Owner Manual

Technical Description

2.6A-20002-C00

Printed Circuit Board for Pump 203

236-13891-1 Models V10 - V13*
236-13891-2 Models V20 - V23*

with Adjustable Pause and Operating Times

Applications for Commercial Vehicles or Industrial Applications
Subject to change without notice

*See page 4 „Applications“

10051327a

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 Owner Manual
Technical Description

2.6A-20002-C00

Survey

Pump Voltage [V] Control unit Setting ranges Part no. Applications

P1: 4 to 60 minutes
12/24 P2: 1 hour to 15 hours
203 integrated A 1: 8 seconds to 120
V10-V13*,** seconds 236-13891-1
V20-V23*,** A 2: 2 to 30 minutes 236-13891-2

integrated P : 4 to 60 minutes
M00-M23*** P : 1 to 15 hours 236-13870-1
Ü : 5 or 30 minutes

without control
unit or with
external control
unit*

12/24
203 integrated
V10-V13*,** ADR 236-13891-1

12/24
203 integrated B : 6 hours, fixed 236-13857-1
H* A: 2 to 30 minutes

12/24
203 integrated B : 6 hours, fixed 236-13857-1
H * ADR A : 2 to 30 minutes

24 VDC external P : 0.5, 1, 2...to 12 hrs 236-13834-1

203 PSG 01 A : 2, 4, 8, 16, 32 min 664-36875-1

24 VDC, 115 VAC,

203 230 VAC external P : 1 min to 160 hrs 236-13860-2
PSG 02 A : 1 min to 160 min

A - Operating time ranges B - Time of availability P - Pause time range Ü - Monitoring time
Subject to change without notice

* 1A1 - Version - Pump without connection for the illuminated pushbutton

**2A1 - Version - Pump with connection for the illuminated pushbutton
***2A4 - Version - Pump with microprocessor control

Note: The applications of the progressive systems are various. There is therefore a corresponding control unit available for each
individual application.

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 Owner Manual
Technical Description

2.6A-20002-C00

Table of Contents

Page Page

Survey ............................................................................. 2 Repair .............................................................................. 9

Printed circuit board V10-V13 and V20-V23 ............. 4 Operational test/To trigger an additional lubrication ..... 9
Applications ..................................................................... 4 Troubleshooting .......................................................... 10
Mode of operation ........................................................... 4 Technical data ............................................................... 11
Pause time ................................................................ 6 Connection diagram - Industrial applications .............. 12
Operating time .......................................................... 6 Connection diagram - Appplications for
Time storage when the power supply commercial vehicles ...................................................... 13
is switched off ............................................................. 6 Connection diagram - Appplications for
Time setting ...................................................................... 7 commercial vehicles ...................................................... 14
Combinations of the jumper positions .................... 15

Further information can be found in the following manu-

als:

Technical Description Pump Model 203

Technical Description Progressive Metering Devices for Grea-
se and Oil, model SSV
Technical Description for ”Electronic Control Units” of the 203
pump
Printed Circuit Board 236-13857-1 - Model H
Printed Circuit Board 236-13870-1 - Models M 00 - M 15
Printed Circuit Board 236-13870-1 - Models M 16 - M 23
Timer 236-13860-2 Model PSG 02
Installation Instructions
Parts Catalog
Subject to change without notice

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 Owner Manual
Technical Description

2.6A-20002-C00

Printed Circuit Board V10-V13 and V20-V23

Applications
The printed circuit boards can be used for the following
applications

1.) Lubrication cycles only as a function of the machine wor-

king hours.

When the machine contact (external contact) is switched on

the centralized lubrication system is ready for operation.

Caution: On the PCB 236-13891-1 (V10-V13)* do not con-

nect the red core of the connecting cable to connection 1,
Fig. 1, 14, 16 (terminal 30) since terminal 30 is connected
internally with terminal 15.

1191c95

Fig. 1 - Machine contact, printed circuit board 236-13891-1 (V10-V13)

Note: The PCB’s 236-13891-1 and 236-13891-2 differ only

as regards their connection of the terminals. In the case of
PCB 236-13891-2 the terminals 30 and 15 are not connec-
ted.

1191d95

Fig. 2 - Machine contact, printed circuit board 236-13891-2 (V20-V23)

2.) Lubrication cycles only as a function of the running hours

of the commercial vehicle.

When the driving switch (terminal 15) is switched on, the cen-
tralized lubrication system is ready for operation

Note: In the case of PCB 236-13891-2 also connect the

battery voltage (terminal 30).

