connected lubrication points

- is designed for the delivery of greases up to NLGI 2 at temperatures 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 the operating time the pump dispenses lubricant to the connected lubrication points via one or several metering devices.

Fig. 2 - Pump components

1 - Reservoir 5 - Plug 2A1 2 - Pump element 6 - Filling nipple, pump 3 - Safety valve 7 - Printed circuit board 4 - Filling nipple, system 8 - Plug 1A1

Emergency lubrication 9 - Return line connection possible

00002618

Low-level control (optional)

• The pump model 203 can be equipped with a low-level control.

• The following versions are available:

- Low-level control in conjunction with printed circuit boards F* and V00-V03*

- Low-level control in conjunction with printed circuit board M00-M23*

- Low-level control for pumps without printed circuit board.

• When the reservoir is empty, the signal lamp flashes, thus indicating the low level. Refer to the chapter Low-level control.

* 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 - 1A1.10 V00

Fig. 3 - QUICKLUB central lubrication pump, 2 l reservoir

1006a93

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Tec hnical Description

2.1A-30001-B96

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Mode of Operation

• The electric motor drives the eccentric 1 (Fig. 5, 6).

• During the operating time:

- piston 2 sucks in lubricant from the reservoir. Ref er to Fig. 5.

- piston 2 dispenses the lubricant to the connected lubrication points via the metering device. Refer to Fig. 6.

• The 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, K7 ..................................................... 7 mm

Lubricant output ........................................ approx. 4 cm³/min

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

Suction Phase

Delivery Phase

1 - Eccentric 3 - Spring 2 - Piston 4 - Check valve

2.1A-30001-B96

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Tec hnical Description

Check valve

• The check valve:

- closes the pressure line during suctionstroke

- prevents the lubricant from flowing back to the housing or reservoir 1 - Reservoir with stirring paddle 2 - Pump 3 - Check valve, spring-loaded 4 - Pressure limiting valve R - Return line p - Pressure line

Arrangement of the pump elements

• If several pump elements are to be installed, the installation arrangement shown in Fig. 8 must be adhered to.

• If there is only one pump element , it can be installed in any position. Standard position is no. 3.

• If there are two elements, install one in position 3 and the other in position 1.

Pressure limiting valve without grease return Important: Each pump element must be secured with a pressure

limiting valve.

• The pressure limiting valve

- limits the pressure build-up in the system

- opens at an overpressure of 250 or 350 bar depending on the safety valve design.

• If lubricant is leaking at the pressure limiting valve, this indicates that the system is malfunctioning.

Note: The pumps model 203 are equipped without pressure limiting valve. When ordering the pumpe, order the safety valve seperatly. See the Parts Catalog under Safety valves.

Pressure limiting valve with grease return (optional)

If the system is blocked, grease will leak from the pressure limiting valve. This grease quantity is returned to the reservoir.

Fig. 7 - Hydraulic diagram of the pump

Fig. 8 - Arrangement of the pump elements

Fig. 9 - Pressure limiting valve

Fig. 10 - Pressure limiting valve with grease return

10012618

00002626

1163a95

1164b95

Pressure Limiting Valve (safety valve)

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Tec hnical Description

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T echnical Data

Pump

Admissible operating temperature ...................... -40° C to 70° C*

Number of outlets .......................................................... 1,2 or 3

Reservoir capacity ....................................................... 2 l, 4 l , 8 l

Refilling ........................ via hydraulic lubrication fitting or from top

Lubricant .................................. greases of at least NLGI grade 2

mineral oils up to 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 temperature 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.

Torsion torques

Electric motor on housing .................................................12 Nm

Pump element in housing ................................................25 Nm

Closure plug in housing .................. ..........................................12 Nm

Pump element

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 ........................................................... 7 mm

Lubricant output ........................................ approx. 4 cm³/min

Max. operating pressure. ................................................ 350 bar

Connection thread. ............................................................G 1/ 4

suitable for tube DIA .................................................... 6 mm

Important! The 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 based on the above values.