1060a95

Fig. 3 - Driving switch

Subject to change without notice

*
This designation shows the version of the PCB installed in the pump. It forms part of the pump designation on the name-
plate on each pump.
In the case of P 203-...-.K.-.A. ...-V10 the PCB 236-13891-1 is installed, see connection diagrams 1, 14 and 16.
In the case of P 203 - ... - .K. - .A.. ..-V20 the PCB 236-13891-2 see connection diagram 2, 17.

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 Owner Manual
Technical Description

2.6A-20002-C00

Mode of Operation
• The printed circuit board is integrated in the pump hou-
sing.

00002616

Fig. 4 - Printed circuit board installed in the housing

• 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 wor-
king hours tB (Fig. 5).
• The sequence of the pause and operating times is activated
when the machine contact or driving switch is switched on.

20002443b

Fig. 5 - Printed circuit board 236-13891-1

• A lubrication cycle consists of one pause time and one ope-

rating time. Once the pause time has elapsed, the operating
time starts to run. This lubrication cycle is repeated perma-
nently after the machine or vehicle has been put into opera-
tion. Refer to Fig. 5.
• During the operating time the pump element dispenses the
lubricant to the lubrication points via progressive metering
devices.

1059a95
Subject to change without notice

Fig.6 - Time sequence diagram

tB - Working hours T - Lubrication cycle

tP - Various pause times T1 -Stored pause times
T2 -Operating times

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 Owner Manual
Technical Description

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The pause time The operating time

- determines the frequency of the lubrication cycles within a - depends on the system’s lubricant requirement ;
working cycle; - is adjustable;
- is started and stopped via the machine contact or driving - is finished when the machine contact or the driving switch is
switch; switched off.
- is adjustable. • The longer the operating time, the greater the lubricant re-
• When the machine contact or the driving switch is switched quirement and vice-versa.
off, the pause times which have already elapsed are stored • When the machine contact or the driving switch is switched
and added up (refer to T1, Fig. 6) until the time which has off, the operating times which have already elapsed are
been set on the blue rotary switch (Fig.8) is reached. stored and added up until the time which has been set on the
• The pause time setting may be different for each application. red rotary switch (Fig. 10) is reached. After this, the lubricati-
It must be adjusted in accordance with the respective lubri- on cycle starts again.
cation cycles. Also see ”To set the pause time”. • The operating time setting may be different for each applica-
tion. It must be adjusted in accordance with the respective
lubricant requirement. Also see ”To set the operating time”.

Time storage

• When switching off the ignition voltage and/or the opera-

ting voltage the times already expired are saved for an un-
limited duration.
• When the power supply is switched on again the printed cir-
cuit board continues to operate from the point where it had
been interrupted.
Subject to change without notice

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 Owner Manual
Technical Description

2.6A-20002-C00

Time Setting
* To set the pause or operating time, remove the cover on the
pump housing.

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

board.

Important: After having set the pause time or operating time,

screw the cover on the pump housing again

00002617

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

To set the pause time

The pause time can be set to 15 different settings by means of

the blue rotary switch.

Time ranges: Minutes or hours

20002451b

Fig. 8 - Rotary switch - Pause time

Switch position 1 2 3 4 5 6 7 8 9 A B C D E F

Minutes 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60

Hours 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Note: When the switch is on ”0” a fault is shown at the right-

hand LED 3, see page 9.
At the same time the factory-set pause time is accepted.

Factory setting

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

Subject to change without notice

or ................................................................................ 24 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 15. The combi-
20002452a nation number can be learnt from the pump type designation
Fig. 9 - Preselection of the time range
code mentioned on the nameplate of each pump.

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 Owner Manual
Technical Description

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To set the operating time

• The operating time can be set to 15 different setting by me-

ans of the red rotary switch.

Time ranges: Seconds or minutes

20002453b

Fig. 10 - Rotary switch - Operating time

Switch position 1 2 3 4 5 6 7 8 9 A B C D E F

Seconds 8 16 24 32 40 48 56 64 72 80 88 96 104 112 120

Minutes 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30

Note: When the switch is on ”0” a fault is shown at the right-

hand LED 3 Fig. 12. At the same time the factory-set opera-
ting time is accepted.

Factory setting

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

or ............................................................................... 24 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 15. The com-
bination numbers can be learnt from the pump type desi-
gnation code mentioned on the nameplate of each pump.