Weights

The weights below include the following ‘‘individual weights”:

- Pump kit with one pump element, safety valve, grease filling (0.75 kg, 1.5 kg)

- Packing (cardboard box)

- Attaching parts

- Operating Instructions

2 l reservoir, standard design (0.75 kg)

Pump 203 without connection cable ................................. 5.4 kg

Pump 203, version E 1 ..................................................... 6.5 kg

Pump 203, version E 2 ..................................................... 7.1 kg

4 l reservoir , standar d design (1.5 kg)

Pump 203 without connection cable ................................. 8.3 kg

Pump 203, version E 1 ..................................................... 9.3 kg

Pump 203, version E 2 ..................................................... 9.9 kg

8 l reservoir , standar d design (1.5 kg)

Pump 203 without connection cable ................................. 8.6 kg

Pump 203, version E 1 ..................................................... 9.6 kg

Pump 203, version E 2 .................................................... 10.2 kg

In the case of pump versions deviating from those mentioned, add the weights of the following components to the mentioned weights.

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 with 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 ha ve the standard design ”filling from top”.

2.6A-20002-B962.6A-20002-B96

2.6A-20002-B96

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Fig. 4 - Printed circuit board 236-13870-1

1059a95

Fig.5 - Time sequence diagram

tB - Working hours T - Lubrication cycle tP - Various pause times T 1 - Stored pause times

T2 - Operating times

20002443

• The printed circuit board automatically controls the sequence of the pause and operating times of the model 203 central lubrication pump as a function of the vehicle or machine working hours tB (Fig. 5).

• The sequence of the pause and operating times is activated when the machine contact or driving switch is switched on.

• A lubrication cycle consists of one pause time and one operating time. Once the pause time has elapsed, the operating time starts to run. This lubrication cycle is repeated permanently after the machine or vehicle has been put into operation. Refer to Fig. 5.

• During the operating time the pump element dispenses the lubricant to the lubrication points via progressive metering devices.

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The pause timeThe 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 driving switch;

- is adjustable.

• When the machine contact or the driving switch is switched off, the pause times which have already elapsed are stored and added up (refer to T1, Fig. 5) until the time which has been set on the blue rotary switch (Fig.8) is reached.

• The pause time setting may be different for each application. It must be adjusted in accordance with the respective lubrication cycles. Also see ”To set the pause time”.

The operating timeThe operating time

The operating time

- depends on the system’s lubricant requirement ;

- is adjustable;

- is finished when the machine contact or the driving switch is switched off.

• The longer the operating time, the greater the lubricant requirement and vice-versa.

• When the machine contact or the driving switch is switched off, the operating times which have already elapsed are stored and added up until the time which has been set on the red rotary switch (Fig. 10) is reached. After this, the lubrication cycle starts again.

• The operating time setting may be different for each application. It must be adjusted in accordance with the respective lubricant requirement. Also see ”To set the operating time”.

20002438

Fig. 6 -Capacitor

Time storage when the power supply is switched offTime storage when the power supply is switched off

Time storage when the power supply is switched off

• When the ignition voltage or operating voltage is switched off, a capacitor takes over the power supply to the printed circuit board, thus the times which have already elapsed are not lost.

••

•

Switching off until 5 daysSwitching off until 5 days

Switching off until 5 days When the power supply is switched on again the printed circuit circuit board continues to operate from the point where it had been interrupted.

••

•

Switching on after 5 daysSwitching on after 5 days

Switching on after 5 days When the power supply is switched on again, the capaci-

tor is charged. The printed circuit board

immediatel immediatel

immediatel

yy

y

starts with an operating time. starts with an operating time.

starts with an operating time.

2.6A-20002-B962.6A-20002-B96

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Switch position Switch position

Switch position

11

1

22

2

33

3

44

4

55

5

66

6

77

7

88

8

99

9

AA

A

BB

B

CC

C

DD

D

EE

E

FF

F Minutes 3,75 7,5 11,25 15 18,75 22,5 26,25 30 33,75 37,5 41,25 45 48,75 52,5 56,25 Hours 1 2 3 456789101112131415

* To set the pause or oper ating time, remove the co ver on the pump

housing.

Note: To reset a jumper (Fig. 9), remove the printed circuit board.

Important:Important:

Important: After having set the pause time or operating time, screw the cover on the pump housing again

Fig. 9 - Preselection of the time range

Fig. 7 - The cover to access the printed circuit board has been removed

00002617

Fig. 8 - Rotary switch - Pause time

20002452

20002451

TT

T

o set the pause timeo set the pause time

o set the pause time

The pause time can be set to 15 different settings by means of the blue rotary switch.blue rotary switch.

blue rotary switch.blue rotary switch.

blue rotary switch.

Time ranges: Minutes or hours

Time SettingTime Setting

Time Setting

Note: The 0 setting has no function.

Factory settingFactory setting

Factory setting

Rotary switch on :............................................................ 6 hours

or ........................................................................... 22.5 minutes

•

The time ranges can be modified by replugging the jumper (Fig. 9) on the printed circuit board.

• Factory setting of the jumper: see chart page 14. The combination number can be learnt from the pump type designation code mentioned on the nameplate of each pump.

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Switch positionSwitch position

Switch position

11

1

22

2

33

3

44

4

55

5

66

6

77

7

88

8

99

9

AA

A

BB

B

CC

C

DD

D

EE

E

FF

F Seconds 7,5 15 22,5 30 37,5 45 52,5 60 67,5 75 82,5 90 97,5 105 112,5 Minutes 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30

TT

T

o set the operating timeo set the operating time

o set the operating time

• The operating time can be set to 15 different setting by means of the red rotary switch.

Time ranges: Seconds or minutes

Fig. 10 - Rotary switch - Operating time

20002453

Fig. 11 - Preselection of the time range

20002437

Note: The 0 setting has no function.

Factory settingFactory setting

Factory setting

Rotary switch on :........................................................ 6 minutes

or ......................................................................... 22.5 seconds

•

The time ranges can be modified by replugging the jumper (Fig.

11) on the printed circuit board.

• Factory setting of the jumper: see chart page 14. The combination numbers can be learnt from the pump type designation code mentioned on the nameplate of each pump.

2.6A-20002-B962.6A-20002-B96

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RepairRepair

Repair

The defective printed circuit boards should be suitably packed and returned to the factory .

•

If the printed cirIf the printed cir

If the printed cir

cuit boarcuit boar

cuit boar

d md m

d m

ust be replaced,ust be replaced,

ust be replaced,

a model a model

a model

V 00 V 00

V 00 will

always be delivered. See chart page 14.

• Before installing another printed circuit board, take care that the setting of the jumper or that of the operating/pause time is the same as on the old printed circuit board.

Note: In the case of model 203 pump, version 2A1, with external illuminated pushbutton, it is also possible to trigger an additional lubrication cycle via this pushbutton.

Fig. 13 - T o trigger an additional lubrication cycle, only pumps with illuminated pushbutton

20002458

20002457

Fig. 12 - LED on the printed circuit board

• To check the pump operation it is possible to perform an operational test.

Pumps model 203 Pumps model 203

Pumps model 203 installed

on machineson machines

on machines * Switch on the machine contact. Pumps model 203Pumps model 203

Pumps model 203Pumps model 203

Pumps model 203 installed

on commercial vehicleson commercial vehicles

on commercial vehicles * Switch on the driving switch For all pumpsFor all pumps

For all pumpsFor all pumps

For all pumps

• To check whether power is applied to the printed circuit board,

observe whether the LED 1 Fig. 10 is lit.

* Press pushbutton 5 on the printed circuit board

(> 2 seconds) (> 2 seconds)

(> 2 seconds) until

the right-hand LED 3 lights up.

• A shorter pause time elapses, followed by a normal lubrication

cycle.

• Additional lubrication cycles can be triggered at any time.

1 - LED, left-hand 4 - Rotary switch, operating time 2 - Rotary switch, pause time 5 - Pushbutton for additional 3 - LED, right-hand lubrication

Operational Operational

Operational

TT

T

est / est /

est /

TT

T

o o

o

TT

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rigrig

rig

gg

g

er an Ader an Ad

er an Ad

ditionalditional

ditional

Lubrication CycleLubrication Cycle

Lubrication Cycle

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Rated voltage ............................................................ 12/24V DC

Operating voltage

12V/ 24V..........................................................9V to 3 0 V

Residual rippple in relation

with the operating voltage ....................... ± 5% acc. to DIN 41755

Motor output ................................ Transistor 7A/short-circuit proof

Reverse voltage protection:

The operating voltage inputs are protected against

polarity reversal

Temperature range .................................... -25°C to 70°C

Lamp current in the case of pump 2A1 ........................... max. 2 A

Class of protection

Printed circuit board installed in housing ........................ IP 6 K 9 K

In order to protect the printed circuit board against condensation it has been covered with a protective varnish.