20002437

Fig. 11 - Preselection of the time range

Fault indication

Rotary switch set at „0“ Pushbutton 5 Fig. 12 continuously actuated (short circuit)
• When one of the rotary switches 2, 3 Fig. 12 is on the „0“ • If a short circuit occurs at the pushbutton or is present at
setting a fault is shown at the right-hand LED 3. the external illuminated pushbutton Fig.13 or at the con-
Subject to change without notice

• The fault is indicated by 4 flashes of the LED. necting parts a fault is shown at the red LED 3, fig. 12.
• The pump motor also runs according the flash frequency. If • The fault is indicated by 3 flashes of the LED when the
the warning is ignored the controller automatically adopts voltage supply is switched on.
the factory-set values for the operating or pause time • The motor of the pump also runs according to the flash
frequency.

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 Owner Manual
Technical Description

2.6A-20002-C00

Repair
The defective printed circuit boards should be suitably packed • If the printed circuit board must be replaced, a model
and returned to the factory. V 10 (V20) will always be delivered. See chart page 15.
• 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.

Operational Test / To Trigger an Additional

Lubrication Cycle
• To check the pump operation it is possible to perform an ope-
rational test.

Pumps model 203 installed on machines

* Switch on the machine contact.

Pumps model 203 installed on commercial vehicles

* Switch on the driving switch

For all pumps

• To check whether power is applied to the printed circuit
board, observe whether the LED 1 Fig. 12 is lit.
20002457b * Press pushbutton 5 on the printed circuit board (> 2 secon-
Fig. 12 - LED on the printed circuit board ds) until the right-hand LED 3 lights up.
1 - LED, left-hand 4 - Rotary switch, operating time
2 - Rotary switch, pause time 5 - Pushbutton for additional • A shorter pause time elapses, followed by a normal lubricati-
3 - LED, right-hand lubrication on cycle.

• Additional lubrication cycles can be triggered at any time.

Note: In the case of model 203 pump, version 2A1, with exter-
nal illuminated pushbutton, it is also possible to trigger an addi-
tional lubrication cycle via this pushbutton.
Subject to change without notice

20002458

Fig. 13 - To trigger an additional lubrication cycle, only pumps with illuminated

pushbutton

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 Owner Manual
Technical Description

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Troubleshooting

Note: The pump operation can be checked from the outside by circuit board are lit or whehter the signal lamp of the illumi-
observing whether the stirring paddle is rotating (e.g. by trigge- nated pushbutton (if any) is lit.
ring an additional lubrication), whether the LED on the printed

• Fault: the pump motor does not run

• Cause: • Remedy:

• Voltage supply interrupted • Check the voltage supply to the pump. If necessary, elimina-
te the fault.

• Voltage supply to the printed-circuit interrupted • Check the line leading from the pump plug to the printed cir-
cuit board.
• If the voltage is applied, the left-hand LED is lit.

• Voltage supply interrupted betweeen the printed circuit board • Triggering an additional lubrication cycle
and the motor • If the voltage is applied, the right-hand LED is lit.

• Printed-circuit board defective • Replace the printed circuit board.

• Fault: Right-hand LED 3 Fig. 12 flashes

• Cause: • Remedy:

• One of the two rotary switches 2, 4 Fig. 12 is on „0“. • Set rotary switch to a number or a letter.
Signal: 4 flashes

• Short circuit at pushbutton 5 Fig. 12 or, if present, at the illu- • Check whether the short circuit is at he PCB or, if present,
minated push button or at their connecting parts at the illuminated pushbutton.
Signal: 3 flashes If necessary, exchange the PCB or the illuminated pushbut-
ton.

.
Subject to change without notice

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Technical Description

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Technical Data

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

Operating voltage
12V/ 24V .......................................................... 9V to 30V Pause time, depending on the jumper position:
Residual rippple in relation ............................................... 4; 8; 12; 24 to 60 minutes
with the operating voltage ................... ± 5% acc. to DIN 41755 ......................................................... 1, 2, 3...to 15 hours
Motor output ............................ Transistor 7A/short-circuit proof Operating time, depending on the jumper position
Reverse voltage protection: ............................................ 8; 16; 24;....to 120 seconds
The operating voltage inputs are protected against ................................................... 2, 4, 6,....to 30 minutes
polarity reversal Factory setting
Temperature range .................................. -25°C to 70°C Pause time .......................................................... 6 hours
Lamp current in the case of pump 2A1 ....................... max. 2 A or .................................................................... 24 minutes
Class of protection Operating time ................................................ 6 minutes
Printed circuit board installed in housing .................... IP 6K 9K or .................................................................. 24 seconds

In order to protect the printed circuit board against condensati-

on it has been covered with a protective varnish.

All the printed circuit boards comply with the EMC (Electroma-
gnetic compatibility) guidelines for road vehicles acc. to DIN
40839 T1, 3 and 4
and the EMC guideline 89 / 336 / EWG
Emitted interference acc. to ................. EN 55011 / 03.91 and
........................................................ EN 50081-1 / 01.92
Noise immunity acc. to ............................. EN 50082-2 / 03.95
The type 203 pumps with PCB V10 - V13 (V20 - V23) comply
with the Automotive EMC Directive 95/54/EEC and with the
EC approval mark e1
021016
shown on the nameplate
Subject to change without notice

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Technical Description

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Connection Diagram - Industrial Applications, Printed Circuit Board 236-13891-1 (V10-V13)

1192c95

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

Connection via Hirschmann type-in connectors DIN 43650-A

A- Printed circuit board 1A1 - Pump without illuminated pushbutton G- Cable connector 2*
B- Pump housing 2A1 - Pump with cable connection for H- Line socket 2 (grey)
C- Cable connector 1 illuminated pushbutton* for connection cable, 3-wire*
D- Line socket 1 (black) F - Machine contact I- Pushbutton for additional lubrication
for connection cable, 3-wire J - Signal lamp in the case of low-level
* on request control

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.

- Low-level control*

31 - Earth N- Level control*

15 - Driving switch Z- Additional lubrication*

Subject to change without notice

M - Motor - Signal lamp*

1009c93

Fig. 15 - Terminals of the printed circuit board

* equipment available on request

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Technical Description

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Connection Diagram - Applications for Commercial Vehicles

Printed Circuit Board 236-13891-1 (V10-V13)

1155d95

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

Connection via square type plug DIN 43650-A

A- Printed circuit board 2A1 - Pump with cable connection K- Cable connector 2**
B- Pump housing for illuminated pushbutton** L- Line socket 2 (grey)
C- Cable connector 1 F - Driving switch with connection cable, 3-wire**
D- Line socket 1 (black) G - Fuse 10 A M- Illuminated pushbutton**
with connection cable, 3-wire H - Cable, black O- Signal lamp in the case of low-level
1A1 - Pump without illuminated pushbutton I- Cable, brown control
P- Battery cutoff*

*does not belong to the scope of delivery

**equipment available on request

Caution: Do not connect the red core (not shown: cf. J Fig. 17)
of the 3-core connecting cable to the wire box 1 (D, Fig. 16)
since the PCB is connected internally between 30 and 15.
Subject to change without notice

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.

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Technical Description

2.6A-20002-C00

Connection Diagram - Applications for Commercial Vehicles

Printed Circuit Board 236-13891-2 (USA)

1155e95

Fig. 17 - Connection diagram Quicklub 203 with adjustable pause time

Connection via square type plug DIN 43650-A

A- Printed circuit board 2A1 -Pump with cable connection K- Cable connector 2**
B- Pump housing for illuminated pushbutton** L- Line socket 2 (grey)
C- Cable connector 1 F - Driving switch with connection cable, 3-wire**
D- Line socket 1 (black) G - Fuse 10 A M- Illuminated pushbutton**
with connection cable, 3-wire H - Cable, black O- Signal lamp in the case of low-level
1A1 - Pump without illuminated pushbutton I- Cable, brown control
J - Cable, red P- Battery cutoff*

*does not belong to the scope of delivery

**equipment available on request

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.

30 - Battery voltage - Low-level control*

31 - Earth N- Level control*

Subject to change without notice

15 - Driving switch Z- Additional lubrication*

M - Motor - Signal lamp*

1009b93
* equipment available on request
Fig. 18 - Terminals of the printed circuit board 236-13891-2

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Combinations of the jumper positions - Survey

Pause time ranges Operating time ranges Jumper positi-

Possibilities of
P I ons
preselection 4 - 60 min 1 - 15 h 8 - 120 s 2 - 30 min See Fig. 8, 10

Combination no.

V 10, V 20
Standard X X

V 11, V 21 X X

V 12, V 22 X X

V 13, V 23 X X
Subject to change without notice

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Subject to change without notice

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