All the printed circuit boards comply with the EMC (Electromagnetic compatibility) guidelines for road vehicles acc. to DIN 40839 T1, 3 and 4. The printed circuit boards model V additionnally comply with the EMC guideline 89 / 336 / EWG

Emitted interference acc. to, ....................... EN 55011 / 03.91 and

......................................................... EN 50081-1 / 01.92

Noise immunity acc. to .................................prEN 50082-2 / 1993

Time setting Pause time, depending on the jumper position:

......................................3.75; 7.5; 11.25; to 56.25 minutes

.......................................................... 1, 2 , 3...to 15 hours

Operating time, depending on the jumper position

....................................... 7.5; 15; 22.5;....to 112.5 seconds

..................................................... 2, 4 , 6 ,....to 30 minutes

Factory setting

Pause time.......................................................... 6 hours

or ............................................................... 22.5 minutes

Operating time.................................................. 6 minutes

or ............................................................. 22.5 seconds

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1192b95

Fig. 14 - Connection diagram Quicklub 203 with adjustable pause time

Connection via Hirschmann plug-in connectors DIN 43650-A

A - Printed circuit board B - Pump housing C - Cable connector 1 D - Line socket 1 (black)

for connection cable, 3-wire

Connection Diagram - Industrial ApplicationsConnection Diagram - Industrial Applications

Connection Diagram - Industrial Applications

1A1 - Pump without illuminated pushbutton 2A1 - Pump with cable connection for

illuminated pushbutton*

F - Machine contact * on request

G - Cable connector 2* H - Line socket 2 (grey)

for connection cable, 3-wire* I - Pushbutton for additional lubrication J - Signal lamp in the case of low-level

control

Fig. 15 - Terminals of the printed circuit board

1009a93

- Low-level control

31 - Earth N - Level control 15 - Driving switch Z - Additional lubrication

M

- Motor - Signal lamp

Attention! If a pump model 103 CS...E2 is replaced by a pump model P203-...-...-2A1.10, the lamp connection of the illuminatedAttention! If a pump model 103 CS...E2 is replaced by a pump model P203-...-...-2A1.10, the lamp connection of the illuminated

Attention! If a pump model 103 CS...E2 is replaced by a pump model P203-...-...-2A1.10, the lamp connection of the illuminated pushbutton must be changed from minus to plus.pushbutton must be changed from minus to plus.

pushbutton must be changed from minus to plus.pushbutton must be changed from minus to plus.

pushbutton must be changed from minus to plus.

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A - Printed circuit board B - Pump housing C - Cable connector 1 D - Line socket 1 (black)

with connection cable, 3-wire

1A1 - Pump without illuminated pushbutton

Fig. 16 - Connection diagram Quicklub 203 with adjustable pause time

Connection via Hirschmann plug-in connectors DIN 43650-A

1155b95

Connection DiaConnection Dia

Connection Dia

gram - Applications fgram - Applications f

gram - Applications f

or Commeror Commer

or Commer

cial cial

cial

VV

V

ehicehic

ehic

lesles

les

2A1 - Pump with cable connection

for illuminated pushbutton** F - Driving switch G - Fuse 10 A H - Cable, black I - Cable, brown

*does not belong to the scope of delivery **equipment available on request

J - Cable red K - Cable connector 2** L - Line socket 2 (grey)

with connection cable, 3-wire** M - Illuminated pushbutton** O - Signal lamp in the case of low-level

control P - Battery cutoff*

Attention! If a pump model 103 CS...E2 is replaced by a pump model P203-...-...-2A1.10, the lamp connection of the illuminatedAttention! If a pump model 103 CS...E2 is replaced by a pump model P203-...-...-2A1.10, the lamp connection of the illuminated

Attention! If a pump model 103 CS...E2 is replaced by a pump model P203-...-...-2A1.10, the lamp connection of the illuminated pushbutton must be changed from minus to plus.pushbutton must be changed from minus to plus.

pushbutton must be changed from minus to plus.pushbutton must be changed from minus to plus.

pushbutton must be changed from minus to plus.

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Operating InstructionsOperating Instructions

Operating Instructions

2.2A-10001-A962.2A-10001-A96

2.2A-10001-A96

Subject to modifications

Note: It must nevertheless be ensured that the oils or greases used do not alter their consistency significantly in the course of time or under the influence of temperature or pressure.

Progressive Metering Devices Model SSVProgressive Metering Devices Model SSV

Progressive Metering Devices Model SSV

• The progressive metering devices model SSV can be used for dispensing

- mineral oils with min. 40 mm²/s (cST) or

- greases up to the penetration class NLGI 2

The progressive metering devicesThe progressive metering devices

The progressive metering devices

- are piston-operated metering devices;

- automatically (progressively) dispense the lubricant fed by the pump to the connected lubrication points;

- have a lubricant output of 0.2 cm³ per outlet and piston stroke;

- when one or more outlets are closed (see ”Combining outlets”) they can dispense a double or multiple lubricant quantity

;;

;

- are available with 6 to 12 outlets or up to 22 outlets;

- offer the option of combining several lubrication points into one centralized lubrication point.

- meter the supplied lubricant into predetermined single quantities.

- can be monitored visually or electronically.

• The installation of max. 3 pump elements allows the supply of lubricant to max. 3 separate lubrication circuits.

• Each lubrication circuit is equipped with a pressure relief valve (safety valve) which limits the pressure to the maximum admissible value.

• Any blockage in a lubrication circuit is indicated by grease leaking from the respective pressure relief valve.

Suitable LubricantsSuitable Lubricants

Suitable Lubricants

Progressive Plunger Metering Devices - GeneralProgressive Plunger Metering Devices - General

Progressive Plunger Metering Devices - General

Features of a Progressive Metering DeviceFeatures of a Progressive Metering Device

Features of a Progressive Metering Device

• The term ”progressive

” refers to the special features of the lub-” refers to the special features of the lub-

” refers to the special features of the lub-

ricant distribution within the metering devices, e.g.ricant distribution within the metering devices, e.g.

ricant distribution within the metering devices, e.g.

- the successive movements of the individual pistons within the metering device due to the supplied lubricant being under pressure;

- the pistons move in a predetermined order and the cycles are repeated constantly;

- each piston must have completed its movement fully before the next piston can be moved, no matter whether the lubricant is dispensed continuously or intermittently;

- the pistons operate interdependently of one another;

- no lubrication point which is connected to the system is omitted.

10002709

Fig. 2: Metering device typel SSV 8 shown as a model

10002710

Fig. 3: Sectional view of a SSV 8 metering device

Subject to modifications

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Owner Manual

Operating Instructions

2.2A-10001-A96

• QUICKLUB progressive metering devices offer the option of combining several lubrication points on a machine to one or more central lubrication points, as shown in Fig. 4 which illustrates this basic feature.

Applications

Fig. 6: Multiline pump expanded by a progressive metering device

• Progressive metering devices can be used in two-line or singleline centralized lubrication systems in order to increase the number of outlets of multiline pumps or to subdivide the single metering devices and measuring valves (Fig. 4 - 8) also as secomdary metering devices in large and small oil circulating systems.

Fig. 4: Central lubrication point

• When they are used in connection with hand-operated pumps, pneumatic or electric pumps the progressive metering devices are a simple and low-cost centralized lubrication system. See Fig.

5.

1 - Hand-operated pump 2 - Pneumatically operated pump 3 - Electrically operated pump 4 - Lubrication fitting block 5 - Hand-operated filling pump

4024b95

Fig. 5: Possible pump connections

4025a95

1207a95

Fig. 7: Two-line system expanded by a progressive metering device

1205a95

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Operating InstructionsOperating Instructions

Operating Instructions

2.2A-10001-A962.2A-10001-A96

2.2A-10001-A96

Subject to modifications

Lubricant DistribLubricant Distrib

Lubricant Distrib

ution ution

ution

Within the MeteringWithin the Metering

Within the Metering

DeviceDevice

Device

Phase 1Phase 1

Phase 1

• The lubricant enters the metering device from above (white arrow) and flows to the right-hand end of piston A.

• Piston A (black arrow) is moved to the left under the pressure of the lubricant, causing the lubricant ahead of the left-hand end of piston A to be dispensed to outlet 2 (dashed arrow).

Lubricant under pump pressure

Lubricant under delivery pressure of the piston

Lubricant, pressureless

Phase 2Phase 2

Phase 2

• Once piston A has reached its left-hand final position, the junction channel to the right-hand end of piston B is opened.

• The lubricant which arrives from above (white arrow) also moves piston B (black arrow) to the left, causing the lubricant quantity ahead of the left-hand end of piston B to be dispensed to outlet 7 (dashed arrow).

Lubricant under pump pressure

Lubricant under delivery pressure of the piston

Fig. 9: Phase 1

Fig. 10: Phase 2

Fig. 8: Single-line system expanded by a progressive metering device

1206a95

• The 5 following illustrations show how the lubricant distribution is made to the individual outlets.

Note: To simplify the description we only show the lubricant distribution for outlets 2, 7, 5, 3 and 1. The remaining distribution operations are derived from the logical pumping sequence.

2007a95

2008a95

Subject to modifications

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2.2A-10001-A962.2A-10001-A96

2.2A-10001-A96

Fig. 12: Phase 4

Fig. 11: Phase 3

Phase 3Phase 3

Phase 3

• Once piston B has reached its left-hand final position, the junction channel to the right-hand end of piston A is opened.

• The lubricant which flows from above (white arrow) moves piston C (black arrow) to the left, causing the lubricant quantity ahead of the left-hand end of piston C to be dispensed to outlet 5 (dashed arrow).

Lubricant under pump pressure

Lubricant under delivery pressure of the piston

Phase 4Phase 4

Phase 4

• The channel to the right-hand end of piston D is now open (black arrow).

• The lubricant which is fed from above (white arrow) moves piston D to the left, causing the lubricant quantity ahead of the left-hand end of piston D to be dispensed out of the metering device via outlet 3 (dashed arrow).

Lubricant under pump pressure

Lubricant under delivery pressure of the piston

Phase 5Phase 5

Phase 5

• In phase 4, piston D had opened the junction channel to the lefthand end of piston A.

• The lubricant flowing in (white arrow) moves piston A to the right (black arrow), causing the lubricant quantity to be dispensed to outlet 1(dashed arrow).

• In the subsequent distribution sequence, pistons B - D are moved from the left to the right one after the other.

• A complete distribution sequence is finished and a new cycle can begin.

Lubricant under pump pressure

Lubricant under delivery pressure of the piston

Fig.13: Phase 5

2009a95

2010a95

2011a95

When the lubricant supply is interruptedWhen the lubricant supply is interrupted

When the lubricant supply is interrupted

- the pistons come to a halt;

- the lubricant is no longer dispensed to the lubrication point.

• When the lubricant is fed again to the metering device, the cycle begins from the point where it had been interrupted.

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Operating Instructions

2.2A-10001-A962.2A-10001-A96

2.2A-10001-A96

Subject to modifications

Fig.15: Indicator pin installed on metering device

Fig. 14: Example of a lubrication system

1064a95

System-dependent monitoringSystem-dependent monitoring

System-dependent monitoring

• The main metering device (B, Fig. 14) and the secondary metering devices are connected by a high pressure plastic hose G. This feature automatically causes the linkage of the progressive system connected downstream of the pump.

• If only one piston does not move in any metering device or if the metering device can no longer dispense any lubricant via its outlets, this metering device will block itself.

• If one of the secondary metering devices is blocked, the main metering device is also blocked. The whole progressive system installed downstream of the pump stops operating.

• The fundamental internal structure of the progressive metering device guarantees the self-monitoring of the sequence within the metering device.

• The linkage makes it possible to monitor the operation of the whole system.

Visual monitoringVisual monitoring

Visual monitoring

• The metering devices can be equipped with an indicator pin which is connected to the piston and moves back and forth during lubricant distribution.

• If there is a blockage in the system, the indicator pin stops moving.

Note: It is also possible to indicate the movements of the indicator pin or any blockage in the system by means of a control switch (KS) or a proximity switch (KN). Electrical monitoring (microprocessor controlElectrical monitoring (microprocessor control

Electrical monitoring (microprocessor controlElectrical monitoring (microprocessor control

Electrical monitoring (microprocessor control

))

)

1011a96

Monitoring of the OperationMonitoring of the Operation

Monitoring of the Operation

D - Secondary metering device SSV 6 E - Lubricant plastic tube F - Secondary metering device SSV 12 G - High pressure plastic hose

A - Safety valve B - Main metering device SSV 6 C - Secondary metering device

SSV 8

Fig. 16 - Piston detector installed on the metering device

00002634

•A

piston detectorpiston detector

piston detector (initiator) which has been installed on a metering device instead of a piston closure plug monitors the pump operating timeoperating time

operating timeoperating time

operating time and brings it to a close after all the pistons of this metering device have dispensed their lubricant quantity.

• If there is a blockage in the system or if the pump reservoir is empty , the piston detector can no longer record the piston movements. The switching off signal is not transmitted to the control unit. A fault signal occurs.

Important! Important!

Important! For the system monitoring it is recommended that

oneone

one

SSV metering device with pre-assembled piston detector SSV metering device with pre-assembled piston detector

SSV metering device with pre-assembled piston detector be used per lubrication circuit. These special metering de vices must be ordered separately for each lubrication system. Refer to the Parts Catalog.

• The pre-assembled metering devices have the designation SSV ...SSV ...

SSV ...SSV ...

SSV ...

- N - N

- N (they are availab le f or SSV 6, 8, 10 and 12). They must

be installed in the system instead of a normal metering device.

Subject to modifications

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2.2A-10001-A962.2A-10001-A96

2.2A-10001-A96

Fig.17: Pressure relief valve

Determining the Lubricant Output by Combining OutletsDetermining the Lubricant Output by Combining Outlets

Determining the Lubricant Output by Combining Outlets

TT

T

ube Fittings,ube Fittings,

ube Fittings,

Scre Scre

Scre

w-Tw-T

w-T

ypeype

ype

5- Outlet fitting assembly 6- Clamping ring (brass) 7 - Valve body 8- Cutting ring 9- Coupling nut

10 - Junction channel 11 - Copper washer 12 - Closure plug, outlet borehole

1- Inlet fitting 2- Delivery hole of the piston 3- Closure plug, installed 4- Closure plug, piston (with champfered),

piston

Fig. 18: Install the outlet fittings and closure plugs in accordance with the dosage

1012a96

4092a97

• The whole system can be monitored visually via the pressure relief valve. If lubricant is leaking at the pressure relief valve during the distribution sequence, this indicates that there is a blockage in the system.

ImportantImportant

Important: In the case of the progressive metering devices models SSV 6 - 12 the

outlets 1 and/or 2 must never be closedoutlets 1 and/or 2 must never be closed

outlets 1 and/or 2 must never be closed. In the case

of the progressive metering devices model SSV 14 - 22,

the twothe two

the two

outlets with the highest numbers must never be closed,outlets with the highest numbers must never be closed,

outlets with the highest numbers must never be closed, otherwise the system would block owing to the structure of the metering device.

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Operating InstructionsOperating Instructions

Operating Instructions

2.2A-10001-A962.2A-10001-A96

2.2A-10001-A96

Subject to modifications

TT

T

ube Fittings,ube Fittings,

ube Fittings,

Push-in-T Push-in-T

Push-in-T

ype (main metering deype (main metering de

ype (main metering de

vice)vice)

vice)

Fig. 19 - Install the push-in type outlet fittings and the closure plugs in accordance with the dosage

1203a95

• The output quantities can be raised by closing outlet boreholes.

• Install an outlet fitting assembly in each outlet borehole which will be used. Refer to Fig. 18, 19, 20.

•

Never remove closure plug 4 Never remove closure plug 4

Never remove closure plug 4 (chamfered) on the piston side.

•

Never useNever use

Never use closure plug 12 (Fig. 18) or 7 (Fig. 19, 20)

as a pistonas a piston

as a piston

closure plug 4.closure plug 4.

closure plug 4.

Important:Important:

Important: Always use valve body 7 (Fig. 18) in conjunction with

clamping ring 6.

• Clamping ring 6 (Fig. 18) closes the junction channels 10 to the other outlet channels.

Note: In the case of push-in type fittings the clamping ring is always a firm component part of the valve body.

Important: Important:

Important: In the case of the progressive metering devices

modelmodel

model

SSV 6 - 12 the outlets 1 and/or 2 must never be closed.SSV 6 - 12 the outlets 1 and/or 2 must never be closed.

SSV 6 - 12 the outlets 1 and/or 2 must never be closed. I n the case of the progressive metering devices

model SSV 14 - 22, the twomodel SSV 14 - 22, the two

model SSV 14 - 22, the two

outlets with the highest numbers must never be closed,outlets with the highest numbers must never be closed,

outlets with the highest numbers must never be closed, otherwise the system would block due to the structure of the metering device.

5 - Va lve body assembly (with reinforced collar) 6 - Junction channels 7 - Closure plug, outlet borehole 8 - Copper washer

1 - Inlet fitting with protective cap * 2 - Delivery borehole of the piston 3 - Closure plug installed in outlet borehole 4 - Closure plug (chamfered), piston

* on request

Subject to modifications

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Operating Instructions

2.2A-10001-A962.2A-10001-A96

2.2A-10001-A96

TT

T

ube Fittings,ube Fittings,

ube Fittings,

Push-inT Push-inT

Push-inT

ype (secondarype (secondar

ype (secondar

y metering dey metering de

y metering de

vices)vices)

vices)

Fig. 20: Install the push-in type outlets fittings and closure plugs in accordance with the dosage

1204a95

1014a96

Single lubricant outputSingle lubricant output

Single lubricant output

• The simple lubricant output is the lubricant quantity dispensed by a piston per stroke and per outlet borehole to one lubrication point. It amounts to 0.2 cm³.

Double or multiple lubricant outputDouble or multiple lubricant output

Double or multiple lubricant output

• If one or more lubrication points require a double or a multiple lubricant amount, this can be performed by closing one or more outlets.

• As shown in Fig. 21, outlet borehole 10 has been closed. The lubricant quantity supplied by this outlet flows out of the metering device via outlet 8.

• Total quantity at outlet 8:

- is the quantity of outlet 8

- plus the lubricant quantity of outlet 10.

• If a triple quantity is needed (at outlet 1), close the outlet borehole located above the discharge borehole. Refer to outlets 3 and 5 on Fig. 21.

5 - Valve body assembly (with knurled collar) 6 - Junction channels 7 - Closure plug, outlet borehole 8 - Copper washer

1 - Inlet fitting 2 - Delivery borehole of the piston 3 - Closure plug installed in outlet borehole 4 - Closure plug (chamfered), piston

Fig. 21: Single, double and triple lubricant output

x - Outlet quantity (1x: single, 2x: double, etc.) 1 - 10 Outlet numbers A - Clamping ring (brass)

Subject to modifications

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2.2A-10001-A962.2A-10001-A96

2.2A-10001-A96

TT

T

ecec

ec

hnical Datahnical Data

hnical Data

Tightening torquesTightening torques

Tightening torques

Metering Device Model SSVMetering Device Model SSV

Metering Device Model SSV

Lubricant output per outlet and per stroke ......................... 0.2cm³

Max. operating pressure ................................................. 350 bar

Min. operating pressure....................................................20 bar

Max.differential pressure

between two outlets ....................................................... 100 bar

Outlet connection for tube................................................Ø 6mm

Inlet connection ................................................................. G 1/ 8

Operating temperature ........................................ - 25° C to 70°C

Push-inTPush-inT

Push-inT

ype ype

ype

TT

T

ube Fittingsube Fittings

ube Fittings

High pressure range, p max. .......................................... 350 bar

Inlet tube fittings of the metering devices Outlet fittings, main metering device

Low-pressure range, p max. ........................................... 250 bar

Outlet fittings, secondary metering devices Inlet fittings to the lubrication pointInlet fittings to the lubrication point

Inlet fittings to the lubrication pointInlet fittings to the lubrication point

Inlet fittings to the lubrication point

LinesLines

Lines High-pressure plastic hoseHigh-pressure plastic hose

High-pressure plastic hoseHigh-pressure plastic hose

High-pressure plastic hose Min. bursting pressure (in connection with

hose clamp, screwed). ................................................... 600 bar

Min. bending radius. ........................................................ 50 mm

Min. temperature ............................................................. - 40° C

Plastic tubePlastic tube

Plastic tube

Min. bending radius ......................................................... 30mm

Bursting pressure at 20° C .............................................approx. 250 bar

Min. temperature ............................................................. - 40° C

Closure plug (piston) in metering device ...........................10 Nm

Closure plug (outlets) in metering device ..........................10 Nm

Inlet fitting in metering device

screw-type.......................................................................17 Nm

plug-type .........................................................................10 Nm

Outlet fitting in metering device

screw-type.......................................................................10 Nm

plug-type .......................................................................... 8 Nm

Compression nut onto inlet fitting ......................................10 Nm

Compression nut onto outlet fitting, screw-type

plastic tube ....................................................................... 5 Nm

steel tube ........................................................................10 Nm

Installation of metering device........................................... 10Nm

Lincoln QUICKLUB 203 Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual